INNOVATION & SUSTAINABILITY

75 YEARS ON... AND THE JOURNEY CONTINUES

Today, Rokbak articulated haulers can be found working in mines, in quarries, and in big construction projects all over the world, operating in all sorts of conditions and terrain, but their journey began in Motherwell in Scotland almost 75 years ago. Awesome Earthmovers recently had the opportunity to tour the manufacturing facilities where technological innovations and sustainable production processes are at the centre of this ever-evolving success story.

The Motherwell site has been producing off-road trucks since 1950, but the company has had several name changes in that time – from Terex Trucks in 2014 when it became part of the Volvo Group, and then to Rokbak in September 2021. Many of the company’s highly-skilled team have worked there for decades – like their parents and even grandparents before thembuilding trucks that are dependable and durable and can perform on the toughest job sites.

That bold step to rebrand almost three years ago, following investments totalling over £35 million together with big technological improvements after Volvo Construction Equipment’s acquisition, marked what was a major turning point in the company’s illustrious history.

It began when Euclid, originally founded by George A. Armington, created the first recognisable rear dump truck, the Model 1Z, in 1934. This pioneering machine was a heavy-hauling powerhouse – forging a path for the ground-breaking haulers that followed.

The 28 tonne Rokbak RA30 and 38 tonne Rokbak RA40 with advanced telematics were the first products developed under Volvo ownership and they have since undergone further refinements and improvements to become what are rock-solid articulated haulers that are meeting the needs of large-scale construction and infrastructure projects around the globe.

As we were shown round the factory, we couldn’t help but be mightily impressed by the expertise and skills of the workforce as they paid close attention to detail throughout each stage of the process to produce a truck that would then be subjected to a rigorous testing programme for durability and performance to ensure that only the best quality haulers reach the customer.

To put that testing in context, an average car undergoes around 43 checks at an MOT whereas a Rokbak hauler is subjected to over 200 final checks by a team of inspectors, a process that could take up to nine hours. In addition, the company has its own purpose built test track with sharp corners, inclines, dips and a rumble strip.

“It is here where our haulers are put through their paces to ensure they are fit for purpose before being shipped out. If any adjustments are required we take them back into the factory to do so before putting them through a final test on the track,” said Scott Pollock, Senior Product Manager.

“We also use the track as a demonstration area for our customers, who are looking for low cost of operation, which includes fuel consumption and high productivity, and they also want to be connected to the hauler which means remote monitoring – and they get all that with our Rokbak haulers.”

CUTTING EDGE ROBOTIC WELDING

In the fabrication area we met up with Product Manager Charlie Urquhart who spoke about the use of two stateof-the-art custom designed, cutting edge robotic welders that produce consistently strong welds with a high quality aesthetic finish. They can lay up to one metre of weld a minute – three times faster than an experienced human welder. It is a streamlined repeatable process which in turn gives a reduced cycle time of over 35%.

IAN GIBBONS PRODUCTION MANAGER ROKBAK

Not only are the welders more efficient but they use a lot less energy which contributes to the sustainability of the site here...

Without the robots, Rokbak would have struggled to meet demand as traditional skills such as welding and plating are in very high demand due to a shortage of skilled people across the UK. “Not only are the welders more efficient but they use a lot less energy which contributes to the sustainability of the site here,” said Charlie.

Indeed, when the customer buys a Rokbak hauler, they are acquiring a truck that has been developed with sustainability in mind. It is a hauler that has been manufactured on a site powered by green energy and redirects waste away from landfill.

Everyone from the factory floor to the head office has an eye on energy reduction. Internal trackers inform Rokbak employees how much energy has been used in comparison to the previous week and “green champions” are recruited from throughout the business to promote sustainable practices in their respective work areas.

“A lot of work has gone into our sustainability drive over the years. Our goal is to achieve zero waste to landfill; currently 95% of our waste is diverted from landfill. All our electricity is from renewal sources and we’ve made a lot of improvements throughout the site to reduce CO2 emissions,” added Charlie.

Fuel consumption, of course, is the biggest cost of operating a machine and the Rokbak RA30 and RA40 EU Stage V Scania engines produce a fuel consumption saving of up to 7%, when compared to the previous EU Stage IV engines. This means lower operating costs and, fundamentally, less impact on the environment, while Rokbak’s load-sense hydraulic system also saves energy and improves fuel efficiency when the hauler is in motion.

The engines can be fuelled with Hydrotreated Vegetable Oil (HVO) which has a fossil free composition and low carbon content, differentiating it from diesel to provide a market-leading option as a sustainable choice.

KEEPING TRACK WITH TELEMATICS

Rokbak haulers also now incorporate Haul Track telematics, a hard-working data-led system with advanced GPS technology enabling customers to pinpoint the hauler’s location and track its movements. It transmits real-time data to an internet connected device which can then be downloaded as reports and printed for safe keeping.

Essentially watching over the machine and protecting it from misuse wherever it is, Haul Track also provides detailed maintenance alerts which are sent directly to the customer’s email inbox in advance of the scheduled maintenance event. The alert email will direct the customer to the relevant Haul Track portal page to provide a list of specific machine items that require servicing or inspection, including part numbers and a link to the relevant pages of the maintenance manual. It also provides machine fault alerts.

Rokbak have also introduced an On-Board Weigh load system. This comes with a separate Human Machine Interface screen included which allows the operator to keep on top of their load. The OBW system connects to Rokbak’s advanced Haul Track telematics, giving the end user live payload data for enhanced productivity reporting.

GROWING GLOBAL MARKET

Over half of all articulated haulers that leave the Motherwell factory are currently destined for North America. The USA is the leading ADT market, with huge infrastructure spend and significant construction activity around house and road building across many of its 50 states.

The total articulated truck market for North America is usually around 3,500 units. However, the market recently exceeded 5,000 units over a rolling 12-month period, with the total global market exceeding 10,000 units in the same period.

Our goal is to achieve zero waste to landfill...

Rokbak’s easy to operate and maintain articulated haulers are also meeting the needs of large-scale construction and infrastructure projects across Europe where the manufacturer’s presence continues to grow, and its global network of dealers was recently strengthened when it partnered with Heavy Machinery Dealership, a premier provider of construction, mining and quarrying equipment in West Africa. The construction market in Africa is currently estimated at $58.42 billion and is expected to reach $74.81 billion by 2029.

West Africa's construction industry is, in particular, experiencing substantial growth, driven by urbanisation, infrastructure development and mining activities. This latest appointment will help bring Rokbak ADTs to an established customer base in Nigeria, Ghana, Senegal, Benin, Guinea and Cote d’Ivoire.

Our visit to the Motherwell factory, with its generations of experience and pride, left us in no doubt that Rokbak is working hard to create a sustainable future. As part of the Volvo Group it is aligned to the Science Based Targets initiative (SBTi). Specific aims include a 30% reduction in CO₂ by 2030, a 50% factory operations emission reduction by the same year and becoming net-zero by 2040. These incentives have influenced the design of Rokbak trucks, the daily operation of the Rokbak Motherwell factory and a strict adherence to the Rokbak sustainability roadmap.

ROKBAK