In today’s construction and mining projects, profit margins can be razor thin, with efficiency and precision often the difference between a great project and one you would rather forget. This is where machine control systems – a suite of technologies designed to enhance the accuracy and efficiency of heavy equipment – can make all the difference.
At the core of this technology are Global Positioning System (GPS) sensors, and other data to guide operators during tasks so as to minimise errors and reduce human intervention, especially in applications where high precision is principal. One of the flagship names in this area is Leica Geosystems, a company that has revolutionised the world of measurement and survey for 200 years.
Part of Hexagon, Leica Geosystems offers a diverse range of machine control solutions for earthmoving, grading and other applications of excavators, graders, dozers, pilers, drillers and compaction, amongst others.
In southern Africa, the focus is largely on grader, dozer and excavator solutions, where a suite of both 2D or 3D solutions is available. The 2D machine control systems provide real-time guidance and accuracy for tasks such as grading and levelling, without the use of 3D models to get level data from either sensors placed on the machine or with the help of rotating lasers, ensuring that the grader blade or excavator bucket achieves the desired slope or elevation. This entry-level solution is ideal for projects that involve simple terrain or require basic grading.
Customers looking for even greater accuracy and more precision on earthmoving applications can go the 3D route. Leica 3D machine control, explains Uys, works by combining a machine’s real-time position, a 3D design model, and sensor data to guide an operator to grade or dig accurately according to digital plans. It uses Global Navigation Satellite System (GNSS) receivers with a correction source for centimetre-level accuracy, calibrated sensors on the machine’s moving parts, and in-cab displays to show the operator where to move the bucket relative to the design.
Increased uptake
While African contractors generally lag behind their European counterparts in terms of adoption of machine control systems, Uys is encouraged by the growing uptake in southern Africa. Central to this uptake, he says, is principally the shortage of skilled operators. For example, there is a widely recognised shortage of highly-experienced and final-level specialist grader operators.
This scarcity is not only unique to Africa, but is a global issue, particularly affecting industries such as construction, mining and roadworks, where qualified operators with ‘final cutting’ expertise are in short supply. The scarcity is driven by several factors, mainly an ageing workforce and the complexity of the skill.
“A significant number of older, experienced operators are retiring. Based on the research that I conducted recently, the average age of a final-level operator in South Africa is 63 years, while their cost-to-company package averages R85 000 per month. A major challenge is that as these ageing operators are retiring, there are fewer young people entering the field to replace them,” explains Uys.
The complexity of the skill, he adds, also makes it difficult to easily replace these skills and attract a new breed of operators. Achieving final-level or final-cutting expertise requires precision and years of practical experience, which cannot be quickly replicated by basic training alone.
The advent of machine control systems from leading suppliers such as Leica Geosystems has therefore changed the face of earthmoving operations, allowing the industry to address the critical shortage of qualified operators by offering enhanced features to simplify machine operation.
Another major challenge driving the uptake, especially in South Africa, is the stricter nature of SANRAL road projects. A few years ago, the national road authority introduced road rideability (ride quality) tests using various automated methods and specific indices, primarily the International Roughness Index (IRI). Meeting these stringent requirements can be a daunting task, but with the use of 3D systems, contractors can easily achieve the level of accuracy and precision required for rideability passes.
“From an accuracy perspective, with a basic GPS system, customers can expect up to 1,5 cm grading accuracy. If one needs to be better than that, a hybrid system – one that comprises GPS and a total station – a 5 mm grading accuracy can be achieved, highlighting the precision with which grading operations can be executed using these systems,” explains Uys.
Key markets and products
South Africa remains a major earthmoving equipment market in the region, and the uptake of machine control systems has over the years been “fair”, says Uys. Interestingly, Zimbabwe is leading the uptake of the technology, with most of the major road construction contractors in the country using the Leica Geosystems technology.
Zimbabwe is currently experiencing a significant road construction and rehabilitation boom, driven by the government’s renewed focus on road infrastructure, involving the upgrading of major highways to improve connectivity, boost trade and stimulate economic growth. According to Uys, no major road construction in the country has been undertaken without machine control technology, with Leica Geosystems delivering about 90% of the systems deployed on all major highways to date.
Some of the major Zimbabwean contractors making use of Leica systems include Bitumen, Masimba and Tensor Systems. In a case study conducted by Masimba in 2024, the company concluded that the use of a Leica grader control system was saving them a ‘whopping’ US$25 000 per kilometre of road.
“While these solutions seemingly come at a premium initial capital investment, which often scares some contractors away, the quick return on investment (ROI) justifies the expense,” says Uys. “Using the Masimba case study, where the company is saving US$25 000 per kilometre of road, the system can literally pay for itself in 2-3 km of road constructed. The longevity of these systems is also unmatched. To provide context, a Leica system installed in a harsh salt harvesting application in Namibia has outlived three earthmoving machines and still going strong.”
Prominent solution
While Leica Geosystems offers a comprehensive range of solutions, the big seller at this stage is the Leica iCON grade iGG3 Dual GNSS Grader solution, confirms Uys. The system uses GNSS or robotic total stations to provide millimetre-accurate control and enable operators to work independently with 3D design surfaces inside the cab.
The iGG3 system dramatically increases productivity and optimises material usage on fine-grading jobs by providing precise, automatic control of the blade, thus minimising rework. Another key feature is its user friendliness – it uses the common Leica MC1 software platform, which has an intuitive user interface designed for ease of use, reducing the learning curve and operational errors.
Amid the industry’s quest for data-driven decisions, the system interfaces with Leica ConX, a cloud-based platform for easy data transfer from office to machines, remote support, fleet management and productivity analysis.
In conclusion, Uys says the benefits of using Leica Geosystems machine control systems abound and adoption is a ‘no brainer’ for contractors seeking to improve their profitability. “Using Leica Geosystems machine control systems helps to improve accuracy, increase efficiency, reduce costs and enhance safety on job sites. Tasks are done correctly the first time, minimising rework. This leads to faster project completion, better profitability, and a more competitive business,” states Uys.
