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Weighing and Pressure Sensing for Mining in Australia
Quick answer: mining and mineral processing use load cells and pressure instruments in a handful of well-understood places: conveyor belt scales, truck weighbridges and haul truck payload systems, crane and lifting scales, tank and reagent weighing, and hydraulic equipment. The conditions are tough, with dust, vibration, heat, shock loads and remote locations, so the right equipment is rugged, well sealed and supported with spares. Hazardous areas and safety-critical functions need certified equipment installed by qualified people. This guide explains where weighing and pressure sensing fit in a mining operation, what to specify, how remote sites change the plan, and what is outside the scope of load cells and pressure gauges.
What this guide covers, and what it does not
People search for “mining safety sensors” and “sensor solutions for mining” and mean very different things. This guide covers weighing (load cells) and pressure measurement (gauges, sensors and transmitters). It does not cover gas detection, proximity detection, ground monitoring or other safety systems, which are separate certified product categories. If a measurement is safety-critical, use equipment certified for that duty, and follow your site’s safety management system and the regulator’s requirements.
Where weighing and pressure sensing are used in mining
| Area | What is measured | Typical instrument |
|---|---|---|
| Conveyors | Tonnes per hour and total tonnes | Belt scale load cells |
| Haul trucks | Payload per cycle | Suspension pressure sensors or load cells, with software |
| Truck weighbridge | Gross, tare and net weight | Compression or shear beam cells |
| Crushers, mills and pumps | Hydraulic and lube pressure | Gauges, sensors and test kits |
| Reagent and slurry tanks | Contents mass | Tank load cells |
| Lifting and maintenance | Load on slings and cranes | Tension load cells, crane scales |
| Bins and hoppers | Stock and feed rates | Hopper and silo load cells |
Conveyor belt scales
A belt scale weighs the section of conveyor that passes over a weigh frame, combines that weight with belt speed, and reports tonnes per hour. Accuracy depends heavily on mechanical alignment, belt tension and cleanliness, so installation quality matters as much as the load cell. See belt scale load cells and load cell installation.
Haul truck payload
Haul trucks use onboard payload systems to avoid overloading, which damages suspension, driveline and tyres. The classic method measures the pressure in the hydropneumatic suspension cylinders: the pressure rises with the load, and a controller converts it into a payload figure, usually correcting for the tilt of the truck. Load cells integrated into the suspension are another route. Published patents and vendor material describe both approaches, and both have limitations. For example, a single-cylinder pressure measurement does not suit every vehicle, so the design must be validated for the truck. This is an area where pressure sensors, not gauges, do the work.
If you work with pressure sensors on mobile plant, read pressure sensors for hydraulic systems, which covers range, overpressure and protection.
Weighbridges at mine gates and loadouts
Where product leaves site by road, a weighbridge records the weight. If the weight sets a price or a royalty, the weighbridge may need to be an approved, certified instrument. See trade approved weighbridges and legal for trade weighing. For cell choice, read weighbridge load cells. Lightning and flooding are the usual enemies, so surge protection and drainage are essential. The Revere ASC2 is an example of a cell with built-in surge protection and IP66, IP68 and IP69K ratings.
Hydraulics on fixed and mobile plant
Mining equipment runs on hydraulics at high pressure. Technicians check relief valve settings, pump output and accumulator charge. Use a gauge accurate enough for the tolerance, with the right adaptors. See digital hydraulic pressure gauges and hydraulic pressure gauges. A PDR250 reaches 700 bar at 0.25% FS, and the PDR500 and PDR1000 suit reference duty.
Tanks, reagents and slurries
Processing plants dose reagents by weight. Weighing a tank gives mass directly, whatever the density, and does not touch aggressive liquids. See tank, silo and hopper weighing and load cell vs pressure sensor. For dirty or corrosive process pressure points, consider diaphragm seal gauges.
Lifting and maintenance
Crane scales and tension load cells help check the weight of components before a lift. Remember that a load cell is not a substitute for rated lifting equipment or for the lifting plan. See tension load cells for crane scales and the load cell shapes guide.
Mining conditions and what they mean for the specification
| Condition | Effect | Specify |
|---|---|---|
| Fine dust | Blocks vents; coats cells and displays | IP66 or better; sealed glands; cleaning routine |
| Vibration and shock | Wears gauge movements; loosens fittings | Liquid filled gauges; secure mounts; shock-tolerant cells |
| Heat | Drifts electronics; ages seals | Check temperature ratings; shade; allow for drift |
| Wet season and flooding | Water in pits and cables | IP68 cells; drainage; hermetic seals |
| Lightning | Surges damage cells and indicators | Surge protection and earthing |
| Corrosive process liquids | Attacks wetted parts | 316 stainless steel; diaphragm seals |
| Potentially explosive atmospheres | Ignition risk | Certified equipment only. See hazardous area equipment |
| High temperature (smelters, kilns) | Heat damage to electronics | Cooling, shields, high-temperature designs. See high temperature sensors |
Customers sometimes ask about high temperature load cells. Standard cells have temperature limits stated on the datasheet, and hot applications usually need heat shields, cooling or special designs. Send us the temperature and we will say honestly whether we have a suitable option.
Planning for remote sites
- List critical points: which weighing and pressure points stop production if they fail?
- Hold spares: one matching spare per critical cell, sensor or gauge type.
- Record model numbers and serials: keep copies on site and off site.
- Plan calibration: use portable references and test weights, and schedule accredited calibration for references.
- Order early: freight to remote sites takes time. Tell us your site location and the date you need parts.
Our regional guides cover the conditions in Western Australia and Queensland, where mining is concentrated.
Example: a belt scale at a crusher
A crusher feeds a conveyor that carries ore to a stockpile. The operator wants tonnes per hour for production reporting. The belt scale uses load cells under a weigh frame, with speed measured by a roller encoder. Good practice: align idlers, keep the belt clean, calibrate with a test chain or material test, and check the zero regularly. A fall in accuracy usually points to build-up or misalignment before it points to the load cell.
Example: a hydraulic shovel service
A service team checks a shovel’s main relief at 350 bar. The handbook allows a tolerance of 5 bar, so the four-to-one rule calls for an instrument accurate to about 1.25 bar. A PDK PDR250 on its 0 to 400 bar range at 0.25% FS has a possible error of 1 bar, which meets the rule. A 1% analogue gauge on the same range could be 4 bar out, which does not. Matching range and accuracy to the tolerance is the key point.
A specification checklist for mining instruments
- Location: surface, underground, wet or dry, remote.
- Hazard classification of the area, if any, and the approvals required.
- Temperature range, including sun on equipment and hot process lines.
- Ingress protection required, with dust and flooding in mind.
- Vibration and shock levels.
- Required accuracy and whether the measurement is used for payment or royalty.
- Output signal and compatibility with the control system.
- Spares, calibration plan and service access.
Common mistakes in mining instrumentation
- Choosing an IP rating for dust but forgetting wet-season flooding.
- Skipping surge protection at exposed locations.
- Not planning access for calibration at remote sites.
- Using a general gauge in a hazardous area.
- Ignoring belt tracking, build-up and alignment when the belt scale reading drifts.
- Relying on a single pressure reading for a safety-critical decision.
A starter kit for a mine workshop
- A digital gauge with hose and adaptors for hydraulic checks, and a higher-accuracy reference.
- A spare stainless steel gauge for the most common range.
- Spare pressure sensors for critical circuits, with matching connectors.
- A spare load cell for each weighbridge or scale type, with the datasheets.
- A set of test weights or an agreed method for checking scales.
- A logbook for calibration dates, repairs and readings.
Keeping records that stand up
Mining operations are audited often. For every weighing and pressure instrument that matters, keep the model and serial number, the datasheet, the location, the calibration or verification dates, the results and any repairs. Records that show a stable history also help you spot drift early, which is cheaper than finding out at a stock reconciliation or a royalty audit.
Frequently asked questions
Do you supply mining safety sensors?
We supply load cells, pressure gauges and pressure sensors. Gas detection and similar safety systems are different product categories.
Can load cells be used underground?
Only with equipment approved for the hazardous area and the site’s rules. Talk to a qualified person first.
How do I choose a belt scale load cell?
By capacity, accuracy, sealing and the maker’s belt scale design. Send us the belt details.
What IP rating suits a mine?
IP66 or better for dust, and IP68 where flooding is possible.
Can you supply to remote sites?
Yes. We supply Australia-wide from Sydney. Tell us the site location and deadline.
Next steps
Read our complete load cell guide and load cell brands and models explained, or contact us with your application.
