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An oddly titled, aggregates-hungry
Emirati megaproject
It may sound like a kind of flying dinosaur from the late Jurassic Period, around 150 million years ago, but an aerotropolis is nothing of the kind. Struggling for a concise definition to include in this column, I used my smartphone which told me, well, via Wikipedia, that an aerotropolis was “a metropolitan sub-region where the layout, infrastructure, and economy are centred on an airport which serves as a multimodal ‘airport city’ commercial core”
Now that’s settled I can explain the reason I’m highlighting the term. I recently read a very interesting article on how Volvo Construction Equipment haulers and loaders are among a huge array of construction machines and aggregates materials suppliers helping create the world’s biggest airport, currently taking shape in Dubai in the United Arab Emirates (UAE).
The US$32 billion expansion of Al Maktoum International Airport will see 140 million passengers pass through its doors by 2025. Following its completion in 2050, the airport will have the capacity to handle 200 million passengers a year – a world away from the paltry-by-comparison current seven million passenger capacity site, mainly used today for cargo traffic.
Al Maktoum International Airport will be a key part of what will be an aerotropolis named Dubai South. When completed, Dubai South will be home to 900,000 inhabitants, and, crucially, reachable within an eight-hour flight for two-thirds of the world’s population.
Dubai is hosting the World Expo in 2020 and the Expo area is being built next to the airport. The bulk of the Expo’s predicted 2.5 million visitors will travel through it.
Given Al Maktoum International Airport’s expansion and other large-scale infrastructure works in Dubai and other parts of the UAE, it is no surprise that the World Bank tipped the GDP (gross domestic product) of the nation comprising seven Emirati states to grow 2.5% in 2018. In its United Arab Emirates Economic Outlook, published in April 2018, the World
Bank says that UAE oil production capacity is likely to increase, and the strength of the non-oil economy will boost economic prospects as key infrastructure projects ramp up ahead of Expo 2020. All this is great news for the region’s aggregates producers and global quarrying equipment manufacturers.
Remaining in the Middle East, GlobalData, a leading global business market research consultancy, reports that Qatar’s economy has largely recovered from a boycott imposed in June 2017 by other Arab states, with economic growth returning in 2018. Construction activity remains resilient, largely thanks to government spending on major infrastructure projects. Construction work related to the 2022 FIFA World Cup will, says GlobalData, help support the country’s construction and aggregates sector growth over the next few years.
Although Saudi Arabia has been undergoing some nationwide fiscal belt-tightening in recent years, the country’s Vision 2030 programme continues. Vision 2030 aims to reduce Saudi Arabia’s dependence on oil, diversify its economy, and develop public service sectors such as health, education, infrastructure, recreation and tourism. Despite geopolitical tensions and fluctuating oil revenues, the emphasis on Vision 2030 has led to the continuation of megaprojects, including the Riyadh Metro and King Abdullah Economic City. The largely steadfast delivery of Vision 2030 is a big plus to aggregates producers who, understandably, have been finding it difficult to plot future income streams.
In the Middle East as a whole, Deloitte’s GCC Transportation Construction Report 2018 predicts that transport infrastructure spending will increase from $6.847 billion in 2018 to $7.509 billion in 2019. Dubai’s aerotropolis project is an example of how such increased investment can benefit such a pivotal and fascinating world region. I hope to visit the aerotropolis project at some stage in 2019. I hope I don’t return with a flying dinosaur in my suitcase! GW gwoodford@ropl.com
“The New Partnership for Africa’s Development (Nepad), an economic development programme of the African Union, notes that infrastructure is Africa’s top priority.”
Features
An
Wacker
African
19 AGGREGATES PRODUCTION
An eye-catching turnkey stationary plant first and a leading global aggregates processing brand’s big investment in production facilities
Global
All
SDLG’s new Indian market wheeled loader; Volvo CE’s Indonesian and UK quarry customer orders
With Germany currently a hotbed for infrastructure projects, Terex Trucks plans to capitalise with a new dealer for its ADTs and customer support in the north of the country 29
– PART 1
A leading global off-highway equipment tyre manufacturer has big plans for its recently inaugurated cutting-edge research laboratory
An MB attachment is helping to facilitate a complicated renovation scheme in Munich, Germany
A leading conveyor manufacturer has completed two giant projects for a Chinese cement firm, while others have been busy launching new models and opening new production sites
COVER STORY: Beumer has installed two giant conveying systems for Sichuan Yadong Cement, in Pengzhou, China
41 CONCRETE PLANT
A top European manufacturer has helped contractors tackle logistical and on-site challenges of concrete supply to a major Alps cable car scheme
Specials
08 INTERVIEW
on the GCCA’s role in strengthening sustainable construction and fostering innovation in the construction value chain
15 QUARRY PROFILE
County 45 Quarry is one of many small to medium-sized aggregates production sites in Kisii county, western Kenya
17 LIUGONG 60TH ANNIVERSARY
Major Chinese global construction and quarrying equipment market manufacturer LiuGong marked its 60th anniversary year by staging a celebration event at the firm’s HQ in Liuzhou, China
42 GAIN
Jim O’Brien looks at the history and impressive growth of GAIN (the Global Aggregates Information Network)
43 BAUMA CHINA 2018
The 2018 edition of bauma China was an action-packed record breaker
47 bC INDIA 2018
Heightened optimism over Indian quarrying and construction equipment demand was reflected in the volume of new model launches at bC India 2018
BUA AND CBMI PARTNER ON CEMENT PLANT
Industrial group BUA has signed a contract with Chinese cement manufacturing company CBMI for the construction of a new plant in Nigeria.
The Kalambaina Cement Line 2 plant will be located in Sokoto State in the north-west of the country and is planned to manufacture 3million metric tonnes of cement per annum.
The announcement comes a few weeks after Nigerian authorities approved the merger between Kalambaina Cement and the Cement Company of Northern Nigeria (CCNN). BUA owns a 90% stake in CCNN.
AWARDS FOR AFRICAN MINING CAMPAIGNER
Nico Pienaar, director of southern African surface mining industry association Aspasa, has been honoured with two separate awards.
For more than 20 years as Aspasa director Pienaar has focused his energy on bringing about fair trade in the mining industry while promoting safer, healthier and more environmentally sustainable mining practices.
He has been given a special award in recognition of his valuable and ongoing contributions to the Mine Health and Safety Council (MHSC) as director of surface mining industry association, Aspasa. Pienaar was also awarded a CEO Global Titans Building Nations Award 2018 for unsung heroes of the African business landscape.
Recycled aggregates sales top 3.7m tonnes
Anew report shows that sales of recycled aggregates were in excess of an estimated 3.7 million tonnes in 2018, with a 5% growth expected for 2019.
China is likely to emerge as the largest consumer of recycled construction aggregates in the coming years, according to the report by market intelligence Fact.MR, where a massive rise in construction is stimulating the market for recycled aggregates in the country.
The study expects Asia Pacific Excluding Japan (APEJ) to remain lucrative in the recycled construction aggregates market, with sales in the region expected to exceed 2.3 million tonnes in 2018. As construction and demolition waste in APEJ is becoming a major issue, leading construction institutions in the region are implementing demolition waste management programmes.
A healthier construction development is also likely to drive
growth for recycled construction aggregates in Eastern Europe. Meanwhile, Germany is expected to hold a strong position.
The report highlights the importance of recycled aggregates for the global construction market and predicts that prospects for the sector remain bullish.
The market for construction and demolition waste in India is likely to increase. Recycling construction and demolition waste by converting it into aggregates is gaining in popularity in India as a sustainable measure.
The European Commission is focusing on introducing new guidelines and protocols on construction and demolition waste management with an aim to build trust in the quality of construction and demolition recycled materials. North America is also witnessing increasing use of recycled construction aggregates in road construction.
The recycled construction aggregates market is projected to register 6% compound annual growth rate (CAGR) in volume terms between 2019 and 2027.
Wacker Neuson officially opens Chinese site
German global construction and quarrying equipment market
manufacturer Wacker Neuson has staged the official opening ceremony for its new production plant and R&D centre in Pinghu, near Shanghai, eastern China.
Over 500 guests including government representatives, suppliers, dealers and their customers from around the globe attended the ceremony and
accompanying programme of events, held in November.
China is a key market for the Wacker Neuson Group, offering future growth potential especially for mini excavators and construction equipment. Reflecting this importance, the group has opened the new production site along with a local research and design centre in Pinghu. The group says the decision symbol-
ises its long-term commitment to customers and partners in China. Chinese customers are closely involved in the development of its locally produced compact and construction equipment.
Production at the Pinghu plant started in 2018 with 1.7tonne excavators, followed during the year by other models including construction equipment products and, more recently, larger excavators.
Wacker Neuson has been distributing construction equipment in China for over twenty years and has established a robust sales and service network over these decades.
The new R&D centre and plant has a good strategic location, between the cities of Shanghai and Hangzhou and covers an area of around 135,000m², with around 30,000m² of building space.
Wacker Neuson’s new production plant in Pinghu, China
China is likely to emerge as the largest consumer of recycled aggregates.
Photo: AR Demolition
Aspasa director Nico Pienaar receives an honorary award from South Africa’s Mineral Resources Minister Gwede Mantashe
MineWare’s new mapping module Pegasys can help locate and recover material up to 100 feet below water
MineWare MTM technology is enabling sub-marine material management in mines and quarries.
In a claimed global-industry first, MineWare’s Pegasys Dragline Monitor has extended its capability to support underwater digging.
Enhanced with MineWare’s new Machine Terrain Mapping (MTM) Technology module, Pegasys can now help miners and quarrying operators locate and recover material up to 100 feet below water.
MineWare North America regional vice president Greg
Ladewig said this is a significant development for the mining and quarrying industry globally, making underwater materials retrieval safer and more efficient.
“Identifying and reaching mineable material on the pit floor is a key challenge for underwater dragline digging and dredging operations,” he said.
Equipped with MineWare’s MTM technology, Pegasys addresses this issue by enabling operations to locate mineable underwater reserves that were previously out of reach.
Ladewig added that the
technology will mean users can now get “a much clearer picture of what’s beneath the surface, improving visibility, productivity and efficiency.”
Bedrock Resources was the first to adopt the technology at their limestone mining/ quarrying operations in Florida, USA. The system has been in place for 11 months.“During a two-week re-mining period, Bedrock successfully recovered approximately 49,000 additional tons of material that may have otherwise gone unrecognised,” said Ladewig.
CEMEX MAKES SENIOR LEVEL CHANGES
Building materials company CEMEX has announced a number of changes to its senior level organisation, effective from 1 February 2019.
Juan Romero Torres, current president of CEMEX Mexico, has been appointed executive vice president of global commercial development. CEMEX says this new role aims to capitalise on the significant progress the company has achieved in its customer-centric strategy, providing it with a formal structure that will allow new
Sunwest grows with new Volvo fleet
The launch of Volvo´s EC200D excavator came at a perfect time for construction and development company Sunwest of the Philippines. Volvo´s new speedy machine is helping them grow and keep up with increasing customer demands.
Over the past few years, Sunwest Resources based in Legazpi City in the Albay province of the Philippines, has gradually
of Volvo´s EC200D excavator, which Sunwest uses at its construction materials facilities for load handling and road building work.
Randolph Zuniga, general manager at Sunwest Resources, said the introduction of the EC200D was perfectly timed for Sunwest, with increasing needs for a fast, 20-tonne machine optimised for general construction and with a more straightforward design.
to fulfil our commitments,” he said.
“These EC200D units are the right fit for us, perfect for the general construction earthmoving we use them for.”
The EC200D machines operate an average of 10 hours per day on Sunwest´s sites. The EC200Ds’ fast cycle times and strong lifting capabilities enable them to get more done. With the powerful D5E Tier 3 engine (with an output of 123kW at 2,000 rpm), and compatible hydraulics, the EC200D is designed to operate fast and with short cycle times.
With the continuing growth of the Sunwest Resources fleet, Civic Merchandising, Volvo´s distribution partner in the Philippines, opened a service branch in Sunwest’s home town of Legazpi.
Sunwest Resources is a division of Sunwest Construction and Development Corporation (SCDC), and specialises in producing highquality asphalt products, ready-mix concrete, and aggregates such as crushed gravel and sand.
has been appointed president of CEMEX Mexico.
Jaime Gerardo Elizondo Chapa, current president of CEMEX Europe, has been appointed executive vice president of global supply chain Development. This is another new role which CEMEX says aims to evolve the company´s supply chain capabilities to gain additional efficiencies in end-to-end operations.
Sergio Mauricio Menendez Medina, current distribution channel vice president for CEMEX Mexico, has been appointed president of CEMEX Europe.
All other regional presidents and executive vice presidents have been ratified in their positions.
“Strengthening capabilities and experiences in our executive committee has been priority as we evolve CEMEX to continue making progress towards our business priorities and capitalising on new opportunities,” said CEMEX CEO Fernando González.
CEMEX CEO Fernando González
One of Sunwest’s new Volvo EC200D excavators
Future-proofing concrete
Established in January 2018 and led by international cement companies, the Global Cement & Concrete Association is dedicated to developing and strengthening the sector’s key contribution to sustainable construction. It is also fostering innovation throughout the construction value chain in collaboration with industry associations as well as architects, engineers and innovators. Guy Woodford met the GCCA’s recently appointed chief executive, Benjamin Sporton, to find out more about the association’s goals.
While thoroughly enjoying the challenges as chief executive of the World Coal Association (WCA), Benjamin Sporton knew when approached about the possibility of becoming the Global Cement & Concrete Association’s (GCCA) first chief executive, that it was too good an opportunity to turn down.
“There was one number that always stuck in my mind when I was working in the coal sector and that was 1.1 billion of the world’s people are moving into cities over the next 15 years. So, when I was first approached about the GCCA job, I thought ‘that’s an awful lot of cement and concrete!’ You’re talking about the need for new infrastructure such as buildings, schools, hospitals and sanitation.
“We were doing work at the WCA looking at sustainable development goals [SDGs] and mapping the coal industry across those, and when I thought about mapping cement and concrete against SDGs, I thought it offered the complete picture. I heard some good stories about Latin America where just putting concrete floors in schools was helping kids learn. All the ways that cement and concrete can help develop the broader global sustainable development story really appealed to me.”
Sporton says a real need for one global voice for the cement and concrete industry had led to the creation of the GCCA. “Our job is to take all the fantastic work done at a national and regional industry and association level and discuss sustainable development and climate change issues with global organisations like the United Nations, development banks, intergovernmental organisations and global NGOs [non-governmental organisations].”
A dual Australian/British national, Sporton says he is excited by the GCCA’s role in encouraging innovation in the global cement and concrete sector. “We are
interested in things like alternative binders, low clinker cements and carbon capture use and storage. Technologies that are still at a pre-competitive phase, and some of the problems that are perhaps difficult for individual companies to deal with, we could have a wider-industry role in helping them address them.
“We will be looking at the role of concrete in construction of the future, tackling questions like how will the built environment change? And what sort of innovations in the concrete sector can help adapt to this change? We also need to fully understand the whole lifecycle contribution of concrete, including articulating the thermal mass benefits of concrete and the role of recarbonisation.”
Sporton is also keen to build on existing work on boosting global concrete and cement sector sustainability. A key part of this was recently taking over the work of the Cement Sustainability Initiative (CSI) which formerly came under the remit of the World Business Council for Sustainable Development. The CSI involved 24 major cement producers with operations in more than 100 countries who saw a strong business case for pursuing sustainable development.
“We will continue driving the work of the Cement Sustainability Initiative forward, but also take it in to the concrete sector,” says Sporton, adding, “The initiative’s guidelines around co-processing, health and safety, and the measuring of CO2 and the GNR (Getting the Numbers Right) database are real strengths to build on.”
At its inaugural annual general meeting and symposium held in London In November 2018, attended by the chief executives of more than 30 major global cement and concrete companies, the GCCA set out its priorities and work programme with the specific aim of strengthening the sector’s contribution to sustainable construction.
The GCCA work programme focuses
on a number of priority areas, including: positioning concrete as the sustainable building material of choice; promoting international best practice in the areas of safety, production and the use of cement and concrete in the built environment; fostering innovation in the cement and concrete sectors; making a positive contribution to global sustainable development; promoting the principles of a circular economy across the value chain. Albert Manifold, chief executive of CRH, was confirmed as GCCA president and will serve for two years.
Fernando A. Gonzalez, chief executive of CEMEX, and Jianglin Cao, chief executive of CNBM, were confirmed as vice presidents.
The London gathering also confirmed the launch of a GCCA Sustainability Charter with reporting guidelines for safety, CO2 emissions, co-processing of waste, and water.
The cement and concrete industry symposium featured a range of renowned speakers leading a discussion on global trends in construction, with panellists Michael Birshan (McKinsey & Co), Elizabeth ‘Beth’ Heider (Skanska) and Haiyan Wang (China India Institute).
“Symposiums are hugely important for two reasons. Firstly, they bring external perspectives to the industry. Beth Heider told us a lot about what customers expect looking forward over the next 20, 30, 40 years, and the impact that will have on us. Haiyan Wang looked at emerging economies’ impact on the sector, which is phenomenal in terms of the built environment – with 300 million people in India alone moving from the countryside
The GCCA Symposium in London on 23 November 2018
into cities, some of which are brand new. Then we had Michael Birshan talking about industry challenges such as those centred on productivity.
“We had more than 30 CEOs of major cement and concrete companies in the room listening to these speakers and sharing ideas among themselves about what they can do to drive some of the sustainability issues forward, such as through best practice. As Beth Heider said during the symposium, ‘Collaboration is the new innovation’.”
Originally from Adelaide, South Australia, and having lived in the UK for the last decade, Sporton joined the London-headquartered World Coal Association (WCA) as its policy director in 2010, becoming its deputy chief executive two years later. Prior to his appointment as WCA chief executive in 2014, Sporton led the WCA’s strategic and business planning and was responsible for its policy and advocacy work, with a key focus on sustainable development and climate change issues.
After taking up the role of GCCA chief executive in October 2018, Sporton’s first few months in post will see him clocking up the miles in the air and on the ground, travelling all over the world meeting leading cement and concrete company chief executives and visiting some of their companies’ major production sites to gain a more detailed understanding of the sector’s challenges.
“We had a really good foundation set for us by the ten founding company members [CEMEX, CNBM, CRH, Dangote Cement, Eurocement, HeidelbergCement, LafargeHolcm, Taiheiyo, Ultratech and Votorantim]. Growing the membership has been and continues to be critical. You come into an organisation and there is still a lot of work to do. Designing a work programme, that was signed off by the board in November, was critical, as was the symposium event. I would also like to develop a five-year strategic plan for the association, which I’d like to have in place by the end of the first half of 2019.
“We’re getting the GCCA management team on board. Claude Loréa started as
“Starting an organisation comes with all the big picture stuff, but you also have to be on top of all the nitty-gritty – like getting the GCCA’s bank account up and running!”
our Cement director in November and [Dr] Andrew Minson starts as our Concrete and Sustainable Construction director in January. It means we will have the association’s two respected technical directors in place. We will also be building up our partnerships to get across the message that concrete, from our perspective, is the sustainable building material of choice.
“Starting an organisation comes with all the big picture stuff, but you also have to be on top of all the nitty- gritty – like getting the GCCA’s bank account up and running!”
The GCCA has 32 member companies and nine affiliate organisations from across the world. It means the association already represents 35% of the world’s cement production. “We want to increase that to 50% in the next 12 to 18 months,” emphasises Sporton, who holds an honours degree in Politics from the University of Adelaide.
“When they set up the GCCA, the ten founding member companies and organisations were very well spread. We had companies from India, China, the Americas, and Europe. What we need to do now is more around deepening the connections we have in those countries and regions.”
Asked about his leadership style, Sporton, who also studied at the University of Buenos Aires in Argentina and the Australian Institute of Management, responds: “I would describe myself as a team captain. The executive team we are forming is a team of experts. Claude [Loréa] and [Dr] Andrew [Minson] are exceptional technical experts on cement and concrete respectively, and we have Paul [Adeleke, communications & policy director] who is a highly experienced
communications professional. We are a team that collaborates.”
Keen to gain more cement and concrete on-site production knowledge, Sporton and Adeleke recently visited Tarmac’s significant and historically important quarrying, lime, building products and cement operations in Tunstead, near Buxton, county Derbyshire, England.
“We were accompanied by Tarmac’s Mike Eberlin, managing director – Cement & Lime, and some of the great team on site. It was a fantastic learning opportunity. We learnt a lot about the process of making cement and saw how the quarry worked. One of the things I was most fascinated by was some of the technology involved in cement production. We saw the bag-packing facility and it was all state-of-the-art stuff, watching bags coming off what was like a cylinder, being filled up and moved on to the next stage of the process. It was also interesting to learn how alternative fuels are being used on the site, which is reducing landfills.
“The people at Tunstead were passionate and committed; the average tenure of an employee is nearly 14 years. Tunstead really does work with the local community. They have people from the area serving apprenticeships and they host school visits. They also have quite a few people with degrees working there, so it’s a highly educated workforce. Quarrying and cement production is also seen as an interesting, challenging and exciting profession to work in. Ultimately, the people working there are helping to build the local hospital and other parts of the wider world. It is our role to tell that story.” AB
GCCA CEO Benjamin Sporton during a visit to Tarmac’s Tunstead Quarry, near Buxton, Derbyshire
THE HEARTBEAT
Munich, April 8–14, 2019
Transport projects drive African construction
With African governments working hard to close the infrastructure gap, transport projects continue to anchor the continent’s construction efforts, representing the bulk of projects currently underway across all regions of the continent. By Munesu Shoko
The lack of infrastructure, most importantly, modern roads and power networks, hampers Africa’s economic development endeavours. Therefore, closing the infrastructure gap is vital for Africa’s future, and governments are well aware of this reality. The New Partnership for Africa’s Development (Nepad), an economic development programme of the African Union, notes that infrastructure is Africa’s top priority. With low levels of intra-regional economic exchange and the smallest share of global trade, Africa is the least integrated continent in the world.
Not only does sub-Saharan Africa’s existing infrastructure fall short of its needs, but it is claimed to lag well behind infrastructure development in other poor regions. Available statistics show that Africa has only about 30% of the paved road per kilometre found in other low-income regions and about an eighth of the electricitygeneration capacity per person.
The Development Bank of Southern Africa says that poor road and rail facilities add almost 30-40% to the cost of goods
traded among African countries, while Nepad notes that infrastructure inefficiencies are costing Africa billions of US dollars annually and are stunting growth. Bridging this gap can only be achieved through regional and continental cooperation, especially when it comes to transport networks.
African governments seem to be responding to the call with infrastructure projects on the go being testimony to the urgent attention on transport development programmes. In its Africa Construction Trends (ACT) Report 2018, Deloitte quotes a Chinese proverb, “if you want to prosper, first build roads”, and it certainly holds true for Africa as the transport sector continues to lead the way with almost 40% of the 482 projects tracked by the report being either roads, bridges or rail.
The 2018 edition of Deloitte’s ACT Report recorded 482 projects valued at US$50 million or above, that had broken ground by 1 June 2018. In total, the projects amount to US$471 billion. This is a significant increase on the 286 projects with a collective value of $324 billion recorded in 2017, translating into an increase of 59% in terms of the number
of projects, and a 53.3% jump in the value of projects.
With a total of 186 projects, the transport sector accounts for the majority of projects currently underway across the continent, representing 38% of the total, with a collective value of US$107 billion. Of the 186 transport projects recorded in the ACT report of 2018, 72.5% (135) fall within road and bridge construction. This is a true indicator of the concerted efforts by African governments to enhance trade and growth-supporting infrastructure across the continent.
North Africa saw the largest change in the number of projects, recording 69 in total, representing a whopping 172.5% increase from the 40 projects recorded in 2017. Simultaneously, the total value of projects in the region grew 92.3% from $77.1 billion in 2017 to $148.3 billion in 2018.
Notably, the transport sector accounts for 30.3% of North Africa’s projects and a similar share (31.3%) in project value terms, buoyed by several transport corridors underway. A project of note is the $11.2 billion Algerian East-West Highway – the six-lane toll highway is being built between
Pilot Crushtec International says the recessionary environment in 2018 had a significant impact on the construction industry in South Africa
The transport sector continues to lead the way with almost 40% of the 482 megaprojects underway in Africa
Algeria’s borders with Morocco and Tunisia, and is deemed an important road project for infrastructure interconnectivity in the region.
East Africa – which comprises Kenya, Tanzania, Uganda, Seychelles, Somalia, Rwanda, Eritrea, Ethiopia, Djibouti, Comoros and Burundi – recorded a total of 139 projects at a combined value of US$87.1 billion.
Compared with the 71 projects recorded in 2017, the 139 projects in 2018 represent a substantial 96% increase. Total US dollar project value also rose 167% from $32.6 billion in 2017 to $87.1 billion in 2018. The region accounts for 28.8% of projects currently underway on the continent and 18.5% value-wise.
Again, the transport sector continues to lead the project frontier in East Africa, accounting for 44.3% of the total projects and 26.6% in terms of US dollar value. A focus on this sector reflects that governments have grasped the fact that a well-developed transport network is integral for the East African Community’s Development Strategy.
Elsewhere, the Central Africa region is currently home to 26 projects worth $26.9 billion. The number of projects as well as the US dollar value represent an increase of 30% and 174.5% respectively compared with 2017. The mining sector leads the sectoral composition of projects with 38.5% of the 26 projects, followed by the transport sector, which accounts for 19.2% of the projects.
West Africa was home to 105 projects with a total value of $82.8 billion in 2018, representing an increase of 32.9%, but a decrease of 15.8% in US dollar value compared with 2017. The transport sector continues to lead the sectoral breakdown with the largest number of projects in the region (52), representing 49.5% of the total projects underway in the region. Projects in the transport sector have a combined value of $16.2 billion, representing 19.5% of the total value.
Southern Africa has a total of 103 projects, with a total value of $125.4 billion, translating into 21.4% of all projects in Africa and 26.6% in terms of value. The total number of projects in 2018 saw an increase of 10.8% from the previous year, while the value jumped 39.8% from $89.7 billion in
2017 to $125.4 billion in 2018.
The transport sector accounts for 32% of projects, followed by real estate activity at 25.2%. The mining sector also recorded the largest growth in the number of projects, growing 125% with five new projects. Notably, Botswana is home to four of the new mining projects. South Africa continues to account for the largest share of infrastructure development activity in the region with 35.9% of projects, followed by Angola with 14.6% and Mozambique with 13.6% of projects.
The general sentiment is that construction has been slow. Commenting on the state of affairs in South Africa and southern Africa at large, Francois Marais, sales & marketing director at Pilot Crushtec International, says from its position in the industry as a supplier of crushing, screening and materials handling equipment, Pilot Crushtec feels that the recessionary environment in 2018 had a significant impact on the construction industry.
“We saw all of our large, traditional construction clients under financial constraints for a number of reasons, but mainly as a result of bad debt and a lack of new large infrastructure projects. Many pending projects were placed on hold and several completed infrastructure works from previous periods were left unpaid by project owners. Our construction clients preferred to retain old equipment and opted to repair
As is the case with construction companies, many aggregate producers are opting to retain older equipment and repair as opposed to replacing with newer models
Despite the tough trading conditions, the southern African trucking sector recorded slight growth of about 7% in 2018
cash flow situation in their businesses,” says Marais.
With construction under pressure in 2018, what was the state of affairs in the aggregates industry? “Aggregates producers retained similar levels of demand in 2018 as they did in 2017, but also remained under pressure, especially in South Africa. Many contractors and aggregate producers looked to branch out across the borders into neighbouring countries to secure contracts and stimulate growth within their businesses. As was the case with construction companies, many aggregate producers looked to retain older equipment and repair as opposed to replacing equipment for newer models,” explains Marais.
Despite the challenging market conditions, the southern African capital equipment market surprisingly defied the odds to even record some slight growth figures. For example, if commercial vehicle sales are anything to go by, 2018 was a year of slight growth in the face of lethargic economic growth and high interest rates which burdened industries that rely heavily on debt financing.
Raimo Lehtiö, MD of Scania South Africa, says from a total volumes point of view, 2018 was actually a little bit better than expected for the trucking sector. The market was expected to slightly dip compared with 2017, but surprisingly recorded growth in the 7% region. “The reason might be the fact that in 2017 several truck owners de-fleeted to reduce the sizes of their fleets in response to the tough business conditions at the time. Then in 2018 there was an unexpected slight market resurgence, which forced them to purchase new trucks to fulfil their new
Elsewhere, the Construction and Mining Equipment Suppliers’ Association (CONMESA) also recorded a continuous growth cycle in consecutive quarters. The growth trajectory started way back in 2017 when construction and mining equipment sales moved strongly upwards to break a three-year downward cycle that had gripped
With a total of 186 projects, the transport sector accounts for the majority of construction projects currently underway across the continent
Peters, CONMESA chairman.
Marais says although Pilot Crushtec International’s equipment sales grew during the course of 2018, the bulk of the growth was contributed by the resilience in the mining sector, as opposed to construction and aggregate industries. “We saw mining as a buoyant sector in South Africa and cross-border markets, sustained by strong commodity prices and an increased demand for raw materials internationally,” says Marais. “Unfortunately, the lack of major infrastructure projects and slowing international investment into South Africa has meant that construction companies and aggregate producers have experienced a stressful 2018 with limited ability to purchase
quarter of 2018, with sales of new equipment reaching levels last seen in the first quarter of 2015. A total of 1,542 units were sold during the period, an improvement of nearly 100 machines during the same period in 2017. It also extended the trend that had seen equipment sales inch upwards since
Looking ahead, what are the prospects for 2019? In the truck industry, Lehtiö believes that 2019 will stabilise, especially considering that it’s an election year in South Africa. Generally, there is a wait-and-see approach whenever an election is looming as the uncertainty creates a lot of risk for any large capital investments. However, it is also common practice for incumbent governments to splash a bit of cash during the run-up to elections, especially on infrastructure
“With the local elections scheduled for 2019, there is an optimistic view that the third or fourth quarter of 2019 may see some positive stabilising of the currency and an improved enthusiasm to initiate overdue infrastructure projects. The drive to develop will hopefully have a positive impact on the industry and we hope that this in turn, will positively affect aggregate producers,” concludes Marais. AB
Francois Marais, sales & marketing director at Pilot Crushtec International
Kisii county in western Kenya is full of highly successful small to medium-sized aggregates quarry operators. Shem Oirere went to visit one of them.
Around 150 kilometres from Lake Victoria, Kisii county is one of the counties in western Kenya where small and medium construction material suppliers are thriving and local quarries, despite their small size, are reporting booming business as county-based construction works continue expanding.
“The rate of construction in all counties is on the rise as county governments allocate more funds for infrastructure development with more private investors taking advantage of devolution to put up housing projects and expand hospitality businesses,” says Obed
Mogambi, quarry manager at County 45 Quarry in Kisii.
The quarry has two sites, about 1km apart, for quarry mining and processing. Its aggregates production started two years ago after a local investor realised there was increasing demand for construction material in Kisii county, whose government has unveiled plans for new roads, better maintenance and expansion of existing highways, and the building of new schools to accommodate an increasing population.
“Ours is not among the biggest quarries in western Kenya but we have managed to grab a huge share of the Kisii county aggregates market. We also have some of the market in
neighbouring Homabay and Migori counties, where current demand for road construction materials is at its peak,” said Mogambi.
Located 5kms from Menyinkwa on the Kisii-Kilgoris road, County 45 Quarry operates eight hours a day. Mineral products processing starts with removal of the top soil at the quarry site, in preparation for drilling.
“We remove the top soil, with either a JCB 205 LC excavator or the CAT 330D model, since both can do the job before we launch the drilling works,” said Mogambi.
He said with the top soil removed and deposited on selected sites, either for landscaping or reforestation of areas close to the quarry, quarry workers then drill 30ft
A Cat 330D crawler excavator at work onsite
deep blast holes which he says are designed “to ensure the direction of throw of the blasted rock is the right one to avoid any injuries among quarry workers.”
In addition, Mogambi said, the design of the blast holes “can be in staggered arrays or patterned irregularly, or in a row, square or rectangular depending on the mapped direction of the throw of the blasted rock.”
To create its blast holes, County 45 Quarry uses a K-323 crawler excavator drill manufactured by Indian rock drill machines and spares company KSC Group. The 2.7tonne, up to 144mm diameter hole drill has been used in the quarry since it launched operations, which Mogambi says has served the quarry well.
He continued: “We use ammonium nitrate mixed with a small portion of diesel and gelignite for blasting after the drilling of the rocks. These are ingredients that are readily available, have a low-cost implication and easy to mix before use.”
Mogambi said it takes 24 hours before work on separating portable rocks from boulders begins. “This allows for the dust and the smell of ammonia to clear. The boulders are broken further to make it possible for our Howo Sinotruk dump trucks to carry, while rocks of the right size are hauled directly to the primary crusher.”
Mogambi said County 45 Quarry currently deploys Howo Sinotruk 290H and 330HP dump trucks which, he says, have 16 and 30 tonne capacities, respectively.
“For processing aggregates, our company is currently relying on an impact crusher from Zenith’s Pf series,” he said.
“Some sections of our crushing system have been fabricated by local engineers, and it serves us perfectly well,” added the quarry manager.
The Chinese supplier-provided primary and secondary crushers at the quarry are secondhand but in good condition.
The Zenith impact crusher at County 45 is the 17tonne Pf 1210 model with a feeder opening of 400x1080mm and feeding capacity of 300mm. The crusher can crush up to 130 tonnes/hour using a motor power of up to 132kW.
maintain and offered bigger capacity and reliable performance. We feel the current impact crusher has met our needs for now,” said Mogambi.
County 45 Quarry makes diverse construction material such as aggregate products sized 14mm-20mm, 10mm-14mm, 6mm-10mm and 0-6mm. The 14mm-20mm and 10mm-14mm is generally used for house building, while the 6mm-10mm grade products are for road construction.
The quarry also produces bricks containing on-site processed dust, makes and supplies road kerbs and channels, and wall and column copings of various sizes, depending on customer needs.
“The future of small quarries in Kenya looks good,” said Mogambi, citing the examples of Kisii and Homabay counties, where county governments have unveiled ambitious infrastructure expansion plans to 2021.
In Kisii for example, the county government plans to compact and gravel 500km of roads in addition to rehabilitating an additional 1000km of highways, building 45 footbridges and gravelling another 100km of roads in urban areas.
“All these projects require aggregates and quarries that are found within the county stand to benefit from these opportunities,” said Mogambi.
With Kenya’s national government continuing to allocate a fifth of the country’s budget to county governments, expansion of infrastructure across the nation’s 47 counties is expected to increase, providing great business opportunities for small yet highly ambitious quarries like Kisii’s County 45. AB
1: Obed Mogambi, manager of County 45 Quarry 2: Aggregates of various sizes produced at County 45 Quarry 3: A County 45 Quarry worker moving material prior to drilling works
ABOVE: To create its blast holes, County 45 Quarry uses a KSC Group K-323 drill attached to a crawler excavator
LiuGong talks growth at 60th anniversary event
Major Chinese global construction and quarrying equipment market manufacturer LiuGong marked its 60th anniversary year by staging a celebration event at the company’s global HQ in Liuzhou, China. Guy Woodford was among those in attendance.
LiuGong chairman Zeng Guang’an says that the firm is fully embracing Industry 4.0 technology. Coupled with ongoing machine development, an expanding global sales and manufacturing network and long-established strong relationships with customers and suppliers, this is enabling the Chinese construction equipment giant to target a significant rise by 2025 on its RMB 18 billion (US$2.6bn) global sales revenues in 2018.
Chairman Zeng outlined the impressive scale of LiuGong’s future ambitions during an impassioned speech in front of an audience of 5,000 attendees, including customers, employees - past and present, dealers and the world’s trade media, during an address in the morning session of the 60th anniversary celebration event on 26 November 2018.
“We have stepped forward on the path of global development and built ourselves from a remote enterprise to an international enterprise,” said Zeng. “We are pushing
ahead with our overseas operations and joint venture alliances. The world today is experiencing a fourth industrial revolution. Our strategy is to bring talents from across the world and develop our manufacturing intelligence capabilities.”
Zeng said LiuGong owed its existence to its customers and close cooperation with its suppliers, adding, “We will work to write more shared stories of success. With passion and determination, LiuGong is moving towards its next 60 years.”
LiuGong used its landmark celebration to unveil six new machines, while also marking the production of the company’s 400,000th wheeled loader.
The 60th anniversary event also included a press conference involving Zeng Guang’an and other key senior company executives, a film-based tribute to the company’s founders, several of whom were present, a product history and achievement exhibition, and a 60th anniversary gala dinner.
The second day of the 60th anniversary event was dedicated
and
to a global dealer conference.
During the press conference, Zeng spoke of the vibrancy of the Chinese construction equipment market – with leading industry market research firms estimating 300,000-unit sales in 2018. He said India had the biggest growth potential for LiuGong, given prime minister Narendra Modi’s huge transport infrastructure investment programme in a country with a population of 1.2 billion, second only to China but tipped to become the world’s most populated country in the coming years.
Zeng also spoke of the success of LiuGong’s now four-year-old Chinese market joint venture (JV) with Metso, the global crusher and screener equipment manufacturer. From next year, all Metso’s product range will be manufactured in China, significantly cutting machine production and shipping costs. “It is currently a niche market business for us, but the joint venture has great potential.”
LiuGong’s chairman said the company’s Metso JV had given its domestic customers access to a complete construction and
Customers, dealers, current
past employees, and the world’s trade media were among the 5,000 attendees at LiuGong’s 60th anniversary celebration event in Liuzhou
LiuGong’s 400,000th produced wheeled loader a 870H – was showcased at the Chinese manufacturer’s 60th anniversary event
LiuGong chairman Zeng Guang’an addressing the company’s global dealer conference in Liuzhou on 27 November 2018
quarrying equipment range.
In his morning session address, Zeng had also stressed how LiuGong’s growing global market reach has allowed it to seize the opportunities brought by the Chinese government’s ‘One Belt, One Road’ (OBOR) programme. LiuGong covers more than 85% of the 65 key OBOR countries and regions and LiuGong has participated extensively in construction projects along ‘OBOR’, such as the Yavuz Sultan Selim Bridge and national power plant projects in Turkey, Ashdod Port and Tel Aviv light rail construction in Israel, China-Laos and China-Thailand railway construction, the PMK expressway in Pakistan and the China-Myanmar gas pipeline project, along with many others.
LiuGong staged a global dealer conference in Liuzhou the day after its 60th anniversary celebration event
technology and products to mature western markets.
extensive global sales networks of any Chinese company, with its 2,650 sales outlets and more than 300 dealers in over 130 countries assisted by 12 regional offices with engineering, marketing and service support. Coupled with LiuGong’s nine regional parts depots and three overseas manufacturing plants, this ensures the rapid availability of parts and service of equipment in local markets.
LiuGong manufactured China’s first modernised wheeled loader in 1966 and in 1976 produced its first articulated and oversized wheeled loaders. In 1993, it became China’s first publicly traded construction equipment company.
Since securing its first overseas dealer in Morocco, North Africa, in 2003, launching its first overseas subsidiary company in Australia in 2004, and opening its first overseas manufacturing plant in India in 2007, LiuGong’s overseas development has been rapid.
In 2012, LiuGong successfully acquired the HSW civil construction machinery business in southern Poland, enabling the firm to become one of only three construction equipment manufacturers in the world to offer a full line of bulldozers. The acquisition also laid a solid foundation for LiuGong to introduce its new
In 2017, LiuGong opened its third overseas manufacturing facility, in Brazil, and moved into a new European headquarters in Warsaw, Poland, while simultaneously opening a new parts distribution centre at LiuGong Dressta’s facility in Stalowa Wola, southern Poland. This has enabled LiuGong to launch ‘Made in Poland’ excavators and wheeled loaders on to the European market.
In 2018, LiuGong India celebrated its 15th anniversary of business and 10th anniversary of the LiuGong India plant, announcing a new investment to further enlarge the facility’s production capacity. Additionally, with the introduction of the production of H series wheeled loaders, LiuGong India has shown its importance as a key growth point for LiuGong’s overseas business.
After more than 15 years of development, LiuGong has established one of the most
LIUGONG’S WHEELED LOADER FIRST
LiuGong has unveiled the company’s first-ever wheeled loader with intelligent remote-controlled shovel.
The 886H’s intelligent shovel senses material penetration; enabling the wheeled loader to shovel independently, provided the driver uses the remote control close to the stack.
The innovation also features intelligent protection technology which enables the model to operate an automatic hazard identification system and an auto emergency stop.
A Cummins QSM11 engine provides dependable power to the LiuGong 886H. Two working modes of Standard
and Economic can be switched easily according to working conditions for additional energy savings. The newly optimized work hydraulic system and power combination increase bucket breakout force and loading capacity. Careful distribution of stress loads improves job efficiency.
The new constant flow hydraulic system, highly efficient, energy-saving and quick responding, takes any compound actions with ease. The integrated forward-neutral-reverse (FNR) joystick is easy to operate.
The intelligent throttle control system can automatically adjust the fuel input to optimise the power output and save energy; the intelligent active protection can
LiuGong has subsidiary companies based in Johannesburg, South Africa; Sydney, Australia; Belo Horizonte, Brazil; Dubai; Europe; New Delhi, India; Poland; Singapore; Moscow, Russia; and Houston, United States. The company also has a highly successful joint venture with Cummins, Guangxi Cummins Industrial Power, which includes a mid-range engine manufacturing facility in Liuzhou. Liuzhou ZF Machinery is a longestablished joint venture between LiuGong and ZF Friedrichshafen of Germany which manufactures driveline and parts of driveline for construction machinery.
Speaking during the LiuGong global dealer conference held in Liuzhou the day after the 60th anniversary celebration, company president Huang Haibo said: “Looking forward to the future, innovation and transformation will remain vital to LiuGong. The company is committed to becoming a world-leading construction machinery manufacturer. As a result, LiuGong’s pursuit of a continuous progress in the overseas market will never stop. We will always stand side by side with our dealers to achieve our goals.” AB
automatically identify the control status and stop the machine in an emergency; the intelligent shovelling system makes the operation easy and reliable.
The LiuGong 886H has a 309° panoramic cab and a large interior space. All key buttons are within reach and the control handle can move with the operator’s seat. At the same time, the fully sealed and micro-pressurised cab can effectively reduce dust and noise, creating a safe and comfortable environment for the operator.
The front-flip hood can be opened and closed by hydraulic lifting system, allowing for additional maintenance space with a 360° surround platform design for easy access to all key components.
The 886H with its intelligent remotecontrolled shovel was due to launch in the Chinese market in January 2019. The eye-catching model was one of six machines unveiled during LiuGong’s 60th anniversary celebration attended by 5,000 customers, dealers, employees – past and present – and the world’s construction equipment trade media at LiuGong’s HQ in Liuzhou, China. Other machines premiered were the 990F excavator; B170DL bulldozer; 4180D motor grader; TC800C5 truck-mounted crane; and the S935 sugarcane harvester.
The 886H is LiuGong’s first-ever wheeled loader with intelligent remote-controlled shovel
Landmark plant & facility investment
A top global crushing and screening equipment manufacturer believes its first complete stationary plant in the UK will lead to many more similar installations for customers in one of Europe’s biggest national aggregates markets. Meanwhile, another multi-brand international aggregates processing equipment giant is investing heavily in several of its major production facilities. Guy Woodford reports.
Sandvik Mining & Rock Technology’s (Sandvik) first turnkey stationary crushing and screening plant in the UK, at Marshalls’ Howley Park sandstone quarry in Leeds, is now fully operational.
The up to 350tonnes/hour, maximum 700mm initial feed bespoke plant includes full Sandvik plant monitoring technology, a feeder and ST1263 grizzly screen, ASRi crusher control, a CJ411 jaw crusher, a CH440 cone crusher with San Remo control system, and SS1233H and SK2163 screens, both with dust encapsulation solutions, the latter including 7-20mm Sandvik rubber screening media. The plant also features an SP1020 vibrating feeder, a 20m³ surge bin, AR400 wear plates, a BR555 boom breaker system, and a galvanised steel-inclusive belt conveyor package. All this allows Marshalls to produce up to seven different products at any one time.
Sitting on a specially dug-out site at Howley Park, the giant tailor-made plant was installed in around three months after foundation stones were laid. It is based on 3D software designs born out of many months of discussion between Sandvik engineering experts and senior Marshalls
executives.
Andrew Robinson, managing director of Marshalls’ minerals division, said: “Our market is very immediate. It is about delivering what the customer wants when they want it. We wanted a plant that would allow us to produce seven different highquality products at once. When we put the project out to tender, Sandvik said they could supply it. Other manufacturers wanted to offer us something more standard.”
The UK’s leading hard landscaping manufacturer, Marshalls has been supplying superior natural stone and innovative concrete products to the construction, home improvement and landscape markets since the 1890s. The company produces a wide range of premium sandstone and limestone products, ranging from -2mm dust to 200mm.
Prior to the cutting-edge Sandvik plant installation, Howley Park had been using third-party crushing and screening contractors. Around 25% of Howley Park is being used for minerals processing, with the site holding around 50 years of mineral reserves.
On the role of 3D design in the Sandvik Howley Park project, Robinson said: “If
ABOVE: Marshalls’ Howley Park sandstone quarry near Leeds, England, is home to Sandvik’s first turnkey stationary crushing and screening plant in the UK
the plant design works in 3D, it works in real life. The 3D plant design answered questions like: Is the plant configuration right and does it allow me easy access to each section of it? What are the stockpiles going to look like? How will the loaders get around the site? Everyone has a different picture in their mind of how something may look. It is always an easier sell to people when they can visualise a plant.”
With the assistance of Marshalls, Sandvik held a customer day at the Village Inn in Tingley, West Yorkshire, on 5 October 2018 to allow influential people from aggregates companies to learn about and explore the entirely Sandvik-designed and manufactured Marshalls’ Howley Park plant.
The event began with a short presentation on the three distinct fixed plant approaches Sandvik can now offer its UK customer base. These are FastPlant, SmartPlant and CustomPlant, the latter being the approach taken for Marshalls, resulting in a fully bespoke installation.
The group of 60 event attendees was
RIGHT: Sandvik customer day attendees learning about and exploring the entirely Sandvik-designed and manufactured Marshalls’ Howley Park plant BELOW: Sitting on a specially dug-out site, the giant tailor-made Sandvik stationary plant at Howley Park was installed in around three months after foundation stones were laid
split in two. One group left for the nearby Howley Park Quarry to see the new turnkey plant up close, with Sandvik plant experts and Marshalls directors, operational management and engineers on-hand to discuss how they thought the installation had gone and answer any questions. The remaining customers at Village Inn were given the opportunity to view the plant in full virtual reality. Group activities were then reversed prior to a wrap-up session involving Sandvik’s team of experts at the end of the event.
Colin Parke, Breedon Group’s central region director, said: “The plant has been designed with safety and maintenance in mind for the future. The double access conveyor walkways, high-quality guarding and full access to maintenance points was of a very high standard.”
Peter Rust, a senior engineer for Tarmac, added: “Every single nut and bolt on the plant is exactly the correct length. We all know this is as it should be but how often do we see this on new plant installations these days? I’m very impressed with the attention to detail.”
to increase capacity and meet growing demand from the crushing and screening industries.
Scott Robinson, director of Robinsons of Longcliffe, the main mechanical installation contractor who was on hand to also discuss the project, said that the 3D drawings and QR bar coding of every component, down to boxes of nuts and bolts, made the Howley Park plant one of the most straightforward the firm had tackled in its long history.
Speaking during the customer day about Marshalls’ Sandvik turnkey plant installation Mark Bodell, sales manager for Sandvik stationary crushing & screening – England and Wales, said: “The plant will have a minimum life of 25 years and represents
a big investment for Marshalls. We have worked as a partnership from day one and it has been an enjoyable experience. We are very proud of the plant. We will continue to work closely with Marshalls and will adjust the plant if they want to process different materials to those currently being produced.
“Sandvik has for some time had turnkey plants in countries such as Australia and Sweden, and when I became Sandvik’s England and Wales stationary plant sales manager in July 2016 I was clear that I wanted to bring complete plant solutions to the UK. The interest we have had from major British building materials suppliers in our turnkey plants has been quite phenomenal. There are a lot of plants in the design stage and Howley Park will be the first of many Sandvik UK turnkey stationary plant installations.”
Terex Materials Processing (Terex MP) – which includes the Terex Finlay, Powerscreen, Terex Minerals Processing Systems, EvoQuip, Terex Washing Systems and Terex Ecotec brands – is undertaking facility improvements and expansion plans
Investments in research and development, a bespoke parts warehouse, and telematics technology, along with broad-based economic growth and construction activity globally has led to demand for Terex MP products being at an all-time high. To cope with this demand and enable an increase in output, while also boosting production efficiency, Terex MP is investing in and expanding three of its manufacturing facilities –Hosur in India, Coalville in England, and Omagh in Northern Ireland, along with a new manufacturing facility soon to be announced.
Kieran Hegarty, president of Terex MP, said: “These plans are due to be completed over the next six months and will support us in getting our machines to our customers, when they want them.”
The Hosur facility is expanding its current 15-acre facility with plans representing over £5 million (€5.6mn) of investment.
Aftermarket support and shot blasting and paint operations will move from the main building into new bespoke buildings – a 3,300m² shot blasting and paint shop facility and 1,980m² integrated aftermarket facility – which will allow for additional space and improved efficiency in the main build area for production ramp-up. The bespoke integrated aftermarket facility, which opened at the end of 2018, will include a new parts warehouse with an upgraded logistics system that deals with all picking, packing, delivery functions and storage. The building will also encompass an office block and dedicated refurbishment shop and engine repair facility. A new rock test lab has also been set up to study rock to aid in the prediction of performance.
To cope with increasing demand for machine components and offset pressure on the supply chain, the team in India is working with existing suppliers to operate a new 1,320m² machine shop within the Hosur site. Hosur will finance the building
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and electrical power for the machine shop, while suppliers will provide equipment and skilled manpower to run it.
Finally, a new training centre to cater for increased training needs – from both Terex and dealer service engineers and for new manpower – is being built and due to be completed in June 2019.
Over the past four years the crushing chamber production facility at Coalville has seen its volumes grow significantly due to Terex MP’s manufacturing footprint consolidation to help meet demand. The site is undergoing continued increase in headcount and £2.5 million (EURO 2.8mn) of investments in equipment and site facilities to enhance manufacturing capability and to take on full plant assembly for some of Terex MP’s leading brands.
Full assembly onsite at Coalville is also now possible thanks to a new paint facility, which has been installed as a new building adjoined to the existing building so that it would not use existing manufacturing floor space.
A new state-of-the-art robotic welder is now helping produce mainframes. As well as improving efficiency, a more consistent final product quality is ensured by the repeated automated process.
Another investment at Coalville includes a new horizontal boring machine. At 2m x 2.2m wide and 6.2m high, the machine is thought to be one of the largest of its type in the UK. As well as handling existing chamber products, it will also handle larger chambers that are currently in the design phase.
Finally, as Coalville is an important source of spare parts for Terex MP, a more advanced machine for producing equipment components and spare parts has been recently installed, and with many new features will enhance the production of spare parts to cope with the increasing demand.
The Omagh crushing manufacturing site is to undergo a £3.5 million (€3.92mn) expansion. This includes building over 1,860m² of welding stations to allow for increased welding capacity, along with 1,020m² of offices and 3,715m² of stores and new product development process assembly. These buildings will also free up production space to support growth across the business.
Due to begin in 2019, production will facilitate Terex MP’s growing Terex Ecotec and conveyor businesses.
Kieran Hegarty said: “These investments will support our ongoing growth and development as we seek to build on the
momentum of increased demand for our products globally.”
Finnish global crushing and screening solution giant Metso is introducing new higher capacity models to its NW Rapid wheel-mounted crusher series.
Metso says that, in addition to the bigger jaw crusher model, NW Rapid units are now available also with a variety of highly robust cone crushers, including the first model with the MX crusher. Over a thousand NW Rapid models have now been sold since 2015.
NW Rapid units can be delivered in standard containers from the factory and are designed to be easily movable from
one site to another, using standard prime movers. Metso says the flexibility of the concept allows producers to profitably offer their customers contracts of various sizes.
The NW Rapid series is designed for producing high-quality end products with multi-stage crushing and screening units. The NW120 Rapid jaw model will now be joined by the screen-equipped NW330GPS and NW300HPS cone crushers. The NW4MXS is the latest introduction to the series and brings the MX4 Multi-Action cone crusher, launched in 2017, to the integrated crushing solution for the first time. Serial production of the NW4MXS will start in the second half of 2019. For other models, Metso says its factories are already working to bring new machines to customers globally.
NW Rapid is designed to be set up and dismantled in 24 hours. It has 11 pre-designed layouts to speed up planning of the crushing process. The solution consists of modules that can be used to create a variety of combinations as needed.
“A large share of our customers supply aggregates for public infrastructure projects that can last from a few months to a couple of years,” says Julius Mäkelä, Metso director of portable and modular solutions. “Depending on the project phase, our customers must have the ability to also offer very high capacity.”
He added that the new NW Rapid models enable production capacity to temporarily be increased up to 500 tonnes/ hour, which is equal to the capacity of a fixed plant.
The NW Rapid series models are electric driven and have Metso’s IC Series crushing automation as a standard feature. In addition, they can be connected to the Metso Metrics remote monitoring service, which allows central monitoring of the entire crushing fleet’s production and energy consumption. AB
BELOW: Terex Materials Processing’s new integrated aftermarket facility in Hosur, India
ABOVE: Metso has introduced new higher capacity models to its NW Rapid wheel-mounted crusher series
High demand for wheeled loaders in India
SDLG is targeting the buoyant Indian market with the launch of a wheeled loader in the country, while Volvo loading products have won orders in the UK and Indonesia.
Liam McLoughlin reports.
With the Indian government continuing to invest in infrastructure, there is high demand for wheeled loaders in the country for heavy-load applications such as material handling, land clearing and general earthmoving.
That is the view of Surat Mehta, head of business in India for the Chinese-based machinery supplier SDLG.
To meet this demand, the Linyiheadquartered manufacturer launched a 5 t-rated wheeled loader to the Indian market at the bauma CONEXPO India 2018 event in December. The machine features a larger bucket capacity, heavier operating weight and a new cooling design system.
Alongside the new loader, SDLG also exhibited the L946 wheeled loader at the bauma India event. SDLG launched the L946 at Excon in December 2017. It features a maximum 3.5 m3 bucket capacity, a maximum 1 m dumping distance and a 129 kW rated power.
Mehta says the construction industry in India has grown since 2015 and he expects the trend to continue.
strong market position in the 3- to 5-tonne range, and we plan to further strengthen our position,” Mehta said. “For motor graders, there is potential to grow our customer base as well, with road construction activity levels remaining high in India.”
In Indonesia, logistics company PT Escorindo Jasa Prima recently bought its first Volvo EC200D excavator to support operations for one of its quarry customers.
PT Escorindo Jasa Prima says the EC 200D has proved so successful and efficient that it has since ordered several more of the machines.
Since starting out in 2000, the company has supplied equipment and services to a variety of customers across Indonesia. One of its latest projects is for a cement producer which operates a quarry in West Java.
At the quarry, minerals need to be mined
before being transported to a cement mixing plant onsite. To facilitate this, the quarry owner turned to PT Escorindo Jasa Prima which selected a Volvo EC200D excavator for the task. The machine performed so efficiently that the cement producer has now expanded its relationship with PT Escorindo Jasa Prima.
“After our customer saw how the EC200D was contributing to the productivity of the quarry and the cement mixing plant, we started talking about similar logistics services for some of their other sites,” said Oggy Hargiyanto, MD at PT Escorindo Jasa Prima. “After those discussions, we went back to our Volvo dealer PT Indotruck Utama and ordered four additional EC200D excavators.”
The first EC200D is expected to put in 16-hour daily shifts at the West Java quarry. Its short cycle times enable it to dig clay, limestone and shale with efficiency and load them into waiting trucks.
The clay, limestone and shale that the excavator mines are raw materials in the production of cement. After they are excavated, the EC200D loads them onto trucks for transportation to a cement mixing plant, which produces up to 5.5 million tonnes of cement annually.
With such high production levels, one of the four new EC200Ds will be deployed to the quarry, while the other three will be sent to other sites. Besides supporting mining activity, the additional EC200D unit to be deployed to the quarry will also help manage stockpiles of minerals.
“The hopper at the cement plant can handle 100 tonnes per hour of minerals,” Hargiyanto said. “When it’s at capacity, then the surplus minerals have to be stockpiled in a yard near the plant. ernment st in re is
“For wheeled loaders, SDLG has a before
A Volvo EC200D excavator at work in a quarry in East Java
SDLG has just launched its 4 t-rated L946 wheeled loader in India
“The EC200D’s job at the yard will be mainly material handling: arranging the stockpiles and conveying them to the hopper when capacity frees up.”
With a typical shift at the quarry involving various tasks around the site, Volvo says the EC200D offers both fuel efficiency and operator comfort.
Hargiyanto adds that when the four new EC200Ds arrive, his company’s fleet of excavators will have more than doubled.
The EC200D was launched at the start of 2018 and is the fastest excavator in the 20-tonne class. It offers exceptionally high swing torque and unique lifting capabilities which make it the natural choice for general construction work. It is configured with a 5.7 m boom, 2.9 m arm and 0.8m3 bucket.
PT Escorindo Jasa Prima is headquartered in Jakarta, with other offices in Narogong, West Java; Cilacap, Central Java; and Tuban, East Java.
Marshalls, a UK manufacturer of natural stone and concrete hard landscaping products, has taken delivery of several Volvo Construction Equipment products, at its Howley Park quarry near Wakefield. The products include an L180H loading shovel, a fifty-tonne EC480E excavator and an A45G articulated hauler and their delivery coincides with the commissioning of a new crushing plant at the Howley Park facility.
“Up until now we’ve engaged contractors to carry out the primary crushing and screening processes here at Howley Park,” says Ian Manley, quarry manager at Howley Park. “With our new plant coming on stream we therefore needed to add these extra machines to fill the gap and consequently settled on Volvos to complement and mirror our existing machines on site. Flexibility is the key to our operations and the ability to interchange attachments on our shovels and excavators when required is crucial.”
Highly abrasive gritstone is quarried at Howley Park, and the new machines have been supplied to deal with the tough characteristics of the material. For example, the EC480E excavator is equipped with an
attachment-mounted heavy-duty 3.0m³ rock bucket, and the 4.8m³ rehandling bucket mounted on the L180H loading shovel has benefitted from hard facing on the leading edge and side plates.
As with five 30-tonne L180Hs that were previously supplied to Marshalls in 2017, the new loading shovel has had Volvo’s co-pilot load-assist weigh loading option installed at the factory. The option allows the operator to calibrate either their bucket or block handling forks via the touchscreen pad in the cab. Bucket loads and the number of buckets filled can be recorded in addition to the system storing an array of product menus. The co-pilot touch screen automatically becomes a rear-view screen when the machine is put into reverse, interacting with the rear-view camera. The co-pilot system is linked in with the care track system – Volvo’s telematics system which can feed back information to a remote location.
The new L180H also features the CDC (comfort drive control) option allowing the operator to steer the machine from the comfort of their left arm rest.
The fifty-tonne excavator has been equipped with double grouser track pads for quarry operations and supplied with a hydraulic quick fit, heavy-duty bucket and hydraulically operated steps for safe access and egress for the operator to and from the cab. The EC480E is installed with a 13-litre Volvo engine developing 378 net hp and its hydraulics are controlled by a system which provides on-demand flow and reduces power losses within the circuit.
The Marshalls group operates its own quarries and manufacturing sites, as well as 12 service centres and 14 offices throughout the UK.
Meanwhile, Caterpillar has launched the 990K Aggregate Handler wheeled loader, designed to handle greater payloads in aggregates yard applications. With as much as a 25% payload increase, as compared to the standard 990K wheeled loader, the new Aggregate Handler is designed to enable customers to load trucks and railcars faster and to move more material in load-and-carry and stockpile handling tasks. The new model has a payload of 20 tonnes and a full turn static tipping load of 43,738 kg. AB
A Volvo EC480E excavator loads an A45G hauler at Marshalls’ Howley Park quarry
The new Cat 990K Aggregate Handler moves crushed stone
New German dealer joins forces with Terex Trucks
With Germany currently a hotbed for infrastructure projects, Terex Trucks plans to capitalise with a new dealer for its ADTs and construction equipment in the north of the country. Liam McLoughlin reports.
Terex Trucks has just signed its third dealer in Germany, and the articulated hauler manufacturer claims the timing could not be better.
Maschinenbau Rehnen is the latest addition to the Terex dealer network and covers northern Germany. The family-run company was established in the 1960s and has since gone onto become a major player in the German construction market. It has three branches – in Heede, Georgsheil and Unna –and employs 50 people including mechanics, engineers and foreign-trade clerks.
Terex says that Germany has become a hotbed for construction, thanks to a growing demand for real estate and a multi-billion euro budget set aside for infrastructure projects.
“Maschinenbau Rehnen has a big share of one of the strongest, most prestigious markets for construction equipment,” says Guy Wilson, global sales director for Terex Trucks.
The dealer will be selling both of Terex Trucks’ articulated haulers – the TA300 and TA400 – as well as providing customers with spare parts, after-sale support and repairs. The TA300 has a maximum payload of 28 tonnes, a maximum torque of 1,880Nm, a heaped capacity of 17.5m³ and can achieve 276kW gross power. This, together with its Scania DC9 engine, means that it can perform in challenging applications including quarries, infrastructure developments and commercial construction projects. The TA300 also comes equipped with true independent front suspension and – as of earlier this year
– the new ZF EP320 transmission, resulting in improved operator comfort, fuel efficiency, performance and productivity.
With a maximum payload of 10 tonnes higher than the TA300, the TA400 is the most powerful articulated hauler on offer from Terex Trucks. The manufacturer says it is a popular choice among customers working on quarries, mines and steep inclines. The heavyweight hauler can lift up to 38 tonnes and has a maximum torque of 2,100Nm.
The TA400 also has a heaped capacity of 23.3m³ and is fitted with an Allison HD4560 transmission, which boasts high-performance oil and extends the time between service intervals to 6,000 hours.
Germany is currently battling with an extreme shortage of affordable homes, which has led to a surge in residential construction. The government has set aside more than €5 billion to help tackle the problem. Real estate isn’t the only area in which Germany is investing its money, though – infrastructure is also a top priority. In fact, state spending on infrastructure has been a central focus for some years – in 2015, the government allocated €7 billion to help fund large-scale infrastructure projects. With Germany being such a hotbed for construction, Terex Trucks is keen to expand and strengthen its presence throughout the country.
In England, the Norfolk-based aggregate extraction and processing firm Longwater Gravel says that the first Bell Equipment machine it has acquired, a B30E articulated
dump truck (ADT), has already proved its capabilities.
With a need to keep three quarries successfully operating throughout the Norfolk area, Longwater Gravel depends on the reliable function of powerful aggregate tipper vehicles with the ability to consistently perform.
In the past, the company has met its operation’s vehicular needs by purchasing pre-owned, off-highway dump trucks. However, recently it found the need to acquire a used truck at a crucial time could not be achieved due to lack of machine availability in the busy current market.
“The shortage of suitable pre-owned trucks naturally led us to look for a new, but highly appropriate ADT solution,” says Will Littleboy, managing director at Longwater Gravel.
“To find the right machine for the job, we chose to test drive demo versions of both a new machine, manufactured by our usual supplier of pre-owned trucks, alongside, for the first time, a Bell Equipment ADT.”
Littleboy explains that he had been talking with Bell Equipment about the ADT options open to him for some time, and had heard promising reports regarding Bell from other industry associates. With his pending need to discover what the market had to offer, he felt the moment was right to put a demo model B30E through its paces.
Following the trial, Longwater Gravel opted to buy a new B30E, complete with onboard weighing and SafeTip systems, as well as the low ground pressure tyres.
Littleboy highlights the benefits of the B30E’s option of Bridgestone extra wide, low ground pressure tyres that better displace the machine’s force and prevent underfoot conditions from becoming too compacted, so ground drainage is improved within refilled quarry environments.
“We haven’t looked back since and have found the machine to be more reliable than anything we’ve used before,” he says. “It gives improved pull and our operator thinks it’s great; comfortable, quiet and capable, proving itself to be a machine that makes his life easier.”
Longwater Gravel has subsequently
The TA400 is the most powerful articulated hauler on offer from Terex Trucks
ordered another B30E, which was delivered in late 2018.
Another UK customer expressing satisfaction with a Bell ADT is Alf Kitching. The North Lincolnshire-based quarry and civil engineering excavation specialist says that a B40D, purchased at Hillhead 2016, has now successfully hauled over one million tonnes of limestone.
The new machine started work in September 2016 and has since racked up 5,000 hours. It has spent the last 15 months operating at Singleton Birch, Melton Ross Quarries, hauling blasted limestone and averaging an output in the region of 130,000 tonnes of stone every month.
The articulated dump truck rental market is highly competitive in the US. From time to time, the truck bodies on these trucks cannot contain the material they need to maximise efficiency. In light of this, a Caterpillar dealer recently enlisted Illinois-based off-highway truck customisation company PhilippiHagenbuch to increase the volumetric capacity of its Cat 745 articulated dump truck by adding 228.6mm (9-inch) sideboards.
Philippi-Hagenbuch claims that, whether the off-highway truck has a tailgate or not, the addition of its PHIL Sideboards is useful in increasing the volumetric capacity of the truck body and assists in minimising material spillage over the body sides.
Installation was carried out at the PHIL factory in Peoria, but can also be done at the dealership or at the client site. When paired with a tailgate, Philippi-Hagenbuch says that this set of sideboards increased the volumetric capacity of the truck by approximately 8.23m3 — more than 28% extra room to be used by haulage rental clients.
PHIL Sideboards are available in 25.4mm (1-inch) increments from 228.6mm (9 inches) to more than 1016mm (40 inches) for most makes and models of articulated haulers and rigid frame trucks.
In addition to rear-eject bodies and trailers, Philippi-Hagenbuch designs and builds end-dump bodies, trailers, tailgates and water tanks for nearly every make and model of articulated and rigid frame off-highway truck available.
At the bauma China trade show in November, Volvo CE exhibited its largest rigid hauler, the R100E.
The vehicle, launched in July 2018, is designed to be suitable for all quarrying and mining applications and offers a 95-tonne payload. It is powered by the premium 783 kW (1,075 hp) engine and the combined drivetrain delivers high torque capabilities. Drivetrain control and machine movements are supplied by the new Volvo Dynamic Shift Control, which automatically tailors the transmission shift points depending on the worksite and operational inputs.
Volvo claims that customers can expect to spend less per haul with the R100E, which features a 60.4m3 capacity V-shaped body for optimum load retention and minimal material carry-back. AB
Marcel Wimker,machine sales leader at the dealership and Heinz Herman Rehnen (right), managing director of Maschinenbau Rehnen
Longwater Gravel MD Will Littleboy says the company’s recent investment in its first Bell Equipment articulated dump truck, a B30E, is already paying off
Alf Kitching’s Volvo CE B40D, purchased at Hillhead 2016, has now successfully hauled over one million tonnes of limestone
A Cat 745 ADT, fitted with one of Philippi-Hagenbuch’s PHIL sideboards
Extra-long tread life
Outstanding cut and puncture resistance
Extra mileage
Designed for hard and rocky surfaces
Big tyre monitoring gains
One leading global off-highway equipment tyre manufacturer has big plans for its recently inaugurated cutting-edge research laboratory. Meanwhile, new tyre-performance monitoring systems are being made available to quarrying and mining fleet owners. Guy Woodford reports.
Continental, the German global technology company and manufacturer of premium on- and off-road (OTR) tyres, has officially inaugurated its Taraxagum Lab Anklam research laboratory in Anklam, a town in the state of Mecklenburg-Western Pomerania, north Germany.
After the ground-breaking ceremony in November 2017, the building covering an area of 30,000m² was ready for occupation, as planned, just one year later. It will house future research on the farming and the extraction process for Russian dandelion as an alternative to tropical rubber as a raw material source for tyres.
of its natural rubber requirement from the dandelion plant.
At the research laboratory opening, Nikolai Setzer, member of the executive board of Continental and head of the Tyre division, said: “We are the first tyre manufacturer in the world to invest such a significant amount in industrialising dandelion rubber. We see Russian dandelion as an important alternative and complementary to conventional natural rubber from hevea brasiliensis, allowing us to meet rising global demand in an environmentally compatible and reliable way.”
If test results are positive, Continental plans to introduce the raw material into serial production within ten years, allowing the firm to obtain an increased proportion
Continental’s RDT-Master range was due to be available in the new cut-resistant version from February 2019
Additionally, the €35 million investment in the new research laboratory is another technological milestone on the road to implementing the Vision 2025 strategy Continental has developed for its tyre business. “As part of our Vision 2025 strategy, we have invested far more than €2 billion in production, research and development as well as in jobs and new products worldwide since 2011. 2018, Anklam now features prominently in the series of unique projects in Europe, America, and Asia,” highlighted Setzer.
In the medium term, around 20 employees with background in agricultural sciences, chemistry, and production and process technology will research plant cultivation as well as developing, setting up, and operating machines for processing Russian dandelion at the new location.
The Ministry of Economic Affairs for Mecklenburg-Western Pomerania supported the future-oriented project with €11.6 million. This is helping create high-quality local jobs. The new business location also creates opportunities for farmers in the region and their cultivation areas, too.
“We have been working to understand the molecular basis of the rubber biosynthesis in the dandelion plant for many years. This biological understanding has now brought industrial use within reach. With the new test laboratory Continental has broken new ground that makes this transfer concept highly visible,” emphasised
ABOVE: Goodyear has introduced a significantly enhanced version of its EMTrack OTR tyre monitoring system
Dirk Prüfer, professor of Plant Biotechnology at the University of Münster (Westfälische Wilhelms-Universität Münster – WWU) and site director of the Fraunhofer Institute for Molecular Biology and Applied Ecology IME, Münster branch.
Continental has been conducting research into replacing natural rubber from the tropics with plants which can be grown in moderate climates since 2011, in collaboration with the Fraunhofer Institute IME in Münster, the Julius Kühn-Institute in Quedlinburg, the plant breeder ESKUSA in Parkstetten and other partners in various research projects, with support from the German Federal Ministry of Education and Research as well as the German Federal Ministry of Food and Agriculture. The first sample of a premium winter tyre featuring a tread made from pure dandelion rubber was brought onto the road in 2014. The first truck tyre with a tread made from Taraxagum then followed at IAA 2016.
In other Continental news, the company has launched a new compound for its RDT-Master tyres for rigid dump trucks (RDTs). The cut-resistant compound was developed for rough and abrasive
applications where tyres need to withstand sharp gravel, rocks and stones.
Thanks to the newly developed polymermeshing system based on high synthetic rubber and selected components, the RDT-Master cut-resistant compound is said to offer excellent protection and wear resistance in rough applications, while still maintaining good levels of heat dissipation.
The new compound complements the standard compound for the RDT-Master, which is the best choice for mixed applications.
As Indian global off-highway tyre market manufacturer Balkrishna Industries Ltd (BKT) notes, monitoring tools have been created to turn subjective takes on equipment performance into objective comparative data. BKT’s new SPOTech solution is an innovative, easy and quick to install technology for quarrying, mining and port applications.
Using a GPS system, a GoPro Camera and a triaxial accelerometer, SPOTech (Satellite Performance Optimisation Technology) can, for example, monitor mine or quarry haul truck journeys along haul roads and create a productivity study to help companies identify ways of reducing operational costs. SPOTech can also be programmed and tailored to an application site’s volumes and type of equipment in use. A triaxial accelerometer positioned on the haul truck records latitudinal, longitudinal, and vertical movements, as well as the forces involved in addition to speed, cycle duration and other useful parameters.
The fact that haul trucks on quarry and mine sites generally perform repeated cycles
BELOW: BKT’s new SPOTech solution is an innovative, easy and quick to install tyreperformance monitoring technology for quarrying, mining and port equipment applications
enables SPOTech to assess TKPH (TonneKilometres Per Hour) value by analysing and comparing the average weight transported to the hauler’s average kilometres per hour over a specific distance. Basically, a higher TKPH index means that a tyre is not suited to its current application. BKT experts can assist SPOTech users by offering practical suggestions on how to correctly interpret the data and to intervene, if necessary, to fix specific problems hindering tyre performance.
Chris Rhoades, BKT senior product manager, said: “Since our tyre lines are available in many sizes and patterns, it is important to choose the most suitable tyre. Which operations should the tyre perform? Where will it operate? The answers to the questions can help our BKT team to offer our customers the best solution. Wouldn’t it be cool if our equipment could let us know what it needs? It’s right here that SPOTech comes into play.”
BKT says that the use of SPOTech saved one company up to US$11 million a year in lost productivity after identifying an uneven haul road that had been causing haul trucks to slow down to ensure they reached their destinations safely. By fixing the haul road, the haul trucks could travel at a higher yet still safe speed, significantly increasing productivity. The new even haul road also improved the working life of the tyres.
Other major tyre producers have introduced their own range of tyre monitoring solutions.
Goodyear has launched a significantly enhanced version of its EMTrack OTR tyre monitoring system. “The completely updated
Goodyear EMTrack tyre-performance monitoring system enables faster and even more accurate collection of critical tyre data like tread depth, inflation levels and other indicators,” said Eric Matson, global field engineering manager, Goodyear.
He continued: “The enhanced EMTrack system also offers convenient, cloud-based data storage and more robust reporting capabilities thanks to the addition of the new Goodyear EMTrack App. This gives mining, construction, quarry and port operators an enhanced platform, so they can make even more informed decisions about their valuable tyre assets.”
The Goodyear EMTrack system initially sees trained Goodyear tyre technicians performing fleet surveys, using a special Goodyear EMTrack scanning tool to capture tyre inflation, tread depth and other critical measurements.
Tyre-performance data automatically uploads via Bluetooth to a cloud-based platform
for password-protected storage and easy access.
End users download the data into easyto-read, customisable reports that show tyre performance.
“Through the Goodyear EMTrack App, a user can view collected tyre data and reports simultaneously and in real time, regardless of their geographic location, for complete visibility,” said Matson.
End users can view performance data for their tyres across their operation and even zero in on specific tyres, calculating cost per hour, cost per tonne and other key metrics.
“Among other benefits, this will help end users identify, if applicable, maintenance opportunities to help ensure optimal tyre performance,” explained Matson. “And the information collected through Goodyear EMTrack can also help in forecasting future tyre requirements.
“The needs of our customers are
Continental has officially inaugurated its Taraxagum Lab Anklam research laboratory in Anklam, Mecklenburg-Western Pomerania, Germany
continually evolving,” Matson added. “The trusted products, worldwide support, reliable services and management tools that Goodyear offers – such as EMTrack – are also evolving. We are confident that the enhanced Goodyear EMTrack system can help improve end users’ operational efficiency and help lower their operating costs.”
Dutch off-highway tyre producer Magna Tyres reports that a Spanish quarry operator is reducing its hourly operating costs using 18.00R33 steel radial Magna MA04 premium tyres with E4 pattern on its rigid dump trucks (RDTs). The RDTs are used in demanding circumstances for heavy transport purposes within the Spanish customer’s quarry site.
Despite the intensive and frequent usage, Magna Tyres reports that the tyres are perfectly and equally worn to the end of their working life. A new set of Magna MA04 tyres was recently delivered to the Spanish quarry customer and mounted on the RDTs by Magna Tyres’ Spanish distributor.
The Spanish quarry customer is satisfied with the Magna MA04 tyres’ ability to lower hourly RDT operating costs and the overall performance of the tyres has led to a further investment in 23.5R25 Magna MA01 premium tyres for their quarry wheeled loader fleet.
The Magna MA04 is specially designed for dump trucks in heavy-duty mining and quarrying conditions. The improved shoulder and sidewall protection offers excellent resistance to damage, and different compounds are available to optimize performance for different applications.
The Magna MA01 is designed for use on wheeled loaders, dozers, scrapers and graders. An aggressive non-directional tread pattern provides superior traction in soft underfoot conditions. The tread compound provides excellent protection against cutting and abrasion. AB
Mecklenburg-Western Pomerania state secretary Patrick Dahlemann, Dr. Andreas Topp, Nikolai Setzer, Boris Mergell, Harry Glawe, Dr. Carla Recker, Dr. Carsten Venz, Michael Gallander and Katherine Herzog
Excavating without disturbing the neighbourhood
An MB attachment is helping to facilitate a complicated renovation scheme in the German city of Munich. Liam McLoughlin reports.
An MB-C50 crusher bucket is being used on a civil construction project in a historic residential area of Munich.
The project is to carry out excavations and construct a building extension in the courtyard of a house at 45 Franziskaner Strasse. The property is at the centre of a network of underground tunnels, some dating as far back as 1700.
The tunnels are underneath modern buildings, houses and shops, with the owners of many of these looking to expand to accommodate new tenants or businesses. The crowded surrounding streets mean there is generally little potential space for development, and MB says the courtyard was the only available choice for the construction scheme.
German company Stöger Baggebetrieb, which is carrying out the project, began to construct the building extension by demolishing part of the inner courtyard and then laying new foundations. Demolition waste from the site is being used to fill the foundations of the new building.
Stöger Baggebetrieb installed the crusher bucket from Italy-based
manufacturer MB on the Cat 305 5E2 excavator that is being used to work inside the yard. The bucket is operated directly from the cab of the excavator, which manoeuvres in a very small space as the crusher bucket collects the material and reduces it on the same spot. MB says that processing the material on the site means there are zero transport costs and hasslefree operations. The required output size can be adjusted by the operator on-site in a few minutes without the need to call in a specialised workshop.
MB says the biggest challenge was to safely manage the construction site, in a short time and without disturbing the neighbourhood. The project faced a number of difficulties: moving the compact equipment through the narrow courtyard entrance; limiting the amount of dust, noise and vibrations produced; managing the excavated material; and working rapidly while containing costs.
At number 45 the courtyard entrance is narrow and the inner yard itself is small. The only equipment capable of fitting without problems to carry out the excavations was a 5-tonne mini-excavator. In addition,
there was the issue of what to do with the material once it had been excavated. At first glance the solution seemed to be to load it onto small lorries and haul it to recycling centres, and then bring back the stabilised material into the yard to fill the foundation base.
MB says this would have been a logistical nightmare in terms of coordinating the number of lorries coming in and out of the site. There would have been timing issues, unforeseen costs, downtime and limits on the operation of trucks in the city centre.
The MB-C50 crusher bucket provided a solution to these issues as there are no haulage costs, and it arrives on-site already installed on the digger.
Vibrations from the construction could have compromised the building structure. To combat this the MB-C50 crusher bucket is equipped with a dust nebuliser, designed for reduced noise compared to traditional means of crushing, fewer vibrations to the arm and zero to buildings.
MB displayed its 12-strong range of crusher buckets at the bauma China trade show in Shanghai in November. Visitors
A Cat 305 5E2 excavator fitted with the MB-C50 crusher bucket at work on the Munich construction site
had the opportunity to see the BF120.4 bucket that is suitable for excavators from 30 tonnes; the BF90.3 for excavators from 21 tonnes; the MB-L200, suitable for loaders, backhoes and skidsteers; the MB-S18 screening bucket; and the MB-R800 drum cutter.
The company says that one of its customers in Indonesia has installed an MB-S23 screening bucket on a Komatsu excavator to clean the alluvial rocks from sand, mud and clay. Once cleaned, the screened material is crushed and used for road maintenance work.
Mounted on a Cat 3360 excavator, the MB crusher bucket BF120.4 has been used in China to crush rocks that are reused for road construction.
MB says that use of its bucket products has helped to reduce problems with delays to road construction projects in a number of developing countries. In Malaysia, for example, new schemes are underway to add to the approximately 65,000 km of roads that connect to every state. The process of construction of a new road – whether from asphalt or concrete – requires the production of an excellently bonded pavement structure, beginning with a stable base layer and going all the way to a precisely levelled surface course.
Although a fairly straightforward process, construction can often be delayed at this stage. Studies have been conducted in Malaysia to identify the problems faced by contractors and the reasons for the many requests for extension of road construction times. These have pinpointed the following challenges: lack of materials, lack of workers, change of design, financial problems and lack of machinery.
MB says these issues were recently improved for contractors in the Sibu district of the country with the use of an MB Crusher Bucket BF90.3 mounted on a Hyundai 210 LC-7, which it says makes excavators easy to manoeuvre and transport around.
Finnish recycling company Remeo has invested in a D series attachment from the Allu range of Transformers. Remeo says the processing power of the Transformer has proven to be particularly effective in dealing with demolition waste and recycling asphalt.
The Allu Transformer series comprises an excavator/loader/tractor-mounted processing bucket which screens, pulverises, aerates, blends, mixes, separates, crushes, feeds and loads materials. This is designed
to result in the feed material being effectively transformed into highly valuable products, with the intention of making businesses more efficient and profitable.
Remeo employs around 350 people and utilises a specialist fleet of over 200 recycling equipment vehicles. With offices located throughout Finland, including Vantaa, Riihimäki, Tampere, Heinola, Lahti, Kotka, Turku, Vaasa, Uusikaupunki, Lappeenranta, Seinäjoki, Vihanta, and Ylivieska, the company’s collection network channels waste for recycling to its nine recycling stations. Here materials are recycled and treated in plants before being delivered for appropriate further processing, or for processing as an industrial raw material.
Remeo says the Allu attachment has enabled it to utilise its existing fleet of excavators and loaders to deal with materials either on site, in the case of demolition waste and road planings, or load screened material directly onto its haulage fleet. The processing power of the Allu Transformer is claimed to reduce weight by up to 50% (by screening out valuable materials prior to hauling), which increases the efficiency of its operation, as well as reducing emissions from its haulage fleet.
Catering for applications of all sizes, and capable of processing any material that can be screened and sorted, the Allu Transformer series comprises the compact DL & D Series as well as the massive M and G Series. All are designed to improve efficiency and profitability for material handling and processing businesses.
Allu exhibited some of the Transformers range at bauma China in November. The models on show were the DH 3-23 X75 drums, the DS 3-23 (with TS 25 mm
standard blades for screening), and the DS 3-12 with 60mm drums.
Italy-based screening bucket manufacturer Simex has started construction work on a new 7,000 m2 production facility at its base in San Giovanni. Once the new unit is operational later this year, Simex CEO Mirco Risi says it will enable the company to organise and manage different processes more efficiently, with improvements extending to its delivery capacities.
Simex supplies a range of screening buckets with an adjustable output size. The VSE screening buckets for excavator mounting feature hydraulic adjustment of drum distance to allow the size of the screened material to be varied in seconds.
Drums are composed of elements with different diameter disks, whose varying peripheral speed generates intense spinning of the material to be screened, which is designed to result in higher output.
The VSE is shaped as a standard bucket, which Simex says facilitates and simplifies loading of material. There are four variants in the range: the VSE 10 (bucket capacity 0.40 m3, recommended excavator weight 8-13 tonnes); the VSE 20 (bucket capacity 0.70 m3, recommended excavator weight 12-18 tonnes; the VSE 30 (bucket capacity 1.00 m3, recommended excavator weight 16-30 tonnes); and the VSE 40 (bucket capacity 1.80 m3, recommended excavator weight 30-45 tonnes). AB
Finnish recycling company Remeo has invested in a D series attachment from Allu
Simex produces the VSE range of screening buckets
An MB Crusher Bucket BF90.3 mounted on a Hyundai 210 LC-7 excavator
The combined challenges of hilly terrain and unstable ground were overcome by BEUMER Group when installing a highly efficient and productive 12.5km long conveyor for Sichuan Yadong Cement
Conveying scale & efficiency
A leading conveyor system company has been talking about two giant conveyor belt projects for a Chinese cement firm. Meanwhile, another top sector player is launching new aggregates processing conveyors and components, while two other manufacturers are opening new state-of-the-art production facilities. Guy Woodford reports.
For nearly a decade, Sichuan Yadong Cement, in Pengzhou, China, has been relying on a 12.5-kilometre overland conveyor from BEUMER Group (BEUMER) to convey limestone from its quarry to its silo and bulk loading system near the company’s cement plant. When constructed in 2009 it was the longest belt conveying system in BEUMER history. The troughed belt conveyor runs through hilly terrain and nature reserves, over streams and unstable ground. A more recent project for Sichuan Yadong Cement saw BEUMER install two additional overland conveyors for transporting limestone directly from the quarry to the company’s cement plant. Unlike the first project, the task here was to build the conveyor across inhabited areas. Noise emission limitations set forth by the government also needed to be considered.
A traditional Chinese proverb says that the roads in Sichuan are hard, harder than climbing to heaven. Depending on the destination, there are rivers and valleys to be crossed and mountains to overcome. The southwestern Chinese province of Sichuan is the source of the majority of different ores in the country, such as titanium, lithium and silver and plays a major role economically. The electronics, mechanical engineering, metallurgical, chemical, medical, food and building material industries are all pillars of the economy. Located near Chengdu, the capital of Sichuan province, Sichuan Yadong Cement is a well-established regional cement manufacturer. The company is a member of the Asia Cement Group (Asia Cement), headquartered in Taipei, Taiwan.
In 2004 Sichuan Yadong Cement decided to build a new cement plant in its home province. During the development phase, Asia Cement received approval from the
Chinese government to use an abandoned railway to transport the limestone. Halfway through finishing the plant however, the government decided to build a new dam. The area intended for the transport was to be flooded, which would have changed the project conditions considerably: roads would be flooded, and the trucks would have to take significant detours. Asia Cement was also planning on building two additional kiln lines at this location. It was determined, as a time- and cost-efficient alternative, to install a troughed belt conveyor able to navigate horizontal and vertical curves. For this, the company turned to BEUMER. For many years now, Asia Cement has been relying on the system supplier’s expertise and is currently operating several of its bucket elevators.
BEUMER’s Chinese subsidiary, BEUMER
Machinery Shanghai, took over the mechanical and electrical engineering, supplying the core components for the overland conveyor and monitoring and commissioning its installation. “Our colleagues were able to work closely with the customer. They know the specific local customs, speak the language and are familiar with the particular market and customer requirements,” said Dr. Andreas Echelmeyer, director of Conveying and Loading Systems at BEUMER.
In May 2006 Asia Cement awarded the contract for the 12.5km-long system. The overland conveyor can reach a mass flow of 1,360tonnes/hour and a conveying speed of four metres/second. “Compared to other conveying solutions, the open troughed belt conveyors are suitable for higher throughputs. Horizontal as well as vertical curve radii are possible,” explains Dr. Echelmeyer. The belt conveyors can be adapted to a specific task and topography. Using its calculation programs, BEUMER could precisely calculate the static and dynamic tractive forces of the belt during the development phase of the system. This is a prerequisite for the safe dimensioning of horizontal curves. The type of drive technology and conveyor belts needed are based on these calculations. This would ensure longevity of the entire system for Sichuan Yadong Cement.
The terrain for the overland conveyor project was hilly and covered with dense bamboo forest, parts of which are listed as a nature reserve. For this reason, the government did not approve a service route nor deforestation. The ground also presented a major challenge for BEUMER engineers. “The ground is unstable due to previous coal mining. In other areas the ground consists mostly of granite that could only be partially
View of an enclosed section of one of the BEUMER belt conveyors installed for Sichuan Yadong Cement
removed,” explains Dr. Echelmeyer. Another 1.5km overland conveyor section had to be guided across a river. These framework conditions contributed to the fact that 90 per cent of the system was installed manually on site. As it was impossible for trucks to transport the components, they were carried by mules, one part at a time, to the place of installation.
The route of the overland conveyor was coordinated between BEUMER and the cement manufacturer. The system supplier calculated the tractive forces of the belt considering the eight horizontal curves with radii of 1,000-5,000 metres. The routing was checked for its feasibility on site. The complete route was checked by employees on foot, passing through rough terrain, in order to reliably check the predefined positions for the 460 supports for their suitability directly on site. Whenever technically possible, the routing of the conveyor was adapted to the topography. Height differences of up to 100 metres had to be overcome within the shortest distances, so several sections were equipped with bridges of up to 55 metres. One section was realised with a 130-metre long tunnel.
requirements. For this project, the first conveyor was to be customised to these requirements. “We were planning a second troughed belt conveyor with an overall length of 13.7 kilometres,” says Dr. Echelmeyer. This was agreed on, making it the longest system in BEUMER’s history.
Projects of that size are often unpredictable, so flexibility was needed from the engineers. During the planning phase, Asia Cement acquired another plant in Lanfeng, approximately ten kilometres away. “Now we had to design the system so that both plants could be supplied with limestone,” explains Dr. Echelmeyer. The team had to divide the overland conveyor in two parts. After 5.4 kilometres, an additional conveyor can be added to be fed to Lanfeng in the future. In February 2015 the system supplier started with the installation of the conveyor frame.
Since February 2009 the overland conveyor has been transporting bulk material from the quarry to the bulk loading system. Since commissioning of the first section, the mass flow of the conveyor has increased in two steps. Today, the system conveys a mass flow of 2,000tonnes/ hour at a conveying speed of 4.5 metres/second.
In July 2013 Asia Cement contracted BEUMER again for an additional, efficient overland conveyor to replace the trucks transporting the limestone from the bulk loading system to the cement plant. A mass flow of 1,995 tonnes of limestone per hour was necessary to meet the plant’s
Both overland conveyors have four horizontal curves with radii of 1,200, 1,500 and 1,800 metres. “We provided the engineering and the individual parts such as pulleys, motors, drive and control technology and the entire automation,” describes Dr. Echelmeyer. The installation was monitored by a BEUMER supervisor and the wiring of the system was supported by a BEUMER electrical engineer. The system supplier was also in charge of the commissioning in May 2016. The troughed belt conveyor is now supplying three kiln lines, and a fourth line is planned.
emission levels so that the residents would not be impacted. “We had to minimise the noise to an extremely low level,” says Dr. Echelmeyer. The system supplier took several constructive measures in order to reduce the noise emissions. “We used noise-reducing idlers and customised protective covers on the drive stations,” Dr. Echelmeyer adds. In collaboration with the operator, BEUMER optimised the conveyor frame and the completely enclosed conveyor bridge.
Across both projects, BEUMER was able to ensure that the limestone is transported safely and quietly, without disturbing the residents or disrupting the surrounding natural environment.
Superior Industries (Superior), an American-based manufacturer and global supplier of bulk material processing and handling systems, has launched two new tracked conveyor models.
The requirements were different for the two Sichuan Yadong Cement/Asia Cement Group projects: the challenges for the first project were the hilly terrain, unstable grounds and crossing through conservation areas and over waterways; for the second project the system had to be built crossing through populated areas. The Chinese government has set out exact regulations on the noise
Joining the manufacturer’s top-selling line of portable conveying solutions are a 23-metre tracked stacker and a 2.4m x 4.9m tracked feed hopper.
Following Superior’s reputation for heavyduty designs, the tracked stacker will be one of the heaviest models available in its class at 15.42tonnes. Each stacker is capable of handling up to 907tonnes/hour, while hydraulic power controls the tracks, folds, and discharge height. Using a cross-bracing design built into the undercarriage of the tracked stacker ensures structural rigidity and stable track travel.
The 8mx16m tracked portable feed hopper processes up to 725tonnes/hour from a 6.1m³ reinforced hopper. A bi-directionally dumping grizzly is equipped with adjustable grizzly bars and can be tilted at one of five pre-set angles. The hopper’s drive and backstop are hydraulically controlled in addition to the discharge conveyor’s fold and raise features.
Part of Sichuan Yadong Cement’s 12.5km overland troughed belt conveyor
Both the stacker and the feed hopper are equipped with Superior brand conveyor components like off-the-shelf idlers, pulleys and Exterra Primary Belt Cleaners. Several units are now in stock and available for immediate delivery from Superior or one of its many conveying equipment dealers.
From its humble beginnings in a garden shed in 1979, Smiley Monroe has grown from a ‘man in a van’ service company supplying local quarries in Northern Ireland, to the world’s leading producer of highly customised Endless conveyor belts, with a global client list that reads like an A-Z of the materials processing equipment manufacturing sector - brands such as Powerscreen, Terex Finlay, McCloskey International, Sandvik, CDE, Astec, Telestack, Maximus, Metso, Kleemann, RubbleMaster and Keestrack.
The family-owned company has risen to its fair share of challenges - not least several recessions and the 2008 global economic downturn - by continually adapting, innovating and remaining true to its core values of staying ‘Close to Our Customers’ and being ‘Problem Solvers’. Having broken sales records in 2018, now Smiley Monroe has entered its landmark 40th anniversary year.
As this issue of Aggregates Business goes to press, Smiley Monroe Inc is finalising the location of its first USA production centre. Set to open its doors in 2019, the facility will be based on its successful production models in Lisburn and India. The US production centre will have a key focus on just-in-time supply of ZIP CLIP Belts to the North American market.
“Demand for our ZIP CLIP Replacement Conveyor Belts has grown exponentially in the States, so the time is right to invest in a facility close to our US customers, so
we can reduce lead times and ensure the fastest turnaround” said Ryan Wright, North America sales manager. “This product is unique in the market place and with a growing industry focus on maximising opportunities for aftermarket sales, ZIP CLIP fits perfectly into this Spares and Wear Parts strategy. Some OEMs even specify ZIP CLIP on new machines, as it suits their existing manufacturing process and it’s both easy to factory fit and fast to replace in the field.”
Unlike the alternatives, ZIP CLIP Belts are produced using industry leading, stainless steel mechanical fastener technology for superior splice strength, durability and belt straightness. Like a spare wheel for your car, Zip Clip is supplied ready-to-fit – to suit the conveyor’s exact Endless belt length, width and specification – so there’s no need for specialist training or waiting on an external vulcanising team and once tensioned the belt can be run immediately. Having Zip Clip belts in stock, close to your most critical conveyors, which can be fitted in as little as 30 minutes, can really help maximise uptime in the event of an otherwise costly breakdown, particularly in operations such as
mobile equipment, not just static or fixed plant; and to comprehensively address some of those frequently asked technical questions we have encountered over many years in the industry. Our content is very visual and has been created as an easy-to-use guide to meet the specific needs of our engineering customers.
“We’re also keen to educate visitors to our stand on the economic and environmental benefits of energy-saving products such as our polymer King Roller, something we’ve seen take on greater importance for our OEM customers as they seek to reduce the overall weight of their machines to reduce shipping costs and meet transport restrictions. It’s always great to catch up with our customers at bauma and with the industry so buoyant, the atmosphere this year promises to be something to look forward to.”
On the other side of the world, Smiley Monroe India has significantly increased the capacity of its Hosur production facility, near Bangalore in southern India, by increasing its footprint to 2,320m². Investment in a new CNC cutting machine and a new automated vulcanising press will enable the company to ramp-up production of Custom Cut Parts and Endless Conveyor Belts for customers in the region such as Terex, CDE Asia and Keestrack.
Telestack has further committed to its future in Omagh, Northern Ireland, by announcing an investment of £5 million (€5.75mn) in a new factory in the Doogary Industrial Estate.
A leading global bulk material handling systems manufacturer serving, among others, quarrying and mining sector customers, Telestack supplies some of the largest bluechip companies in the world. Designed, manufactured and exported from its current 9,755m² manufacturing facility in Omagh, Telestack plans to extend their manufacturing capacity by initially building a phase one 4,180m² factory on a greenfield site next to the current Fane Valley factory. The new factory will incorporate state-of-the-art manufacturing premises, a dedicated research and innovation development centre and modern office suite, all of which is central to the firm’s continued growth strategy.
The engineering acumen within Co.Tyrone is renowned globally, and the expertise within
Superior Industries’ new 23-metre long tracked stacker, one of the heaviest models in its class
Smiley Monroe’s first US production centre will have a key focus on just-in-time supply of ZIP CLIP Belts to the North American market
Telestack has grown and developed significantly over its 34-year history. In addition to its Aggregate and Mining Group, Telestack has matured within another material handling niche in the ports and inland terminals sector, designing and manufacturing equipment to load and unload dry bulk onto vessels up to Panamax (80,000tonnes size limits for ships travelling through the Panama Canal). The company’s equipment is involved in some of the most groundbreaking, exciting and forward-thinking projects across the globe, with Telestack gaining serious traction in other industries such as the rail, power, cement and steel plants.
Employing almost 160 local people, Telestack has demonstrated enviable year-on-year sales growth, with sales more than doubling in the last three years. In the last two years alone, the Northern Irish firm has invested almost £4million (€4.6mn) in its current Bankmore site within Doogary Industrial Estate. This has included the installation of a state-of-the-art shot-blast, two paint booths and additional manufacturing facilities, all contributing to the business’s impressive sales and operational performance.
Martin Dummigan, Telestack managing director, said: “Telestack has grown rapidly over the last number of years and we have firm plans to double our revenue again in the next three-and-ahalf years. We have outgrown our current facility and we need to extend our footprint to meet the international demand for our
Visit us! bauma, Munich, Germany April 08 – 14, 2019 Hall B2, stand 413
SOME THINK RAW MATERIAL TRANSPORT REQUIRES A COMPLEX
products. We have made a conscious decision, even in the face of Brexit uncertainty, to invest locally. We have a unique skills base in Omagh and we need to protect Telestack’s engineering acumen. The marketplace has become somewhat flooded with companies who try to copy our designs, but you simply can’t buy experience. For want of a better cliché, you have to earn your stripes. We have the experience, the commitment and the enthusiasm to continue forging ahead and continue leading the market, hence the purpose-built research and innovation development centre. We have an aggressive strategy to continue growing our sales and we are committed to Omagh, to the people that we employ and to the local suppliers and businesses that will continue to benefit from the Telestack success story.”
Telestack recently designed and manufactured what is thought to be the largest international mobile bulk reception feeder in the world. The unit is currently loading aggregates onto barges for a large American multi-national corporation at loading rates in excess of 14,000 tonnes/day.
Telestack has also recently installed a unit as part of the multibillion pound Thames Tideway Tunnel in London. Tideway is building a major new sewer under the River Thames, nicknamed the ‘super-sewer’, which is urgently needed to stop millions of tonnes of sewage overflowing into the river. At 15 miles long, seven metres
STRUCTURE.
Mined raw materials travel along extensive transport routes. Overland and pipe conveyors are an energy efficient, reliable and environmentally friendly way of transporting the commodities over long distances to the plant or storage area. We customise the curved belt conveyors to overcome any challenging topographical circumstances. This minimises the transfer points and the number of systems and reduces investment, operational and maintenance costs. For more information visit www.beumergroup.com
Telestack’s factory in Omagh (pictured) has benefited from a near £4mn investment in its manufacturing capability and paint facility in the last two years. The company is to make a further £5mn investment in a new 45,000sq ft. factory on a nearby greenfield site in Omagh to meet the international demand for its product
wide and up to 65 metres deep, the Thames Tideway Tunnel is the biggest infrastructure project ever undertaken by the UK water industry. The Telestack unit is at the end of the tunnelling process, loading the tunnel clay onto barges fed from a fixed conveyor. Meanwhile, Telestack is currently completing the installation of a £5 million (€5.74mn) system in Oman for the Port of Salalah. The equipment will be another global first in terms of innovation, providing a novel shiploading system to handle the additional capacity needed by the port. The four-unit
installation comprises two shiploading systems, both featuring a TB60 All Wheel Travel Shiploader fed by a Titan dual-feed All Wheel Travel 800-6 Bulk Reception Feeder. Telestack says this represents the new generation of mobile shiploading, offering all of the performance of traditional systems but with the added benefits of mobility, flexibility and, ultimately, a lower cost per tonne achieved by increased production rates, reduced cycle times and reduced labour costs. The equipment is designed to load limestone, gypsum and cement clinker
at average rates up to 1,200 tonnes/hour to Handymax, Panamax/Post Panamax vessels. Telestack began discussions in 2013 with the Port of Salalah technical and operational teams to design a customised shiploading system as part of an ongoing $15 billion infrastructure investment to cater for the export requirements of its local mining, quarrying and cement industries.
Telestack opens 2019 with its largest order book ever as it builds on the successes of 2018. This includes projects for Africa, USA, South America, Europe, Russia and Asia. AB
Europe’s leading aftermarket manufacturer and supplier of precision crusher spare parts and premium manganese wear parts for the Mining and Quarrying Industries.
Telestack’s fully mobile shiploading system for the Port of Salalah in Oman
www.telestack.com sales@telestack.com
Liebherr mixer supports Swiss mountain project
Liebherr says that its concrete technology operation, one of eleven divisions within the Liebherr Group, saw growth during 2018.
Construction waste such as concrete washout is under scrutiny from environment agencies around the world, largely due to its heavy metal content, notably chrome.
Manufacturer helps contractors to tackle logistical and on-site challenges of concrete supply for major Alps cable car scheme Liam McLoughlin reports.
ALiebherr Compactmix 1.0 mixing plant is supplying the construction site for the V-cableway (or V-Bahn) project in the Swiss mountains with concrete. The CHF470 million (€417m) project is scheduled to open for the 2020/2021 winter season.
German-based equipment manufacturer Liebherr says the project was a challenge both in terms of logistics and on-site operation.
The Grindelwald-Männlichen Gondola Cableway company and Jungfraubahn railway company are planning to build the V-cableway that will open up both the Eiger Glacier and the Männlichen (Bernese Alps). From a joint terminal in Grindelwald-Grund, a tri-cable aerial cableway will lead to the Eiger Glacier and a ten-seater aerial gondola cableway to Männlichen. In addition, the new Rothenegg station will give the V-cableway a direct connection to public transport.
The project managers at ARGE V-Bahn Oberland were looking for a mixing plant with special properties that could be transported by cable car. They opted for the Compactmix 1.0 A-R/ RIM-M due to its compact design, system performance and pre-assembled, transportoptimised modules.
Since the aerial cableway was not ready for operation by the specified assembly date, the plant components were transported to the construction site by a 2-axle truck and dump truck. The plant itself was then built on the Eiger Glacier at an altitude of 2,340metres. For optimum mixing results, the plant is equipped with a ring-pan mixer with agitator system.
For concrete production at low
temperatures, the plant is fitted with a winterproof housing. The aggregates and cement are also delivered to the plant by aerial cableway and fed directly from the cable car into the series silo. The clients as well as the contractors are Jungfraubahn AG and Männlichenbahn in Grindelwald.
At the forthcoming bauma 2019 trade show in Munich (8-14 April), Liebherr will be showcasing its completely redeveloped 42 M5 XXT automatic concrete pump for the mid-range class. Many technical parts come from Liebherr’s own component production.
The company says that another outstanding product to feature at bauma will be its new Powerbloc drive unit for the pump system. All hydraulic switching and metering elements are fully integrated, which eliminates the need for many hydraulic lines and other parts.
The Liebherr Group stand at bauma 2016
Concrete washout is the process of cleaning construction site equipment, such as the chutes of ready-mixed concrete trucks and hoppers of concrete pump trucks, to remove the remaining concrete before it hardens.
With the rate of construction unlikely to slow down, the Watson-Marlow Fluid Technology Group (WMFTG) predicts there will be no let-up in the quantity of concrete washout produced. The UK peristaltic pumps manufacturer says there needs to be an increased awareness of technology that can help concrete plants and construction firms meet growing demand, without suffering legal, financial or environmental consequences associated with waste disposal.
It adds that among such technologies are WMFTG’s latest Qdos chemical metering pumps and Bredel hose pumps, which are designed for tough applications such as construction sites, aggregate and concrete production plants.
Water contacting freshly exposed or poured concrete takes on an alkaline pH (circa 13) due to chemical reactions between the water and free lime particles within the cement. At a typical concrete plant, up to 12,000m3 of water is consumed every year, which means that the
The Liebherr Compactmix 1.0 produces concrete at a height of 2,340 metres for one of the largest aerial cableway projects in European history.
washing down of machinery, equipment and transportation vehicles becomes problematic.
WMFTG says the issue is equally prominent at construction sites, where there are many common sources of alkaline waters, including: washing chutes and drums used with fresh concrete; cutting or coring concrete structures; hydro-demolition processes; surface water run-off from recently lime-stabilised sites; stockpiled or spread-crushed demolition materials; placement of fresh concrete beneath groundwater (such as piled foundations).
While most are familiar with the dangers of acids, highly alkaline substances such as concrete wash water can be just as corrosive, and if left untreated can cause concrete burns, damage to vegetation and the surrounding ecosystem.
So, how does the industry go about resolving the high pH of wash water? WMFTG says that to adjust high pH wash water in line with consent levels, a process of neutralisation using controlled amounts of reagent is required. Typical reagents include mineral acid (either sulphuric or hydrochloric acid), citric acid, carbon dioxide (CO2) and self-buffering solutions.
The company adds that its peristaltic pumps are increasingly favoured for concrete washout applications, due to their extremely low maintenance requirements, and safe, non-contacting pumping method. Without mechanical seals or valves to leak or corrode, Qdos and Bredel pumps completely contain the pumped fluid, preventing operator contact with chemicals or spillage of untreated sludge.
Turkey-based ELKON has been chosen by a Hungarian contractor to supply its ELKOMIX-135 Quick Master compact concrete batching plant for a major road construction scheme. The EU-funded project, in an area close to the Austrian border, involves the construction of the second phase of the M85 motorway.
The M85 motorway is part of the European E65 road, which begins in Malmö, Sweden, and ends in Chaniá on the Greek island of Crete.
The ELKON plant will provide high-quality and non-stop concrete for the 21.8 km portion of the 88 km long motorway between the cities of Felsirákos-Sopron and Sopran-Nagylózs.
The plant is equipped with winter covering that enables the production of concrete even in heavy winter conditions down to -30°C.
Cubis Industries operations director Nick Cowley in front of the company’s new static concrete batching plant, co-developed with Advance International
The concrete batching plant is closed with completely insulated panels and features an aggregate heating system with steam generator and aggregate heating pipes, along with automated cover over the aggregate bunker.
ELKON says the new project plays an important role in Hungary’s access to central Europe,
The Bredel hose pump from the Watson-Marlow Fluid Technology Group (WMFTG) is used in the process of concrete washout. Image courtesy of concrete waste water solutions provider Siltbuster
Northern Irish building materials provider Cubis Systems (a division of building materials company Cubis Industries) has co-developed a bespoke static concrete batch plant with Rapid International.
Until 2019, Cubis’ prior concrete production system involved the use of a volumetric truck mixer. This production method made the process of achieving desired outputs and tensile strength of the final product more difficult to control and time-consuming.
With a desire to continue targeting key global markets, Cubis required a new system which offered a greater degree of consistency, flexibility and increased outputs to keep pace with growth
The plant at the Cubis site in County Armagh integrates a Rapid RP500 1 door Planetary mixer, positioned on a specifically designed platform, granting easy access for maintenance.
The Rapid Planetary concrete mixer features outputs of 0.5m3 per batch, a pneumatically operated
pyp discharge door with heavyduty mechanisms, ump from w p (WMFTG) ess of ete waste ovider
and will reduce traffic congestion, shorten journey duration and help alleviate the burden of road transport in the region.
ELKON has been providing plant to the Hungarian contractor since 2015, having supplied a previous concrete batching plant for work on the bypass section of the EU-funded 8 highway (M8) project.
The two batching plants supplied have largely the same configuration, being equipped with 4500/3000 l. ELKON Twinshaft Mixers that have 120m³/h concrete production capacity. Their compact design is designed for easy installation and transportation. The 6x20m³ aggregate bins in both concrete mixing plants allow the storage of six different aggregates to be used in the special concrete mixture required by the project.
BELOW: The ELKON concrete batching plant being used for phase 2 of the M85 road construction project in Hungary
extra thick chill-cast wall and floor tiles and a 22kW 3-phase motor.
The mixer is intended for precast applications, making it a suitable choice for Cubis. The mixer’s star mixing action is designed to create high turbulence, resulting in a consistent and homogenous mix. The mixer’s motor and gearbox are positioned on top of the mixer allowing easy access for cleaning and maintenance.
Cubis also opted for an optional Rapid Jetwash to enable fast and powerful mixer cleaning. The Rapid Jetwash is a fully galvanised, self-contained, high-pressure mixer washout system. Each wash cycle takes four minutes and the 2,000psi unit can power up to four mixers simultaneously. AB
Record-breaking bauma China
The 2018 edition of bauma China was an action-packed record breaker. Guy Woodford was among the visitors keen to see the latest aggregates processing equipment for Chinese customers.
Bauma China 2018 in Shanghai set impressive new records for exhibitor and visitor numbers. In all, 3,350 exhibitors showed new products at the event, up 13% from the previous show in 2016. And 212,500 visitors attended the show, a rise of 25% on 2016. Of the attendees, 94% came from Asia and in addition to Chinese visitors there were strong showings from India and Vietnam for example.
The event was run under the theme, Smart technologies for an exceptional market, and covered an area of 330,000m², using the entire available exhibition space at the Shanghai New International Expo Centre (SNIEC). The 9th International Trade Fair for Construction Machinery, Building Material Machines, Mining Machines and Construction Vehicles was held from 27-30 November 2018. According to the show organisers, the event highlighted the future of the Asian construction, quarrying and mining industries: smart, digital and more sustainable.
Keen to maintain its status as the biggestselling tracked mobile crushing equipment manufacturer in China, Kleemann, a Wirtgen Group company, unveiled a trio of new models.
The up to 650tonnes/hour MOBICAT MC 120 Z PRO mobile jaw crusher, the 470tonnes/hour capacity MOBICONE MCO 11 PRO mobile cone crusher, and the up
to 500tonnes/hour MOBISCREEN MS 953 EVO classifying screen could be seen on the Wirtgen Group’s huge indoor stand.
“The big challenge here is to sell not only these machines, but also the concept of crushing on tracks,” said Mark Hezinger, Kleemann’s marketing manager. “There is huge potential for our tracked-based plant in the Chinese market, and we can benefit from the Wirtgen Group’s wide dealership reach and established status.
“We are seeing that it is easier for many Chinese plant operators to get permits for tracked mobile plant crushing than for stationary plant crushing. There is also great potential resale value with tracked mobile plant.”
Hezinger said that growing competition in the Chinese tracked mobile plant market would likely lead to a fall in model prices in the coming years.
Meanwhile, Kleemann’s first Chinese market model, the MOBIREX MRI 30 EVO 2 mobile impact crusher launched in 2012, continues to prove a popular model with customers. “The model gives you a good final product in one crushing stage. It also gives you a very good shaped product,” explained Hezinger.
Kleemann has staged several highly successful Technology Days in China in the last two years. “We are really happy about how the Chinese market is developing. All the effort that we have put in are starting to
pay off.”
With the three PRO Line models being showcased in Shanghai, Kleemann is developing innovative plant which are very powerful and efficient, leaving them well equipped to cope with the demands of natural stone processing.
Emphasising Kleemann’s focus on premium state-of-the-art crushers and screeners, Hezinger said that 90% of the firm’s current global sales are generated by models less than four years old.
During show week, Terex staged a breaking-ground ceremony on the site of what will be a new assembly and fabrication facility for Genie aerial work platforms in Changzhou, eastern China.
Kieran Hegarty, president of Terex Materials Processing (Terex MP), and Colin Clements, Powerscreen global product line director, attended the event – marking the latest stage of ambitious Terex’s Chinese market development.
Powerscreen, the major Terex MP global quarrying equipment manufacturer, which offers a full product line-up to Chinese customers, is expected to share the facility with Genie at some stage in the future.
Joe Cassidy, Powerscreen’s sales and applications support manager, said: “We now have five dealers in China and are concentrating on the eastern part of the country. We’ve focused on getting boots on the ground in sales and machine servicing,
ABOVE: The 2018 edition of bauma China was a record year for visitor and exhibitor numbers. pic: Messe München
including two Chinese-speaking equipment servicing technicians. We’ve also been educating the market on the great benefits of tracked mobile machines.”
Cassidy said Powerscreen had sold 13 machine models [up to late Nov 2018] since entering the Chinese market in early 2017.
“The Premiertrak 400X [jaw crusher], the 1000 Maxtrak [mobile cone crusher] and the 1700 Chieftain [screener] are popular models, and the Trakpactor 500 [horizontal impact crusher] and Warrior 1400 [screener] are starting to get traction in the market. We see great potential here. We are market leaders elsewhere, so the ambition is to be market leaders here.”
Cassidy said Chinese aggregates market demand is very strong, and he stressed the immense potential for equipment manufacturers like Powerscreen in China’s construction and demolition waste recycling sector.
In its first five months as Sandvik Mobile Crushers & Screens’ Chinese market dealer, Pota Environment (Shanghai) sold 20 unitsand is forecasting a strong sales year in 2019.
Three jaw-cone-screener plant trains have been bought by Xindadi, a Beijing-based aggregates processing company, which is using the nine machines to process gneiss into 0-8mm and 8-28mm final products for highways and other infrastructure works’ customers in and around China’s capital.
“The customer is able to produce 600 tonnes an hour of material, 200 tonnes an hour with each plant train, and the plant have been working for over 2,000 hours, 16-18 hours a day. He has a full machine servicing package because of the hard nature of the material,” said Simon Unwin, Sandvik sales and applications support manager. “The customer was with us at the first two days of the show and is looking to buy more Sandvik Mobiles’ equipment.”
Unwin said that Chinese aggregates processing customers are moving away from buying Chinese crushing and screening equipment because they like the quality,
durability and reliability of the equipment that Sandvik and other leading premium global market manufacturers can supply.
He also stressed how Sandvik customers welcome the way in which the manufacturer’s PlantDesigner software package can tailor their plant to their application needs. “With it, we can assess how abrasive the material is, likely throughput volumes and other factors. This allows us to build in contingencies,” explains Unwin.
“There’s a big urbanisation process taking place in China which is leading to a lot of construction and demolition waste recycling; this is creating a big potential market for Sandvik’s Prisec impactors,” said Lingnan Hua, Pota product manager for Sandvik Mobile Crushers & Screens.
“There is a lot more environmental regulation coming into the Chinese aggregates sector. The government is trying to merge smaller quarries into bigger ones. They are giving bigger quarries more longterm licences. With less aggregates suppliers in the market, the price of aggregates will go up.”
Pota, whose eastern and southern China sales network coverage includes Beijing, Jiangsu, Shanghai and Guangdong, was
BELOW: Joe Cassidy, Powerscreen’s sales and applications support manager, has been highlighting the manufacturer’s growing presence in the Chinese market
also in Shanghai promoting Sandvik’s new automation and control telematics system, My Fleet. Developed initially for the Q range of Sandvik mobile crushers, the innovative digital solution provides remote access to critical data on location and machine utilisation, enabling operational machine optimisation. It also assists customers in their planning of service and maintenance schedules, leading to more efficient and costeffective operations.
“Chinese customers have immediately taken to it,” said Hua, “as they are keen to monitor the performance of their machines very closely. Customers also like a nice back story and very much like Sandvik’s long global history in the aggregates business.”
In China, Pota offers customers the complete range of Sandvik Mobiles Crushers & Screens. “There’s big potential here for the larger Sandvik mobile jaw crushers,” said Unwin. “In 2019 in China and elsewhere, we will be making a big push on our U range of heavy-duty equipment, including the UJ440i jaw crusher and UH440i mobile cone crusher.”
Keestrack increased its Chinese unit sales by more than 20% in the first 11 months of 2018, compared to the same period of 2017. The mobile crushing and screening plant manufacturer was on course to sell around 60 machines in the full calendar year.
Thomas Hagspiel, the company’s China and Southeast Asia managing director, said the Belgian global crushing and screening equipment firm had been delighted with Chinese customers’ response to Keestrack’s product offer over the past four years.
The company is currently second only to Kleemann in annual China market mobile track-mounted plant sales.
The latest encouraging unit sales figures are a vindication of Keestrack’s decision to
ABOVE: Mark Hezinger, Kleemann marketing manager, in front of the MOBICAT MC 120 Z PRO mobile tracked jaw crusher
launch its own subsidiary in China, Keestrack Construction Equipment, in 2007. Keestrack China covers the Chinese and South Asian markets with a state-of-the-art production facility located in Chuzhou. The subsidiary also has a fast-growing sales organisation. In 2012, the Chinese factory produced the first hybrid, diesel/electric classifier, the Keestrack C6e, especially for the Chinese market.
Four key models were unveiled at bauma China 2018. The track-mounted B4 jaw crusher, also available in hybrid plug-in B4e version with drop-off power-supply module, ensures less wear and better crushing capacities due to its double-deck vibrating pre-screen (2300mm x 1000mm). The 600mm maximum feed-size plant has a throughput capacity of up to 400tonnes/hour.
Also on show were the up to 250tonnes/ hour fully-hybrid H4e cone crusher, the up to 500tonnes/hour tracked R6 mobile impact crusher, and the proven 600tonnes/hour capacity K6 scalper, now also available with an energy-saving hybrid plug-in electric drive.
Kjell Sorlie, owner of Oslo Pukk Kjell Sorlie AS, a granite aggregate processing business near Oslo, Norway, has become the first buyer globally of Keestrack’s B7 hybrid mobile tracked jaw crusher, fitted with a Sandvik CJ412 jaw box. “I’m using 25 litres of fuel an hour compared to 60 litres with my previous jaw plant,” said Sorlie, “that will
save me NOK 450,000 a year (US$52,200).
I’m very happy with its productivity as well as its fuel saving.”
Michael Brookshaw, Keestrack global distributor manager, said: “We are having an incredible show. It’s like another bauma Munich. It’s really been an international exhibition. We’ve had visitors from South America, Russia and other countries.”
Austrian global compact crusher manufacturer RUBBLE MASTER is benefiting
from a growing dealership presence in the Chinese market – with 11 local sales partners signed up in just one year.
The latest local sales partner, based in Beijing, has been recruited recently by RUBBLE MASTER’s five-employee strong, Tianjin-based sales subsidiary, Tianjin RUBBLE MASTER Technology. RUBBLE MASTER’s sales reach now stretches from Jilin in China’s north-east, to Guangdong in the south, and as far west as Sichuan.
The company is exhibiting the RM 100GO!
ABOVE Pictured left to right: Lingnan Hua, Pota product manager for Sandvik Mobile Crushers & Screens, and Simon Unwin, sales and applications support manager
compact crusher, which is said by Shaun Montgomery, RUBBLE MASTER’s sales manager, to be proving a popular model among customers, along with the larger RM 120GO!
Both the 29tonne RM 100GO! and the 35tonne RM 120GO! are low-noise level crushers said to be durable, reliable and long lasting. The RM 100GO! has a capacity of up to 250tonnes/hour, depending on feed material. The RM 120GO! can process up to 350tonnes/hour of material. The crusher duo is said by RUBBLE MASTER to produce an excellent final aggregate product.
Speaking about the popularity of the RM 120GO! machine, Sheng Shi, RUBBLE MASTER China sales manager, said: “Customers like the fact that they can process a lot of aggregates material with just one crusher. They are forward thinking and know that if they have a bigger mobile crusher they can do a wider range of work. It is also a great model for construction and demolition waste recycling.”
Tianjin RUBBLE MASTER Technology has staged two successful ‘Product Champion’ events in Tianjin in 2018.
“Customers are very important to us and we can’t service their needs properly without having well-trained sales teams. The training done at these events falls under the RUBBLE MASTER Academy Programme,” explained Montgomery.
“We’ve sold five machines since our Tianjin subsidiary began recruiting local sales partners in December 2017. The feedback we have been getting from customers has been really pleasing. The weight to throughput ratio is extraordinarily good with our compact crushers.
“With RUBBLE MASTER’s acquisition of Maximus, we are fully into the natural stone side of the materials processing industry. We will continue with the current two-brand strategy.”
Montgomery said production facilities at
MASTER’s Linz, Austria HQ are set to expand within the next 18 months as the company looks to cater for rising demand for its machines.
Chinese aggregates processing equipment firm Yifan says its comprehensive product portfolio is in big demand not only in China, but also in other markets, including Latin America, the Middle East and Africa.
Headquartered in Zhengzhou, eastern China, Yifan offers a complete range of crushing, screening and washing plants to the aggregates sector. The company has manufacturing and assembly factories in Zhengzhou, Jiangxi and Shanghai, and offices in Beijing, and emphasises that its production process is based on lean manufacturing. Yifan also has a highly successful wear parts supply business.
“We are renowned for the quality of our machines and for our aftersales service,” said Demi Wei, Yifan sales manager. “The Chinese market is good and it’s getting
better. Our government is supporting the construction market in cities and has introduced more environmental regulation around aggregates processing. Both are good things and we are gaining more domestic sales.”
Wei said Yifan’s Zhengzhou operation alone had posted RMB 1 billion (US143.76mn) in unit sales in 2017. “We want to develop our sales reach and sell into Europe and North America. Currently, we are focusing on appointing more sales agents.”
Among Yifan’s many successful installations are a large up to 400tonnes/ hour civil manufactured sand production line for eastern China-based Zhejiang Richangsheng Building Materials Company; a 250tonnes/hour granite production line for a customer in Jeddah, Saudi Arabia; and a 200tonnes/hour stationary stone crushing plant with steel foundation for a customer in Sri Lanka. AB
ABOVE: RUBBLE MASTER’s Shaun Montgomery and Sheng Shi in front of the at-show RM 100GO! compact crusher
RUBBLE
LEFT TO RIGHT: Michael Brookshaw, Kjell Sorlie and Keestrack group president Kees Hoogendoorn in front of the exhibition-showcased K6 scalper
Celebration of the new at bC India 2018
Major global and leading Asian regional construction and quarrying equipment manufacturers are bullish about unit demand within the Indian market. Their heightened optimism was reflected in the volume of new model launches at bauma Conexpo India 2018. Partha Pratim Basistha reports.
The fifth edition of bauma Conexpo India 2018 took place between 11-14 December 2018 at Huda Ground in Gurgaon, south-west of Delhi, India’s capital. Spread across 195,000m² of exhibition space, the event included 700 exhibitors from 26 countries, including India. Heightened business confidence was exhibited by manufacturers, as they displayed newer solutions across extracting, breaking, mineral processing and loading against the backdrop of India’s continuing buoyant roads infrastructure growth.
Volvo Construction Equipment India (Volvo CE India) displayed its new L90Gz wheeled loader. According to Surat Mehta, head of SDLG’s India business, the 5-tonne class model is well suited to work with 200-250tonnes/hour crushing plants and for railway wagon loading applications.
He added: “The loader, with axle, transmission and Volvo D6e engines from Germany, is seven per cent more fuel efficient [than its predecessor] and delivers 10 per cent higher breakout force. One of the features of the engine in accordance with Volvo’s engine standards is that it develops
high torque at low RPM, enabling excellent load carrying capabilities, thus saving on fuel consumption. Higher operational efficiency of the wheeled loader is contributed by the high breakout torque throughout the working range, excellent bucket rollback, parallel lift, better fill factor and low centre of gravity for superior load carrying operations.” Mehta said the new L90Gz wheeled loader will be imported from Volvo CE’s China assembly plant.
Volvo CE India also displayed its new L958F wheeled loader. “The loader comes with a larger bucket, new improved cabin for better operator’s visibility and altogether robust structure will be offered for wagon loading and ports material handling,” explained Mehta.
Hyundai Heavy Industries India (Hyundai India) showcased its new HL 635 3-tonne wheeled loader. The loader will be imported from Hyundai’s China facility and assembled in India at the company’s Chakan plant in Pune. The product is said to be ideal for working with 200-300tonnes/hour crushing units and within the ready-mixed concrete industry.
India’s wheeled loader market, a modest 1,000 unit sales/year a few years back, is expected to expand to 3,000 unit sales/year. Hyundai India is targeting sales of 40-50 units of its loaders. “The wheeled loader market in India is seeing good demand with many manufacturers offering high-tech products. We are confident of getting a sizeable share of the pie in this growing space with our price-competitive, reliable, fuel-efficient and intelligent wheeled loaders,” said Anup Nair, vice president and business head, Hyundai India.
The company plans to expand its excavator business in India, which is projected to grow to 35,000 units. Nair added: “Hyundai has been operating in India since 2008 and has seen rapid business growth with an active fleet of 20,000 8-51 tonne units, taking our market share to 20 per cent in the 20-tonne class range. We are now ramping up our excavator production from 6,000 units to 10,000 units by 2023 by adding a fully automated assembly line. We have earmarked an investment of Rs 300 crores for the expansion. We will also export excavators to Southeast Asian market customers from
this facility.
“Hyundai India has set up a 1,393m² global R&D and training centre in Hinjewadi, Pune. The R&D team is working with engine manufacturers to meet the 2021 emission norms, and to develop higher productivity and fuel-efficient excavators for pricesensitive Indian customers. Hyundai India will also introduce 30 tonne and above international models of excavators.”
Sany Heavy Industries India (Sany India) launched its new SY215C-9 21 tonne and SY230LC-9H 23 tonne hydraulic excavators during bC India 2018. The excavators feature Dynamic Optimisation Matching Control System (DOMCS), which matches engine output and external load demand to ensure better fuel efficiency, reinforced front attachments, strengthened upper structure and robust undercarriage. The models’ cabin also offers wider visibility and easy access to switches.
“All the products are designed to stay true to the company’s focus on quality, technologically advanced design, fuel efficiency, superior performance, high reliability and digitalization,” said Deepak Garg, CEO, Sany Group, India and South Asia. “I am confident that Sany will soon be among the top three players in the industry with its ultra-modern and global quality products, strong dealer network, and state-of-the-art [Pune] manufacturing facility.”
Doosan Bobcat India is making a big push to capture greater market share in the growing Indian compressor market with its medium-and high-capacity compressors, ranging between 400 and 650 CFM. “Our compressors are highly suitable for big quarry and limestone sites, which demand high productivity at higher pressure along with fuel economy,” said B.S Srinivas, directorPortable Power & Compressors.
Doosan’s P 260, P 315, P 360 and P 415 models have an operating pressure of 100psi, making them suitable for quarrying applications, for use with jack hammers and for shot blasting applications.
“The high performance of our compressors is due to the design of the screw air end, a rugged enclosure designed for dusty environments, a cool box design for maintaining low temperature inside the box, air filters mounted with pre-cleaners, maintenance-free batteries, and wide doors for ease of service.” added Srinivas. Doosan compressors come with an option of Indian Ashok Leyland and Cummins engines.
Eyeing huge potential in the Indian tracked crushing and screening market, Keestrack, the Belgian tracked crusher and allied equipment manufacturer, showcased its B4e hybrid diesel electric jaw crusher. The company has drawn a broad business roadmap to tap the growing Indian tracked
crushers market – both in the construction aggregates and mining segments.
Michael Brookshaw, Keestrack global distribution manager, said: “We are setting up a new plant at Neemrana [Rajasthan, northern India] for manufacturing our tracked solutions. In conjunction with this, we are creating a very competent Indian team, placing great emphasis on training our associates and distributors so that they can extend the right product support to the customers.” The Neemrana-based plant was commissioned in January 2019, and the first product is due to be manufactured in April 2019.
Swapan Das, managing director of Keestrack’s Indian venture, eTrack Crushers, added: “The machines from the Indian factory will be re-engineered for Indian applications, taking into consideration rock and climatic characteristics and operation methods. However, the overall unique character of the machinery will be kept intact. The reason for choosing Neemrana for setting up our plant is because the area possesses a sound vendor base in the region, catering to a large number of heavy construction and mining equipment manufacturers including JCB India and Metso, along with many allied sub-system manufacturing companies producing conveyors, hydraulic components, castings and rubber parts.”
Peter Hoogendoorn, from the Hoogendoorn family which owns Keestrack Group and a director within the company’s Indian venture, said: “We are very convinced about the opportunities and growth that India offers as one of the future major markets globally. The new Indian plant’s manufacturing standards will be on a par with the company’s European manufacturing facilities and will be enhanced further in time.”
Keestrack aims to sell 25-30 mobile track-mounted units, including jaw crushers, cone crushers and screeners, made at the new Indian facility over the course of the next year. The firm also plans to export Indian-manufactured models to other Asian countries, as well as countries in Africa and the Middle East.
Meanwhile, Volvo Penta is looking to benefit from rising demand in India for track-mounted crushers. “Their higher levels of mobility, low operating costs and faster set-up times make them suitable for road contractors requiring crushed granular sub base materials close to construction sites. The rising demand is likely to catalyze demand for our engines,” said Miron Thoms, vice president & head of Volvo Penta India. Volvo Penta has recently supplied its engines for the tracked crushing and screening units of Indian crushing equipment major Puzzolana Machinery Fabricators.
Thoms continued: “To ensure more efficient performance of the diesel hydraulic driveline, our application team is working in close association with the OEMs (original equipment manufacturers) to minimise total cost of ownership, and improvisations are
Volvo’s L90Gz wheeled loader was a key exhibition attraction
ABOVE: Hyundai India’s HL 635 wheeled loader BELOW: Keestrack had a strong machine and personnel line-up at bCIndia 2018
major exporter of crusher boxes to European manufacturers, plans to enter the demolition waste recycling business.
“Though the market of demolition waste recycling is moderate in India, we do see its potential due to the government’s emphasis on urban renewal through setting up smart cities,” explains Ravi Varma, managing director, Marsman India. “Demand for manufactured sand is also growing so we are promoting our 100 and 300 tonnes per hour vertical shaft impactors (VSIs) more aggressively, along with our washing solutions that use less water.”
Marsman has recently introduced its new range of PJC 30”x 20”, PJC 44”x 33”, PJC 48”x 38” primary jaw crushers and SJC 42”x 09” secondary jaw crusher. The new jaw crushers have a more advanced design: they are fitted with hub and sleeve, making the withdrawal process easier. They also feature hydraulic systems for setting the jaw plate to gain the desired output material.
Marsman is also keen to broaden its presence in mobile plants. Varma added: “Our impactor, jaw and screens have been finding a favourable response in India and abroad. Demand for mobile crushing plants have gone up due to their easy transport from site to site, and a standard designed plant can be erected, commissioned and dismantled in a very short time, which is also a big advantage.”
use in north India due to the region’s higher productivity requirements in two-stage production configuration. They can be used with VSIs in a two-stage plant, and as part of a three-stage plant alongside VSIs and a screener. With both the combinations, the PROcones can deliver -20 mm of aggregates,” said Proman managing director, R S Raghavan.
For higher optimisation of its crushing plants, Proman is offering new mortar production solutions. Made under technical collaboration with Spanish firm Sotecma, the mortar plant in 35 and 45tonnes/hour variants can be coupled as an extension to the crushing plant. It comes with bins, with the sand drawn from the VSI sieved and mixed proportionately and added with additives for preparation of the mortar.
excavators. “The new generation heavy breakers have a high impact rate of 300-400bpm, making them most suitable for demolition work, recycling, mining,
The drill, with a heavy-duty hydraulic feed and rotation system, has an automatic tow drill changing provision, which is an added feature. We are offering five variants of the pneumatic drill for varied applications.”
According to Raghavan, the final product coming out of the plant can be bagged and commercially sold through cement and building hardware dealers and used to fix tiles, or for plastering and other jobs. “This will ensure more viability of the crushing plant in the highly competitive Indian aggregates market,” he emphasised.
Pune, western India-based Indus Rock Tools showcased a series of new products for primary and secondary surface rock breaking requirements. This included the company’s new heavy-duty RB 7580 hydraulic rock breaker, compatible with 70-100tonne
Indus also showcased a new Hartl bucket crusher and screener. The company has entered into a joint venture with the Austrian firm for manufacturing bucket crushers and screeners in India under a Make in India Commitment initiative. Production will commence by mid-2019. The products will be marketed and exported from India, and Indus has already placed a few Hartl bucket crusher orders.
With their Hardox material centralised lubrication system, the buckets are said to be ideal for crushing materials such as granite, basalt, gypsum and limestone. The Hartl bucket crushers have capacities ranging between 0.60 to 1.53m³ and are compatible with 10-50 tonne class excavators. AB
Marsman has recently launched a new range primary and secondary jaw crushers pic: Messe München
Hartl HBC 750 bucket crusher and screener and IRB 220 TOE crawler drill showcased by Indus
bC India 2018 attracted thousands of construction, quarrying and roadbuilding sector representatives over the course of the four-day event pic: Messe München
Vibrating screen conversion kit from Haver & Boecker
Aggregates and mining equipment manufacturer Haver & Boecker is offering a conversion kit for older model H-Class vibrating screens.
H-Class models V-50 and older can be updated to the current V-85 H-Class model to reduce operating noise to levels below 100 dBA, gain better control over the running frequency and decrease maintenance costs by as much as 50%.
The modular design of the H-Class uses pre-engineered components that are designed to enable the machine to be easily configured based on an operation’s requirements. The machine can be used for screening hot materials, such as phosphate, potash and asphalt. The V-85 conversion kit can be installed in one day and the package includes the heavy-duty welded bridge, A/C drives, controls and optional rubber dust covers for hot or cold applications.
Two new next-gen excavators from Cat
Caterpillar has launched the 300 and 330 GC next-generation 30-tonne size class excavators.
The manufacturer claims the two new machines increase operating efficiency, lower fuel and maintenance costs, and improve operator comfort compared to previous models.
Haver & Boecker’s H-Class vibrating screen
Prior to beginning the conversion process, the machine will be evaluated by a Haver service technician to determine if it is eligible for an upgrade. The conversion process begins by removing the entire interior portion of the machine, including the screen media, brackets, post and centre strips. Once removed, the interior is cleaned and prepared for the new deck.
New deck brackets are installed and adjusted to the correct level. The vibrating centre strips can be upgraded using silicone liners to handle higher temperatures. Tensioning hardware is also updated, as well as the variable-frequency drive (VFD) unit, to provide optimum screening efficiency. www.haverboecker.com
The new excavators offer unique combinations of features designed to match contractors’ productivity and cost targets.
The Cat 330 features standard integrated Cat Connect technology and the most power and lift capacity of the two models. Caterpillar says that the Cat
Talbert
Connect technology increases operating efficiency by up to 45% over traditional grading operations.
The Cat 330 GC combines a balance of productivity features with reduced fuel consumption and maintenance costs.
Cat says its next-generation excavators are designed to consume less fuel per unit of work than the models they are replacing — up to 20% for the 330 compared to the 330F and as much as 15% for the 330 compared to the 330D2.
New smart mode operation automatically matches engine and hydraulic power to digging conditions, with the intention of
optimising both fuel consumption and performance. To further reduce fuel usage, engine speed is automatically lowered when there is no hydraulic demand.
The excavators feature a new main control valve that eliminates the need for pilot lines, reduces pressure losses, and lowers fuel consumption.
The new cooling system employs auto-reversing electric fans, which independently monitor hydraulic oil, radiator and air-to-air aftercooler temperatures to deliver the exact airflow required. www.cat.com / www.caterpillar.com
offers telescopic trailers
North American heavy-haul solutions provider Talbert Manufacturing is offering the 55SA-TELE 55-tonne extendable heavy-haul trailer.
The trailer has a deck length of 16.46 metres (54 feet) when open, which allows users to haul a wide range of large equipment,
such as bridge beams, conveyors, generators, pressure vessels and tanks. Operators can then retract the trailer to 9.9 metres (32 feet 6 inches). This shortens the overall trailer length to 16.15 metres (53 feet), eliminating the need for overlength permits which saves time and money.
“Our customers needed a way to minimise costs to remain competitive when transporting the ever longer loads, and the retractable deck helps them do that,” said Troy Geisler, Talbert Manufacturing vice president of sales and marketing. “The 55SA-TELE gives customers the long deck length they need to transport equipment yet offers the retractable option to fall within legal length on return trips.”
Talbert designed the 55SATELE with a 2.29 metre (90 inch) swing radius that can be extended to 2.9 metres (114 inches) with the use of a gooseneck extension. This is designed to optimise the deck length while keeping it within the legal 16.15 metre (53 feet) limit when retracted. www.talbertmfg.com
The new Cat 330 30-tonne excavator
The 55-tonne extendable trailer from Talbert Manufacturing
FEBRUARY
12-14 Agg1 2019
Indiana Convention Center, Indianapolis Organiser: NSSGA
Throughout the year Aggregates Business travels the globe attending conferences, events and equipment shows, keeping you informed of the latest offerings. Why not come and join us for a chat at any of the events below?
APRIL 2019
8-14 bauma 2019
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