Differentiators that are relevant and meaningful to our clients

Shermac design and manufacture custom-built water cartage and support vehicles for the mining, civil and commercial sectors. While manufacturing is based in Western Australia, through a national footprint of support offices, we serve customers Australia-wide. 

Shermac has designed, engineered and fabricated products for some of the worlds’ largest mining and civil engineering contractors, including BHP, Rio Tinto, Fortescue, Thiess, Komatsu and Alcoa. Much of this work has been to address highly specialised requirements demanding one-off engineering solutions to operate in some of the most hostile environments on earth. 

In addition to corporates and multinationals, Shermac has successfully completed a large number of projects for smaller and owner-operated businesses. 

Shermac believe it is entirely reasonable for a customers to ask “Why should we use Shermac?” 

Shermac CEO, Mike Ray says,”We must differentiate ourselves on dimensions that are relevant and meaningful to our clients. Based on our experience, there are three key dimensions that are important to our clients – minimising supply risk, eliminating operation risk and lowest lifetime cost of ownership”. 

Minimising supply risk 

One-stop describes an end-to-end process that takes a service from beginning to end and delivers a complete functional solution. Shermac is a partner that can see a project through from beginning to end, and supply everything needed to create a workable solution.  

Shermac’s in-house capabilities include design and engineering, procurement, complete fabrication capabilities including assembly, testing, hydraulic engineering, auto electric, paint and commissioning, and extends to transport, delivery, operator training, after-sales support and parts.  

From Shermac’s perspective, this end-to-end capability is the realisation of a philosophy that helps to optimise the performance and efficiency of the business by eliminating the middle-man and provides a much more predictable cost base with complete control over quality and improved management of project timelines.  

From a customer perspective, it means that Shermac has a complete and unbroken line-of-sight from initial concepts through to final delivery and has full accountability for every aspect of the project.  

While many contractors may argue they have one-stop capability, this often only applies to fabrication of standard, off-the-shelf products, and any level of customisation will require extensive use of third parties for design, sourcing and fabrication, with the resultant loss of control and breakdown of the accountability trail. 

Eliminating operational risk 

Shermac was founded on the understanding that the operational needs and operating environments of customers were so diverse that standardised equipment did not offer them sufficient flexibility, and while customers were looking for customised equipment options, these were not available in the equipment manufacturers marketplace. 

Customisation ensures Shermac equipment is fit-for-purpose, optimising productivity, utilisation and effectiveness, and minimising operational risk for our customers. 

The Shermac team has a deep understanding of operating in remote areas of Australia, so we can relate to the tough conditions that customers deal with on a daily basis, and the company has unprecedented experience in custom-built, fit-for-purpose and lowest cost of ownership service vehicles for mining, civil and commercial environments.  

Lowest total cost of ownership 

Total cost of ownership (or TCO) includes the purchase price of a particular asset plus all operating, service, maintenance and repair costs over the asset’s lifespan, including cost of disposal and residual value on disposal.  

For assets with a long service life, the initial up-front cost of a product is often only a small part of TCO and purchasing managers know that while good procurement is achieving the right price, best value for money is the lowest lifetime cost.  

While minimising lifetime operating and asset care costs requires best practice by management, the manufacturer can make a significant contribution to TCO through quality design, engineering and product build. There are three critical factors in managing TCO to minimise the incurred cost of operations and maintenance. 

The most crucial factor in minimising TCO is to ensure that operating practices adhere absolutely to operations within the asset’s designed operating envelope. This highlights the critical importance of customisation to ensure that each asset is designed to perform a specific range of work and bound by a specific range of inputs and outputs.  

A second critical requirement is effective operator care. The operator plays a vital role in controlling total cost of ownership as properly maintained assets require less energy, can consistently maintain rated performance and generate near perfect product quality. Shermac design and engineer equipment to ensure that operator maintenance can be performed quickly and easily including ‘self-reporting’ products that alert the operator to maintenance needs.  

Finally, in conjunction with proper operation, effective asset care has a direct impact on total cost of ownership, including preventative maintenance, scheduled replacements and periodic rebuilds. Again, Shermac’s focus on details such as chassis selection, product selection and durability, ease of access and maintenance and availability of spare parts all contribute to effective asset care.  

Shermac’s end-to-end capability allows us to relentlessly focus on customisation, operator maintenance and asset maintenance ensuring lowest lifetime cost of ownership and maximising value for our customers. 

The globalised mining industry is a competitive space. Operators are continually looking to achieve higher production rates by utilising more reliable equipment with higher performance capabilities. The mining industry is a punishing environment and equipment is subject to degradation from the moment it enters service. 

Total cost of ownership (or TCO) represents the total cost required to own and operate equipment and includes the purchase price plus all operating, service, maintenance and repair costs over the asset’s lifespan, including cost of disposal and residual value on disposal.  

Given all of these factors, a key question for maintenance and asset managers is when to replace equipment to minimise cost? The optimum replacement age of equipment is defined as the time at which the total cost is at its minimum value. To keep equipment operating past this point will increase total costs and result in negative economic consequences. 

TCO analysis helps decision makers justify equipment replacement on the basis of total costs over the equipment’s useful life and allows the maintenance manager to specify the optimal replacement date at the time of equipment purchase. 

The timing of retiring equipment assets and replacing with new equipment is carefully planned and there is a long lead time for decision-making. 

Failure to effect a change over as planned might have significant financial consequences as the operator might have to perform expensive maintenance and rebuilds that cannot be fully amortised by the time the equipment is replaced. 

Shermac are wise to this issue and understand the critical importance that maintenance and asset managers attach to delivery timing. 

Shermac has been providing customised, engineered-for-purpose service vehicles and water carts to the resource sector for two decades. Over this time, Shermac has evolved into a ‘one-stop shop’, that can see a project through from beginning to end, and supply everything needed to create a workable solution. 

Shermac’s in-house capabilities include design and engineering, procurement, complete fabrication capabilities including assembly, testing, hydraulic engineering, auto electric, blast/paint and commissioning, and extends to transport, delivery, operator training, after-sales support and parts. 

This end-to-end capability helps to optimise the performance and efficiency of the Shermac business by eliminating the middle-man and providing a much more predictable cost base with complete accountability for quality and project timelines. For customers, it means that Shermac has an unbroken line-of-sight from initial concepts through to final delivery that minimises delivery timing risk and supports total cost of ownership goals of maintenance and asset managers. 

Shermac has been providing customised, engineered-for-purpose service vehicles and water carts to the resource sector for two decades. Over this time, Shermac has evolved into a ‘one-stop shop’, and in this blog, we’d like to examine why this is important and how it benefits customers.

One-stop describes an end-to-end process that takes a service from beginning to end and delivers a complete functional solution. Shermac is a partner that can see a project through from beginning to end, and supply everything needed to create a workable solution.

Shermac’s in-house capabilities include design and engineering, procurement, complete fabrication capabilities including assembly, testing, hydraulic engineering, auto electric, blast/paint and commissioning, and extends to transport, delivery, operator training, after-sales support and parts.

From Shermac’s perspective, this end-to-end capability is the realisation of a philosophy that helps to optimise the performance and efficiency of the business by eliminating the middle-man and provides a much more predictable cost base with complete control over quality and improved management of project timelines.

From a customer perspective, it means that Shermac has a complete and unbroken line-of-sight from initial concepts through to final delivery and has full accountability for every aspect of the project.

While many contractors may argue they have one-stop capability, this often only applies to fabrication of standard, off-the-shelf products, and any level of customisation will require extensive use of third parties for design, sourcing and fabrication, with the resultant loss of control and breakdown of the accountability trail.

There are two key elements here. Customisation is the norm and is critical as vehicle design must reflect the specific operational needs for the unique environment of the customer. Customisation is not just tinkering with standard designs and configurations. It means ground-up design that reflects the specific operational needs and unique operating environment of the customer.  When it comes to service vehicles, one-size definitely does not fit all.

If, for example, a client’s operational needs demand a non-standard hydraulic system that required the services of a third-party contractor, and there was a subsequent issue with the system, it can be a nightmare for the client to identify and contact the contractor for documentation, servicing and repairs. With Shermac, all these processes are completed in-house by our team of specialists, meaning one point of call for the client if there are any queries down the track.

For Shermac, customisation is part of our DNA and the natural accompaniment to customisation is concept-to-delivery engineering and manufacturing capabilities. Not only does this ensure a product that is designed to perform as intended within defined parameters, it also ensures complete control over quality and project timelines while ensuring transparency and accountability that minimises buyer risk and minimises total cost of ownership.

Customisation 

Shermac has been building customised, engineered-for-purpose service trucks and other service vehicles for the resource sector for two decades. Customisation is not just tinkering with standard designs and configurations. It means ground-up design that reflects the specific operational needs and unique operating environment of the customer.  

Customisation requires a desire to understand the specific challenges faced by a customer, a deep-seated intellectual curiosity to look for ways to solve problems and do things better, and concept-to-delivery engineering and manufacturing capabilities. Our engineers and designers seek input from all stakeholders including operators, supervisors and maintenance staff to get a detailed understanding of performance objectives and operating environment. 

Innovation 

The mining support vehicle market is highly competitive and is congested with options for buyers. At Shermac we believe we cannot stand still, and so innovation is part of our DNA. 

We are focussed on supporting asset and maintenance managers and protecting them from the risk of unnecessary and costly downtime. We thrive on complexity as this is where the problems lie. Complexity helps us to surface all the issues and to apply our problem-solving and innovation skills to solve every potential challenge faced by our customers. 

Safety 

At Shermac we say, “safety is engineered in; hazards are engineered out”. An operator of a service vehicle will visit a number of different locations during the course of a shift and will perform a range of service tasks and Shermac are relentlessly driven to create safer operating systems and improved operator ergonomics. 

Operator ergonomics 

The most common task performed by an operator is refuelling and an operator might be required to access the hose reel up to 50 times per day.  While many service vehicles have hose reel access above shoulder height, Shermac position the hose reel as low as possible at an ergonomic height for handling and reduce the risk of shoulder injuries. 

On many service vehicles, filters are located behind the hose reels and operator access is difficult. Shermac service vehicles are designed to position pumps and filters away from hose reels and be accessible from the opposite side of the truck. The result is that operators performing routine maintenance tasks on their vehicles are no longer working in a confined space, improving task efficiency and reducing risk.  

Safe systems 

Grease is essential for lubricating heavy production machinery, but because of its high viscosity, grease injection systems operate under high pressure. Our optional remote-controlled grease pressure release system is a good example of system safety, as it allows the operator to immediately relieve pressure in the grease line and eliminate the risk of grease injection injuries. 

Lowest risk 

We look at risk through the eyes of our customers and we actively minimise design and engineering risk, delivery risk and performance risk. This means that customers get a custom designed and engineered product on-time, on-budget and as-specified, that is entirely fit-for-purpose and ready to do the job it is expected to do. The Shermac design process is fastidious and seeks inputs from all stakeholders, fabrication and testing is fully transparent, and documentation and handover is extremely comprehensive. At the time the asset is put into service, owners can be assured that the equipment is designed and fabricated in accordance with its required operating envelope.   

Lowest cost of ownership 

The total cost of ownership (or TCO) includes the purchase price of a particular asset plus all operating, service, maintenance and repair costs over the asset’s lifespan. With a long service life, the initial up-front cost of a product is often only a small part of TCO and purchasing managers know that while good procurement is achieving the right price, best value for money is the lowest lifetime cost. 

The most crucial factor in minimising TCO is to ensure that operating practices adhere absolutely to operations within the asset’s designed operating envelope. This highlights the critical importance of customisation to ensure that each asset is designed to perform a specific range of work and bound by a specific range of inputs and outputs. 

A second critical requirement is effective operator care. The operator plays a vital role in controlling total cost of ownership as properly maintained assets require less energy, can consistently maintain rated performance and generate near perfect product quality. Shermac design and engineer equipment to ensure that operator maintenance can be performed quickly and easily including ‘self-reporting’ products that alert the operator to maintenance needs. 

Finally, in conjunction with proper operation, effective asset care has a direct impact on total cost of ownership, including preventative maintenance, scheduled replacements and periodic rebuilds. Again, Shermac’s focus on details such as chassis selection, product selection and durability, ease of access and maintenance and availability of spare parts all contribute to effective asset care. 

Experience 

Established in 2002 and an Australian family-owned business, Shermac has unprecedented experience in custom-built, fit for purpose and lowest cost of ownership service vehicles for mining and civil environments.  

The Shermac team has a deep understanding of operating in remote areas of Australia, so we can relate to the tough conditions and environment customers deal with on a daily basis. 

With our global procurement network and concept-to-delivery engineering and manufacturing capabilities, we have the resources and expertise to design and build individual vehicles or entire fleets for any industry, operational requirement, or environment. We operate from our state-of-art manufacturing facility in Western Australia, and we are constantly updating our processes to keep up with the latest equipment and technological advances to maximise efficiency. 

The crucial part of our process is the ability to listen to our customers, build relationships, and design solutions that best suit our clients’ needs and requirements.  

That’s it. That’s why we’re successful. 

Total cost of ownership (or TCO) includes the purchase price of a particular asset plus all operating, service, maintenance and repair costs over the asset’s lifespan, including cost of disposal and residual value on disposal. 

Whole of life costs can be categorised into purchasing, operating and disposal, and might include the following: 

Purchasing 

Developing a business case, the tender process, purchase price of equipment, delivery costs, staff training and annual insurance.

Operating & Asset Care 

Maintenance and servicing, spare parts, repair costs and consumables.

Disposal 

Decommissioning, transport away from the worksite, fees for disposal of parts and money received on sale.

With a long service life, the initial up-front cost of a product is often only a small part of TCO and purchasing managers know that while good procurement is achieving the right price, best value for money is the lowest lifetime cost.

While minimising lifetime operating and asset care costs requires best practice by management, the manufacturer can make a significant contribution to TCO through quality design, engineering and product build. There are three critical factors in managing TCO to minimise the incurred cost of operations and maintenance. 

The most crucial factor in minimising TCO is to ensure that operating practices adhere absolutely to operations within the asset’s designed operating envelope. This highlights the critical importance of customisation to ensure that each asset is designed to perform a specific range of work and bound by a specific range of inputs and outputs. 

A second critical requirement is effective operator care. The operator plays a vital role in controlling total cost of ownership as properly maintained assets require less energy, can consistently maintain rated performance and generate near perfect product quality. Shermac design and engineer equipment to ensure that operator maintenance can be performed quickly and easily including ‘self-reporting’ products that alert the operator to maintenance needs. 

Finally, in conjunction with proper operation, effective asset care has a direct impact on total cost of ownership, including preventative maintenance, scheduled replacements and periodic rebuilds. Again, Shermac’s focus on details such as chassis selection, product selection and durability, ease of access and maintenance and availability of spare parts all contribute to effective asset care. 

The net result is predictable and low lifetime cost of ownership of Shermac equipment, and outstanding value for money. 

Weight distribution  

Shermac has been providing customised, engineered-for-purpose service trucks and other service vehicles to the resource sector for two decades. Customisation is critical as vehicle design must reflect the specific operational needs for the unique environment of the customer. When it comes to service vehicles, it is quite apparent that one-size definitely does not fit all. 

A good example of Shermac’s approach to customisation is the critical matter of weight distribution that can be summarised in the following schematic: 

Operating environment 

If the vehicle will be used on public highways, weights are limited by both the technical weight the vehicle can carry as specified by the manufacturer, and the legal restrictions as defined in the relevant road transport legislation. For instance, on the highway the allowable weight on a single front axle is seven tonnes but the vehicle’s technical weight limit might be twelve tonnes. Even though the truck is designed to carry the higher weight, it is illegal to do so on a public road. 

For exclusively off-road use, weights are limited solely by the manufacturers technical weight limit, and these will typically be higher than the on-road limits. For off-road applications, an understanding of site conditions is critical to determining chassis and configuration. 

Intended use 

The intended use of the vehicle will determine the number and type of tanks, the fluid volumes to be carried and the configuration of delivery systems. In addition, items such as roll-over protection, bull bars and tools all add weight that must be considered in load and distribution calculations.  

Chassis 

Once all the critical operating parameters are understood, the appropriate chassis can be determined. Off-road specifications vary greatly; for example, one 8 x 4 chassis may have double the carrying capacity of another, and this might be the difference between carrying 10,000L or 15,000L of fuel and result in significant changes in vehicle uptime and productivity. 

Custom Configuration 

A manufacturer of standard service vehicles has a severe disadvantage when it comes to weight distribution. Mounting a standard body on any given chassis eliminates the capability to optimise design and configuration, and ultimately this impacts compliance, productivity and utilisation, and, potentially, safety. 

Shermac engineers utilise technology that allows them to exactly measure vehicle load and to ensure that the load is properly distributed between the axles.  

Weight distribution and compliance is verified at several stages in the Shermac customisation process. An initial weight report is submitted at quotation, another is submitted at completion of detailed design and engineering, and a final weight report is submitted pre-delivery. This is a precise art as the smallest shift can move a service vehicle from compliance into non-compliance. 

In addition to weight distribution, Shermac engineers ensure that operator ergonomics, safety and productivity are all optimised ensuring the highest level of performance. 

Customisation requires an understanding of the specific challenges faced by any customer, a deep-seated intellectual curiosity to look for ways to solve problems and do things better, and concept-to-delivery engineering and manufacturing capabilities.

MINE SPEC Industries was established in April 2014 to provide maintenance solutions for mobile and fixed plant in the mining, industrial and transport industries. Services include transport and logistics, equipment procurement, wet and dry equipment hire and project management. 
 
MINE SPEC Industries will inspect, maintain, diagnose, repair and overhaul mobile and fixed plant and equipment such as work platforms, lighting towers, material handling equipment and on / off road vehicles of all types and descriptions. MINE SPEC personnel will perform these services at client facilities, on job sites or at one of its service centres. 

MINE SPEC has experienced tremendous growth since start-up and, in part, its success has been attributable to the decisions the company has made about the equipment it uses to service its customers, and a strong focus on achieving uptime, productivity and utilisation goals. 

When MINE SPEC wanted to procure a service vehicle for its rental fleet, they were introduced to Shermac through a business associate who invited them to inspect Shermac equipment that they owned. 

Jason Tatchell from MINE SPEC said “We were extremely impressed with our findings and while we investigated multiple options, it was the Shermac product that outshone the competition, and nothing came close to the customer service and build-quality that Shermac offered us” 

Shermac has been providing customised, engineered-for-purpose service vehicles to the resource sector for two decades. Customisation is critical as vehicle design must reflect the specific operational needs for the unique environment of the customer. MINE SPEC are no different and had specific customisation requirements, and Jason commented “Shermac communicated with us constantly and implemented any custom requirements that we needed with ease” 

The vehicle was delivered in-time and on-budget, and Jason noted, “the equipment successfully solved the specific challenges and business needs that MINE SPEC wanted to address” adding, “We have been involved with the hire industry since 1991 and the Shermac product is the best on the market in our opinion and in our experience thus far. We are now experiencing less downtime due to a superior product being used in harsh and hostile working environments. Nothing else comes close” 

Jason concluded, “Shermac were professional and instrumental in seeking a fast solution to the issue at hand. This support and service has ensured that Shermac are our preferred heavy vehicle and body provider for our operations here in South Australia” 

Oil spills on mining, construction, and civil sites are often associated with static fuel storage. However, many spill risks actually arise during routine field servicing operations.

Service vehicles carry and dispense large volumes of diesel, oils, and other fluids, making their design critical to environmental protection. Understanding where spills occur, how bunding applies to mobile equipment, and what to look for in a purpose-built service vehicle can help reduce risk, improve compliance, and protect site productivity.

Why oil spill risks in service vehicles are different in static tanks

When people think about spill containment, they typically think about fuel farms, bulk storage tanks, and other fixed infrastructure. As a result, Australian bunding standards have largely been developed around static storage systems rather than mobile equipment.

Service vehicles operate in a very different environment. They travel across rough terrain, are exposed to constant vibration, and regularly transfer diesel, oils, coolants, and other fluids directly to equipment in the field. Every servicing task creates multiple connection points where leaks or spills can occur.

This creates a unique challenge for fleet operators. While static tanks remain in a controlled location, service vehicles must safely transport, store, dispense, and recover fluids across constantly changing site conditions.

Importantly, the greatest spill risk isn’t usually the storage tank itself. In most cases, spills are more likely to occur during fluid transfer and servicing activities. That’s why effective spill prevention relies on more than tank design alone. It requires careful consideration of pumps, hoses, filters, waste oil systems, and containment measures throughout the vehicle.

Where oil spills usually occur on service vehicles

Pump and fluid transfer systems

Pumps are responsible for moving diesel, oils, coolants, and other fluids throughout the vehicle. As high-use mechanical components, they are subject to wear over time. Damaged seals, fittings, or pump failures can result in leaks if not properly contained.

What to look for:

• Bunded pump compartments
• High-quality pumps and fittings
• Easy access for inspection and maintenance
• Clear separation between fluid systems

Hoses, reels, and connections

Hoses and reels are regularly exposed to vibration, harsh weather, abrasion, and frequent handling. Connections can loosen, fittings can wear, and hoses can become damaged during normal operations. Because these components are directly involved in fluid transfer, even minor failures can lead to spills.

What to look for:

• Protected hose routing
• Heavy-duty hose reels
• Quality fittings and couplings
• Secure connection points designed for field use

Filters and waste oil handling

Servicing activities often involve changing filters and collecting used oils. If these materials are not managed correctly, residual oil can drain onto the ground long after the servicing task is complete. Waste oil handling systems play a critical role in preventing contamination and maintaining a clean work area.

What to look for:

• Dedicated waste oil collection systems
• Filter storage and drainage solutions
• Easy-to-clean service areas
• Integrated spill containment measures

How purpose-built service vehicles reduce spill risk

Effective spill prevention requires a practical understanding of where spills are most likely to occur and engineering the vehicle accordingly.

Purpose-built service vehicles are designed with containment, fluid management, and operator usability in mind. Rather than focusing solely on storage tanks, they incorporate systems that help reduce risk throughout the servicing process.

Small service vehicles and trailers

In smaller service vehicles and service trailers, individual storage tanks can be housed within a chassis-mounted collective bund. At Shermac, these bunds are designed with a capacity equal to 110% of the largest single tank, providing containment in the unlikely event of a tank failure.

This approach offers an effective balance between environmental protection, vehicle weight, and operational practicality.

Large mining service vehicles

The same approach isn’t always practical on larger mining service vehicles. Many units carry between 15,000L and 20,000L of diesel fuel, and providing a bund with a capacity equal to 110% of the largest tank would significantly increase the vehicle’s empty weight.

In some cases, this could reduce fuel carrying capacity by as much as 50%, limiting the vehicle’s operational effectiveness and increasing the number of refuelling trips required on site.

Because storage tank failures are relatively uncommon, a more practical approach is to focus containment around the components that present the highest spill risk.

Bunding high-risk areas

Rather than attempting to fully bund large storage tanks, purpose-built service vehicles often incorporate bunded pump and reel compartments where fluid transfer activities take place.

At Shermac, these compartments typically provide approximately 1,000L of containment capacity, helping capture potential leaks caused by pump, hose, reel, or fitting failures. By concentrating containment where spills are most likely to occur, operators can achieve a higher level of environmental protection without compromising vehicle performance.

Dedicated filter management systems

Used filters can continue draining oil long after a servicing task has been completed. Without proper containment, this residual oil can easily find its way onto the ground.

To help manage this risk, Shermac service vehicles and trailers include dedicated filter bins that allow used filters to drain directly into the waste oil tank. This keeps servicing areas cleaner, improves waste management practices, and further reduces the likelihood of environmental contamination.

Why improvised servicing methods create environmental risk

Not every maintenance task is performed using a purpose-built service vehicle. On construction sites, civil projects, and remote worksites, equipment is sometimes serviced using drums, funnels, collection trays, and other improvised methods.

While these approaches may appear convenient, they introduce significantly more opportunities for spills and contamination.

Unlike purpose-built service vehicles, improvised servicing setups often lack integrated containment systems, dedicated waste oil collection, and controlled fluid delivery equipment. This increases reliance on manual handling and creates more opportunities for leaks, overflows, and operator error.

Common risks associated with improvised servicing methods include:

• Oil spills during fluid transfer
• Overflowing collection trays
• Poor waste oil management
• Used filters draining directly onto the ground
• Contamination of soil and waterways
• Increased clean-up and remediation requirements

Even relatively small spills can have significant consequences on active mining, construction, and civil sites. Environmental incidents can result in costly clean-up activities, project disruptions, regulatory scrutiny, and reputational damage.

Purpose-built service vehicles help reduce these risks by providing controlled fluid delivery, integrated waste collection systems, and engineered containment measures that support safer, cleaner servicing practices.

Reduce spill risk through better service vehicle design

Reducing the risk of oil spills starts with understanding where spills are most likely to occur and choosing equipment designed to manage those risks effectively.

If you’re evaluating service vehicles for your fleet, speak with the Shermac team. We can help you identify the right configuration for your site, operational requirements, and environmental objectives.

Explore our range of mine-spec service trucks or contact our team to discuss a custom-engineered solution.

Shermac engineer safety in and hazards out 

An operator of a service vehicle will visit a number of different locations during the course of a shift and will perform a range of repetitive service tasks. The most common task is refueling, and the link between the service vehicle and the equipment to be refueled is the fuel hose, and an operator might be required to access the hose reel up to 50 times per day. 

Because refueling volumes are large, they need high capacity delivery systems and fuel hoses are often heavy and large hoses that may be 15 metres or more in length. The challenge of handling heavy hoses increases when working in hilly terrain or on soft surfaces that are common on mines sites. 

The constant need to roll-out and rewind the hose reels present a potential ergonomic risk to the operator of repetitive strain injury. The process is further exacerbated by the need to keep the discharge nozzle clean to prevent contaminants entering the fuel tank. 

To minimise the risk of repetitive strain injuries, Shermac actively optimises operator ergonomics on all its vehicles. 

While many service vehicles have hose reel access higher than shoulder height, Shermac position the hose reel as low as possible,at an ergonomic height for handling and reducing the risk of shoulder injuries. 

Lightweight hoses might have a spring rewind system, but this is not suitable for fuel hoses as the spring tension required to rewind a long, heavy hose increases the effort required for an operator to pull out.  

The typical Shermac fuel hose has a manual roll-out and hydraulic or pneumatic assisted rewind. On roll-out, the hose clutch is disengaged and the reel free-wheels for easy delivery, and the powered rewind does all the rewind work. 

Once refuelling is finished, the operator has to walk back to the service vehicle holding the nozzle-end of the hose off the ground to prevent it getting dirty and leaving a loop of hose on the ground. Once at the vehicle, the operator activates the rewind switch and manages the rewind while all the time keeping the nozzle off the ground and clean. 

While this is an ergonomic solution, there is a better option available from Shermac. Once refueling is finished, the operator can activate the rewind via a remote rewind switch on a wrist-band and simply walks the hose reel back to the service vehicle. 

Continuous improvement is part of Shermac DNA, and future fuel delivery developments potentially include the use of fuel booms with short flexible hose lengths to further improve operator ergonomics and optimise productivity. 

These examples illustrate Shermac’s commitment to engineering safety in and hazards out and to maximise operator well being, vehicle up-time and productivity with predictable lifetime cost. 

On mining and civil sites, service vehicles are constantly in motion. They support critical equipment, respond to breakdowns, and keep operations running across large and often remote environments. The people operating these vehicles play a direct role in maintaining uptime, safety and productivity.

Yet the design of a service vehicle can either support the operator or work against them. Small engineering decisions influence how efficiently tasks are completed, how safely equipment is accessed, and how consistently performance is maintained across long shifts.

Understanding what operator ergonomics really means, and how it shapes day-to-day performance, is the first step toward building safer, more capable heavy equipment support vehicles.

What operator ergonomics means in heavy equipment operations

Operator ergonomics in heavy equipment refers to how a vehicle is designed to support the physical demands of daily servicing tasks. In mine-spec service trucks, operators spend extended hours driving between locations, accessing compartments, handling equipment and completing repetitive maintenance activities.

Practical ergonomics focuses on key design elements:

• Reach zones: How far an operator must extend to access controls, hoses or components.
• Control placement: How naturally tasks can be performed without twisting or overreaching.
• Visibility: Clear sightlines around machinery, personnel and the service area.
• Vibration management: Reducing long-term physical strain during operation and travel.
• Safe access systems: Minimising unnecessary handling when entering, exiting or working on the deck.
• Environmental factors: Conditions within and around the vehicle that influence overall usability.

When these elements are poorly considered, risk increases and performance suffers.

How poor operator ergonomics increases fatigue and injury risk

In heavy equipment servicing, small inefficiencies compound over time. Operators repeat the same movements across long shifts in mining and remote conditions. They open and close compartments, handle hoses, access tools and move between ground level and the service deck.

When vehicle design does not support these tasks, operators are exposed to:

• Awkward postures when reaching into poorly positioned compartments
• Repetitive actions that increase cumulative strain
• Musculoskeletal stress from constant bending, twisting and climbing
• Reduced concentration as physical fatigue builds
• Higher error risk when working around live machinery

Across extended shifts, the body’s ability to reduce strain diminishes. Fatigue increases. Focus declines. In high-risk environments, that combination directly impacts safety, servicing accuracy and overall site performance.

Engineering ergonomic improvements into daily workflows

At Shermac, operator ergonomics is engineered into every service vehicle from the initial design stage. Each build is shaped around real servicing conditions on mining and civil sites, where operators repeat tasks throughout long shifts in demanding environments.

Below are several examples of how this approach is applied across our mine-spec service trucks.

Lighter service doors that reduce repetitive strain

Service vehicle doors are opened and closed dozens of times per shift. In traditional builds, steel doors combined with gas struts require force to close, especially after repeated use.

That repetitive motion increases operator fatigue over time.

Shermac manufactures service doors from lightweight aluminium, reducing weight by approximately 66 percent compared to steel alternatives. The benefit is practical:

• Less force required to close doors
• Reduced repetitive strain across the shift
• Lower cumulative fatigue
• Improved operator comfort

A simple material change, engineered for long-term usability in harsh conditions.

Repositioned pumps and filters to eliminate awkward postures

In many service trucks, pumps and filters are positioned behind hose reels. Operators must reach into confined spaces to complete routine maintenance.

That layout creates:

• Awkward postures
• Overreaching
• Increased musculoskeletal stress
• Slower servicing workflows

Shermac separates pumps and filters from hose reel assemblies and positions them on the opposite side of the truck. This redesign delivers:

• Reach minimisation
• Clearer access to service components
• Reduced confined access risk
• Improved workflow efficiency

Operators can complete routine checks and maintenance in a more natural working position.

Permanent walk-in access that improves safety

Fold-down steps require repeated handling and introduce additional movement at every stop. In dusty or uneven site conditions, entry and exit risks increase.

Shermac incorporates a permanent walk-in access configuration designed to support safer access to the service deck.

This approach provides:

• Stable entry and exit points
• Better three points of contact alignment
• Reduced repetitive handling
• Safer access in dusty environments

The result is consistent, controlled deck access throughout long shifts on remote sites.

Environmental factors that affect operator comfort on site

Mining and civil environments introduce additional physical stress that directly affects operator ergonomics. Key environmental factors include:

• Dust and air quality: Fine particles entering cabins or compartments increase discomfort and distraction.
• Heat and air conditioning performance: High ambient temperatures elevate fatigue without effective cooling systems.
• Noise exposure: Constant equipment noise contributes to mental and physical strain.
• Vibration: Rough terrain and heavy equipment movement increase cumulative fatigue over long shifts.
• Remote site conditions: Extended travel distances and limited recovery time amplify physical demand.

Mine-spec vehicles must be engineered to manage these conditions through durable construction, effective sealing and well-designed enclosed compartments.

Removing high-pressure hazards through engineered design

Grease systems are essential for maintaining heavy equipment, but they operate under extremely high pressure. If a grease nipple becomes blocked, pressure can build in the line, increasing the risk of injection injuries when disconnecting the gun.

Shermac offers an optional remote-controlled grease pressure release system that allows operators to safely relieve line pressure before disconnection. This design eliminates unnecessary exposure to high-pressure hazards and reduces the risk of serious injury.

By engineering risk out of routine servicing tasks, operators are better protected, unplanned incidents are reduced, and downtime linked to injury or equipment damage is minimised. It also supports site WHS expectations around safe servicing practices.

Designing for safety, compliance and long-term uptime

Operator ergonomics directly affects how safely and efficiently your team can service equipment. When vehicles are engineered around real site conditions, tasks are completed with less strain and fewer delays.

Shermac mine-spec service trucks are designed to meet strict site requirements while supporting practical, operator-focused layouts. Every Shermac build follows ISO9001:2015 quality processes and is engineered for durability in harsh Australian conditions.

If you are reviewing your fleet or planning a new service vehicle, speak with our team.