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All systems go for China’s greener quarrying tomorrow
What do you get when you marry the world’s biggest-consuming nation of aggregates, by a massive margin, with a round-the-clock work ethic and huge government financial backing? The answer is the Chinese green quarrying revolution.
I was among more than 1,200 attendees, including many international guests, in the audience at the 6th China International Aggregates Conference in the city of Wuxi, eastern China, when China Aggregates Association (CAA) president Hu Youyi gave a keynote speech on how a comprehensive switch to environmentally minded production, coupled with the ecological development of quarries and their neighbouring areas was the only option to secure the long-term sustainability of the country’s aggregates industry.
Chinese aggregates demand currently accounts for 40% of the overall 50 billion tonnes of annual global aggregates demand. But while national government investment in infrastructure projects such as the Belt and Road Initiative (an up to US$8 trillion global development strategy adopted by the Chinese government in 2013 involving infrastructure development and investments in 152 countries and international organisations in Asia, Europe, Africa, the Middle East, and the Americas), and the need to house 300 million people as part of continuing national urbanisation, drive up aggregates demand, the green quarrying agenda has become president Xi Jinping’s government’s key focus for the national aggregates industry.
As a result, future Chinese quarries will have four development models: Aggregate 1.0 – green environmental protection aggregate plant; Aggregate 2.0 – extending the aggregate industrial chain; Aggregate 3.0 – green building materials industrial park; Aggregate 4.0 –eco-industrial park based on a quarry.
Expanding on his speech during an interview with me the following day, which forms part of the feature titled ‘China’s green quarrying
the
revolution’ in this issue of ABI, Hu predicted that 80% of Chinese quarries will reach the required green standard within five years. This rapid adoption of the green quarrying concept would, he said, be achieved with the help of the Chinese government and the CAA, but also, crucially, through the hard-work and efficiency of quarry operators and their employees.
In response to my gentle scepticism about the five-year prediction, Hu said: “We can dismantle a bridge and build another in one day. A 1,200-bed hospital in Beijing can be built in just one week, if demand dictates.” Having seen first-hand over several years how the Chinese quarrying sector has evolved in terms of the integration of more premium plant technology, leading to an improved final aggregate product, I can see why Hu is confident about the swift realisation of the Chinese green quarrying vision.
As well as attending the conference in Wuxi, I visited Xinkaiyuan quarry in Huzhou, northern Zhejiang province, around two-and-a-half hours drive south-west of Wuxi. In 2010, the quarry was one of the first batch of recognised green quarries in China. You can read my thoughts on what was a fascinating tour of the site in ABI March-April 2020 issue’s Quarry Profile feature. In the same issue you’ll also find a wide-ranging interview with Fang Libo, general manager of SBM Industry and Technology Group (SBM), China’s biggest manufacturer of crushing plant and associated equipment and the Chinese market distributor for McCloskey International. I spoke to Fang after a tour of SBM’s impressive museum complex at the group’s Shanghai headquarters.
A business of around 3,000 employees, SBM’s quarrying customer base stretches across China and beyond – with export customers in Africa, South America, South East Asia, India and Australia. The group has big growth plans and, given it’s a Chinese enterprise, it would be foolish to doubt that they will not only fulfil them, but fulfil them in double-quick time. GW gwoodford@ropl.com
Silver Lots 1&2
Booth S5555
All
Global
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Leading quarry conveyor and associated kit manufacturers are finding their products in big demand globally
The global screening buckets and attachments market is competitive, with innovation and aftermarket support key features of many leading manufacturers’ product offer
Buyers of environmentally sound off-the-road (OTR) retreads are being given discounts and a certificate attesting to the amount of raw
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Quarry
COVER STORY:
LiuGong’s new global Quarry & Aggregates team is part of the Chinese off-highway machine maker’s increased focus on customer segments
Specials
08 INTERVIEW
Njombo Lekula, MD of PPC RSA Cement, talks about the major threat to consumers and the integrity of the country’s cement industry at large
11 QATAR WORLD-CUP BUILD
Qatar has worked hard to overcome major construction hurdles in order to meet its FIFA World Cup 2022 hosting commitments
14 CHINA’SGREENQUARRYING REVOLUTION
The 6th China International Aggregates Conference in Wuxi heard how China is embarking on a green quarrying revolution that will transform the country’s aggregates -production industry
17 LIUGONGQUARRYING& AGGREGATESFOCUS
LiuGong, the Chinese off-highway machine maker, has created a new international team to develop its global quarry and aggregates business
36 CONEXPO-CON/AGG 2020 PREVIEW
The full lowdown on all the major equipment launches and North American product debuts at the big Las Vegas construction and quarrying machine exhibition
43 MARKET REPORT
Vietnam, Thailand and the Philippines have enjoyed recent economic growth and their construction materials markets are being fuelled by high levels of government investment in infrastructure
47 QUARRY PROFILE
Indonesian firm CV Putra Kartini is said to be making big fuel cost savings by using a Volvo EC200D excavator at its sand quarry operations in Lumajang, East Java
INDONESIAN PRODUCER JOINS WCA
Indonesian cement producer Cemindo Gemilang has become the latest international member of the World Cement Association (WCA).
The company joins as a corporate member of the WCA, whose membership spans 34 countries.
Cemindo Gemilang produces Semen Merah Putih brand cement as well as ready-mix concrete, which is available throughout Indonesia. Cemindo is also a major producer in Vietnam through its Chinfon Cement subsidiary.
Welcoming Cemindo Gemilang as a member, WCA chief executive Ian Riley said: “As we work to address the key global challenges facing the cement industry, in particular the goal of full decarbonisation, it is important that we engage dynamic emerging-market players.”
China expands Asian infrastructure reach
China’s involvement in infrastructure developments in emerging markets across Asia continues to expand, according to a new report. The GlobalData report estimates the total value of infrastructure projects (including building materials) in which Chinese contractors are at least partially involved at around US$235bn, while in south Asia the project values total US$191bn.
Chinese influence is expanding via the Belt and Road Initiative (BRI), which was launched in 2013 to develop the modernday versions of the land-based ‘Silk Road Economic Belt’ and the ‘Maritime Silk Road’. Under
the initiative, China is seeking to improve infrastructure in emerging markets across the world, facilitating economic development through the companies that are able to transport goods more easily and cheaply between countries along various routes.
Danny Richards, lead economist at GlobalData, commented: “Although wariness has been increasing among the governments in emerging markets over the risks of relying heavily on China for funding and construction contracts, the opportunities provided under the BRI can be attractive for governments with limited funding capacity and rising infrastructure needs.”
In Asia, reflecting political challenges and concerns over the build-up of debt, new governments in Pakistan, Malaysia, and the Maldives, in particular, have been challenging contracts that had hitherto been signed with China or have been delaying progress on existing projects.
Nevertheless, the report states that it is clear that China is heavily influencing the development of infrastructure in Asia’s emerging markets. Based on GlobalData’s analysis, if all infrastructure projects in the pipeline proceed as planned, spending on projects involving Chinese contractors could reach US$64bn in 2020, up from US$23bn in 2014.
CEMEX rated highly on climate change
The CDP (formerly Carbon Disclosure Project) has raised its rating of Mexican building materials giant CEMEX from B in 2018 to A- in 2019 for the company’s commitment to climate protection.
CEMEX says the rating upgrade reflects its improvement in governance, risk management, CO emissions reduction initiatives, low-carbon products, and valuechain engagement.
Vince Indigo, president commissioner of Cemindo, said that the company wants to become one of the world’s leading building materials companies by adopting innovative and eco-friendly solutions.
To date, CEMEX says it has reduced its direct CO per ton of cementitious product by more than 22% compared to its 1990 baseline, allowing the company to avoid approximately eight million tons of CO2 during 2019, equivalent to the carbon emissions of 1.6 million passenger vehicles.
The heavyweight building materials group is now taking the further steps to reduce its direct CO emissions. These include producing new types of low CO cement, and concrete products; increasing its use of alternative fuels as a substitute for fossil fuels; using waste from other industries as an alternative raw materials
substitute for clinker; expanding and protecting natural carbon sinks from its El Carmen Nature Reserve to all CEMEX quarries; and developing and testing disruptive technologies like carbon capture, technologies.
CEMEX adds that it also plans to reduce indirect CO2 emissions from electricity through the company’s use of renewable energy. Close to 30% of its power consumption
An SDLG machine fleet working on a Belt & Road Initiative project
Specially designed and eco-friendly CEMEX concrete was used in the construction of the Presa Bicentenario
Specially designed and eco-friendly CEMEX concrete was used in the construction of the Presa Bicentenario (Bicentennial Dam,) located in the state of Sonora, in north-west Mexico
WCA membership spans 34 countries.
GCCA India elects chair and co-chair
Mahendra Singhi, managing director & CEO – Dalmia Cement (Bharat), and Nilesh Narwekar, CEO – JSW Cement, have been elected as the chair and co-chair respectively of the Global Cement & Concrete Association India (GCCA India).
Serving an initial two-year term, the pair will provide strategic direction and drive ongoing sustainability across the Indian cement sector.
Based in Mumbai, GCCA India took over the work of the Cement Sustainable Initiative (CSI) India (which formerly served as the sector’s sustainability alliance) with its launch last year in July 2019. It focuses on driving forward the key sustainability work underway within the Indian cement sector, in the second-largest cement producing industry in the world.
Speaking at the GCCA India CEO meeting of the member companies in Mumbai, Benjamin Sporton, GCCA chief executive
officer, said: “I’m delighted to have overseen the first CEO meeting of the GCCA India member companies. It is important for the Indian cement sector to continue to work collaboratively on sustainability and innovation work.
“We now have eight major Indian cement companies contributing to the GCCA India work programme. India is a significant market in terms of cement-producing capacity and, with population growth, the growing demand and need for affordable houses and infrastructure, cement and concrete are going to play an important role in the future development of the country.”
Members of the Indian cement industry have been working together to achieve low-carbon growth for the Indian cement sector with GCCA India committed to taking this work forward. Sporton recognised the efforts of UltraTech Cement and Heidelberg India in helping to establish GCCA India.
China as the world’s biggest cement producer.
Research from the World Cement Association (WCA) predicts that India will increase from the 24% market share it held in 2018 to 30% by 2030.
Caterpillar reopens Chinese sites after coronavirus scare
Caterpillar reopened most of its facilities in China on Monday 10 February after getting the go-ahead from local government following the coronavirus outbreak.
The US global off-highway equipment-making heavyweight has multiple facilities in the world’s second-largest economy.
While none of its factories were in the worstaffected province, the company had delayed their reopening after the Lunar New Year by a week.
China accounts for up to 10% of Caterpillar’s sales.
A company spokesperson is quoted by Reuters news agency as saying the manufacturer is following local government direction and monitoring the epidemic’s impact on its dealer network and supply chain.
Meanwhile JCB is reducing production levels at its UK factories due to anticipated component shortages from Chinese suppliers impacted by the coronavirus outbreak.
The equipment manufacturer said the move would mean a shorter working week for around 4,000
JCB and agency shop-floor employees from February 17. This follows an immediate suspension of all overtime.
The measures have been discussed with the GMB union and will see the introduction of a 34-hour week for UK production employees until further notice. JCB employees will be paid for a 39-hour week and will bank the hours, working them back later in the year.
JCB chief operating officer Mark Turner said: “The disruption to the component supply chain in the UK comes at a time when demand for JCB products is very strong, so while this course of action is very unfortunate, it is absolutely necessary to protect the business and our skill base.
“Production in the UK has so far been unaffected by the situation in China. However, more than 25% of JCB’s suppliers in China remain closed and those that have reopened are working at reduced capacity and are struggling to make shipments.”
Turner added that it was therefore clear that the inbound supply of certain components from Chinese partners will be disrupted in the coming weeks as they seek to replenish their stocks.
In contrast China, which accounted for more than half (53%) of global production last year, will decline to 35%.
The WCA predicts that the European Union will double its market share of production from 8% in 2018 to 16% by 2030, while Japan will drop out of the top 10 to be replaced by Pakistan.
An Ashok Leyland rigid dump truck working at a cement plant in Rajasthan
Nilesh Narwekar
Cat at bauma China 2018
Plugging the quality cracks in SA’s cement market
To prove deliberate flouting of standards by some third-party cement blenders in the South African cement market, PPC appointed an accredited independent laboratory in September 2017. Njombo Lekula, MD of PPC RSA Cement, reveals that the exercise has unearthed a serious breach of standards, which poses a major threat to consumers and the integrity of the country’s cement industry at large. Munesu Shoko reports
In building or civil construction, cement is the glue that binds the structure together. Yet, Njombo Lekula, MD of PPC RSA Cement, South Africa’s leading cement manufacturer, laments the influx of sub-standard products in the South African market, which are threatening the built environment and placing people’s lives at risk.
Lekula says usage of sub-standard cement has various implications that may negatively affect the sustainability of buildings and structures, thus leading to increased repair or maintenance costs, and in worst-case scenarios, resulting in injuries and fatalities due to structural failures or collapse.
Speaking to Aggregates Business International, Lekula notes that there has been an influx of third-party cement blenders in the South African cement market in the past two years. He estimates that third-party cement blenders, also known as non-integrated cement producers, now account for more than 1.8 million tonnes of cement sales per year, in a market that is selling about 13.5 million tonnes of the country’s available capacity of 18-20 million tonnes per year.
During a normal market surveillance exercise whereby it tests competitor products for benchmarking purposes, PPC found that there was huge quality gap in some of the products in the market, which warranted further investigation. In an effort to protect the wider South African cement industry and the consumer at large, PPC appointed BetonLab, a South African National Accreditation System (SANAS)-accredited independent laboratory in September 2017 to prove intentional thwarting of standards by thirdparty blenders.
“When we realised the extent of non-conformance to standards, we decided to conduct quality checks on a continuous basis. Despite the fact that we have a very capable laboratory, which I consider to be one of the best in the African cement industry, we decided to engage the services of an independent laboratory to ensure transparency and non-bias in the results. We have been monitoring this for about 18 months and the results are shocking,”
The report was recently released and the findings were shared with the National Regulator of Compulsory Specifications (NRCS) and the South African Bureau of Standards (SABS), largely showing continued non-performance of the cement tested.
Explaining the process and requirements, Lekula says the weights of the bags were checked and the EN strength-testing in accordance with SANS 50197 for two, seven and 28 days was performed. The SABS’ prescribed uncertainty of measurement allowance of 2.5% was applied when analysing the resultant data. The results showed the inability to produce a consistent quality product and thwarting of standards in most cases.
“Some of the products failed horrendously,” says Lekula “Firstly, the products failed on bag weight. In some instances, some of the bags were found to be weighing around 46kg, which is 4kg short of the required 50kg. That is unfair to the consumer. Secondly, we picked up products that did not meet the standard in terms of strength development.”
Explaining the strength-testing process, Lekula says the laboratory makes a standard cube of concrete and keeps it in a controlled condition for the prescribed two, seven and 28-day intervals. In any of those intervals, a
LEFT: Njombo Lekula, MD of PPC RSA Cement ABOVE: Integrated cement producers like PPC ensure quality is maintained throughout the process, all the way from the quarry
cube is crushed to measure strength. If a product is a 32.5, for example, it means that in 28 days it should crush at 32.5 MPa. “To give an idea of the extent of the quality shortcomings, one of the products tested crushed at 3 MPa after a 28-day period,” says Lekula, adding that non-conformity of strength and weights of some products ranged from 11% to 73% of the sample set.
The third aspect of concern was the standard deviation. “When we talk about standard deviation, we refer to inconsistency in the product, where fluctuation of quality is a major concern,” explains Lekula. “The failure to conform to local standards not only has an impact on the structural integrity of buildings, but also poses a threat to possible damage of property and even loss of life should the walls come tumbling down.”
It was also found that most of the sub-standard cement products carry the SABS
Njombo Lekula notes that there has been an influx of third-party cement blenders in the South African cement market over the past two years
mark. The SABS stamp is a mark of regulatory approval, instilling trust in the product being sold and, if used in accordance with the instructions, will result in a structure that is robust and safe.
Lekula believes one of the challenges for the relevant authorities in policing the industry is that the two organisations that are responsible – the SABS and the NRCS – are seriously underfunded, which affects their capacity. “Both the SABS and NRCS should be conducting regular surveillance visits on sites to check if producers are compliant at all times. Unfortunately, the two organisations are basically funded by the levies that they collect from the SABS mark and the NRCS trade certificate, and it is not adequate for them to properly fulfil their duties,” says Lekula.
Following PPC’s findings, the results have been presented to both the SABS and the NRCS, and action has already been taken in some instances. “We know of one blender that has been shut down completely by the NRCS due to poor quality. We are also aware that another third-party blender is in the process of being shut down because of non-adherence to quality standards. The SABS is also taking this matter very seriously and is currently looking at random testing. Previously, the SABS would advise entities of dates and time of testing, which allowed companies to adjust standards for complying purposes only,” says Lekula.
large cement producer trying to “bully” small players in the market. In fact, he is of the view that it was a matter of moral responsibility on the part of PPC.
Following these actions, Lekula says there has been an improvement in the quality of the product from some of the non-integrated cement producers in recent months. However, to ensure consistent quality going forward, PPC is lobbying the South African cement industry to self-police. One of the ways of doing that is through capacitating an independent lab like Beton-Lab to randomly conduct tests on every cement producer’s
“We believe that part of our mission as a business is to better the quality of life within the communities we operate. We have a responsibility as an industry leader, and part of leadership is to always do the right thing. Keeping quiet about this non-compliance would have been irresponsible on our part. This non-conformance doesn’t only paint a bad picture on those caught on the wrong side of the law, but the cement industry at large. So for PPC, it was about protecting the industry image and the end user,” says Lekula.
More importantly, Lekula says PPC felt it had the responsibility to protect the vulnerable markets where these low-priced, poor quality cement products are mostly sold. He reasons that these products are mostly destined for price-sensitive markets like rural areas and townships. These are areas where poor workmanship is also commonplace.
into smaller lots as a means to grow the upcoming contractor fraternity. “There is far less infrastructure development in South Africa at this point and it’s no secret that construction companies in the country are disintegrating into smaller entities. There is rapid growth of what we call ‘bakkie builders’ (medium-sized contractors) because most of the available work is in infrastructure maintenance and renovations,” reasons Lekula.
Unlike the big construction companies that had resources to check the cement products they used, the smaller companies don’t necessarily have that capacity to test their own materials, and that’s where the sub-standard cement products are infiltrating significantly. These companies also generally have an insatiable appetite for cheaper products to maximise profits, which places the country’s infrastructure builds at risk.
“The unfortunate part is that this small contractor market also accounts for a big chunk of government-subsidy housing
One of PPC’s cement plants in South Africa
PPC is a leading producer of construction materials in Africa
Qatar is up to tough World-Cup-build challenge
Qatar has worked hard to overcome major construction hurdles in order to meet its FIFA World Cup 2022 hosting commitments. V L Srinivasan reports
When the Saudi Arabia-led coalition including the UAE, Bahrain and Egypt imposed an economic and diplomatic embargo on its neighbour Qatar in June 2017, the latter was thoroughly shaken initially as the country was in the middle of constructing megainfrastructure projects worth more than US$200 billion in its run-up to holding the FIFA World Cup in 2022.
The gas-rich Gulf nation needed at least 25 million tonnes of construction material such as gabbro, cement and steel for the construction of eight World Cup stadiums, Doha Metro Rail, Lusail City, new ring roads and seaports. Most of the material was routed mainly through Ras Al Khaimah and Fujairah seaports in the UAE, and also by road from Saudi Arabia.
But there was no dearth of companies in the countries beyond the Middle East region coming forward to supply primary construction materials to Qatar. Imports from countries including Oman, Turkey, China, India, Iran, Pakistan, Kuwait and Malaysia, allowed for the timely completion ofa number of projects.
With the nearest seaports in the UAE and Saudi Arabia’s roadway closed for Qatar, the material started arriving into Qatar through its own three sea ports - Hamad, Ruwais
and Doha. Hamad port was opened a few months after the Saudi-led boycott came into force in 2017.
Soon after the Gulf crisis surfaced, the president of Qatar’s Public Works Authority (Ashghal), Dr Saad bin Ahmad Al Muhannadi, said the authority found new markets from which to import building materials at competitive prices for its ongoing infrastructure projects.
“We are coordinating with several countries for sourcing construction materials. We have sufficient stock of construction materials to implement infrastructure development projects and they will be delivered on scheduled time,” said Al Muhannadi, adding that some building materials in these new markets were available at very competitive prices compared to those coming previously from siege countries.
Qatar also started using pipes for drainage and rainwater, lamp posts and some types of steel made by local companies in place of material previously sourced from neighbouring countries. “We were able to provide alternatives
for all materials from different markets, and there is stability in supply of all type of construction materials,” added Al Muhannadi.
In December 2019, Qatar’s Ministry of Municipality and Environment and Qatar Primary Materials Company (QPMC), which is responsible for ensuring unhindered supply of building materials to the local market, decided to recycle the huge volumes of construction waste generated while demolishing hundreds of old buildings and then dumped at Rawdat Rashed landfill near Doha.
The Rawdat Rashed landfill is spread over an area of 7 million m² and has about 40 million tonnes of construction waste, which QPMC realised could be converted into usable aggregate products for many projects linked to the FIFA World Cup and for use after the tournament.
This was done following research conducted successfully by government agencies like the Ministry of Municipality and Environment, Ashghal, Qatar University and some private firms for the last four years.
Sheikh Ali bin Hamad Al Thani (second right), president of HBK Contracting Company, greets Servet Serdar Ucar (second left), chairman of Referans Holding, in the presence of Fikret Ozer (centre), ambassador of Turkey; Serkan Ucar (left), CEO of Referans Holding, and Sheikh Faleh Ali H K Al Thani from HBK Contracting Company, during the memorandum of understanding (MOU) signing ceremony in Doha in 2018. Picture courtesy of The Peninsula
“We have sufficient stock of construction materials to implement infrastructure development projects and they will be delivered on scheduled time.”
Dr Saad bin Ahmad Al Muhannadi president Qatar’s Public Works Authority (Ashghal)
One of the FIFA World Cup stadiums, Ras Abu Aboud Stadium, which has a seating capacity of 40,000, is being constructed using the shipping containers which transported materials for its development. After the tournament is over, Ras Abu Aboud stadium will become the first fully demountable stadium in FIFA World Cup history.
As many as 158 containers have been delivered to the construction site, with 30 already installed. The fabrication for the steel structure is nearing completion while the fabrication of bleachers, concourse slabs and roof steel continues. Underground utilities, including the drainage network, are more than 50% complete.
Imports
Several Qatari construction companies signed agreements with their counterparts engaged in supplying construction material in countries such as Turkey, Oman and India.
Qatar’s volume of gabbro imports from Oman stood at 37,000 tonnes in June 2017 but rose to 633,000 tonnes over the next two years. The number of Omani quarries exporting the material to Qatar also rose significantly - from two to 16.
Doha-based Dolphin Integrated Company (a subsidiary of Rafa Holding) is among the firms which have partnered with Marafi ASYAD, an integrated logistics group owned by the government of Oman, to establish Marafi Sohar, a new company for transporting, shipping and storing gabbro between Qatar and Oman in June 2018.
These firms have also developed an aggregates terminal in Oman’s Sohar Port, which is expected to increase the exports of gabbro and limestone to Qatar. The first phase of the terminal has a loading capacity of approximately eight million tonnes per year and exports a huge volume of gabbro, a coarse-grained rock used in asphalt, and other minerals.The second and soon-to-be permanent terminal phase is equipped with a state-of-the-art stacker-reclaimer system. A conveyor and semi-automated ship loaders will be commissioned later in 2020. Sohar Port terminal’s capacity will be increased to 12 million tonnes after the completion of the permanent phase.
Some two dozen Turkish companies are also presently handling projects worth over $11.6 billion in Qatar. Most of them are geared towards preparations for the 2022 FIFA World Cup. Many Turkish contractors have been bidding for Qatar’s projects as the country starts fast-tracking
In an interview with a Turkish magazine, the deputy general manager of Istanbulbased Expotim-Ladin Group, Cagatay Ersahin, said that Qatar was diversifying its oil-dependent commercial structure with different sectors including construction.
“Turkey has almost been a single largest market in Qatar creating new opportunities and our export of construction material to Qatar exceeded $260 million, as Qatar has been spending $500 million a week for its projects,” he added.
Referans Holding is another multinational company in Turkey, which signed
A Gulf Rocks building materials storage site.Picture: Gulf Rocks
Parveez Aslam, general manager of Aamal Co. subsidiaries Aamal Readymix, Aamal Cement Industries and Gulf Rocks. Picture: Aamal Co.
HBK Contracting has been awarded the main works contract for Ras Abu Aboud Stadium while the same company is part of the joint venture awarded the contract for Lusail Stadium. The scaffolding and formwork services market in Qatar is estimated to be around QR600 million ($163.2 million).
Alternatives identified
Aamal Co., one of the biggest corporate houses in Qatar, has three subsidiaries which are involved in supplying construction material to Qatari infrastructure projects.
While Aamal Readymix manufactures and supplies ready-mixed concrete, Aamal Cement Industries, is engaged in manufacturing and supplying concrete blocks, interlocking paving stone and curb stones. The other subsidiary is Gulf Rocks, which imports and supplies gabbro aggregate from Oman.
The three subsidiaries supplied around one million m³ of ready-mixed concrete, 1.5 million linear metres of concrete blocks, interlocking paving stones and curb stones and one million tonnes of gabbro aggregates between 2017 and 2019.
According to the general manager of the three subsidiaries, Parveez Aslam, they have faced some challenges since the economic and diplomatic embargo imposed in June 2017, not so much due to the closure of a road link by Saudi Arabia but by the sea and air blockade by embargo-backing countries.
“Before the blockade, all the requirement of gabbro aggregates was fulfilled by imports from Fujairah (UAE) which was shipped by sea route. After the ban, we switched to Sohar port in Oman for gabbro imports,” said Aslam.
While Sohar Port was expanding its facilities and capacity to fulfil the Qatari demand for gabbro, the Qatari construction market was affected for some months, but the situation has gradually improved since the beginning of 2018, he added.
In addition, sourcing direct channels to import spare parts and other items, which were imported from the UAE and Saudi Arabia prior to the blockade, presented some challenges, especially on prices.
Overall, Qatar has moved forward quickly by finding alternatives for sourcing materials and promoting made-in-Qatar initiatives wherever it was appropriate, Aslam said.
Pakistan also joined the nations which were helping Qatar and for the first time, one Pakistani company, Attock Cement Pakistan Ltd (ACPL), exported 55,000 tonnes of clinker, valued at around $1.5 million, to Qatar in November 2019.
While gypsum used to make drywall is being imported from Iran, gabbro used in manufacturing asphalt and concrete is now being imported from Oman instead of the UAE.
International rating agency Fitch Solutions feels that with most of the
mega-infrastructure projects in Qatar on the verge of completion, its construction industry is expected to shrink by 4.1% this year.
The development of the transportation system has been completed while most of the FIFA World Cup stadia, hotels and other tourism projects are in the final stages of construction. “These projects have driven rapid but unsustainable growth in Qatar’s construction sector over the five years prior to 2018, which averaged 22.1% annually,” Fitch noted. AB
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Cagatay Ersahin, deputy general manager of Expotim-Ladin Group. Picture: Business World Global
China’s green quarrying revolution
The 6th China International Aggregates Conference held at the InterContinental hotel in Wuxi heard how China is embarking on a green quarrying revolution that will transform the aggregates production industry across the world’s most populous country.
ABI editor Guy Woodford was one of many international guests among the 9th-12th December 2019 conference’s more than 1,200 attendees
China Aggregates Association predicts that more than 80% of Chinese quarries will reach the required green standard within the next five years
Hu Youyi, China Aggregates Association president, outlined the environmentally-minded future for the Chinese aggregates industry in his keynote speech at the 6th China International Aggregates Conference in Wuxi
The Xinkaiyuan quarry in Huzhou, eastern China, is a leading example of a ‘green’ Chinese quarry
need to house 300 million people as part of continuing national urbanisation, is fuelling aggregates consumption, green quarrying and realising environmentallyminded commercial opportunities on land surrounding quarry sites has become president Xi Jinping’s government’s key focus for the national aggregates industry.
To help deliver a bold green quarrying revolution, the Chinese government is working closely with China Aggregates Association (CAA), the voice of the Chinese aggregates sector. This led to 10 national government departments jointly issuing on 4th November 2019 a document titled ‘Opinions on promoting the highquality development of the manufactured aggregates industry’. As well as being China’s first official government guidance on the development of its aggregates sector, it was a rare example of a multi-government department promotion of a specific Chinese industry.
Many local Chinese authorities have also adopted CAA’s recommendations in a September 2018 letter outlining how best to safeguard aggregates provision and standardise the production process. Aggregates producers now must
simultaneously complete re-habitation of their sites. Tighter controls have also been placed on the direct extraction of natural sandstone from China’s rivers and mountains.
The green quarrying revolution was the key theme of association president Hu Youyi’s keynote speech at the 6th International Aggregates Conference staged in Wuxi, a city of more than three-and-ahalf million people and a major business hub around two hours’ drive north-west of Shanghai, eastern China.
Hu stressed that China’s five major future sources of aggregates would be natural sand and gravel mining (including river and fairway dredging); construction solid waste recycling; road and other engineering construction slag recycling;
tailings and waste rock resources recycling; and primary mineral stone mine material. The manufactured aggregates processed by primary stone will be the main source of supply in the future.
Future quarries, said Hu, would have four development models: Aggregate 1.0 – green environmental protection aggregate plant; Aggregate 2.0 – extending the aggregate industrial chain; Aggregate 3.0 – green building materials industrial park; Aggregate 4.0 – eco-industrial park based on a quarry. Hu also noted that with the support of 5G technology, digital, unmanned quarries and smart mines in the aggregates industry will become a mainstream trend. The same technology will also see a rapid rise in the intelligent transportation of aggregates and the use of intelligent logistics.
“If we do not make these changes the Chinese aggregates industry will have very low efficiency,” said Hu during an interview with ABI after his keynote conference speech. “We want the industry to develop more inclusively rather than on traditional lines. This will benefit not only aggregates
More than 1,200 aggregates industry professionals, including many international delegates, attended the 6th China International Aggregates Conference
producers but also their surrounding communities. I want to help our industry reach a higher cultural level – that we share the same values as the people in the areas we work in. I also want our aggregates industry to learn from other industries; to adopt good ways of working and learn why other things did not work.”
Hu predicts that within five years more than 80% of Chinese quarries will reach the required green standard. “We will be helping quarries do this through our knowledge. We are also looking to cooperate with professional certification organisations so that quarry operators can receive official recognition for meeting a higher green standard.”
Flexibility is another key aspect of the Chinese green quarrying revolution, according to Hu. “All quarries are different. If a quarry and its surrounding area is big enough, you can look at introducing different elements, such as an eco-hotel. You also need to consider China’s varied climate. For example, in southern China where the weather is much warmer and wet, we can plant a lot of trees and plants to make the area around a quarry very beautiful.”
Hu stressed that many aggregates companies are already adhering to a higher standard of environmental protection than the government requires.
“We have visited other countries to learn about what they are doing around greener quarrying, and I have found that our values and practices in China appear to be at an advanced level. This is not just due to the size of our market.”
I asked Hu if there is a danger that increased aggregates production to meet rising Chinese infrastructure development need may harm attempts to fully implement the admirable national green quarrying plan.
Huzhou Xinkaiyuan Crushed Stone Co. Ltd, which operates the Xinkaiyuan quarry, said: “We have always paid a lot of attention to ecological protection.
Through support from the Chinese government and the China Aggregates Association, we have been able to develop our green quarry concept. In 2010, we were among the first batch of recognised green quarries in China.
“While aggregates demand linked to new infrastructure construction is very high, the speed of our quarry environmental restoration is also very high. China is renowned for its efficiency; our people are very hard-working. For example, we can dismantle a bridge and build another in one day. A 1,200-bed hospital in Beijing can be built in just one week, if demand dictates. We can balance a rise in production with the eco-quarrying plan.”
With its use of waterways to transport its aggregates products, use of production mud waste to create ceramics, electric-powered haul truck, the breeding of animals, such as chickens, to help feed employees, and the sensitive replanting of trees to allow for previously unworked areas of the site to be quarried, Xinkaiyuan quarry, in Huzhou, northern Zhejiang province, is an impressive current example of a Chinese green quarry. Speaking to ABI at the conference about the four million tonnes/ year andesite aggregates production site in eastern China, Yao Yifan, chief engineer of
“For me, there are several main aspects that make a green quarry. You need to make the best of your valuable mineral resources and not waste anything; you need to minimise the quarry’s impact on the environment and look to achieve zero emissions; and you need to know how to run the whole quarry in a good way, with a strong emphasis on product quality and added value. We can see at Xinkaiyuan quarry that after years of effort we can look around and see lots of wild animals and plants on site. We always wanted our quarry to resemble a beautiful garden.”
Song Shaomin, head of the CAA expert committee and professor of materials science at Beijing University of Civil Engineering and Architecture, also spoke to ABI during the conference. On the subject of China’s green quarrying revolution, he said: “Over the past 30 years China has developed very fast, but if we don’t change the way the aggregates industry works, it won’t be sustainable. High-quality aggregates are very important when it comes to ensuring the long life of buildings. Ensuring long life to buildings is the best way to achieve the biggest energy saving and emissions reduction. To achieve highquality aggregates, you need to invest significantly in premium technology and equipment. China wants to express to the whole world how we pay close attention to the environment.” AB
Artistic topiary at Xinkaiyuan quarry
A waterfall feature at eco-orientated Xinkaiyuan quarry
LiuGong eyes aggregates ascendancy
LiuGong, the Liuzhou, China-headquartered global off-highway machine maker, has created a new international team to develop its quarry and aggregates business. Guy Woodford reports
Headed by John Calder as director – Quarry and Aggregates, LiuGong’s new international quarry and aggregates team is part of the ambitious global off-highway machine market manufacturer’s increased focus on customer segments.
An Australian national, Calder has worked with LiuGong for the last two years in product support and brings extensive industry knowledge. After university, where he studied economics and business, Calder worked at International Harvester in Australia for five years. He then joined Caterpillar in Geneva, Switzerland, in 1986, where he held various senior international positions in marketing, sales and dealer development over a 30-year career.
Calder’s new and vastly experienced team will focus on ‘Back to Basics’, lowering quarry and aggregate customers’ costs and making them more productive and more profitable.
“Based on feedback from many customers, the competition seems to be doing it the other way around, so we see great potential to grow internationally. Whereas a lot of the competition are
suffering from cost creep and a focus on their shareholders, our strategy is simple and based on going back to four basic critical success factors: people, product, parts and service, and price,” said Calder.
“Our team is initially targeting a few countries that have large quarry and aggregates industries and knowledgeable dealers for this customer segment already in place. Half the team are also developing training packages for LiuGong field and product support representatives, along with the company’s dealers, focused on earthmoving, and quarrying and aggregates haulers, wheeled loaders and excavators.
“The industry is changing. Some of our competitors have got a little bit complacent. There’s an opportunity for us to relook at customer support seminars, operator training, site assessments with a focus on haul roads and loader platforms. It’s basic stuff to ensure an efficient and well-run quarry or aggregates job site.”
Calder is developing a truly international team that has over 250 years of experience in the quarry, aggregates and mining industries. Containing some of Calder’s former Caterpillar management colleagues
and longstanding dealer associates, the team members are multicultural, speak 10 different languages and are all deep subject-matter experts with sales, marketing, product development, product support, rental and used, finance and dealer development backgrounds. Their primary role will be to work side by side with global dealers to ensure their teams are well trained and focused on the specific needs of quarry and aggregates customers.
LiuGong is well covered product-wise with a well-balanced range that includes large wheeled loaders, 50, 70 and 90-tonne excavators and rigid-frame and wide-bodied trucks. More products and services are also under development.
“We have built a strong portfolio of quarry wheeled loaders and excavators. We have had a lot of positive feedback from customers about the 856H wheeled loader. It’s a good machine around stockpiles and if a customer needs to mix stockpiled material, it’s got enough power to do that. Its fuel burn is reduced due to its new Cummins-powered engine and ZF axles. It’s our flagship wheeled loader,” explained Calder.
“Our 50-tonne and 70-tonne crawler excavators are also performing very well; with quite a lot of units running at 10,000 hours and beyond. We’d like to improve our crawler excavator range even further, and, as part of that, a 90-tonne LiuGong crawler excavator will be launched in certain markets in the coming months. We are also working on new crawler excavator rock buckets and an extension to our dozer and motor grader product lines. This continuous product development means that for most quarry load and carry and stockpile applications, we will in 2020 be able to offer a pretty full range of machines.”
The third critical success factor within LiuGong’s ‘Back to Basics’ approach within the quarry and aggregates customer sector is parts and service. Machines working in quarries are in tough environments with tough materials, so speedy parts replacement and engineering service backup is essential. LiuGong has eight
LiuGong’s larger crawler excavators are proving popular among quarry and aggregates customers – with a sizeable number of 50- and 70-tonne units running at or above 10,000 hours
regional parts distribution centres (PDCs) with local support and is committed to world-class parts availability of 95% within 48 hours.
Calder continued: “In the quarrying and aggregates industry there is always something that’s going to go wrong due to the material or the vibration, so having parts availability is the biggest concern among customers. We’ve just appointed a Global Parts Operations director, a new Global Service director, and a Global Rental & Used director.
“We are not there yet [on achieving our parts availability target]. The challenge is making sure you have the knowledge and experience to identify what are the recommended parts that should be stocked by the dealer, the fast-moving and maintenance parts; what parts should be stocked by the regional PDCs, the fast- and medium-moving parts for some major and more minor repairs, and the headquarter PDC stocking fast-, medium- and slowmoving parts, covering all kinds of repairs and maintenance needs. For example, if you have a catastrophic machine failure due to a fire, you can still get replacement parts.
It’s in the areas of slower-moving parts at the headquarter PDC and the mediummoving parts at regional PDCs that we’ve still got work to do. We are focusing a lot of attention on these areas and are making good progress.”
Calder said the continuing success of LiuGong’s joint ventures was an important part of establishing the firm as a premium global player in all its customer segments, including quarrying and aggregates.
“Our joint venture with Metso in China is going particularly well, and I believe we were on track to make a big impact in the country’s tracked mobile crusher market in 2019. We have other successful joint ventures with high-quality global brands such as Cummins (engines), producing something like 35,000 engines last year in China. Then there’s the 20-year joint venture with ZF axles. We try to have all our products fi tted with world-class components. It illustrates to quarry and aggregates customers globally how much emphasis we place on quality machine parts. We also have a wonderful engineering team that are hugely responsive.”
Calder also highlighted how LiuGong’s state-of-the-art Global R&D Centre in Liuzhou has been at the forefront of research on lowering machine emissions. “We are very keen on being good corporate citizens,” he stressed.
LiuGong sees lower costs and higher profits for customers as the fi nal keys to its success within the quarry and aggregates customer sector. Through high-performance machines using lower manufacturing costs, lower fuel and operating costs and lower parts and service costs through its dealers, LiuGong says it is committed to providing the lowest possible total cost of ownership for its customers.
“I believe our aftermarket costs for our customers are lower than our major competitors,” emphasised Calder. “We are going to be doing more local [parts and service] sourcing in regions to get the best source cost. Chinese companies in general don’t have the same short-term shareholder pressure as some of our major rivals.
“Our obligation is to ensure that this industry stays extremely viable. We need to not become a major disruptor, but at the same time offer fair value and consistent performance. This will enable our credibility to continue to grow, slowly and surely.
“Our goal is to be a world-class international player. We think we’ve got world-class products, and we think we’re getting world-class international people in to help us reach our goal. We should be regarded as an international player rather than just a Chinese one.”
Commenting on LiuGong’s new international Quarry and Aggregates team, Kevin Thieneman, vice president, LiuGong Machinery, who worked with Calder at Caterpillar China from 1996 to 1999, said: “By focusing on the unique requirements of our quarry & aggregates customers, we want to develop enduring partnerships. John and his team are a great addition to LiuGong and are well placed to help LiuGong develop and maintain long-term relationships in this industry segment.” AB
John Calder, LiuGong’s director – Quarry and Aggregates, says the 856H has become the manufacturer’s flagship wheeled loader model
John Calder is heading up LiuGong’s new international Quarry and Aggregates team
A LiuGong 890H wheeled loader at work on a quarry site
contribution to screening media
Guy Woodford visited the European headquarters of MAJOR, a leading global manufacturer of high-performance wire screening media, to learn more about the North American firm’s ambitious expansion plans for the key regional market. Meanwhile, a Keestrack plant solution is proving a big energy cost saver for a major Estonian quarrying firm
AHaver & Boecker company, MAJOR’s European operation (MAJOR Europe) is based in Battice, Belgium. The company currently sells its product range directly to customers in Germany, France, Belgium, Switzerland, Austria, Slovenia and Croatia. While working to increase its direct dealership reach in Germany and France, MAJOR is supported by dealer-led sales in the UK, Finland, Sweden, Netherlands, and Turkey.
Manufactured in Canada, Flex-Mat highvibration wire screen media – available in TENSIONED and MODULAR form and in D, S, DD (impact resistance), L (sand screening), and T (fine screening) series variants - is seen by MAJOR as a key product range for European customers.
Flex-Mat TENSIONED allows wires, bonded to lime-green polyurethane strips, to vibrate independently from hook to hook for faster material stratification. The screen media is available in a side-tensioned or end-tensioned configuration.
Flex-Mat MODULAR comprises direct switch-and-replace polyurethane modular panels said to provide substantially more open area than traditional panels, increasing the throughput of spec material.
Unlike imitation self-cleaning screens, MAJOR designs Flex-Mat to fit all decks, from scalping to finishing screening. It features up to a claimed 40% more screen capacity than traditional woven wire and a claimed up to 50% more than traditional polyurethane and rubber panels.
As of late October 2019, over 1,000 FlexMat applications had been carried out on quarrying, mining and construction job sites in Europe since 2015 – 30,000-plus globally.
A further 100-150 plant assessments have also been conducted in Europe over the past four years.
During a visit to MAJOR’s European HQ in autumn 2019, Aggregates Business learnt that plans are in place to begin producing the Flex-Mat product range in Europe within the next two years. MAJOR’s Woven Screen product range for European customers is currently made in Battice.
MAJOR’s original Battice workshop, excluding office space surface, was 1500m². The firm expanded the workshop surface up to 3700m² in 2016 by adding a new 2200m² facility. The company is in the process of extending the automation of its wire weaving machines in North America and Europe.
Globally, around 60% of MAJOR’s customers are in the aggregates sector; with 30% in mining and 10% in the recycling industry.
Speaking to Aggregates Business, Lars Bräunling, MAJOR Europe director of product technology, talked about why MAJOR, a company with a proud 130-year plus history, needed to operate differently in Europe, and not simply mirror its successful North American business set-up.
“We have a homogenous dealer-led approach to market in North America, where you can largely operate in one language and customer product needs are pretty consistent. In Europe, company type and size, produced product standards and how the products are made varies a great deal. Then there are 15-20 countries featuring many different languages that we are targeting sales-wise.”
Matej Grm, MAJOR Europe sales manager, said the diversity of the European
have a particularly strong focus on localised customer service, both in assessing and installing the best product solution and subsequent aftersales support.
“We are in the process of building a ‘tool kit’ to allow our dealers to serve our customers even better,” added Bräunling.
MAJOR’s research and development (R&D) focus is on wire screen media products delivering continuous improvement, better performance, and longer wear life. New products must also be capable of more varied applications.
The R&D focus ties in with MAJOR’s corporate philosophy, which it refers to as ‘the MAJOR way’. It includes the company’s emphasis on advanced technology, screening know-how, and business operation – helping drive materialsproducer profitability.
In November 2019, MAJOR introduced the Flex-Mat Sensor, a valuable and easyto-operate vibration data-measurement tool users can utilise to review results and finetune their screen machine without shutting down equipment. The app-controlled vibration analysis sensor enables readings of screen-box vibrations within seconds and generates a report that can be sent or reviewed.
The operator connects the single sensor to the Flex-Mat Sensor app on their phone before placing the sensor on one corner of
Staff working at MAJOR Europe’s Battice factory
the machine. The user continues to move the sensor to each corner of the machine until finished. Once the measurement process is completed, the information will be delivered to the phone in the time it takes to climb down from the machine. Alternative systems may not provide the data until the following day. Machine information is stored locally for ease of use and viewing in areas with cellular limitations. Once a signal is available, the information uploads to MAJOR’s cloud service where it is viewable from a web browser. Historical equipment performance data is also viewable through the cloud.
of Keestrack’s track-mounted R6e impact crusher and three-deck C6e classifier as part of a comprehensive modernisation of its processing technology is set to save Paekivitoodete Tehas (PT) nearly €100,000 a year in energy-related operating cost at the company’s flagship quarry near Estonia’s capital city, Tallinn.
The impressive saving forecast by PT and Keestrack was made after the R6e and C6e began operating at PT’s Väo Quarry in June 2019. Connected to the grid, the new plant set-up cuts PT’s cost per final product tonne to €0.42, compared to the calculated total of €0.58 per tonne of the same machine duo’s annual diesel-electric powered operation (approx. 600,000 tonnes a year).
The reduction of pollutant emissions on site through all-electric crushing and classifying is also significant, with around 400 tonnes per year of climate-damaging CO2 avoided.
Since the installation of the R6e and C6e, the three-man working teams (excavator-wheeled loader-all-electric plants operator) have also been reaching their daily production target of 3,000 tonnes in one long or two short shifts, bringing further significant savings compared to the previous three-shift pattern, requiring 15 PT personnel.
The modernisation of the PT quarries’ set-up cost just under €1mn, with 35% of funding being provided by the Estonian Environmental Investment Centre (EIC) using EU regional funding. The significance of the project was demonstrated by the presence of numerous high-ranking representatives from politics and business
offering the full flexibility of the dieselelectric hybrid drive.
Since 1959, Paekivitoodete Tehas – ‘Limestone Factory’ in English – has supplied high-quality mineral and aggregates for the Estonian road and construction industry. Since 1989 the former state-owned enterprise has been gradually transformed into a private company and developed into one of Estonia’s leading construction materials suppliers, under the leadership of the long-standing director, today’s chairman of the board and majority shareholder, Vladimir Libman.
Today, up to 20% of the Estonian annual demand for crushed aggregates comes from PT’s Väo and Maardu quarries, with their combined extraction quantity of around 750,000 tonnes of material per year. Together with washed sand and gravel from mining residual masses with high contents of fines or clay and marl impurities and the company’s recycling activities, PT’s total production amounts to around 1.2 million tonnes per year.
On the Baltic coast, high-quality limestone is found close to the surface in 5-6-metre widths. In the past, PT has responded to the rapid growth of aggregates demand with three decentralised stationary processing units (totalling 400 tonnes per hour), whose raw materials, intermediate and end products had to be extensively hauled by rigid trucks. This low efficiency operation became problematic as the mining zone with its dust and noise emissions moved ever closer to the rapidly expanding Tallinn residential district of Lasnamäe, and its 120,000 inhabitants.
relief has been achieved through investment
The modernisation of PT’s quarries’ set-up cost just under €1mn, with just over a third of funding provided by the Estonian Environmental Investment Centre (EIC) using EU regional funding
Eddy Depraetere, Euroquartz’s chief technology officer, has highlighted how MAJOR Europe’s installed Flex-Mat high-vibrating wire screens have helped lower his company’s production costs
AMMANN ABP HRT ASPHALT-MIXING PLANT
•Is ideal for production volumes with large proportions of RAP
•Can use discarded consumables such as printer cartridge toner and tyres
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The Ammann ABP HRT (High Recycling Technology) plant is the industry’s recycling leader. The HRT plant:
of the production processes has focussed especially on the protection of residents and a general reduction of the environmental impact. To replace the existing installations, a mobile processing line for the production directly in the mining zone was favoured for the main Väo quarry site as well as for temporary operations in the smaller Maardu quarry (150,000 tonnes per year), 10kms away.
The entire PT processing modernisation project was supervised by Johann Prüwasser, CEO of Keestrack Engineering, the Austrian design and development branch within the Keestrack Group.
operation in the Väo quarry with all the advantages of our proven track-mounted technology,” he adds.
Two 200-metre cables from the specially installed 400V transformer station on the quarry floor now feed the Keestrack R6e and the downstream C6e classifier, directly connected to the crusher via power supply and communication cable for data exchange between the plant controls.
Powerful electric motors for the crusher drive (250kW) and the pump units of the central plant hydraulics (R6e: 90kW, C6e: 45kW), as well as electric belt drives and ancillary units, enable complete emission-
A combination of Keestrack’s R6e impact crusher and three-deck C6e classifier is set to save Paekivitoodete Tehas (PT) nearly €100,000 a year in energy-related operating cost at the company’s Väo Quarry, near Estonia’s capital city, Tallinn
Belgium, produces around 60,000 tonnes of building material products each year, with just over 50% for export customers in Europe or further afield.
In early 2019, the company identified a lack of consistent quality in every other truckload of variously sized quartz, silica, marble or limestone products processed through its Mogensen SN1544 four-deck sieving machine.
The company turned to screening wire system manufacturer MAJOR Europe, a leading manufacturer of high-performance
of Euroquartz’s other screening machines, for a solution. This led in May 2019 to MAJOR Europe installing its Flex-Mat high-vibrating wire screens on two of the Mogensen SN1544 unit’s four decks.
Eddy Depraetere, Euroquartz’s chief technology officer, said the introduction of Flex-Mat wire screens is expected to reduce the Mogensen SN1544’s production cost by 30%, with the company set to fit Flex-Mat to the machine’s two other screen decks.
When Aggregates Business visited Euroquartz in late October
of material with the Mogensen SN1544 without any problem.
“We are now able to produce a better quality product, while saving a lot of time and money through reduced maintenance. Before, we were losing one to one and a half hours of production time every time we had a problem with material throughput, such as plugging” said Depraetere.
“We initially installed the FlexMat on two decks of the Mogensen unit as we wanted to compare its performance against the screen media that came with the machine.
The successful introduction of Flex-Mat on the Mogensen SN1544 could not have been better timed as demand for Euroquartz’s product range is growing year on year. The company’s six-hectare manufacturing and storage site has been operational for more than 10 years.
“We have a wide client base. Our biggest export market is other European countries, but we also sell our products to customers in South America, China and Thailand. We also sell our sand products to the Saudi Arabians!”
crawler excavator range cabin more spacious. Each cabin also has an eight-inch hi-res display screen and reduced noise and vibrations compared to its predecessors.
Loads of ambition
The global quarry loading machine market is vibrant with many leading manufacturers due to unveil new models over the next 12-18 months. Guy Woodford spoke to experts at two leading wheeled loader and crawler excavator manufacturers to find out more about their new model plans, along with the key benefits of their current quarry-suited machine line-up
Hitachi Construction Machinery (Europe) NV (HCME) has been talking to Aggregates Business about current excavator and wheeled loader demand among European quarrying and mining customers. The major original equipment manufacturer (OEM) is launching its next-generation Zaxis-7 crawler excavators for the European market in spring 2020, and its upcoming wheeled loader models will be introduced later.
“Our large quarry and mine-suited excavators are very reliable workhorses that are thoroughly tested before coming to market. Customers using our machines recognise all these aspects,” said Wilbert Blom, HCME’s excavator product manager. “When you look at our European market share for excavators, we have close to 20% share for the 50-tonne class and up to 30% for the 85-tonne class. Customers for these models demand uptime and performance. They do not want to lose money on excessive maintenance and other issues. The machines need to deliver.”
Blom said that as HCME large crawler excavators have Hitachi-designed and engineered hydraulic systems, the manufacturer has “total control” of their quality.
He continued: “I think we can grow our market share in around 50-tonne class excavators. The market is flattening a bit. Customers are a bit more hesitant on purchasing new equipment. In the shortterm, this may help with lead times.”
Commenting on what quarrying and mining customers can expect from the next-generation large HCME Zaxis-7 crawler excavators, Blom said: “We’ve been able to make some significant improvements to the hydraulic system. This will deliver significant savings on fuel consumption, which equates to lower TCO [total cost of ownership].
“Since 2018, we’ve also had the ConSite oil sensor in our up-to-85-tonne class ZX890-6 model. It’s an oil sensor in the engine and hydraulic system, monitoring engine and hydraulic oil quality 24/7. What is unique about the oil sensor is that it’s Hitachi patented system. It detects various material contamination and the algorithms behind it measures the quality of the oil before something happens. This might, for example, detect an increase in iron particulates in the engine or hydraulic system oil and stop the main control valve from getting seriously damaged, preventing major maintenance work.”
Blom said that HCME had also listened to customers by making the new Zaxis-7
Focusing on another area of improvement, he said: “In 2018 we started supplying Hitachi-branded buckets for excavators, like we have done for some time with our wheeled loaders. Some of our excavator customers had been flagging up to their Hitachi dealer that their bucket attachments didn’t seem to work well with their machines. After exploring the root causes, we were finding that the installed bucket was too big. Now we can safeguard performance by supplying our own buckets.”
Asked about the potential for electricpowered large crawler excavators for quarrying customers, Blom said: “We already have electric-version machines for mining customers that hook up to the grid. I’ve not seen many requests from quarry customers to connect, say, an 80-tonne machine to the grid. If hydrogen fuel cell systems really become commercially viable for quarry machines, that will be interesting. Maybe some hybrid solutions can be developed which are less sophisticated. I think quarrying and other jobsite machines will become smarter, making more use of sensors to further measure productivity and safeguard their uptime. There will also be far more localised spare parts provision.”
Bill Drougkas, HCME’s wheeled loader product manager, said quarrying and mining customers are focusing on easy wheeled loader bucket filling, resulting in fast cycle times and very low total cost of ownership. “There are several sub parameters connected to this: the wheeled loader must be of high quality, come with low fuel consumption and maintenance cost, while also demonstrating an investment in operator cabin comfort, and an absolute focus on safety. With excavators, the machine is standing safely and operating in one area at a time. But for wheeled loaders, they are constantly travelling around a quarry or mine and there are on- and off-highway trucks coming in and going out of the work site. This means safety is of utmost importance.”
A Hitachi ZW310-6 wheeled loader and Hitachi Zaxis ZX350LC-6 crawler excavator at work in a Bulgarian quarry
Drougkas said the current ZW-6 wheeled loaders have additional safety features compared to their predecessors. “One of these is for example our remote fleet monitoring system, ConSite, that could indirectly inform the operator that their operational behaviour will not result in a long lifetime for the machine. It’s important to note that doing this does not sacrifice in any way the performance of the wheeled loader. An identified problem might be, for example, an operator constantly pushing the brake pedal. Through our global e-Service platform we can detect operator behaviour that is below the average for Hitachi wheeled loaders globally. We can then pass on advice to the operator on how they can change their behaviour. By doing this, machine lifetime is significantly increased.
“We have also invested a lot of time on how to best position the engine on the frame in order to allow direct visibility to the rear two sides of the counterweight. Of course, operators use their rear-view monitor camera, but they are also always looking around as they drive the wheeled loader.”
The ZW-6 wheeled loader range also has improved traction force, said Drougkas, which has increased the filling capacity of their buckets. “Being Hitachi, we are experts in hydraulics, and can match a higher quality powertrain with high-quality components.
“In recent years Hitachi wheeled loaders have also been well received in quarries and mines due to their proven low fuel consumption. It depends on the customer work site and how they are used, but generally current generation ZW-6 wheeled loaders achieve a 10% reduction in fuel consumption than previous generation machines. Some of this is due to improved axle components and reduced friction meaning lower hydraulic losses therefore reducing fuel used to run. Overall, we have seen that the ZW-6 generation machine is very competitive.”
Drougkas said that HCME was also investing heavily in its aftermarket business. “Our Hitachi-branded buckets allow us to give a total solution to our wheeled loader
customers. There are also many initiatives for our dealers, such as how to promote Hitachi Genuine Parts. We are also providing tools like a ‘preventive maintenance cost planner’. This enables dealers and customers to really prepare servicing and maintenance needs in advance, so that when a technician visits a customer work site, they have the correct replacement parts and will not need to make one or more repeat visits. Doing more preventive maintenance also means that customers will not experience unnecessary downtime and cost due to the need to replace major wheeled loader components.”
Highlighting what quarrying and mining customers will see in the heavier upcoming models of the wheeled loaders range, Drougkas said: “They will take the machine performance and health information available to the operator to the next level. This means using a smart monitor to convey key messages via this monitor about operator behaviour and what is happening to the machine. The messages might say: ‘If you do X, you will reduce fuel consumption by Y and increase the lifetime of your machine by Z. It is moving to a kind of artificial intelligence where it comes from machine to operator communication.”
Drougkas emphasised that the design of the upcoming wheeled loaders range will follow Hitachi’s concept to preserve their strong emphasis on safety. The “highly advanced” joystick control of ZW-6 models will be enhanced further on the nextgeneration machines, he added.
Turning his attention to current European heavier wheeled loader line market demand, Drougkas said: “The demand is still there thanks to the number of major infrastructure projects taking place. We are expecting demand to remain stable in 2020.”
In the November-December issue of Aggregates Business we reported on Hyundai Construction Equipment Europe’s (HCEE) launch of its new HL900 A-series wheeled loader range with three Stage V compliant wheeled loaders: the HL940A, HL955A and
the HL960A.
For this issue, Stefan Schwill – HCEE’s wheeled loader product specialist, spoke to us about forthcoming quarrying-suited HL900-A series models. He also discussed HCEE’s plans to develop its market share for heavier, 20-tonne class plus wheeled loader models.
“We will be launching the 24.2-tonne HL970A with a 4.2m³ bucket and 31-tonne HL980A with 5.6m³ bucket models in the first half of 2020, and the 26.5-tonne HL975A with 4.8m³ bucket and CVT (continuously variable transmission) in the second half of next year,” said Schwill. “We also have the HL965 20-tonne Stage IV engine machine with 3.6m³ bucket, but there is no launch date currently for an A-series Stage V version of that model.”
Like the smaller models in the range, the 20-tonne plus A-series wheeled loaders come with an in-cabin menu allowing for three engine operation modes: Power, Power Smart and Economy, offering full engine power or reduced fuel consumption depending on the application. The new-for-Stage V models Power Smart mode in addition with EGR (exhaust gas recirculation) removal is said by Schwill to result in reduced energy losses and up to 5% fuel savings. In addition, the engine performance is optimised to deliver higher torque at lower rpm. This provides another means for improved fuel efficiency, while optimising engine power and improving engine response time.
Schwill said: “All Hyundai A-series wheeled loaders are equipped as standard with a rear-view camera developed in-house. Hyundai also offers an optional reverse-drive radar system, like a car’s, allowing the operator to quickly and reliably detect obstacles within 10 metres during day or night.”
For increased safety on the job site, Schwill highlights Hyundai’s new AAVM (advanced around view monitoring) fourcamera system which is available as an option with Hyundai Stage V A-series wheeled loaders and crawler excavators.
A Hitachi ZW370-6 wheeled loader in a Finnish quarry
“The system has around view monitoring [AVM] and intelligent moving object detection [IMOD]. IMOD alerts the operator when a person or potentially dangerous object is moving too close to the machine. There are audio and visual alerts at five
in the jobsite office. The heavier A-series wheeled loaders also come with five-speeds and a lock-up function, offering further assistance with fuel saving.
Schwill continued: “A remote door opener allows you to use a small smart key
from Bosch Rexroth. Our Stage V models will only have Cummins engines, which don’t use EGR and have increased engine combustion efficiency. Having only one engine supplier allows Hyundai to connect it through ECD (engine connected diagnostics)
The HL960A is one of Hyundai’s new HL900 A-series wheeled loaders
Hyundai is launching its quarrying-suited HL970A in the first half of 2020
Liebherr’s next-generation 27-tonne TA 230 articulated dump trucks are now in production
What’s next in hauling?
Liebherr has launched the first of a new three-strong, next-generation articulated dump truck series, while Terex Trucks has big plans to increase its presence in Algeria’s strong construction sector. Guy Woodford reports
The first of Liebherr’s keenly awaited next-generation 27-tonne TA 230 articulated dump trucks (ADT) has gone into production. From April 2020, the initial production machines will be delivered to Liebherr rental parks and dealer rental parks in Europe, with wider sales to European customers following on in 2021. In 2021, the TA 230 will also be available from dealer rental parks in North America. The TA 230 will be followed by next-generation Liebherr 36-tonne (TA 240) and 41-tonne (TA 245) ADTs in 2023.
Last autumn, Aggregates Business watched a pre-series, next-generation TA 230 ADT being put through rigorous semi-autonomous testing at Liebherr’s cutting-edge test track and development facility in Kirchdorf an der Iller (Kirchdorf), Germany, during the manufacturer’s 2019 information event for the international construction industry press.
During the well-attended event, Werner Seifried, managing director, Research and Development, Liebherr-Hydraulikbagger, gave a presentation on how Liebherr develops and tests its earthmoving machines, citing as an example the TA 230, TA 240 and TA 245 next-generation ADTs.
During a section on the testing element of Liebherr ADT development, he said: “Articulated dump trucks are frequently used in environments where their task is to transport materials over long distances. These roads, often referred to as haul roads, are usually gravel or dirt tracks with rough services. As the usage duration of these haul roads increases, their condition deteriorates, i.e. the number of potholes and bumps rises while the quality of the road worsens.
These haul roads are now simulated on our [Kirchdorf] rough road track. This way, we can simulate realistic conditions in detail and with high-quality reproducibility in tests.”
After showing a video of four ADTs being subjected to partially autonomous, varied ground-profile testing at the Liebherr Kirchdorf facility, Seifried widened his presentation to include all earthmoving machines.
“Before we dispatch our machine, we firstly conduct an internal test for over 100 hours”
“Despite ideal conditions in our development and test centre here in Kirchdorf, tests under real conditions at our customers’ premises are indispensable. Our field test managers in technical testing have a pool of customers at their disposal who have kindly agreed to test our vehicles in their specific applications. However, before we dispatch our machine, we firstly conduct an internal test for over 100 hours. This needs to be passed successfully without any issues.
“It goes without saying that we attempt to enable the broadest possible range of applications and to find out and learn from the special requirements that many customers have. This way, we can plan for all kinds of unexpected and unanticipated
events that may occur in real-life conditions at the site of use.
“For documentation purposes, the data loggers installed in the vehicles are, of course, assessed on a regular basis. In addition, specialists perform examinations specifically at the defined critical points and check the status of crucial components at fixed intervals. Evaluating these documents is indispensable in order to better understand how components are stressed under specific conditions and how they then behave.
“After all product development milestones have been successfully completed, there are no longer any obstacles to the successful start of series production and a long and successful product life.”
Amid falling revenues from oil and gas exports in Algeria, non-oil sectors such as construction are driving the country’s economy. Algeria sees a robust and stable construction industry as a key component for a successful future – so Terex Trucks sees it as the right time to reinforce its commitment to deliver its robust, straightforward articulated haulers to customers across the country.
As one of Africa’s main oil producers, the Algerian economy is heavily dependent on revenues from oil exports. However, the low oil and gas prices of the last few years have weighted on the country’s economic performance. To reduce its dependence on oil, the Algerian government aims to diversify into non-oil sectors such as construction, to drive private and foreign investments.
This year, the total construction project pipeline in Algeria – as tracked by data provider GlobalData – stands at £109 billion (DZD 16.3 trillion). Due to a focus on residential construction and building affordable houses, GlobalData expects the residential construction market to account for 38.8% of the construction industry’s total value in Algeria in 2023. The development of transport infrastructure is also expected to further drive the construction industry.
The upward trend in investment in infrastructure, residential and energy construction projects in Algeria coupled with the recent investments Terex Trucks has made in its products, people, processes and facilities make it the perfect time for the company to reinforce its commitment to customers in the region – together with Matera, Terex Trucks’ dealer in Algeria. A successful collaboration that spans 15 years,
Terex Trucks and Matera are reaching out to new customers, introducing them to the robust articulated haulers, the TA300 and TA400.
“At Terex Trucks, we are dedicated to building powerful articulated haulers,” said Etienne Lalande, regional sales director at Terex Trucks. “That’s what we are specialised in. Our customers in Algeria know that they can rely on our haulers even in the toughest environment. Our dealer Matera is particularly strong in providing excellent service and support to customers, and together we want to bring our haulers to more customers in the region.”
“With our deep knowledge of Terex Trucks’ machines and our broad network, we maintain great relationships with our customers and stay in touch with them at all times,” said Benoit Strauven, managing
director at the Matermaco Group, Terex Trucks’ dealer in the Benelux region and parent company of Matera. “In a country like Algeria, good geographical knowledge and strong local connections are key. It’s a vast country – the last Terex Trucks hauler we sold was delivered to a place that’s farther away from the Algerian capital than Brussels.”
Algeria’s economy is dominated by public companies which use Terex Trucks’ articulated haulers for construction work, infrastructure developments and earthmoving projects. Customers appreciate the simplicity, quality and reliability of the haulers. Terex Trucks has recently made significant investments to ensure their machines support customers in the toughest applications. Towards the end of 2018, the TA300 was upgraded and it’s now manufactured with the latest EP320
transmission. The updated machine delivers a 5% improvement in fuel efficiency, a 5 km/h increase in speed to 55 km/h, an extended maintenance period and enhanced performance when compared with the previous model. All of this means that customers can be more productive, achieving faster cycle times, lower cost per tonne and reduced carbon emissions.
The TA400 boasts a heaped capacity of 23m³ and is powered by a high-performance, fuel-efficient engine that develops a gross power of 331kW and a maximum torque of 2,255Nm. The planetary gear transmission provides smooth, efficient gear shifting for optimized fuel consumption and reduced cost of operation. Ground-level test points and a fully tilting cab, combined with an electronically raised hood, ensure ease of service and reduced downtime. AB
Göltas Cemento opts for modernised belt apron conveying
Two companies in Turkey and East China have both updated their conveyor systems to achieve greater efficiency and ease of maintenance. Liam McLoughlin reports
Turkey’s recent building boom has led to growing demand for cement, and manufacturers in the country are modernising their cement production methods.
One of these is Göltas Cemento, located close to Isparta in western Turkey, approximately 130 kilometres north of Antalya. The company opted for modernising its kiln and increasing the performance. An increase from 250 to 400 tonnes per hour of the conveying-technology capacity was required, for a chain apron conveyor that transports the clinker from the kiln-cooling system to the silo.
To achieve more economical production, Göltas Cemento has been increasingly opting for alternative fuels in recent years, which meant that the content of fines particles also increased continuously. The existing conveyor already transported high quantities of material, and the process had become extremely dirty, with personnel constantly needed to perform cleaning work.
To find an efficient solution Göltas Cement turned to its long-standing partner,
system provider Beumer Group. Germanheadquartered Beumer has supplied two clinker transport systems and four belt bucket elevators over the course of their existing partnership. The project phase began mid-2015 and the contract was awarded in the beginning of 2016, followed by the installation and commissioning in the autumn of that year.
“For a more powerful chain apron conveyor, we would have needed to take down the entire system including the building structures and the concrete tunnel,” said André Tissen, sales manager for customer support at Beumer Group, who was responsible for the project with his team. “This wasn’t necessary when opting for the belt version. It reaches double the conveying speed, so that the Beumer Group engineers could design the system for an increased capacity while keeping the same width. The conveyor bridge and the selfsupporting steel structure, as well as the concrete foundations remained.”
According to Tissen, Göltas Cement was able to considerably reduce costs and put
the system quickly into operation.
“The silo is 50m high. In order to overcome an inclination of 40 degrees, we installed a steel box conveyor,” he said, adding that it releases almost no material to the environment, despite the higher content in fines particles, which is designed to create a cleaner work environment.
Tissen says that apron conveyors are particularly efficient for the transport of clinker. In general, the clinker should cool down to the ambient temperature plus 80°C, but during the process a so-called ‘raw meal flash’ can occur in the shell section of the preheater tower, caused by breaks in the kiln outlet sealing. “It doesn’t happen often, but it does happen. It can’t be completely avoided,” Tissen explained. Within a few seconds, several tonnes of raw meal or clinker run through the cooler. The material cannot cool down and arrives on the conveyor at extremely high temperatures.
“The cement plant operators are still not able to ensure with 100% certainty that the material does not leave the clinker cooler at temperatures of 500 to 800°C,” said Tissen.
He adds that Beumer Group apron conveyors are completely heat-resistant. The specific design of the cells allows safe, low-friction transportation of any hot material. Sealed and overlapping side walls and bottom plates in the cells prevent the clinker from exiting and minimise the escape of dust. Operators get the Beumer apron conveyors SZF and GSZF with cell-width gradations from 500mm to 2,000mm, centre distances of more than 250m and conveying capacities of over 1,300m³ per hour.
LEFT: Track-mounted designs allow components to slide in and out easily for maintenance
The Göltas Cemento plant in western Turkey
Beumer claims that the use of its steel wire belt instead of a chain lowers maintenance costs and extends maintenance intervals. Chains can also break, if preventive maintenance is not performed properly, which will lead to the conveyor collapsing. “The belt with the steel wires only ages and the rubber becomes brittle, but it would never completely break,” said Tissen. Lubrication is also not required for the belt, whereas it is used frequently on a chain, if for no other reason than to reduce noise levels.
Grease and oil are not only a cost factor, but are also detrimental to the environment and the conveyor. The clinker dust gets stuck on it and settles in the chain links, which accelerates the wear and tear. Beumer’s belt apron conveyors are in operation for nearly 150 companies.
In Eastern China a coal plant had belt damage, spillage and dust issues at two conveyor transfer points with outdated equipment in the loading zones. Raw coal ore was loaded onto the 1,000mm-wide belts traveling at 500 fpm (2.56 mps). The first chute had a 5m-high drop chute that loaded into a 12m-long loading/stilling zone. The second chute had a similar drop, discharging into a 26m-long loading/stilling zone.
Suffering from an old design, the belts were supported by impact idlers and a troughed roller system, neither of which was equipped to cope with new production demands. Equipment failures happened regularly, and without proper accessibility for routine maintenance, long periods of downtime were common. Belt sag created gaps between the belt and rollers, causing fugitive dust emissions throughout the facility.
Inadequate impact control led to spillage becoming entrapped between the belt and tail pulley, damaging them both. Excessive downtime, costs for cleanup and equipment replacement seriously impacted profitability. Managers at the coal plant sought a solution that better protected the belt, sealed the chute from dust and spillage, and offered easier inspection and ongoing maintenance.
Technicians from the Chinese division of bulk materials-handling solutions provider Martin Engineering were invited to perform an on-site assessment and suggest an affordable solution.
After offering a detailed proposal, the team installed modern equipment that addressed the issues on both conveyors. The first chute was equipped with a track-mounted impact cradle to improve loading and protect the belt and tail pulley. In addition, slider cradles for smoother centering were installed, along with a full-length apron seal to prevent dust and spillage from escaping. A comparable solution was installed in the longer chute, with added cradle support down the entire length. Both chutes featured non-powered dust-bag systems to collect emissions.
Since installation, Martin Engineering says that spillage around the loading zones is under control and dust emissions have been drastically reduced. Operators report that a considerable drop in equipment failure rates has resulted in a substantial increase in productivity. Contributing to the success was workers’ ability to easily inspect and service components by sliding them out and servicing them outside of the conveyor.
“After more than 75 years of working with bulk handlers all over the world, Martin Engineering has discovered that ‘access’ is a common element for both safety and productivity across all industries,” said Daniel Marshall, product engineer at Martin Engineering. “By adding easy access and monitoring in the design phase, equipment can be better maintained using less labour, leading to reduced downtime. This is reflected in the cost of operation, offering a better overall return on investment.”
Many conveyor transfer points still have an antiquated roller system tasked with
absorbing impact and centering the cargo, according to Marshall. “These components often break and seize, causing friction and a potential fire hazard,” he said. “To replace them, several workers must remove the skirtboard and break the plane of the conveyor to reach across the stringer with heavy tools to assess and repair equipment.”
To reduce maintenance time and labour, improve safety and extend equipment life, operators should consider track-mounted impact cradles and belt support cradles. Located under the skirtboard and mounted with rugged steel assemblies, the cradles feature large impact-absorbing UHMW polymer ‘box bars’ engineered with smooth surfaces that the belt can slide across with little friction or belt wear. These assemblies can be pulled out by a single worker and – working safely from outside the conveyor and using only a single tool – the box bars can be simply removed and flipped in a matter of minutes to double the service life.
Along the cargo path in the settling zone and beyond, retractable idlers support the belt and maintain the trough angle. Exposed to the punishing environment, gritty dust and extreme weather, rollers can seize over time. Often set closely together in the loading zone to avoid belt sag, slideout/slide-in roller frames permit workers to perform idler service outside of the belt plane without the need to raise the belt or remove adjacent idlers.
“Wear parts such as belt cleaner blades need to be monitored, serviced or changed regularly to prevent carryback from causing dust and spillage along the belt path,” Marshall said. “However, blade adjustments and changes can require several hours of downtime.” AB
Inspection doors and track-mounted components facilitate maintenance for extended equipment life
ALLU’s M-Series Transformer screener crusher
Bucketloads of potential in 2020
Guy Woodford reports
Finnish company ALLU has big growth plans aided by the growing popularity among quarrying and other industry customers of the firm’s Transformer screener crusher. By reducing the number of process steps needed, the hydraulic attachment helps achieve maximum efficiency on job sites, across all kinds of applications.
Aggregates Business spoke to Jeroen Hinnen, ALLU sales director, to find out more about the firm’s plans for 2020 and beyond.
Commenting on the current state of the global quarrying attachments market and ALLU’s position within it, Hinnen says: “ALLU can help benefit customers by providing a new, cost-efficient (and improved) way of crushing material by, for example, pre-screening it before it is fed into the crusher. This simple process eliminates fines and therefore will increase throughput and lower wear in the crusher. Customers also benefit from removing big rocks and large particles from harming the conveyer belts with the ALLU Transformers.
“Competition in the quarry market comes mainly from different methods used. ALLU, although present in the quarrying market for many years, is in many ways a rather new name to this market and proving that ALLU reduces Capex [capital expenditure] and maintenance needs to be proven in practice. That said, our Transformers are now working globally in many soft rock quarries and mineral surface mines where the results have been exceptional, as shown by the number of repeat purchases.
“We respect all manufacturers, as we know how hard it is to make the right
product for the right application, but in our ‘attachment’ business, we do not feel that we really have a like-for-like competitor due to the advanced nature of our solutions.”
Hinnen says ALLU works with professional partners all over the world, making it possible for the company to stay close to and provide “true added value” for its customers.
“The range of applications for ALLU is wide to say the least. In cases of selective use of material, the primary optimisation would be separating waste rock before transportation - eliminating wear, need and cost of transportation. With other typical cases, ALLU benefits customers with lowered running and maintenance costs and enhanced material separation which leads to
ALLU sales director Jeroen Hinnen
The global screening buckets and attachments market is competitive, with innovation and aftermarket support key features of many leading manufacturers’ product offer.
improved (customer) business performance. In all of these cases, everything starts from understanding the customer’s process at the site. By finding the bottle necks, we can really add value.”
Focusing on the popularity on ALLU’s M-Series Transformer range with quarry customers, Hinnen says the crusher screener buckets benefit from being a “unique” example in the industry. “The best customer testimonials come from surface mines where hardened, lumped material needs to be returned to a flowing, granular format. In these kinds of applications, the production has reached 600 tonnes per hour and has been a highly cost-efficient solution to the problem for the customer.”
Hinnen says ALLU has enjoyed strong growth in recent years, both in terms of sales volume and geographical footprint. A huge modernisation of processes in the back office has, he notes, also contributed greatly to the manufacturer’s success.
Asked about the success of his first couple of years as ALLU sales director, he replied: “Personally, growing the sales team and people has been the greatest achievement. This business is all about the people and the team serving the customers. When we’re able to grow the people, we’re able to have happy customers.
“For ALLU, growth opportunities exist in numerous areas and applications. Being able to facilitate the growth and support the team to grow strongly further is my main aim.”
Speaking about how his experience and knowledge gained in previous roles have assisted him in his senior executive role at ALLU, Hinnen says: “I guess life is about
lessons learned; some bring great memories, and some provide great food for thought. I do remember many wonderful people who wished to be of support along the way. The international market has its ways and tricks and when you have somebody walking side by side with you, that’s the greatest gift I feel anybody can receive. I’ve been very lucky with those supportive people. Whoever you work for, or whatever you do in life, you must learn. During my time with other companies I learnt many things daily, but the global nature of business, dealing with unique individuals and being exposed to some of the latest thinking, have certainly stood me in good stead.”
Hinnen stresses how ‘Customer First’ is one of the three guiding ways of working with ALLU. “ALLU invented the methodology of the transforming and processing attachment being used today and innovation is in the DNA of the company. There are many projects in the pipeline, and I’m convinced all of them are for the benefit of our customers. We will be introducing some
Commenting on how ALLU’s manufacturing capabilities and footprint have evolved during his time as sales director, and future company plans in this area, Hinnen says: “Strategically ALLU wishes to work together with professional partners in all fields of the business and this applies to manufacturing as well. For ALLU, being a Finnish family company, Finland has a special place in our hearts. Thus, we have strong partners in Finland. However, the business is highly competitive, and ALLU needs to follow the most cost-effective and productive path. We have a duty to our shareholders, stakeholders, employees, partners and customers to run a highly efficient operation.”
The aftermarket side of ALLU’s business is very close to Hinnen’s heart, as he explains: “ALLU Support is one of the major attributes of our business. We have a specialist team in charge of the customer service, which includes training, effective equipment usage, and parts. We ensure our dealers are stocked with the most commonly occurring wear
from the equipment and can advise the customer how to best use their ALLU. If the dealer requires more specialist advice, we possess a global team who literally travel the world visiting customers and dealers. We have found this to be particularly appreciated.
“In 2019, ALLU introduced the ALLU APP, which provides customers and dealers with access to all ALLU information, data and support. Safety and speed of information sharing are very important when it comes to supporting customers. Therefore, the ALLU APP was developed, which we believe was a first in the world in our niche business.”
German aggregates supplier TBS Transportbeton Schüssler (Schüssler) has invested in Hitachi rock buckets to support its quarrying operations in Kerpen-Manheim. The company is also using a fleet of four Hitachi wheeled loaders at its two sites, from which it supplies 600 types of readymixed concrete, sand and grain from several locations across Germany.
Schüssler’s two ZW310-6s and two ZW370-6s have been equipped with Hitachi rock buckets, which are designed for heavyduty work and loading of rocks. They are also said to be optimised for good penetration and breakout performance. On site, the ZW370-6 wheeled loaders are excavating material and transferring it to a conveyor. Around 200m³ of filtered material is loaded onto trucks by each ZW310-6 per eight-hour shift.
Said by the Japanese manufacturer to be exceptionally reliable and durable, Hitachi buckets have been designed to enhance the performance of Hitachi wheeled loaders in a wide range of working conditions. By contributing to maximum productivity and uptime on the job site, they not only help to increase profitability, but also provide peace of mind to companies who want to get the most from their machine.
Schüssler selected the Hitachi buckets based on the advice it received from authorised local dealer Kiesel. “It recommended them based on our requirements, and we trust in their opinion,” said Schüssler’s executive director Jochen Wonka. “We have a very good relationship with Kiesel. They provide an excellent
Also, Conexpo will be important for us.”
A Simex VSE 20 screening bucket performing soil screening for green areas as part of a major renovation of a Lombard farmstead
A Schüssler Hitachi ZW310-6 wheeled loader with Hitachi rock bucket attachment
MB Crusher’s MB-S14 screening buckets were used in site preparations works for a new five-star luxury resort in Qatar
service, provide us with everything we need, and the Hitachi wheeled loaders have proven to be very reliable.”
Simex CEO Mirco Risi spoke of the continuing success of the Italian manufacturer of hydraulic attachments for earthmoving machines in a festive December 2019 message praising the “efforts and excellent work” of the company’s employees, associates and distribution network.
“2019 is drawing to a close and we look back on a positive year, considering that after years of double-digit growth our numbers stabilised with respect to 2018,” said Risi. “This success is a result of various factors that, depending on market demand, have led our products to be winners.”
Risi said that while strengthening of Simex’s distributor network and the company’s work to support it had a positive impact on the firm’s year end, he was convinced that the result was also thanks to the constant R&D focus on new products to expand the company’s attachments range, or variations on existing products.
He continued: “Another factor I believe very important for maintaining growth is the ability to adapt to the constant variations in the markets and the demands of our customers, who are always in search of attachments that provide a concrete response to their application requirements, but without shortcuts when it comes to reliability, productivity and profitability.
“Towards that goal of delivering a better and faster response to the market and users’ needs, 2019 saw us making an important investment that in early 2020 will materialise in the completion of our new 7,000m² structure containing a large area for loading/ unloading and sorting of materials, a warehouse with high storage capacity, new offices, and, in a second phase, the new painting plant. This new structure meets two needs: first, it will allow us to avoid production slowdowns caused by our suppliers’ longer delivery times, especially regarding hydraulic components; and second, it will lead to faster order fulfilment. Over the last few years we have noticed an overall tendency on the part of users to place orders after having the certainty of the work order, for us which entails accelerated turnaround times. As a result, having more attachments ready for delivery means a concrete support to our customers throughout the world.
“Altogether, 2019 was a positive year that saw us making strides on several fronts to assure our growth and performance on all markets where we are present. On that premise, our success should not be viewed as a point of arrival, but as a step along our path.”
A Simex VSE 20 screening bucket has been recently performing soil screening for green areas as part of a major renovation of a traditionally designed Lombard farmstead in Trivolzio, near Pavia, in south-west Lombardy, northern Italy. Ripristina, a construction and renovation contractor, is turning the farmstead, which also contains a building dating back to the Middle Ages, into a mixeduse residential and commercial complex.
Giacomo Negri, Ripristina’s technical manager, said the VSE 20 took care of all the project’s screening problems. “We were looking for a screening system that would achieve good productivity and allow for a certain amount of mobility. We excluded a mobile screening unit due to space restrictions, but on the suggestion of CGT Edilizia we solved the problem by renting a CAT 313F excavator mounted with a VSE 20 screening bucket. Besides its great productivity, this solution afforded us great mobility on the job site, a critical factor for screening in all the areas designated for green spaces.”
MB Crusher’s MB-S14 screening buckets were used for site preparation works for the five-star waterfront resort in Salwa, Qatar, which opened in 2019.
The MB-S14s were used with Hyundai 220LC crawler excavators during works aimed at reducing environmental impact by using material already available at the site.
This Salwa luxury resort comprises a hotel managed by Hilton Hotels & Resorts, 2800m² of health clubs and spa, several outdoor pools, meeting rooms for events, 13 fine dining restaurants and 90 villas. AB
Bärnreuther+Deuerlein has been using environmentally sound retreads at its seven quarries in Germany
Rewarding retread customers with a ‘green bonus’
Customers who buy environmentally sound off-the-road (OTR) retreads are being given discounts and a certificate attesting to the amount of raw materials they are helping to save. Liam McLoughlin reports
Bavarian quarry operator
Bärnreuther+Deuerlein has been rewarded and received a certificate attesting to the environmental benefits created by its choice of premium quality OTR retreads.
Until the end of 2019, any end user from the DACH countries (Germany, Austria and Switzerland) purchasing at least four Marangoni OTR retreads from a selection of specific tyre sizes (up to 24.00R35), obtained a discount of up to €90 per tyre. In addition, the eligible customer receives a certificate from the company attesting to the savings in terms of raw materials achieved with their sustainable choice.
The document was delivered to Frank Eichler, purchase - QS - plant manager at Bärnreuther+Deuerlein by Anton Zehner, OTR tyres area manager at Marangoni. It declares that, having opted for the 24.00R35 MDT retread, the company has preserved 550 kg of material per tyre, equivalent to 64% of the original product weight.
Bärnreuther+Deuerlein places careful focus on the environment and has been relying on the retreading of its tyres for many years, thereby helping to save significant amounts of resources in addition to reducing their operational costs.
The enterprise was founded in the 1930s and employs 150 workers. It operates seven quarries in Bavaria, where it produces quality-controlled gravel material for road construction, asphalt pavement, concrete manufacturing, as well as for landscape-design projects.
Bärnreuther+Deuerlein has been working with Marangoni for almost 10 years. At the beginning of the cooperation a delegation visited the Italian plant in Rovereto to observe the retreading production.
Eichler commented on the visit: “During our stay, we also took an in-depth training on the OTR-casing selection that provided us with great best practices for tyre management. ”
In order to make the most out of its tyres, Bärnreuther+Deuerlein ensures that they run out in good conditions with recommendations from Marangoni and on-site regular checks.
The company says it is committed to continuously improving the efficiency of its operation by using tyre-monitoring sensors and raising awareness among its drivers of optimum tyre use, thanks to specific training activities and rewards for the most ‘green’ driving performances.
In addition, Bärnreuther+Deuerlein enforces a tyre policy which always involves the combination of premium new tyres and Marix OTR retreads supplied by Marangoni. The latest 24.00R35 Marix MDT retreads supplied to the Bavaria-based firm were mounted on its Komatsu HD605 rigid dump truck. The MDT pattern is particularly suitable for use on dump trucks operating in heavy-duty applications, such as those at the Bärnreuther+Deuerlein quarries. The tread compound developed by Marangoni for this product is characterised by a very low heat development, which is designed to ensure optimal hourly performance.
Romanian truck retreading company
PneuMaxx, which operates as Bedelco East Europe, produced its 100,000th retread using Marangoni’s RINGTREAD system in October 2019. The event was marked with a commemorative plaque presented by Daniel Brichta, area manager of Marangoni Retreading Systems to Mihai Ionescu, executive director of Bedelco East Europe.
PneuMaxx was founded in 2005 and, since the beginning, has focused on premium quality truck tyre retreading using the RINGTREAD System.
Ionescu commented: “In 2020, we’ll keep focusing on high-quality retreading, since it is an important part of our business.” Bedelco East Europe owns a retreading facility with a capacity of 18,000 retreads per year, reached after the addition of a second TRM autoclave and a shearography machine. The company operates through a network of four sales outlets located in Bucharest, Arad, Constanta and Ploiesti.
At the forthcoming 2020 ConExpo construction show in Las Vegas (March 10-14), Continental is introducing several new and improved tyre products to cover complete solutions for the construction and other on/ off-road industries.
The company will highlight its newest technologies including three new truck tyres, off-road tyres (including a new General Tyre bias line), a large mining tyre, conveyor belting products, industrial fluid hose, air springs, rubber tracks and an interactive truck-cab model demonstrating in-cab technologies as well as other cabin elements and materials.
Bridgestone Specialty Tire Manufacturing (Thailand), a subsidiary of Japanese multinational Bridgestone, has held an opening ceremony for its new factory for radial tyres for construction and mining vehicles in Thailand. The opening ceremony last October was attended by executives as well as members of the Board of Investment for Rayong Province, and representatives from the Japanese Embassy.
Italy-based OTR tyre maker BKT has renewed its agreement as the official and exclusive tyre manufacturer for the Monster Jam truck competition. The partnership, started in 2014, will continue for a further six years.
The renewed agreement with Monster Jam promoter Feld Motor Sports will see BKT as the official tyre manufacturer at the more than 100 Monster Trucks events being staged in the US and around the world this year.
BKT says its event sponsorship has generated a big increase in brand awareness for the company and its tyre products. AB
BKT has renewed its sponsorship of Monster Jam events
A LONG WAY TOGETHER
EARTHMAX SR 41
No matter how challenging your needs, EARTHMAX SR 41 is your best ally when it comes to operations that require extraordinary traction. Thanks to its All Steel radial structure and the special block pattern, EARTHMAX SR 41 provides excellent resistance against punctures and an extended service life. In addition to long working hours without downtime, the tyre ensures extraordinary comfort.
EARTHMAX SR 41 is BKT’s response to withstand the toughest operating conditions in haulage, loading and dozing applications.
europe@bkt-tires.com
All set for a record-breaking CONEXPO-CON/AGG 2020
Welcome to the Aggregates Business magazine preview of the CONEXPO-CON/AGG 2020 exhibition. Over the next six pages, we will highlight all the key product launches and North American debuts during what promises to be the event’s biggest-ever showcase.
Metso says that its new MX3 boosts crusher productivity and reduces operating costs with a design optimised for mid-sized quarries
Premium Metso aggregates plant
Premium aggregatesprocessing plant maker Metso is showcasing its innovative MX3 crusher and a special Lokotrack mobile crushing plant equipped with an MX4 crusher.
Metso’s cutting-edge MX Multi-Action conecrushing technology has been embraced by quarry operators globally, with nearly 100 units sold worldwide.
Metso’s new Lokotrack ST4.10 mobile screen is a high-capacity screening plant for quarrying, which further adds to the Finnish company’s range of hybrid equipment.
A pioneer in collecting and utilising operational data to optimise machine
performance, Metso’s Metso Metrics Services package can manage and monitor a Lokotrack fleet to optimise utilisation, reduce surprises, and keep costs in check. It is backed by Metso’s industry-leading portfolio of parts, including the new Contender Series for thirdparty equipment, upgrades, and worldwide service and partner network.
Metso is also introducing the Nordtrack product family with purpose-designed and field-proven features for general contractors and small- to medium-capacity aggregates producers. The new Nordtrack range includes track-mounted crushers
and screens as well as track-mounted and wheelmounted stacker conveyors for recycling, demolition and small quarries.
Kleemann versatility
Kleemann says that its latest mobile crushing and screening equipment offers versatility for customers.
The latest MOBICAT MC 120 Z PRO jaw crusher and MOBISCREEN MS 952 EVO mobile screening plant are said to offer high-quality output, combined with high throughput for more efficient operations onsite. Highly mobile for units in their capacity classes, the units can be commissioned quickly onsite as well as being folded down for transport again with minimum effort.
A tough, long-lasting truck body designed to suit any hauler is another Metso product introduction.
Lightweight and robust, the design can help to boost payloads and productivity. According to the firm, its innovative Metso Truck Body can allow customers to haul more with fewer truck cycles.
The complete solution is available for all major off-highway truck models used in quarrying and mining operations. www.metso.com
Effective diagnostics allow users to ensure that the units are maintained efficiently, while servicing is said to be easier due to grouped service points and extended intervals. www.kleemann.info
Versatility and ease of transport are claimed for Kleemann’s MOBISCREEN MS 952 EVO mobile screening plant
Sandvik crushing excellence
Sandvik says that its CH840i cone crusher features mechanical upgrades, connectivity, advanced automation and rebuild possibilities.
Advances also include predicting performance, maximising uptime and low cost of operation. The crusher comes with the firm’s sophisticated Automation and Connectivity System (ACS) as standard. This package can continuously monitor and optimise crusher performance and control the complete lubrication system, increasing uptime and reliability.
Connected to My Sandvik, Sandvik 800i crushers allow managers
and operators to make decisions and identify areas for improvement, increasing uptime and availability.
Meanwhile the new SJ circular motion screen range is specially designed for extra heavy-duty, medium- and fine-screening applications. This inclined screen range suits screening after primary and secondary crushing as a splitter screen to divide flows within a plant and for final screening of a finished fraction.
Sandvik’s UJ440i mobile jaw crusher is said to be sophisticated, fuel-efficient and user-friendly. The firm claims that the machine is a high-quality, robust and reliable unit that is well-proven in an array of
ALLU’s versatile attachments
Finnish firm ALLU is offering an expanded range of hydraulic attachments, with existing models also benefiting from major improvements.
The versatile units can be used with an array of carriers such as excavators, wheeled loaders and skid steers.
The firm says that its products offer a one-stop-shop for screening, crushing, aerating, mixing and loading operations. It also says that this helps boost profitability as less material goes to landfill, lowering haulage costs and landfill fees. The re-use of material on site also means that there is no need to purchase virgin material due to the recycling of left-over materials.
climactic conditions. New technology means that the UJ440i is automatically monitored by the control system that operates the unit, helping optimise production.
Sandvik claims high performance for its Leopard DI650i downthe-hole (DTH) drill rig.
This machine has been designed for demanding high-capacity production drilling applications in large surface-extraction applications. In addition to a powerful engine and compressor, Leopard DI650i benefits from a new iCAB cabin that offers efficient ergonomics. www.sandvik.com
Simex broadens screening horizons
Simex’s current VSE screening bucket range comprises the VSE 10, VSE 20, VSE 30 and VSE 40 models compatible with 8-45-tonne excavators with load capacities ranging from 0.4m³ to 1.8m³. Independent of model, all the screening buckets feature easy loading, simple use and high productivity. In addition, the exclusive Simex patent is said to allow a rapid size adjustment of the material to be screened in only a few seconds via a control in the operator cab.
Simex says that thanks to its patented system, the Italian manufacturer’s screening buckets are the only ones that enable output size adjustment even when emptying material loaded into the same bucket without long downtimes or complicated mechanical procedures. This is said to ensure optimum productivity and profitability.
The VSE range also offers excellent levels of production due to the rhomboid-shaped elements with disks in varying diameters that make up the shafts. This specific shape of the tools produces an intense whirling of the material to be screened, all to the advantage of hourly productivity. www.simex.it
The company says that its Transformer range now offers improved performance. The DL
thinnest blade model), while the DH 3-17 uses 16/32 TS blades, the DH 4-17 uses 25/50 TS blades
3-20 uses 50mm TS blades. The company says that its innovative TS blade structure is a modern development for the screener/ crusher market. According to ALLU, it offers new levels of efficiency and productivity and will further enable customers to use their Transformer units in more than one way.
Meanwhile the firm says that its Processor is a power mixer attachment that converts an excavator into a versatile tool capable of penetrating and mixing a variety of difficult materials. Powered by the excavator’s hydraulic system, the Processor 300 HD can reach difficult or soft areas to mix materials.
www.allu.net
Sandvik’s new cone crusher range benefits from advanced automation features
Versatile hydraulic attachments are offered by Finnish firm ALLU
CDE has added new enhanced features to its Combo all-in-one wet processing & water treatment system
Latest CDE cutting-edge Combo
CDE is showcasing its latest Combo all-in-one wet processing & water treatment system.
The patented Combo – said to be world’s first all-in-one wet processing plant – was unveiled at bauma in April 2019. It was the first fully integrated, modular, patented turnkey sand classification and water treatment solution for the production of premium manufactured sands.
The latest model in the Combo range has a number of enhanced features that CDE says have been specifically designed to enable operators in the Americas to capitalise on new opportunities.
Lower power consumption complemented by claimed industry-leading water treatment and management allows customers almost total independence of water supply with up to 90% of process water
Terex FM UltraFines efficiency
Terex FM UltraFines plant is said to guarantee efficient management and recovery of ultrafines material from wastewater streams produced during material washing processes. The ultra-fines recovery unit from Terex Washing Systems can process up to 450m³ per hour of slurry, recovering material as low as 40 microns. This reduces the volume of solids entering storage ponds or water treatment plants.
Bringing together a centrifugal pump, a hydrocyclone cluster and a high-frequency dewatering screen on one chassis, the FM UltraFines also boasts an innovatively designed conical tank and anti-turbulence system, an essential element of ultra-fines recovery.
Part of Terex Washing Systems (TWS), Terex AquaClear Water Management Solutions (Terex AquaClear WMS) offers a full portfolio of water management equipment including clarifying
tanks, flocculent dosing systems and filter presses, creating a onestop solution for washing and water management.
Terex AquaClear WMS is supported by a dedicated technical team consisting of a product manager, engineers
MAJOR’s innovative Flex-Mat
recycled for immediate re-use in the system.
Importantly, the Combo is portable and incorporates all fi essential processes – feeding, sizing, sand washing, stockpiling and complete integrated water management – onto one compact and modular chassis. With a 30% reduced footprint compared to traditional setups it requires less civils expenditure & planning requirements. www.cdeglobal.com
MAJOR is introducing the Flex-Mat Sensor to its range of products for highperformance screening media. This vibration datameasurement tool allows users to review results and fine-tune a screen without shutting down the equipment. The appcontrolled vibration-analysis sensor allows fast readings of screen box vibrations and generates a report that can be sent or reviewed. The design also provides data without the requirement for a plant shutdown for sensor
and applications specialists, together with a new, cutting-edge laboratory specifically designed for material testing and sample pressing. This ensures optimum equipment selection and specification for customers. www.terex.com/washing
the single sensor to the Flex-Mat Sensor app on a smartphone before placing the sensor on one corner of the machine. The user moves the sensor to each corner of the machine and information is then delivered to the phone in seconds. Data is stored locally for and viewing in areas with cellular limitations. Once a signal is available, the information uploads to MAJOR’s cloud service where it is viewable from a web browser. Historical equipment performance data is also viewable through the cloud. The sensor measures g-force, stroke, rpm and orbit, including lateral movement. Producers can use the data to monitor and fine-tune screen box performance as well as make parameter decisions. The data can also give indications of what kind of screen media would best suit the machine. Though the sensor is not meant to serve as a diagnostic tool, the information can point to possible problems.
www.majorflexmat.com
Terex FM UltraFines offers efficient recovery of ultrafines material from wastewater streams produced during material washing processes
Caterpillar efficiency gains
Caterpillar says that its advanced new 325 and 395 excavator models offer increased efficiency. According to the firm, sophisticated engine technology and an advanced control system have been fitted to the new 325 medium excavator.
These features help to reduce fuel consumption by up to 25%, while a precise combination of lower engine speed and large hydraulic pump pressure and flow delivers more work/unit of fuel. Extended maintenance intervals mean that the new 325 offers more productivity while reducing maintenance costs by up to 20%.
The new 395 excavator is built to move material more quickly and efficiently.
With 10% more swing torque and 10% more stick force than the model it replaces, the firm says that operators can achieve faster
cycle times with bigger buckets for greater groundbreaking power and production. Cat PAYLOAD is also offered as standard, allowing operators to validate production at the end of every shift. The machine is said to be twice as durable structurally than previously, allowing a longer service life. In addition, extended service intervals will help to lower maintenance costs by up to 20%.
Caterpillar claims to have improved the performance of its highly successful 725 articulated hauler, providing faster cycle times and better productivity.
New cab features make the machine easier to operate over a full shift and include assisted hoist, automatic retarder control and advanced automatic traction control. www.cat.com
Hitachi wheeled loaders with increased tractive effort
Hitachi Construction Machinery says it has increased tractive effort by more than 30% on its ZW310-6 and ZW370-6 wheeled loaders.
“This technological advance is accomplished by creating more advanced software,” said Mel Wade, Hitachi applications engineer. “The end user will experience the difference when digging, dozing, climbing hills, or other high rimpull-requiring applications.”
In the larger Hitachi ZW370-6 and ZW550-6 loaders, the Traction Control System (TCS) can be operator-activated and deactivated via the display main menu. As these machines are less likely to move from site to site, this is a ‘set and forget’ feature. In the smaller,
compact hydrostatic Hitachi wheeled loaders, the tractive effort is regulated with a TCS switch. TCS is useful for snow applications, as well as muddy environments, because it eliminates unnecessary tyre slippage and increases tyre life.
“It’s an intuitive system that balances hydraulic power consumption with powertrain consumption,” said Wade. This system maximises the use of the available power. The software collects real-time data, such as hydraulic pressure, engine torque, and application demand. TCS determines the appropriate balance to make the wheeled loader as efficient as possible for that situation. www.hitachicm.com
Volvo CE’s largest excavator now available globally
The 90-tonne crawler excavator is equipped with a 603 hp (450kW) Volvo D16 Tier 4 Final engine that delivers high torque at low rpm.
The machine is designed for fast and efficient on-site production. Volvo says that pairing the EC950F with the company’s A60H articulated hauler can enable customers to realise extreme productivity potential. The
EC950F fills the 54-tonne, 33.6 m³ haul truck in just four bucket passes, with an average cycle time of 20-25 seconds.
Volvo’s optimised hydraulics are designed to deliver constant high pressure across each phase of the digging and lifting cycle. The hydraulic system increases pump power for fast and smooth operation, while the electro-
hydraulic system controls on-demand flow and reduces internal losses in the hydraulic circuit. The EC950F also comes with a boom-swing priority valve which adjusts the priority of hydraulic flow between boom-up and swing so that truck-loading cycle times can be set to truck-loading working conditions.
Volvo’s ECO Mode is designed to help the EC950F achieve outstanding fuel efficiency while the integrated work mode allows operators to choose the best work mode for the task at hand: select from I (Idle), F (Fine), G (General) and H (Heavy).
To boost machine versatility, the attachment management system can store settings for up to 20 different attachments, enabling the operator to pre-set hydraulic flow and pressure through the in-cab monitor. Smart features such as the optional Dig Assist – powered by Volvo Co-Pilot – are designed to assist the operator in digging more efficiently. www.volvoce.com
Caterpillar claims increased productivity for its new generation excavators
A Hitachi ZW370-6 wheeled loader
The 90-tonne EC950F is Volvo CE’s largest excavator
Metso
Töölönlahdenkatu 2
00100 Helsinki Finland
www.metso.com
MARKETS SERVED
Metso is a world-leading industrial company offering equipment and services for the sustainable processing and flow of natural resources in the mining, aggregates, recycling & process industries and serve our customers all over the world.
TARGET CUSTOMERS
We focus on innovation and technology to provide more sustainable solutions, efficiency and productivity to our customers in the quarry, mining, recycling and flow control industries. At the heart of Metso is our drive to make the big difference to our customers.
PRODUCTS AND SERVICES
Our products range from mining, aggregates, and recycling equipment to industrial valves and pumps including services that cover their whole lifecycle.
Dependability matters. Choose the brand known for it.
In the world of construction, dependability matters. At Metso, we’ve turned our 150+ years of crushing and screening experience into solutions that aggregate producers and contractors all over the world depend on to increase production and profitability.
At CONEXPO/CON-AGG 2020, we are proud to present our new compact size Nordtrack™ mobile range for recycling, demolition and small-scale aggregate production.
Experience our latest innovations and special previews:
• Lokotrack® ST4.10™, a new large mobile screen
• Lokotrack® LT4MX™ special edition for ConExpo
• Metso MX3™ cone crusher and crusher automation
• NW™ Rapid portable units for North America
• Metso Metrics Services for remote monitoring and management
• Hammerless attachment system for new generation polyurethane screen panels
• Metso Trellex™ Poly-Cer liners, a unique design with ceramic inserts
• Metso Truck Body, a lightweight haul truck body that lets you haul more with less
• Contender™ Series premium parts designed for non-Metso crushers
Komatsu’s connectivity focus
Komatsu’s more than 20-machine line-up includes a number of models making their North American market debuts. The Japanese manufacturer says it’s focused on creating connections to empower the success of its global network of distributors and customers in the aggregates, construction and other industries.
Featured new and current machines include the PC238USLC-11, PC210LCi-11, PC290LCi-11, PC360LCi-121, PC490LCi-11 and PC1250-11 crawler excavators; WA320-8, WA480-8 and WA500-8 wheeled loaders; the HM400-5 articulated hauler and HD605-8 rigid hauler; and D51i-24, D61i-24 and D155AX-8 LGP dozers.
Komatsu D51i-24 and D61i-24 dozers are configured with claimed industry-first technology in the form of patent-pending proactive dozing control. It enables operators to use machine control from “grass to grade”. The machine records terrain data as it moves. Using real-time conditions and the recorded terrain data, the system makes calculated decisions about whether to cut and carry material, spread or fill that material, or whether to perform finish grading. www.home.komatsu/en/worldwide
Terex Trucks TA300 & TA400 ADTs
Terex Trucks, the Motherwell, Scotland-headquartered articulated dump truck maker, is showcasing its TA300 and TA400 models.
• Symons™ crusher upgrades
Find out more on www.metso.com/company/ See us at ConExpo-CON/AGG 2020 booth C31531
In North America, the TA300 and TA400 are sold with a threeyear warranty, telematics and planned maintenance included as standard – and there are competitive finance packages available for lease and wholesale. One example of the recent improvements Terex Trucks has made is the product upgrade on the TA300. Since the beginning of last year, the TA300 has been manufactured with a new transmission, leading to improvements in fuel efficiency, performance, productivity and operator comfort, when compared to the previous model working in the same application. The 28-tonne workhorse delivers a 5% improvement in fuel efficiency, a 5km/h increase in speed to 55km/h and an increase in the length of time between oil maintenance intervals from 1,000 to 4,000 hours.
The TA400, the largest articulated hauler on offer from Terex Trucks, has a maximum payload of 38 tonnes and a heaped capacity of 23.3m³. Powered by a high-performance, fuel-efficient engine that develops a gross power of 331kW, the TA400 is designed to meet the demands of the most extreme operations such as quarries, mines and large-scale construction projects. www.terextrucks.com
More info: metso.com/events/2020/conexpoconagg/
Komatsu’s PC1250-11 crawler excavator
The TA400 is Terex Trucks’ largest articulated hauler
High-quality asphalt from Ammann
Ammann claims that its ACP 300 ContiHRT continuous asphalt plant offers high-quality production. Designed to meet the needs of the North American market, the ContiHRT is capable of producing high-quality mix with more than 60% recycled asphalt (RAP). The new plant features Ammann’s novel recycling technology, already proven worldwide, which maximises RAP utilisation and meets the world’s most stringent emissions guidelines. The gentle pre-heating of the RAP, compared to the application of traditional cold feed to superheated virgin aggregates, prevents thermal stress on the asphalt concrete (AC) content and ensures a highly homogenous final mix. That process also minimises fuel burn and reduces the levels of CO₂ and other pollutants.
The plant incorporates a RAP dryer for the addition of recycled materials and a separate cold recycling feed. The plant is capable of
incorporating shingles, liquid additives, fibre granulate and foam AC. It can access a recycling system for RAP utilisation up to 60%; a separate cold recycling system for 30%; or a combination of the two. The ACP 300 ContiHRT can also produce high amounts of mix without any RAP. Warm mix can be produced with or without RAP. Continuous
Doosan’s top-of-the-range wheeled loader
production capacity is 300tonnes/hour. The system utilises proven technology and is also said to address the need to reduce emissions. Additional plant innovations include the proprietary as1 Control System. This advanced system provides data that enables high production while optimising the use of fuel and aggregates.
Installation and relocation are said to be quick and uncomplicated. The horizontal design ensures fast and easy assembly and disassembly.
www.ammann.com
With a bucket capacity of 5.4m³, Doosan’s DL580-5 top-of-the-range wheeled loader has a similar look to the next machine down in the range, the DL550-5, while also featuring robust structural components and an advanced sophisticated double circuit axle oil cooler system. This is said to provide an ideal solution for applications such as block lifting and other heavier material-handling needs in industrial, construction, recycling, mining and quarrying applications.
To meet these requirements, the DL5805 has a 36.03-tonne operating weight and higher static tipping loads (straight/full turn 40°) of 29.7 tonnes and 26.2 tonnes, respectively.
The DL580-5 has reinforced Z-bar kinematics for heavier lifting with few moving parts. This design also helps stabilise the loader, enables rapid bucket movements and keeps the bucket at a right-angle position.
The DL580-5 is powered by the Scania DC13 6-cylinder engine producing 283kW
of power at 1800rpm. The Scania DC13 engine provides a generous maximum torque of 1765Nm at 1300rpm and up to a 10% reduction in fuel consumption and excellent response.
Doosan’s new Stage V-compliant DA45 articulated hauler has a 41-tonne payload and is powered by the new Scania Stage V DC13 13-litre diesel engine with an output of 368kW.
While the core of the Scania engine, which has been responsible for its exceptional reliability, has not changed, the main difference in the new engine from its predecessor is the improved after-treatment system.
The new DA45 Stage V machine features a new cab and a semi-levelling front suspension that adjusts itself independently depending on the operating conditions to ensure a comfortable working environment for the operator.
www.doosanequipment.eu
Epiroc adds automation-ready platform
The new Epiroc SmartROC D60 down-thehole (DTH) surface drill rig for quarrying, mining and construction has been updated with Epiroc’s automation-ready platform.
The SmartROC D60 is designed to provide the intelligence and power to efficiently drill high-quality blast holes with accuracy and precision. It has smart features such as automated drilling and rod handling to increase safety, efficiency and consistency for a lower total cost of ownership (TCO).
The automation-ready platform also includes the new Auto Feed Fold feature. With a single action, Auto Feed Fold enables the operator to fold the feed for tramming or position it for drilling. This is also useful when operating one or more drill rigs remotely with the BenchREMOTE option.
Available with a shorter boom specially designed for efficient and demanding quarry work, the D60 can drill holes of 4.6 to 7 inches (116.84mm to 177.8mm) in diameter and to a maximum depth of 182 feet (55.47m).
www.epiroc.com
Ammann is offering a new continuous plant designed for the North American market
Doosan’s top-of-the-range DL580-5 wheeled loader
The SmartROC D60
Government infrastructure investment drives growth in closely linked markets
The quarrying and aggregates markets in the South-East Asian countries of the Philippines, Vietnam and Thailand are generally fragmented with a range of companies from small scale right up to large ones. Liam McLoughlin reports
The Philippines, Vietnam and Thailand have enjoyed recent economic growth and their construction materials markets are being driven by high levels of government investment in infrastructure.
Commenting on collective market conditions across the three countries, Ben Weetman VP, minerals, Asia-Pacific at Metso said: “Because of the close geographical proximity [of Thailand, the Philippines and Vietnam], the market is quite price sensitive as there is significant competitive pressure from both Western, Chinese and Indian OEMs [original equipment manufacturers] as they also see significant potential in this geographical region.”
The Philippines construction industry registered a growth of 15.1% in real terms in 2018, according to a report from GlobalData. This was preceded by an average annual growth of 9.6% during the preceding four years. Growth between 2014 and 2018 was driven by positive developments in regional economic conditions and government investment in residential, transport and energy infrastructure.
There were 61 major quarrying sites operating in the Philippines in 2018,
according to the country’s Department of Environment and Natural Resources. These comprised 35 limestone/shale quarries, five silica quarries, 15 aggregate quarries, one dolomite quarry, three clay quarries, two sand & gravel quarries. There were also 3,389 small quarries and sand & gravel operations that were covered by permits issued by LGUs (local government units).
A M Muralidharan, VP sales support and dealer development for Volvo Construction in APAC (Asia-Pacific region), says that the company sees most demand in the Philippines for wheeled loaders with capacity between three and six tonnes and excavators with load capacities between 20 and 50 tonnes.
“Typically the wheeled loaders and excavators are used for handling stockpiles and loading materials into trucks,” Muralidharan adds. “In the Philippines, wheeled loaders are typically used in the stockpile area or in a local redistribution centre/sales zone, and each aggregate site usually deploys one to two units to load aggregate trucks. Excavators in the Philippines are mainly used in the quarry area handling blasted raw materials.”
In terms of excavators in the Philippines, Muralidharan says that contractors typically select breaker piping to use in quarries.
ABOVE: A Volvo EC200D excavator operated by Sunwest in the Philippines
Weetman says the Philippines market is characterised by a strong infrastructuregrowth agenda which is being driven by government policies on the back of the highest population growth rate in SouthEast Asia.
“There is also a renewed focus on long-term infrastructure development,” he adds. “The Philippines is driven by the government’s strong focus on infrastructure and nation-building initiatives, thereby creating strong growth in aggregates demand in the Philippines.”
One such example is the ‘San Miguel’ project to build what is claimed to be the world’s second largest airport. The US$15bn, four runway airport is to be built 30km north of Manila and will be able to handle up to 100 million passengers a year when completed. The project is being conducted by the brewing, food, energy and infrastructure conglomerate San Miguel.
Such projects are expected to continue the expansion in real terms of Philippines construction industry output value for the period through to 2023. The GlobalData report states that, in addition, public and private sector investments in residential,
commercial and educational infrastructure construction projects are expected to support growth in the industry over the next three years.
“The government’s investment in the development of the country’s transport infrastructure under the ‘Build, Build, Build’ programme is expected to support industry growth,” the report adds.
In the 2019 budget, the government proposed to spend PHP909.7bn (US$17.2bn) under the ‘Build, Build, Build’ programme to develop the country’s crumbling transport infrastructure. In addition, the government’s aim to improve local energy resources is expected to support investment in energy infrastructure projects, which will in turn fuel growth in the industry.
The industry’s output value in real terms is expected to rise at a compound annual growth rate (CAGR) of 8.6% through to 2023.GlobalData expects the Philippines’ residential construction market to retain its leading position and account for 34.7% of the industry’s total value in 2023, driven by ongoing urbanisation, population growth and positive developments in regional economic conditions. The government’s efforts to build affordable housing units for the country’s low- and middle-income population in order to address the country’s housing shortage are also expected to support the market.
The total construction project pipeline in the Philippines – as tracked by GlobalData, and including all megaprojects with a value above US$25m – stands at PHP19.1 trillion (US$361.6bn). The pipeline, which includes all projects from pre-planning to execution, is skewed towards early-stage projects, with 55.0% of the pipeline value being in projects in the pre-planning and planning stages as of April 2019.
Volvo CE equipment is being used in a preservation project to protect Filipino villagers’ homes from erupting volcanoes.
The project is also designed to keep local economies thriving by ensuring that valuable aggregates found within those lava streams are contained safely. The Mayon volcano near the city of Legazpi is one of the most active volcanoes in the Philippines. While volcanic soil is extremely fertile for farming, lava flows are always a hazard. In addition, the wet season from July to December also poses challenges with the high volume of rainwater and debris it brings from the volcano.
To alleviate this, the local government financed construction of a network of spillways around the volcano, to direct the flow of rain, debris and lava. As a result, four Volvo CE EC210D units helped enable protection to villagers living near the Mayon volcano by directing volcanic materials away from populated areas and into designated and contained areas. The heavyduty machines have just finished building the spillways for this particular project with Sunwest Construction and Development Corporation, but Volvo machines are still at work around Mount Mayon with another contractor.
“The fear of an eruption is always present among the villagers and they are really grateful that these spillways are being constructed,” says Joel Banzuela, project foreman at regional contracting company Sunwest Construction and Development.
The Thailand quarrying and aggregates market is currently enjoying strong economic development, according to Amarit Maneesaovanop, general manager – aggregates, Bangkok Siam City Concrete Company. He added that its national consumption of aggregates is estimated at about 203.2 million tonnes per year. The national geology is very varied, and, correspondingly, so is the type of aggregates produced in each region. The estimated overall breakdown is around 60% crushed rock and 40% sand & gravel.
TOP: Volvo CE equipment is being used in a Philippines project to protect homes from erupting volcanoes
RIGHT: Metso equipment at a quarry in Thailand
“Aggregates are typically transported 150-200km to market, in almost all cases by truck; the main markets are in the Greater Bangkok and Eastern Seaboard areas,” Maneesaovanop stated. “There is a small amount of rock export, but no imports.”
He added that there is growing investment in new quarries.
Thailand is mature in the aggregates industry, according to Metso’s Weetman. “There is a strong history of aggregates production supporting the local and Indochina area with high usage of Western OEM equipment,” he adds. “There’s a positive sentiment and a need for new and upgrading of existing infrastructure in Thailand with large projects like the highspeed rail linking Malaysia and Singapore. There is renewed optimism in the aggregate industry.”
Aggregates consumption in Thailand for 2019 was estimated at over 350 million tonnes per annum in a GlobalData report.
Muralidharan of Volvo CE said that demand for excavator-class-size in Thailand depends on the aggregate type and quarry size. “Thailand quarries are 80% limestones and 20% granite, and 70% of quarries in Thailand produce less than 300 tonnes per hour,” he added. “This is why sometimes excavators over 35-tonnes are above what’s required on the quarry, and one of the reasons why 20-tonne class excavators like the EC200D and EC210D are popular.”
He said that quarry owners in Thailand like the EC200D and EC210D because they offer high return on investment while delivering fast cycle times and high productivity.
“Over the next five years, the Thai government is pushing spending on new megaprojects as part of the Eastern Economic Corridor, which will see investments in major facilities like highspeed trains, deep-sea ports and new airports,” Muralidharan says. He expects to see higher demand for aggregates in Thailand thanks to infrastructure investments.
Beyond 2025, Muralidharan says it is unclear how high demand for aggregates
will be, but he adds there could be demand for aggregates from Thailand’s connection to China’s ‘One Belt, One Road’ project, which is also investing in industrial buildings and transport connections.
Thailand’s construction industry regained growth momentum in 2018, according to GlobalData. Output expanded by 2.7% in real terms – up from -2.8% in 2017.
The industry is expected to continue to expand in the period up to 2023, but at a slower pace than in recent years. Growth will be driven by the government’s efforts to develop the country’s transport infrastructure, coupled with efforts to boost the residential construction market. In the first half of 2019, the government announced plans to allocate THB4bn (US$125.6m) to finance five low-cost housing projects in the country, while in the 2020 budget, the government allocated THB650bn (US$20.4bn) towards capital expenditures. The focus on the development of the energy sector is also expected to drive industry growth.
Investments to develop infrastructure in Chachoengsao, Chonburi and Rayong provinces under the Eastern Economic Corridor (EEC) scheme are also expected to support growth in the industry over the next three years. In order to attract foreign manufacturing companies, create a valuebased economy and reduce social disparity, the government is developing the EEC, a new industrial zone. In October 2018, the government agreed to approve four more large-scale infrastructure projects under the EEC scheme.
GlobalData predicts the residential construction market will account for 40.3% of the industry’s total value in 2023, supported by ongoing urbanisation and government efforts to balance housing demand and supply through the construction of low-cost housing units.
To transform Thailand into a gateway to South Asia and develop a link to the Eastern Economic Corridor, in January 2019 the government approved THB106.8bn (US$3.4bn) to develop the Southern Economic Corridor (SEC) over the next
four years. The plan seeks to develop 116 projects in Chumphon, Surat Thani, Nakhon Si Thammarat and Ranong provinces during the period of 2019-2022. Infrastructure construction market growth over the forecast period will be driven by public and private sector investments in the development and modernisation of the country’s transport infrastructure. In the first half of 2019, the State Railway of Thailand (SRT) announced plans to invest THB90bn (US$3m) to develop and upgrade railway tracks in the country’s southern region, in a bid to reduce travel time and encourage tourism in the region.
In January 2019, the National Energy Policy Council approved the updated Power Development Plan (PDP 2018-2037). Under this plan, the country’s power production capacity is expected to increase by 67.5%, going from 46,090MW in 2017 to 77,211MW in 2037.
The total construction project pipeline in Thailand – as tracked by GlobalData, and including all megaprojects with a value above US$25m – stands at THB11.5 trillion (US$355.9bn). The pipeline, which includes all projects from pre-planning to execution, is skewed towards late-stage projects, with 60.3% of the pipeline value being in projects in the pre-execution and execution stages as of October 2019.
Promoting industrialisation and modernisation are among the major goals of the Vietnamese Central Government and this is accompanied by fast urban growth, according to an academic study published in August 2019 by MDPI. The proportion of urban population is expected to grow from 38% in 2015 to 45% by the end of this year and 50% by 2025, according to government estimates. The academic study states that the main driving forces behind this fast urbanisation are public investment in infrastructure and the opening up of land to leaseholds entitlement.
“These driving forces put housing and infrastructure development in all urban areas under enormous pressure, causing an unprecedented demand for aggregates in the construction sector,” the study’s authors add.
Most Thai quarries produce less than 300 tonnes per hour
Driven by foreign investments Vietnam is emerging as a key player in the SouthEast Asia regional economy, according to Weetman.
“As Vietnam grows and develops, there is a high level of trajectory of infrastructure spend,” he adds. “Because of this, [Vietnam] is looking for more efficient and effective ways in productivity through innovative products, high level of technology and automation as it develops. As the economy opens up for further foreign direct investment, coupled with the government opening up to western investment and fuelled by strong population growth, Vietnam has shown an increase in demand for infrastructure and aggregate products to sustain [this].”
Vietnam’s construction industry registered growth of 8.5% in real terms in 2018, according to GlobalData. This follows an average annual growth rate of 9.3% during the preceding four years, when growth was driven by positive developments in regional economic conditions and government investment in energy and transport infrastructure.
The industry’s output value is expected to continue to expand in real terms over the forecast period (2019-2023), with investments in infrastructure construction, tourism infrastructure and housing projects continuing to drive growth. According to government estimates, the country requires an investment of VND1.0 quadrillion (US$48bn) until 2023 to develop its transport infrastructure. In addition, the government’s aim to improve local energy resources is expected to support investment in energy infrastructure projects, which will in turn fuel growth in the industry.
The trade war between the US and China is also expected to divert foreign investment towards Vietnam, given the relative improvement in the country’s attractiveness as a manufacturing destination. GlobalData predicts this is likely to have a positive impact on the construction industry, particularly in the industrial and logistics sectors.
The industry’s output value in real terms is expected to rise at a compound annual growth rate of 7.87% between 2019 and 2023.
GlobalData expects the residential construction market to account for 42.6% of the industry’s total value in 2023 driven by the country’s rising population, ongoing urbanisation and positive developments in regional economic conditions. Market expansion through to 2023 is also expected to be driven by public and private sector investments in the construction of new residential buildings to meet the increasing demand for housing.
Forecast-period growth in the energy and utilities construction market will be driven by the government’s plan to increase the share of renewable energy in terms of the total energy mix, encouraging investment in renewable energy infrastructure. The government aims to generate 31% of the country’s total consumer primary energy through renewable sources by 2020, 32.3% by 2030 and 44% by 2050. The plan is to generate 3.3% of the country’s total electricity production through solar power by 2030 and 20% by 2050.
The Vietnam National Cement Corporation (VICEM) and cement equipment company FLSmidth have started a cooperation to develop new solutions to improve the sustainability of Vietnam’s cement sector. The Vietnamese government has set objectives to reduce the environmental impact of cement production.
The two companies say the goal is to implement technologies that radically
reduce greenhouse gas emissions, pioneer solutions for using alternative fuels and improve air quality.
Vietnam is a fast-growing country in terms of cement production with output expected to double in the next ten years, and it is also a big exporter of cement. The Vietnamese government has set objectives to improve efficiency and reduce the environmental impact of its cement production.
Cement producer VICEM says its ambition is to take an industry-leadership role and implement solutions to reduce the environmental impact of cement production. This will specifically focus on reducing the emission of particulate matter, CO2, NOX and SO2 to prevent air, soil and water pollution from waste burning and landfills.
The total construction project pipeline in Vietnam – as tracked by GlobalData in January 2019, and including all megaprojects with a value above US$25m –stood at VND13.4 quadrillion (US$588.6bn).
Looking at general demand for quarrying and aggregates equipment across the Philippines, Thailand and Vietnam, Weetman says that large fixed plants are looking at economies of scale, high productivity and high efficiency.
Smaller operators/contract quarries/ construction contractors are looking to grow mobile (tracked and wheeled) solutions. “More efficient asset utilisation is key for them,” Weetman adds. “In addition, productivity and efficiency plays a role, as well as reducing reliance on quarry haulage investment.” AB
Vietnam has set objectives to cut the environmental impact of cement production
VOLVO EC200D IS A FUEL COST-SAVER FOR CV PUTRA KARTINI
New Volvo Construction Equipment customer CV Putra Kartini bought an EC200D excavator to support its sand quarry operations in Lumajang, East Java, Indonesia. The new excavator has cut fuel consumption by a quarter, equating to a welcome reduction in the ambitious firm’s production cost.
Guy Woodford reports
It’s building boom time in Indonesia. Re-elected in May 2019, president Joko Widodo has been delivering on his pledge to green-light more than US$400bn-worth of new public infrastructure projects. This has seen a notable acceleration of megaprojects including the Trans-Sumatera toll road and toll roads across Java, the Jakarta Mass Rapid Transit (JMRT), the Jakarta Light Rail Transit (JLRT), the new Jakarta airport and the new Priok port (also known as Kalibaru port) which will more than triple annual capacity of Tanjung Priok when fully operational in 2023.
All Indonesia’s impressive infrastructure works require vast volumes of building materials, including sand. This has created huge commercial opportunities for ambitious companies such as sand quarry business newcomer CV Putra Kartini. In the past, the two-year-old firm has rented machines to support its sand quarry operations in Lumajang.
After discovering the Volvo Construction Equipment (Volvo CE) EC200D excavator’s exceptionally high swing torque and unique lifting capabilities, the company decided to purchase the 20-tonne class excavator.
“This is the first Volvo CE machine we own. At our sand quarry, we need speed and fuel efficiency, which is exactly what the EC200D delivers for us,” said Ahmad Alfandi, director of CV Putra Kartini. “Previously the machine I was using used up 20 litres per hour. After switching to Volvo CE, it has dropped to 15 litres per hour. This greatly reduces my fuel consumption and I am able to see at least 25% fuel savings with Volvo CE.” Alfandi says the 25% fuel savings equate to around US$8,500 a year.
Deployed in September 2018, the EC200D works about 12 hours a day, six days a week, digging and loading sand on to trucks.
CV Putra Kartini’s Volvo EC200D excavator uses 25% less fuel than its predecessor – equating to a saving of US$8,500 a year
On average, the excavator loads about 50 trucks of sand daily and has currently worked a total of around 3,000 hours.
Alfandi said that his operators love using the EC200D for its easy operation and comfortable cabin. Operators say they feel right at home in the cab thanks to the ergonomic design, comfort and visibility that are synonymous with Volvo machines.
“The EC200D is extremely easy to control and the superior stability ensures smooth and efficient operation of the
power at 2,000 rpm, and strong hydraulics, the EC200D is designed to operate quickly and with short cycle times. In addition, the EC200D is extremely well balanced which gives the machine exceptionally good loading capabilities.
Established in September 2017, CV Putra Kartini primarily focuses on sand quarry operations. Headquartered in Lumajang, East Java, Indonesia, the company owns one sand quarry with an exploration permit of 85,000m². Among the company’s key
us and for ensuring we receive top-quality aftermarket service. Their response is exceptionally fast, and the spare parts are reasonably priced,” Alfandi said.
Volvo CE has established a strong footprint in the Indonesian roadbuilding sector and the national quarrying market, where bigger equipment is needed to cope with expanding quarry footprints.
In ABI July-August 2019, we reported on how contractor Mutiara Batang Toru CV is also using Volvo EC200D excavators to
The Volvo EC200D excavator’s very high swing torque and unique lifting capabilities are said to be key factors behind CV Putra Kartini’s decision to purchase the 20-tonne class model
SDLG rolls out its largestever wheeled loader
SDLG has introduced the new Stage III L975F wheeled loader to market – the biggest wheeled loader it has so far produced.
The loader is made with a focus on durability, fuel efficiency and improving productivity on a job site. It can be used for a range of tough applications on construction sites, as well in quarries, mines and port terminals.
The 24.9 tonne L975F is designed with robust rear and front frames to withstand load distribution. Fitted with a 199kw engine, its transmission uses a HTE205C fixed-axis electrohydraulic automatic shifting gearbox for flexibility and ease of operation — SDLG’s first machine that uses a fully automatic transmission built by Volvo. An integrated cooling system uses intelligent technology to automatically adjust fan speed according to engine temperature, which is particularly advantageous in hot climates.
The standard 4.2m³ bucket with eight bolted-on teeth and two wear plates features a spill guard plate to prevent material loss. The maximum dump height, at 3.2m, is supported by a 3.6m boom. The second stage 93 sand filter in the hood of the machine filters over 95% of particles when working in dusty conditions such as mines to keep the job smooth and efficient.
Featuring six standard LED lights with high-brightness capacity for darkness, SDLG says the operator’s line of vision is never compromised. The machine’s newgeneration cab includes a safety lock, increased sealing, field-ofview width and 12% more space. www.sdlg.com
Cat launches new D5 dozer
Caterpillar has launched its new D5 dozer, replacing the previous D6N model.
The vehicle is now available in South Korea, Europe, Australia and New Zealand, having already been rolled out in North America in October.
The new D5 is designed for superior performance and the broadest choice of technology features, with power for dozing
net power of 127kw and has an operating weight range of 17.18 tonne to 19.17 tonne.
Cat says the update from D6N to D5 is part of an effort to
make all its dozer model names simpler. Over the next couple of years, the Cat dozer range will be renamed from smallest to largest – D1 to D11 – with one model per size class and no “K,” “T.”
The D5 has more weight and horsepower than its D6N predecessor, improved steering capability and a range of technology offerings designed to help operators increase their productivity.
It features a fully automatic 3-speed transmission with lock-up clutch to offer faster
cycle times, as well as optimal
Cat says the automatic transmission, steering improvements and enhanced power train controls offer improved steering performance and control.
The redesigned cab provides more space, multiple seat and control adjustments for optimal comfort and a new, easy-to-use 254mm touchscreen operator interface. A standard highshows prominently in the main display.
www.caterpillar.com
New compact mobile range from Astec
Astec Mobile Screens is launching a new line of compact, track-mounted crushing and screening equipment. The new equipment, marketed through licensed dealers as the Ranger line, will include a variety of jaw crushers, impact crushers, cone crushers, incline screens and trommels.
require powerful equipment with a limited footprint. The Ranger line will be represented by a network of dealers that has the capacity to support the equipment and sustain a strong rental programme for its customers.
The compact units are designed to serve a variety of new markets including quarry operations, building and construction, landscaping, and plant and tool hire.
Astec says that the ease-of-use, ease-oftransport, versatility and flexibility of the units make them ideal for smaller operations that
“The new Ranger line will help us reach a wider range of industries and customers. The compact units are going to be a great tool for contractors, quarry operators and many more. We are remaining very focused on providing excellent support for these units, just like our other products,” says Patrick Reaver, inside sales director at Astec Mobile Screens. www.astecindustries.com
The new Cat D5 dozer (pictured) replaces the D6N model
Astec’s new mobile range is designed for versatility
The new 24,900kg L975F loader
Global rollout for Epiroc Tier 4 drill
Epiroc is launching its Tier 4 engine-equipped PowerROC D60 drill rig onto the global market.
The PowerROC D60 hydraulic down-the-hole (DTH) rig drills the largest holes in the PowerROC family, and is designed to meet the requirements for operating in countries with the highest emission standards.
“This is the first PowerROC DTH rig which complies with
the higher emission regulation,” said Wei Wen Xu, senior product manager at Epiroc. “It is an important step to keep on reducing the environmental footprint.”
The first unit was delivered to the USA earlier this year. The PowerROC D60 can drill large holes ranging from 110mm to 178mm. In addition, the 5+1 rod-handling system makes it
possible to drill holes down to a depth of 30m. Epiroc says that its proven technology also helps to ensure that holes are straight and of a good quality.
The rig features a pilot hydraulic system, straightforward electronics and a powerful rotation unit designed to ensure that the rig can operate reliably in all types of rock conditions. In addition, a highly effective dust
collection system is designed to ensure that the work environment is kept clean and safe, which protects both machine and personnel.
The Tier 4F version of PowerROC D60 will be available in North America, Japan and Korea immediately. The Tier 3 version of PowerROC D60 has been available since June 2019.
www.epirocgroup.com
LESS DOWNTIME IS MORE UPTIME
KPI’s pre-screen option
Kolberg-Pioneer has added a twodeck, 132cm x 213cm pre-screen option to its FT4250 mobile impactor plant.
through the chamber, reducing wear costs and increasing the amount of final product by 30%.
Kolberg, part of aggregates equipment provider Astec Industries, says the new option allows producers to scalp the feed, crush the material and postscreen all on one unit.
By pre-screening the feed, users can maximise their scalping ability and minimise the amount of undersized material passing
“Several of our customers are trying to produce products that have a significant amount of fines in the feed material,” said Tim Harms, crushing and screening product manager at KolbergPioneer. “The pre-screen allows producers to remove those fines while also minimising the amount of rejected in-spec product.”
www.kpijci.com
The D60 drills the largest holes in the PowerROC family. Image: Epiroc
2020
MARCH
10-14 CONEXPO-CON/AGG
Las Vegas, NV
Organiser: AEM
Tel: +1 414 274 0644
Email: customerservice@ conexpoconagg.com www.conexpoconagg.com
21-25 SaMoTer Verona, Italy
Organiser: Veronafiere S.p.A. Tel: +39 045 8298561
Email: customercare@samoter.com http://www.samoter.it/en
JUNE
23-25 Hillhead
Hillhead Quarry, Buxton, Derbyshire, England
Organiser: The QMJ Group Tel: +44 (0)115 945 4377
Email: Harvey.sugden@qmj.co.uk https://www.hillhead.com/ exhibitors/hillhead-2020#/
JULY
08-11 EIG 2020
Exeter, UK
Organiser: EIG Conferences marcus.dorey@hanson.biz https://www.eigconferences.com/ future-conference 2020
AUGUST
26-29 Steinexpo
Homberg/Nieder-Ofleiden, Germany
Organiser: Geoplan GMPH
Tel: +49 7229 606 30 +49 7229 606 30 https://www.steinexpo.eu
SEPTEMBER
16-18 Construction Indonesia
Jakarta, Indonesia
Organiser: PT. Pamerindo Indonesia Tel: +49 3999905 0 contact@merebo.com
16-18 Concrete Show
South East Asia Jakarta, Indonesia
Organiser: PT. Pamerindo Indonesia Tel: +49 3999905 0 contact@merebo.com
MEET THE TEAM
Aggregates Business travels the globe attending conferences, events and equipment shows, keeping you informed of the latest offerings. Come and join us for a chat at any of the events below.
MARCH 2020
10-14 CONEXPO-CON/AGG 2020
MARCH 2020
21-25 SaMoTer 2020 Verona, Italy
JUNE 2020
23-25 Hillhead 2020
Hillhead Quarry, Buxton, Derbyshire, England
JULY 2020
08-11 EIG 2020 Exeter, UK
Ammannp21www.ammann.com
BKT Tires p35 www.bkt-tires.com
Caterpillarp13www.cat.com
ConExpop42www.conexpoconagg.com LiuGongOBCwww.liugong.com
