A new crawler developed for Debmarine Namibia’s flagship vessel, Benguela Gem, is setting new standards in marine diamond recovery. After nearly four years of development by Upstream Technology in Cape Town, the crawler has been installed and is now operating off Namibia’s coast. A second identical unit is already under construction to ensure seamless operations during servicing periods, minimizing downtime.
According to project manager Rudi Agostinho, the crawler represents a fusion of automation, precision engineering, and decades of operational experience. The upgrade allows Benguela Gem to increase recovery rates by around 20% while keeping operating costs stable, unlocking the full potential of the vessel’s onboard treatment plant.
The crawler is significantly larger than earlier versions, weighing 370 tonnes and measuring 28 meters in length, with a mining arm capable of sweeping a 21-meter arc in just 25 seconds. Operating at depths of 100 to 135 meters, it draws diamond-bearing material through an 800 mm pipeline, supported by powerful new systems.
Key design advances include a hydraulic track tensioning system that automatically adjusts to operating conditions, reducing wear and extending the lifespan of key components. Automation plays a central role, embedding consistent best-practice performance while reducing stress on the machine, extending its service life, and enabling smoother deployment from the vessel. A forward-looking sonar system further improves recovery precision by giving operators clear seabed imagery.
The build process itself drove new innovations at Upstream Technology’s Cape Town facility. Engineers perfected synchronized crane lifting to install the 47-tonne dredge motor, while logistics teams carefully managed the crawler’s transfer to the harbour, where a 750-tonne crane hoisted it onto the quay. Before deployment, full-scale land simulations tested every system under realistic loads, with over 2.2 km of cabling and 10,000 connections individually verified. Close collaboration with Debmarine Namibia’s crew ensured operational insights were integrated into the final design.
Agostinho notes that the crawler delivers a resilient platform for the future of marine diamond recovery, combining automation, adaptive systems, and predictive maintenance to achieve higher throughput, greater consistency, and reduced downtime even in challenging environments.
