Full overhaul, including major component re-manufacture, of over one hundred DA Rams.
Case study: Large-scale longwall cylinder overhaul for a Hunter Valley coal mine
Scope: Full overhaul and major component re-manufacture of 118 Double-Acting rams
Delivered: 10 weeks, completed in-house by a 15-person multi-discipline team
The challenge
As part of a longwall upgrade, a major Hunter Valley underground coal operator needed a fast, reliable overhaul program for more than one hundred DA rams, without blowing the budget or extending downtime. The job demanded mining-ready reliability, tight scheduling, and confidence that every cylinder would return to service performing to specification.
The Berendsen solution
Berendsen Fluid Power Newcastle delivered the overhaul entirely in-house, bringing together our engineering, fluid power and machining capability under one roof. From the start, our team worked closely with the mine’s longwall department to align on performance requirements, timelines, and cost constraints, then translated that into a clear, documented scope of work.
What we did (end-to-end overhaul process)
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Consultation and scoping
We collaborated with the longwall team to understand operating conditions, priorities, and budget, then developed a detailed work scope for the full program. -
Strip and condition assessment
Each cylinder was stripped in our workshop and every major component was inspected to determine whether it should be re-used, repaired, or replaced based on condition. -
Component re-manufacture (where required)
Using Berendsen’s 3,200 m² machining facility, we manufactured critical components for all 118 cylinders, including:-
barrels
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end caps
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glands
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pistons
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port blocks
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Rod refurbishment for extended life
Piston rods were crack tested and straightened, then the nickel chrome surface was refurbished as required to restore performance and durability. -
Transducer verification
Linear transducers were tested in our purpose-built test unit, producing a linear graph output for each test to support repeatable, objective verification. -
Assembly and full-function testing
After final assembly, every refurbished cylinder underwent a full-function test on our purpose-built test system to confirm performance before release. -
Finish, pack and staged delivery
Cylinders were painted, packaged, and delivered in batches to a strict schedule to help keep downtime to an absolute minimum during the longwall upgrade window.
The result
A month after the rams returned to service, the client reported they were extremely happy with the outcome. They specifically commended:
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our quality control procedures
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our ability to meet the tight delivery schedule
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the cost analysis methodology used to make smart decisions on re-use vs repair vs replacement
The customer has since indicated they intend to adopt Berendsen’s proven methodology for future overhaul programs.
Why mining teams choose Berendsen for hydraulic overhauls
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OEM-quality focus: engineered repair decisions, controlled machining, and verification testing
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End-to-end capability: engineering support, machining, refurbishment and testing coordinated as one workflow
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Reduced downtime risk: disciplined scheduling, staged deliveries, and repeatable processes
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Cost-smart outcomes: condition-based decision-making to protect performance without replacing what doesn’t need replacing
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National support: specialist hydraulic services available across Australia when you need backup capacity
Want to learn more about Berendsen Newcastle?
Backed by our Engineering and Design team, our ISO-accredited manufacturing hub in Newcastle specialises in the design, manufacture and supply of hydraulic cylinders and manifolds for demanding applications. With high-spec CNC machining, we deliver the repeatability, accuracy and speed needed to produce high-quality components cost effectively.
If you’re looking for mining industry hydraulic services that prioritise uptime and reliability, contact Berendsen Fluid Power on 1800 660 249.
