The critical role of support blocks in mining maintenance
Heavy machinery maintenance in mining is one of the highest-risk activities in any operation. Trucks weighing 250 tonnes, excavators over 400 tonnes, and front-end loaders exceeding 100 tonnes require reliable temporary support every time components such as engines, transmissions, differentials, or axles are removed. The choice of support system — whether Stacko™ modular blocks, Timba™ blocks, or Tray Support for truck trays — is a decision that directly impacts maintenance personnel safety.
According to the European Agency EU-OSHA, between 14% and 17% of workplace accidents are maintenance-related. In the Peruvian mining context, where the Ministry of Energy and Mines recorded 17 fatal accidents in 2024, every improvement in workshop processes can mean the difference between an incident and a safe operation. This guide analyzes the technical criteria that should be evaluated when selecting support blocks for mining workshops.
Technical criteria for evaluating a support block
Not all support blocks are the same. When evaluating options for a mining operation, the following technical criteria should be prioritized:
- Certified load capacity: the block must have a documented rated load under a recognized standard. Without certification, there is no way to verify that the support will withstand the component weight. The Australian standard AS1170.0:2002 (structural loads) and the ASTM D1621-10 standard (cellular material compression) are the most widely used references in the industry.
- Known safety factor: a 3:1 safety factor means the block was tested to withstand three times its rated load without failure. This data must be backed by a test certificate, not by an unsupported manufacturer claim.
- Operating temperature range: mining operations in Peru span from the coast (up to +40°C) to the highlands (down to -15°C). The block material must maintain its mechanical properties across this entire range. Timber, for example, has no verified performance data at extreme temperatures.
- Chemical resistance: mining workshops expose supports to hydraulic oils, diesel fuel, water, and solvents. The material must be resistant to absorption and degradation from these agents.
- Weight and ergonomics: a lighter block reduces the risk of musculoskeletal injuries during handling. The difference between a 12 kg timber block and an 8 kg engineered alternative is significant when building support towers multiple times per day.
Timber: the traditional option and its limitations
Timber has been the default support material in mining workshops for decades. Its availability and low initial cost make it attractive, but it has fundamental technical limitations that make it increasingly unacceptable in modern operations:
Timber strength varies enormously depending on the species, moisture content, grain orientation, and storage conditions. It is not possible to assign a repeatable and verifiable load capacity to a generic timber block. This means that every time a timber block is used, one is relying on an estimate, not on engineering data.
Additionally, timber absorbs liquids (oils, fuels, water), swells, shrinks, and develops internal cracks that are not externally visible. In high-altitude environments with freeze-thaw cycles, this degradation accelerates significantly. Timber also produces splinters during handling, an additional ergonomic risk that requires the use of protective gloves.
From a regulatory standpoint, timber does not meet the documentary traceability requirements demanded by the "Zero Harm" policies of major mining companies. There is no test certificate backing its use as temporary structural support.
Engineered polymer: the certified alternative
Engineered polymer blocks represent the technical evolution of temporary support in mining workshops. Manufactured from materials such as rigid industrial polyurethane or UV-stabilized virgin polymer, these blocks offer certified load capacities, documented safety factors, and consistent batch-to-batch performance.
In this category, two products from National Plastics & Rubber (NPR) of Australia have become the global industry reference:
- Stacko™ Blocks: modular interlocking block system made from virgin polymer. Each block weighs 8 kg and supports up to 23,000 kg individually. In tower configuration with top plate, it reaches 60,000 kg with a certified 3:1 safety factor under AS1170.0:2002. Operates from -50°C to +40°C. UV-stabilized for outdoor storage.
- Timba™ Blocks: rigid industrial polyurethane blocks designed as a direct timber replacement. Rated load of 30 kg/cm² certified under AS1170.0:2002 and ASTM D1621-10. Available in three series (100, 200, and 300) with capacities from 18 to 108 tonnes depending on the model. They do not splinter, do not absorb liquids, and are reusable for years.
Both products are manufactured in Australia from virgin raw material (not recycled), ensuring consistency in mechanical properties between batches. Unlike recycled plastic blocks, whose composition varies and can exhibit deflections of up to 20% under load, Stacko™ maintains deflection below 2%.
Technical comparison: timber vs engineered polymer
The following table summarizes the key technical differences between available support options:
- Load certification: Timber: no certification | Engineered polymer (Stacko™/Timba™): certified under AS1170.0:2002 and ASTM D1621-10.
- Safety factor: Timber: unknown | Stacko™: certified 3:1 with RE16081 test results.
- Operating temperature: Timber: no verified data | Stacko™/Timba™: -50°C to +40°C tested.
- Liquid resistance: Timber: absorbs oils, fuels, and water | Polymer: resistant, non-absorbent.
- Service life: Timber: weeks to months | Polymer: years of continuous use.
- Traceability: Timber: no documentation | Stacko™/Timba™: test certificates for OHS audits.
- Ergonomics: Timber: heavy, produces splinters | Polymer: up to 30% lighter, no splinters.
Implementation considerations in Peru
Peruvian mining operating conditions present specific challenges that favor the use of engineered polymer blocks. Sierra operations at altitudes above 4,000 masl face temperatures that can drop to -15°C overnight and freeze-thaw cycles that destroy timber within weeks.
The "Zero Harm" policies adopted by Peru's major mining companies (including Komatsu, Marcobre, and GoldFields) require verifiable documentation for all equipment used in maintenance tasks. NPR's test certificates provide exactly that traceability, simplifying safety audits and demonstrating compliance to OSINERGMIN and Sunafil.
In Peru, Stacko™ and Timba™ are exclusively distributed by Endeavant S.A.C., which provides technical advisory for configuration selection based on machinery type and operating conditions.
Conclusion: verifiable safety, not estimated
Choosing a support block for heavy machinery maintenance should not be based on tradition or immediate availability. It should be based on engineering data: certified load capacity, documented safety factor, and proven performance under actual operating conditions. For a detailed analysis of Stacko™ and Timba™ in the Peruvian context, read our article on mining safety with Stacko and Timba. Timber belongs to an era before mining safety standardization.