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Grains of truth
50
billion tons is a big number. It is enough, the United Nations Environment Programme (UNEP) says, to build a wall 27 metres wide and 27 metres high around Earth. The same source notes that it is also the volume of sand and gravel used each year, making it the second-most used resource globally after water.
A new UNEP report concludes that given our dependency on it, sand must be recognised as a strategic resource and its extraction and use needs to be rethought.
The hard-hitting and fascinating report, Sand and Sustainability: 10 strategic recommendations to avert a crisis, by UNEP’s GRID-Geneva team, provides the necessary guidance gathered from world experts to switch to improved practices for the resource’s extraction and management.
The report states that extracting sand where it plays an active role, such as rivers, and coastal or marine ecosystems, can lead to “erosion, salination of aquifers, loss of protection against storm surges and impacts on biodiversity, which pose a threat to livelihoods through, among other things, water supply, food production, fisheries, or to the tourism industry”.
According to the report’s authors, sand must be recognised as a strategic resource, not only as a material for construction, but also for its multiple roles in the environment.
They stress that governments, industries and consumers should price sand in a way that recognises its true social and environmental value. For example, keeping sand on coasts may be the most cost-effective strategy for adapting to climate change due to how it protects against storm surges and impacts from sea-level risesuch services should be factored into its value.
An international standard on how sand is extracted from the marine environment should also be developed, the report proposes. This could bring about dramatic improvements as most marine dredging is done through public tenders open to international companies. Meanwhile, the report recommends that the extraction of sand from beaches be banned due to its importance for coastal resilience, the environment and the economy.
“Our sand resources are not infinite, and we need to use them wisely”
“To achieve sustainable development, we need to drastically change the way we produce, build and consume products, infrastructures and services. Our sand resources are not infinite, and we need to use them wisely. If we can get a grip on how to manage the most extracted solid material in the world, we can avert a crisis and move toward a circular economy,” says Pascal Peduzzi, director of GRID-Geneva at UNEP and overall programme coordinator for this report.
The authors note that solutions exist for moving towards a circular economy for sand. Banning the landfilling of mineral waste and encouraging sand to be reused in public procurement contracts are among suggested policy measures. Crushed rock or recycled construction and demolition material, as well as ‘ore-sand’ from mine tailings are among the viable alternatives to sand that should also be incentivised, the report details.
The UNEP report adds that new institutional and legal structures are needed for sand to be more effectively governed and best practices shared and implemented. “Sand resources must furthermore be mapped, monitored and reported on,” the report recommends. “Meanwhile, all stakeholders must be involved in decisions related to the management of sand to allow for place-based approaches and avoid one-size-fitsall solutions,” the paper stresses.
The timely report follows a resolution on mineral resource governance adopted at the fourth United Nations Environment Assembly (UNEA), calling for actions on sustainable sand management.
This mandate was confirmed at UNEA-5 in 2022 in the new resolution titled Environmental aspects of minerals and metals management, adopted by all member states. GW
• Read the full UNEP report at www.unep.org
Quality
Specials
08 INTERVIEW
Avi Bhoora discusses AfriSam’s exciting aggregates business growth plans
12 MARKET REPORT
Rising oil prices and notable COVID-19 suppression have boosted MENA construction sector
16 QUARRY PROFILE
PPC’s highly efficient Mooiplaas dolomite quarry is producing over 1 million tonnes a year
35 IQ SOUTHERN AFRICA CONFERENCE
IQSA conference reconnects the southern African quarrying industry
37 UGANDAN SAND Uganda’s many sand-seeking challenges
EPIROC TO RELOCATE OPERATION FROM JAPAN TO CHINA
Epiroc will relocate the production and development of its drill rigs for surface construction from Japan to its facility in Nanjing, China.
The production facility in Yokohama, Japan, has been sold and will be closed. Epiroc’s customer centre will be relocated within the Yokohama area to keep supporting customers in Japan with product and application know-how and provide overhauls, rebuilds, and upgrades of their existing fleets.
In Nanjing, manufacturing will benefit from larger-scale production, sourcing, and logistics infrastructure, which will increase efficiency. With about 50 employees, the Yokohama production facility will be closed by mid-2023.
“We continuously strive to increase operational excellence, and this move will improve our long-term competitiveness and agility,” says Helena Hedblom, Epiroc’s president and CEO. “Our facility in Nanjing provides clear benefits with its significant infrastructure for production, sourcing, and logistics. We are saddened that this will affect some of our colleagues in Japan.”
The production and development that will be relocated is part of Epiroc’s PowerROC range of equipment used for drill and blast applications in construction, such as the PowerROC T25 surface drill rig. The net effect on operating profit from the sale of the property and the restructuring cost will be positive with approximately SEK 250mn. It will be reported in Q2 2022.
Adani Group to acquire Holcim India business
Holcim has signed a binding agreement to sell its India business to the Adani Group for CHF 6.4 billion (€6.13bn). The deal includes Holcim’s 63.11% stake in Ambuja Cement, which owns a 50.05% interest in ACC and a 4.48% direct stake in ACC.
Adani Group is a leading and highly recognised company in India, with a portfolio of worldclass businesses ranging from infrastructure to energy. Since entering India in 2005, Holcim has established a track record of sustainable value creation with strategic investments ranging from new best-in-class plants to green technologies such as heat recovery systems.
Jan Jenisch, CEO of Holcim, said:
“With the Adani Group, we have found a perfect owner to unleash our Indian business’s next era of growth for our people and all stakeholders in a swift and efficient transaction. I am proud of Holcim’s track record in the Indian market, where we significantly increased our capacity over the years while advancing our leadership in sustainability.
“The construction sector has never been as attractive as it is today, with so many opportunities to build better and more with less, to improve living standards for all, sustainably. In the last twelve months, we have invested CHF 5 billion in Solutions & Products as a new growth engine for the company while continuously pursuing bolt-ons in aggregates and ready-mix concrete. Holcim is
an essential role in the development of our business over the years with their relentless dedication and expertise. I am convinced that the Adani Group is the right home for them as well as for our customers to continue to thrive in the future.”
Gautam Adani, chairman of Adani Group, said: “With Holcim’s global leadership in sustainability, we are acquiring some of the most efficient building materials
start in the decarbonisation journey that is a must for Indian industry.”
Ambuja Cement and ACC are among India’s most iconic building material brands, with a track record of leadership in sustainability and innovation. Their combined footprint includes 31 cement manufacturing sites and 78 readymix concrete plants employing 10,700 people across India.
Volvo CE Q1 hit by China decline
A depressed Chinese market was the key factor in Volvo Construction Equipment (Volvo CE) announcing a 9% fall in overall global sales for the first quarter of 2022.
Although the construction and quarrying equipment heavyweight achieved sluggish Q1 growth in all areas outside Asia, Volvo CE’s trading in the industry’s largest equipment market was significantly disrupted, partly due to tough COVID19-linked restrictions introduced by the Chinese government.
During Q1 2022, Volvo CE saw net sales decrease to SEK 22.61bn (US$2.244bn) from SEK 24.742bn (US$2.455bn) in Q1 2021. Adjusted operating income amounted to SEK 2.81bn (US$278.92mn - SEK 3.822bn (US$379.37mn) in Q1 2021), corresponding to an adjusted operating margin of 12.4%, down from 15.4%.
Economic crisis hits Sri Lanka construction sector
Sri Lanka is currently battling the worst economic crisis since its independence, and its construction sector is set to contract this year as a result.
Data and analytics company GlobalData says the crisis has been triggered by an acute shortage of foreign currency, ill-timed tax cuts, losses to tourism, fall in foreign workers’ remittances, shortages of food and fuel, and high foreign debt.
Considering the current turmoil, GlobalData forecasts the Sri Lankan construction industry will contract by 4.6% in real terms in 2022 against the previous projection of 9.2% growth.
The outbreak of the COVID-19 pandemic exacerbated weakness in the tourism sector of Sri Lanka that
had already been battered by the ‘Easter Sunday bombings’ in April 2019. The weakness in the sector –which is the third-largest source of foreign exchange – is expected to
continue over the coming months due to the ongoing Russia-Ukraine crisis, given that Russia is one of the largest tourism markets for Sri Lanka.
GIOVANNI BARTOLI TO STRENGTHEN KEESTRACK IN AFRICA & MIDDLE EAST
Giovanni Bartoli is Keestrack’s new sales manager for Africa & the Middle East.
Drawing on 15 years of experience within the international construction equipment industry, Bartoli will initially focus on establishing reliable and sustainable relations with the Belgiumheadquartered crushing and screening plant maker’s new dealers.
Based at Keestrack’s Italian office, Bartoli’s career has largely focused on business development, mainly in the earthmoving and concrete equipment markets. He has travelled extensively in Southeast Europe, Africa, the Middle East, the Far East, the Indian subcontinent and Oceania during his varied global roles.
Tech-led demand
According to a new report by Freedonia, investment in new and replacement off-road equipment featuring state-of-theart technologies will fuel unit sales growth of 5.5% between 2021 and 2022 to $481 billion, slightly above 2019 levels.
The U.S.-based business market intelligence consultancy notes in Global Off-Road Equipment Technology 2022 that many buyers are attracted to more smart tech-equipped machines due to their offer of greater efficiency and productivity. These include autonomous and semi-autonomous equipment, such as robots; fuelefficient and low- or zero-emission equipment units with advanced ergonomics that provide improved operator comfort and safety; and drones, global positioning, predictive maintenance, and other solutions made possible by devel-
opments in the Industrial Internet of Things (IIoT)
Smart off-road equipment sales are projected to grow 35% in 2022 and then more than double by 2026, when they will account for nearly 5% of all off-road equipment demand. Construction is currently the largest market for smart equipment. However, demand will expand most quickly in the mining sector (which is expected to become the leading market for smart offroad equipment technology by 2026) as operators increasingly use advanced technologies – such as autonomous equipment and digital mine management solutions – to lower costs and boost output.
High production costs and labour shortages mean that advanced off-road equipment is typically most cost-effective in highincome countries like Australia, Canada, Germany, and the US. The
use of state-of-the-art technology will remain limited in lower- and mid-income nations, where profits are less influenced by labour costs and emissions standards are generally less stringent. The mining industry is a notable exception since many of the world’s largest mines – which are operated by multinational companies that can afford advanced, high-end machinery – are located in lower-income countries.
Freedonia notes that China is by far the largest consumer of off-road equipment, accounting for 31% of demand in 2021. The country is forecast to represent 26% of absolute global gains in 2022.
The global construction machinery market is expected by Freedonia to decelerate in 2022, while the mining machinery and agricultural equipment markets will continue to grow at a rate similar to that of 2021.
“Keestrack has already established some good dealerships in Africa and the Middle East, but there is still a lot of ground to cover,” said Bartoli. “At first, Keestrack wants to target the North-West Africa markets, South Africa and Middle East countries like Israel, Saudi Arabia, United Arab Emirates & Qatar. We’re looking to expand our dealer network with A-rated, reliable and organised international and local dealers working as our importers and distributors.
“Besides growing the market in these regions, Keestrack will keep growing its product range, while supporting its dealers with the right service and training is a challenge for me in these markets.” Bartoli says Keestrack will also support its dealers with a good financial plan, offering floorplans to keep machines in stock locally.
Freedonia says demand for off-road equipment featuring state-of-the-art technologies will fuel unit sales growth
High-rise buildings under construction in Sri Lankan capital Colombo
Adapting to new market conditions
Despite a protracted downturn in the South African construction materials market, Avi Bhoora, construction materials executive at AfriSam, is encouraged by the emerging pockets of opportunity. In a one-on-one with Aggregates Business International’s Munesu Shoko, Bhoora outlines AfriSam’s response to a low-volume market, emerging trends and key projects in the pipeline
The South African construction materials market has endured a protracted downturn in recent years. Having experienced a decade of growth and success, particularly at the height of considerable infrastructure spending in the run up to the 2010 Soccer World Cup, construction materials suppliers have grappled with a depressed market in the past five years.
Construction development related to the 2010 Soccer World Cup took centre stage from around 2007 to 2012, recalls Bhoora. The momentum carried through to 2015 at the height of the Gauteng Freeway Improvement Programme, which saw the South African National Roads Agency (Sanral) ploughing in excess of ZAR20 billion (around £1 billion) to upgrade nearly 200km of highway.
From around 2017, government’s reduced infrastructure budget has resulted in depressed market conditions. “We, however, managed to tighten our belts and maintained our aggregates and ready-mix concrete footprint. When it looked like conditions could not get any worse, the COVID-19 pandemic hit, and we had to go into a rationalisation mode to survive the tough market conditions,” explains Bhoora.
Consequently, AfriSam had to reduce its Construction Materials (CM) division’s capacity by almost 50%. Only nine out of the company’s 17 aggregate quarries, and 17 out of the 40 ready-mix plants were kept operational. Through a Section 189 process, the company had to reduce its CM staff complement by half.
However, a COVID-19 recovery rescue plan has demonstrated the company’s
adaptability. Bhoora highlights that the experienced management team, with the support of the board, was able to navigate this difficult process independently – without having to rely on outside consultants.
“We classified our operations into three categories,” he says. “In the first category, operations would continue with operations aligning capacity with anticipated demand. In the second category they would be put under care and maintenance, and in the third category we would exit the operation from the respective micro-market completely.”
Based on this strategy, the company disposed of three of its operations, Olifantsfontein quarry in Gauteng, as well as the Newcastle and Ladysmith quarries and ready-mix plants in the KwaZulu Natal region. The sand mine in Macassar near Cape Town was also sold.
To further tackle the severe impact of a depressed market, AfriSam has evolved its business strategy. “We have adopted a demand-driven strategy across all our operations, where production is based, as far as possible, on actual customer orders rather than market projections,” he says. “Putting unwanted stock on the ground costs money, and from a cashflow perspective, that’s something we can’t afford to do anymore.”
“The rules of the game have changed significantly. We have recently seen a much-increased appetite for lower quality construction materials”
AfriSam is encouraged by the emerging pockets of opportunity
While the depressed market conditions persist, the good news is that the company has managed to maintain its 50% capacity levels since the outbreak of the pandemic. “In other areas, we have managed to restart operations on a temporary basis. For example, we have recommenced operations at Ferro Quarry in the Tshwane area, and we are also looking at restarting our Sub Nigel crushing facility in Gauteng on a project basis. If a project comes up in the area and it makes sense to restart operations, even on a short-term basis, we will commit to doing that. This applies to our ready-mix plants as well. In fact, we have restarted two of our operations on that basis,” he says.
AfriSam has also adopted a new maintenance philosophy across its operations. To gain important insights into the running of its mission-critical assets, the company has always measured its overall equipment efficiency (OEE). One of the traditional ways of maximising OEE was the avoidance of any maintenance-related downtime during weekdays. Given that the run time for operations has decreased significantly, maintenance is now done during weekdays to ensure that all tasks are completed during normal working hours, thus eliminating any additional overheads related to weekend work.
“As part of the new philosophy, we also had to forgo some of the ‘nice to haves’ such as predictive maintenance and had to adopt the ‘fix as it breaks’ approach. Because of the 50% reduction in demand, it’s no longer imperative for us to maintain the usual 90% plant availability levels,” explains Bhoora. Affordability issues are not only affecting construction material suppliers, but the industry at large, including civil engineering contractors. As a result, contractors are ‘buying down’ on quality of both aggregates and ready-mix concrete.
“The rules of the game have changed significantly. We have recently seen a much-increased appetite for lower quality construction materials, probably due to affordability. This is prevalent across both public and private development projects. Surprisingly, even developers and consultants are embracing this concept,” says Bhoora.
A key attribute of AfriSam’s demanddriven approach is accuracy of forecasting, to enable a synchronised, closed loop between customer orders, production scheduling and execution. In fact, accurate forecasting is part of the sales team’s incentive scheme.
As part of the forecasting accuracy drive, the company has in the past three years developed better intelligence and tracking of projects in the regions in which it operates.
AfriSam’s construction materials business is strategically located in three key regions of Gauteng, KwaZulu-Natal and the Western Cape, where Bhoora has seen sizeable pockets of opportunity.
“For the past three years, we have been tracking an estimate of our share of the market, competitor activity and the pipeline of projects in these areas,” he says. “The ‘pipeline’ has matured significantly, with some good pockets of opportunity emerging in these regions.”
In the Cape region, AfriSam has picked up five major construction projects of interest. The company’s Rheebok Quarry is currently supplying the N7 highway upgrade project from Malmesbury to Moorreesburg, which entails the widening of the cross section of
The Gauteng Freeway Improvement Programme, saw Sanral invest ZAR20 billion in upgrading 200km of road infrastructure
AfriSam’s Rheebok Quarry in the Western Cape is supplying a major upgrade to the N7 highway
the N7 Section 8 for about 25km, as well as the construction of additional climbing lanes for improved road safety and ease of traffic flow. The ZAR600 million Sanral project is being executed by civil engineering company, Martin & East.
One of the key projects in the pipeline is the dualisation of Main Road 201 from the N1 (Paarl) and OP5255 (Kliprug Road). While the project has gone out to tender, it is still to be awarded. In addition, the City of Cape Town has proposed the upgrade of Jip de Jager Drive. The scope of the project entails the dualisation of the road between Kommissaris Street and Van Riebeeckshof Way, as well as the construction of a median between the existing Jip de Jager Drive (which will be the future southbound dual carriageway) and the proposed northbound dual carriageways.
The ZAR4.5 billion River Club Development, which will host global tech giant Amazon’s new African base, is another project of note in Cape Town. The new mixed-use development will include almost 60,000m² of office space, with Amazon as the anchor tenant. However, the project has been put on hold, following a court ruling that the developers must consult meaningfully with all affected parties.
In Gauteng, AfriSam has listed a total of eight important projects in its sights. Several of these are still to be awarded, and these include the Villiers N3 Toll Road Rehabilitation; Road P122 to Solomon Mahlangu project (still on tender), construction of the K60 Road between Maxwell and Allandale Road in Midrand; the Sunnyside office development and the South African Reserve Bank Extension.
Other projects that have been awarded in Gauteng include the African Data Centre and the Barlow Park Mixed-Use Development.
In KwaZulu-Natal, AfriSam is tracking six major projects. Most of these are Sanral projects, with the national road agency set to undertake massive upgrades to South Africa’s busiest highways, the N2 and N3, which could take up to eight years to complete.
However, only three of these have commenced on the N3 between Cato Ridge and Ashburton, with several others have been delayed due to the recent floods in the region, among other reasons. The N2 upgrade from Kwa Mashu to Mdloti has been awarded, however, the project is yet to commence.
“There has been much talk about government’s Recovery and Reconstruction Plan, which hinges on infrastructure investment due to construction’s clear multiplier effect, but very few projects are coming to market. Sanral has been talking about spending over ZAR30 billion, but many of the projects have been hamstrung by lack of capacity and legal issues around National Treasury’s procurement rules. We, however, remain optimistic that the market will rebound at some stage, as there is certainly a limit to the deterioration of our existing infrastructure,” concludes Bhoora. AB
AfriSam has adopted a new maintenance philosophy across its operations
The company has also restarted operations on a temporary basis following the pandemic
The company has developed better intelligence and tracking of projects in the regions it operates
AfriSam has adopted a demand-driven strategy across all its operations
AfriSam had to reduce its Construction Materials division’s capacity by almost 50%
A Cat 988K wheeled loader at work on a MENA quarrying site
MENA construction rebound
A combination of factors is boosting construction materials demand in North Africa and the Middle East. V L Srinivasan reports
Encouraged by the success of COVID-19 vaccination programme and recovery in oil prices, the Middle East and North Africa (MENA) nations awarded various infrastructure projects valued at around US$156 billion in 2021.
The trend continued as the US and European Union imposed economic sanctions on Russia which invaded Ukraine in February this year. With the ban, Russia’s oil and gas did not reach global markets resulting in a spurt in crude prices benefiting the oil-exporting nations in the region.
According to BNC Projects Journal, the largest project intelligence database in the Middle East and Africa, the Gulf Cooperation Council (GCC) construction market alone in the MENA region is estimated to be $1.6 trillion, with over 21,000 active projects at the end of Q1 2022.
The report said Saudi Arabia doubled its new scheme announcements in the quarter, contributing 56% towards total project announcements in the GCC. Driven by the mega industrial facility by Foxconn, the Saudi Arabia industrial sector grew by 29% yearon-year (Y-o-Y) and drove the GCC Industrial sector to register 11% Y-o-Y expansion.
Saudi Arabia also registered 9% Y-o-Y expansion in terms of the overall project market supported by the major expansion in the utilities and the oil and gas sector. This led the GCC utilities sector to record 16% Y-o-Y growth.
“We have a COVID-gap of around 24 months in the project development cycle”
Avin Gidwani, CEO of Industry Networks, publisher of the BNC Projects Journal
“The overall story of construction is not as good as one would expect with giga projects splashed across the media and seemingly on the horizon, but nor is it as bad as crisis storylines would have you believe,” says Avin Gidwani, CEO of Industry Networks, publisher of the BNC Projects Journal.
“We have a COVID-gap of around 24 months in the project development cycle and you will experience this painful delay
depending on which stage you play at in the cycle of construction. The good news is that the region’s new project cycle appears to be kicking in again and high oil prices will fuel it to go quicker.”
In Egypt, the construction market has gathered paced due to the execution of several projects including the new capital city, Cairo monorail project, and the Iconic Tower. As political stability returned, tourism picked up and oil prices increased, the government undertook economic reforms to deliver more projects.
The World Bank estimates the Arab world needs $100 billion every year for a reliable, strong, secure, and resilient infrastructure. Conflicts and wars have amplified this need, with the destruction of roads, buildings, and water, electricity, and communication networks in many countries. Syria, for example, saw the loss of an estimated $117.7 billion in housing and infrastructure in 2017.
In an interview with Asharq Al-Awsat, Navid Hanif, director, Office for Financing for Sustainable Development at the United Nations, said that the MENA region would need to spend at least 8.2% of GDP to achieve infrastructure goals by 2030. The average spending on infrastructure over the past decade has reached just 3% of GDP, with financing coming mostly from the public sector.
“With the population in the region expected to increase by more than 40% over
the next few decades, and with increasing industrial demand, the region will need to invest more than $100 billion annually to maintain and build the infrastructure to serve the growing communities and cities,” Hanif said.
The new investments need to focus on making the infrastructure more resilient as large parts of the Arab world are in harsh climate zones, he adds.
Energy transition
As a follow-up to the UN Climate Change conference meetings, the six GCC countries –Qatar, the UAE, Saudi Arabia, Oman, Qatar, Bahrain – as well as Egypt and Turkey, are among the nations which pledged to reduce carbon emissions by 2070.
The GCC countries have announced renewable energy (RE) projects worth billions of dollars. They are even planning to produce and export green hydrogen to other countries. At present, the installed capacity of the MENA region’s RE projects is below 3 GW, but plans are underway to increase it to 98 GW by 2050. In fact, close to 40 GW are expected to be produced by developing clean technologies by 2025.
WCA’s call
As cement is one of the prime raw materials for these projects, the World Cement Association (WCA) said this would be an opportunity for the MENA region’s cement producers to take the lead and embark on their decarbonisation journeys to cut emissions and save on operational costs, including energy and fuel.
In fact, Dubai-based consulting group A3 & Co, which is a WCA member, estimates that there is potential for local companies to reduce their CO2 footprint by as much as 30% with no investment required.
At present, the number of companies and factories in operation has reached 171, with 32 additional cement mills. The share of the MENA region in global cement production is 15%.
“Cement companies in the region have some low hanging fruit to take advantage of”
Ian Riley, World Cement Association CEO
WCA CEO Ian Riley says that there has been a lot of discussion in Europe and North America about decarbonisation roadmaps for the cement industry, and good work has been done to start on this journey. However, 90% of the world's cement is produced and used in developing countries; to impact overall industry emissions, we must include these stakeholders, he said.
“Cement companies in the region have some low-hanging fruit to take advantage of, which will lower costs at the same time as
reducing CO2 emissions. At WCA, we have a number of programmes that can help them realise this opportunity,” Ian Riley adds.
Demand for aggregates
With construction activity at its peak, there is a great demand for both limestone and gabbro in the GCC countries, according to Gary Martin, senior market professional for heavy construction and quarry industries, Caterpillar.
Martin says the two main drivers of the quarry and aggregates industry in recent years have been the demand for aggregates in the region and a high quantity of produced materials exported outside to Qatar, Bangladesh, and India, to use in steel manufacturing and infrastructure projects.
“Some of the limestone in the region has the correct chemical base that the steel works require for different applications and for the cement industries, roads and infrastructure projects.
“There are many projects such as Etihad Rail and the construction of offshore oil & gas exploration islands in the UAE where there is demand for aggregates. Even the real estate sector needs more aggregates as several private developers are constructing massive projects in the Emirates.”
With Saudi Arabia pushing forward with its 2030 vision to diversify some of their income away from oil and gas to the tourist industry, many megaprojects are starting or are within very close scope of starting, explains Martin. Projects range from building new zero-emission megacities supplied by green energy to luxury resorts on the Red
“Each project is valued in multi-billions of dollars and require new roads, airports, ports, and concrete for infrastructure, which will increase the demand for aggregates from crushing plants, and concrete and cement factories.
“In Saudi Arabia, the biggest demand for aggregates is from cement factories
Cat 374: Demand for construction equipment has been on the rise in the GCC region, with Cat 374 excavators among popular models due to their low cost per ton guarantee
A Volvo L150H wheeled loader at work on a quarry site
and cement products in addition to the megaprojects and there is growth in the housing market requiring all products for new housing projects within the Kingdom.”
Echoing similar feelings, Ilkay Fidan, commercial manager for Market Area Middle East, Volvo Construction Equipment (Volvo CE), says with the development of megaprojects in the Gulf region, they expect the demand to increase gradually in 2022 and 2023. “We have already seen demand increase since July 2021. Exceptional oil prices are the main driver for the construction boom in the Middle East.”
Fidan notes that demand for aggregates in the Middle East is partly influenced by its young population’s desire to diversify the economies from oil and gas revenues. Government infrastructure spending and sustainability-linked projects were other key demand drivers, he explains.
Safak Tugut, commercial manager for Market Area Africa at Volvo CE, says the demand in North Africa will continue to increase except in Algeria. In Morocco, public spending will continue to support growth in fixed capital formation, which will converge to its historical average following the 2021 surge.
“By tripling its allocation to the Mohammed VI Fund from $1.41 billion to $4.44 billion, the Moroccan government will continue to issue debt to fund the development of capital-intensive projects, such as the Dakhla Port in Rabat, which has an estimated cost of $1.28 billion, and the 3,800 km high-voltage direct current transmission line between Morocco and the UK, worth $25.7 billion which are due by 2027,” he points out.
The instability in Algeria is still ongoing but in the coming years, its economy will benefit from elevated hydrocarbon prices as authorities will have more fiscal space to stimulate economic growth, notes Tugut.
However, there is little demand for recycled aggregates within the construction sector except on some remote road construction or widening projects where material is difficult to transport, and one may find the paving teams recycling the existing material as the first sub-base.
“Recycling isn’t that common in the construction industry. For road paving, it can be found as the recycled material is used to build up the first base course of material under the finished grade,” Caterpillar’s Martin said.
Demand for construction equipment
Demand for construction equipment has been on the rise in the GCC region, says Martin. The most popular excavators among quarry operators are Cat 349, 352 and 374 as they offer a low cost per ton.
“In the Northern Emirates in particular, the Cat D9R dozer is a very popular machine because of its weight and ripping capabilities.
“While Cat 966 medium wheeled loaders are commonly used in the yard to load the
the hoppers and smaller crushing plants, the Cat 980 medium wheeled loader is also used to load the road trailers in some of the larger and busier quarries and at the face in the smaller quarries as they are equipped with a larger bucket.
“The Cat 988K is found in two different applications. In some of the larger or super quarries within the Northern Emirates they are yard loaders as the continuous fleet of trailers come into the yard to take the finished material to the port for exporting. The Cat Payload onboard scale system provides on-the-go weighing to assist operators with hitting precise load targets which help maximise productivity.”
Volvo CE’s Fidan says that while GCC customers still want conventional machines, attention is likely to be increasingly paid to sustainable products that can reduce carbon footprint in the entire production process.
Tugut says it is a similar trend among North Africa customers, where quarry operators and aggregates-processing firms have long favoured strong, reliable equipment with high production and low fuel consumption. Volvo L150H, L180H and L220H wheeled loaders and Volvo EC350D, EC380D, EC480D and EC750E crawler excavators are all particularly popular, he highlights.
Reliance on technology
In addition to the machines themselves, quarry operators rely on technology and support. Cat Product Link is very useful to
“We anticipate far stricter monitoring of site operations will come into play to maximise production efficiency”
Gary Martin, senior market professional for heavy construction and quarry industries, Caterpillar
such as location, productivity, idle time, and diagnostic codes are also available through the online web applications. Connectivity is available through either cellular or satellite.
“The back-up service from the dealership is always critical in a quarry and we work very closely with our customers to provide the support they need as the more efficient the service support, the more efficient the quarry business is since a lot of equipment is in continuous operation,” Martin says.
Future
Caterpillar’s Martin says that from a GCC quarry- and aggregates-operations perspective, high oil prices equate to increased production costs. “With this in mind, we anticipate far stricter monitoring of site operations will come into play to maximise production efficiency.”
Regarding commercial opportunities for Caterpillar in Saudi Arabia, Martin says they vary by region. “Our focus is supplying the lowest cost per tonne solutions to the cement and quarrying industry and providing cost effective equipment to support the crushing process.”
“Within the many regions of Saudi Arabia, there are different demands on aggregates, which drives different production requirements. The equipment serving the industry ranges from the Cat D11T to D9R dozers, loading excavators are typically the Cat 349 and 352 models. In some areas, the 395 too.
“In addition, the Cat 992K and 988K wheeled loaders are perfectly matched to load the 777G to 775G off-highway trucks. Quarries with a lower output use the 980 wheeled loader and 770 off-highway truck or the 966L wheeled loader in combination with the Cat 745 articulated truck.”
As far as Volvo is concerned, the company has been adapting to supply chain challenges in the Middle East and North Africa and being alert to potential changes in regulations.
“We are launching a CO2 reduction programme to reduce carbon footprint for conventional loading and hauling units soon. This will be a step-by-step approach to help customers realise their own unique goals towards carbon neutrality,” says Tugut.
He believes that Volvo CE and other off-highway equipment manufacturers will benefit as countries emerge from COVID-19pandemic-induced disruption, with pent-up unit demand addressed and governments’ infrastructure spending increased, partly to meet goals linked to supporting the younger generations and sustainability. Furthermore, Tugut says the switching of economies from being oil-dependent to focusing on non-oil income will create more unit-sale opportunities.
Sustainability trends to continue
Louise Collins, UAE country director, project and development services at JLL, a leading professional services firm specialising in
real estate, investment management and development consultancy services, believes sustainability trends will continue to gather momentum in the long term as the GCC and wider world's construction industry moves towards greater digitialisation and the decarbonisation of real estate assets.
She notes that an estimated $9.2 trillion is expected in global capital spending on low-carbon equipment by 2050. A considerable amount of the current investment is focused on infrastructure-based technologies such as renewables, hydrogen, and industrial process recovery.
“On the building side, the focus is on everything from carbon-free concrete and recycled steel to the most advanced heating and cooling energy systems, geothermal heating and even carbon-capture technology,” says Collins.
“There is still a big push for digitisation across the construction industry”
“Sustainability is a continuing trend within the construction sector, specifically relating to the recently announced net-zero carbon commitments. There is still a big push for digitisation across the construction industry, and we also see an increasing interest in modular construction.” AB
Actionable Insights
Louise Collins, UAE country director, project and development services at JLL
PPC’s Mooiplaas Quarry is blessed with a vast composite and homogeneous dolomitic reserve that allows it to supply several industries
FIRING ON ALL CYLINDERS
Leveraging a vast and homogeneous dolomitic reserve that allows it to spread its wings across an array of industries, complemented by several efficiency improvement initiatives, PPC’s Mooiplaas Dolomite Quarry is one of a few South African quarries currently producing more than a million tonnes a year. Munesu Shoko reports
Since 2017, the South African construction sector has seen a steady decline in volumes, with the COVID-19 outbreak in 2020 providing a devastating blow to an already ailing industry. That many quarries in the country are in dire straits is no overstatement. In the face of it all, business is still firing on all cylinders at PPC’s Mooiplaas Dolomite Quarry, despite a dip in overall volumes, especially on the aggregates side of things.
The quarry’s key competitive edge is its homogeneous dolomitic reserve, one of three of this type in the Gauteng Province. Apart from the traditional aggregates market, the dolomitic nature of the rock allows the quarry
to supply three other industries, namely the steel industry (metallurgical dolomite), the chemical industry (metallurgical dolomite powder to fertiliser manufacturers) and the agricultural sector (agricultural lime).
“Most of the products we manufacture add real value to our customers’ businesses. For example, due to the cementitious properties of dolomite, many readymix concrete producers prefer our super sand because it helps them reduce both cement and water content in their mixes,” explains Arthur Ndindani, general manager PPC Aggregate Quarries.
Apart from super sand, Mooiplaas also produces a unique -2mm product, a very fine type of sand mostly used for finishing in the
production of paving bricks. Even the general aggregate products from Mooiplaas, such as 19mm, 13mm, 9.5mm, 6.7mm and washed crusher sand are much sought after because of the cementitious values of the rock. This is further complemented by the fact that the quarry washes all its products to improve quality.
Aggregate, by its nature, is a highvolume, low-margin material and usually cannot be transported over 80km from a cost perspective. However, because of the high-quality nature of the product, Mooiplaas supplies its aggregates to areas as far as Polokwane, Limpopo (about 300km) and Nelspruit, Mpumalanga (about 350km), according to Shadrack Molawa, Works
Manager at Mooiplaas. The metallurgical lime produced here is of very high quality and is supplied to areas as far as the Eastern Cape, which is over 600km away.
The quarry’s footprint in the agricultural sector also worked to its advantage during the COVID-19 influenced hard lockdown in 2020. When all other operations had to close shop, Mooiplaas was considered an ‘essential service’ operation because it had to continue supplying agricultural lime to the farming community. This placed the business in good stead to survive the pandemic better than traditional aggregates quarries.
It was during the COVID-19 lockdown that the management team at this operation also had to rethink its business, resulting in a number of efficiency improvements that have had a vast impact on the overall business to date.
“The year 2020 was undoubtedly one of the most difficult in recent memory. It, however, compelled us to find new ways of improving our business in an uncertain environment. In order to tackle this reality, we all agreed that our post-lockdown success lied in efficiency,” explains Ndindani.
“We identified some problem areas in our processes and the mining area was our first point of focus. We also realised that improvements in the pit would have a big ripple effect in downstream processes.”
Firstly, the team looked at all the factors that affected the tonnes per hour (tph). One of the problem areas identified was the long cycle times, largely due to the long hauling distances from the quarry face to the primary crusher. Consequently, a decision was taken to redesign the quarry to shorten the hauling distances.
“As part of this process, we also redesigned our haul roads. The hauling distances from the face to the primary tipping point have become shorter, thus improving our cycle times significantly. Previously, we were achieving between seven-and-a-half and eight-minute cycles times, but we have now cut that down to about five minutes. Consequently, our tonnes per hour have jumped from around 550 to 620tph. We also saw a huge decline in our fuel burn, which reduces our costs significantly, given the soaring prices of diesel,” explains Molawa.
As part of the mine redesign (with the help
from the group’s mining team) the mining direction was changed. Traditionally, the team had always mined towards the western side. Because of inherent safety issues, the previous mining team put less focus on the northbound section. “We had to redesign the mine to allow us to tap into the northward deposit. After the redesign we actually realised that the deposit is outcropping as you move to the north, reducing the amount of overburden we had to strip. By changing the mine design, we have managed to reduce our stripping ratio from the previous 25% to 16%,” explains Ndindani.
Evaluation of blast efficiency in quarrying, stresses Ndindani, is one of the most important decisions that should be made by quarry operators for productivity assessment. Based on this understanding, the Mooiplaas team reviewed its blasting practices to improve fragmentation. This has also improved other downstream operations such as load and haul as well as crushing and screening.
As part of the new blasting regime, Mooiplaas adopted electronic blasting, moving away from traditional shock-tube
An aerial view of the Mooiplaas pit after the performance improvements
An aerial view of the processing plant.
technology. The quarry was one of the first operations to adopt BME’s latest-generation AXXIS Titanium electronic detonation system. Having been involved in the testing phase of this product well before its commercial rollout last year, the Mooiplaas team experienced first-hand the efficiency benefits of electronic blasting, which outweighed the initial higher capital outlay.
“With electronic detonation, we have managed to improve our blast outcomes, mining efficiencies, environmental impact control and safety. Because of better fragmentation capabilities of this technology, we have managed to increase our burden and spacing, which reduces our powder factor and total metres drilled, thus cutting costs related to drilling and blasting,” says Molawa.
Although Mooiplaas is blessed with a soft rock, the geology traditionally dictated for close burden and spacing using the previous shock-tube technology. This is because within the dolomite itself, there are pockets of soil fissures. If not managed properly, the blasts end up with big boulders which require secondary blasting or further mechanical breaking. Secondary blasting or breaking of oversize material costs money, and a lot of it. Industry statistics show that it could be as much as four times the cost of the initial blast. With electronic blasting, the soil pockets are easily intercepted without the need to close the burden and spacing, which reduces the overall cost of blasting.
Working closely with suppliers has been another success factor for Mooiplaas. A significant portion of the processes at Mooiplaas are outsourced to contractors. Drilling is outsourced to Bustque, which has been on site for many years, while load and haul is done by Alpha Plant Hire. Outsourcing these processes is aimed at a combination of downsizing the company’s fixed costs and reducing capital investments.
“We work closely with our contractors, and they have been part of our optimisation process. They understand what we are trying to achieve. Consultation was a big process of our efficiency-improvement programme. For example, we had to demonstrate to the drilling contractor that reducing burden and spacing didn’t necessarily translate into reduced metres drilled. The more efficient we are in all our processes, the more we deplete our run of quarry material on the ground, which increases our drill and blast frequency,
“We work closely with our contractors, and they have been part of our optimisation process”
Arthur Ndindani, General manager PPC Aggregate Quarries
thus translating into more business for the drilling contractor,” explains Ndindani.
“On the load and haul side of things, we have brought in a new contractor, Alpha Plant Hire. They have a big focus on efficiency, which speaks to what we are trying to achieve at Mooiplaas. We also involved them in the optimisation process from the start, and they fully understand our goals,” adds Ndindani. “A close working relationship with blasting technology supplier, BME, has also translated into massive efficiency gains. Their guidance has helped us realise the massive gains associated with electronic blasting.”
Blasts are kept large to meet the high demand of material from the various markets. The quarry blasts about 150,000t of material on the ground every month, with 100,000t destined for the aggregate market and the remaining 60,000t to the dolomite market. A chemical analysis is conducted on the material inside the company’s laboratories. Anything with a silica content of below 2.5% is classified as metallurgical dolomite, and anything above that is considered aggregate material.
To further grow its market reach, PPC has
broadened its footprint by catering for the informal market. “During the hard lockdown in 2020, one of our resolutions was to approach the informal market. With all the developments happening in the townships, we targeted township brickmakers. The majority of them were not aware that they could buy material directly from us. Because of the cementitious properties in our sand, they have seen massive cost reductions in their brickmaking processes,” explains Ndindani.
PPC’s strategy also entails ‘keeping everything at home’. There are two divisions within the company, namely PPC Cement and PPC Materials Division, which consists of PPC Ash, PPC Readymix and PPC Aggregates. The Readymix business is a major volume driver for the other three divisions – Cement, Ash and Aggregates. While the quarry supplies to various other external customers, PPC Readymix is the largest customer in terms of aggregates.
PPC is one of the largest readymix suppliers in the country, with a national footprint of 32 sites. To meet the high demand of its products, PPC runs a 24/7 operation at Mooiplaas. AB
Redesigned haul roads have been central to better cycle times and safety on site
The load and haul function has been outsourced to Alpha Plant Hire
Practical crushing & screening excellence
A new Kleemann MOBISCREEN has been excelling in its first practical quarry site application, while other new crushing and screening plant and their linked technology are catching industry attention. Guy Woodford reports
The first practical quarry site application for Kleemann's new MOBISCREEN MSS 802i EVO has been taking place over recent months at Ernst Krebs & Co.'s gravel quarry in Neumünster, Germany.
Owned and run by Caren Krebs and her son André, Ernst Krebs & Co. operates several gravel quarries between Hamburg and Kiel in northern Germany. The company portfolio includes demolition and recycling, earthwork, roadbuilding and a transport and logistics section.
Last year, André was in the market for a flexible new screening plant that could comfortably switch from processing sand and fine-grained material in a gravel quarry to handling particularly cohesive topsoil and recycling rubble and rail ballast at the company's recycling site.
André took his request to his contact partner at Wirtgen Germany, Henning Lüdtke, who he had worked with for many
years. After hearing how Ernst Krebs & Co. wanted to use their new plant, it was clear to Henning Lüdtke that the new Kleemann screen for coarse elements, the MOBISCREEN MSS 802i EVO, was an ideal fit.
At the time, the machine was not yet available on the German market. So, Henning Lüdtke found an unconventional solution. He offered André a pilot series model of the plant, which André happily accepted. "Even though it was a bit like buying a pig in a poke. There were hardly any documents on the product", said the business operator, smiling.
Given that Ernst Krebs & Co. had been long-term Kleemann customers, André knew that taking the pilot screen was not really a gamble. "In our gravel quarries and our recycling, we have been using Kleemann machines for a long time. I was, therefore, fully confident that this machine would also do a good job and based on the description from Henning, I knew that this was exactly the machine we needed here.
"It's obvious that with this new MOBISCREEN, Kleemann has once again looked at what makes work more effective in practice. Everything is so much quicker: set-up times are shorter, and output is higher. All in all, it pays off."
“The numerous wellthought-out details all make the plant userfriendly and thus safer”
The flexibility begins with the MOBISCREEN MSS 802i EVO's large feed hopper. The hopper rear wall and the filling aids can be folded variably so that loading from different heights, from both sides and the rear, can proceed optimally. The screen surface change is comparatively easy even in the lower deck because the screen casing can be completely horizontal. The screening parameters can be adjusted precisely, and even conversion, for example, from three to two final grain sizes, is uncomplicated. Transport from one work site to another is also fast: the discharge conveyors can be folded in without disassembling parts. Thanks to the stepless driving control, the plant can also be moved and placed precisely.
The MOBISCREEN MSS 802i EVO plant at Ernst Krebs & Co.'s gravel quarry in Neumünster
Metrics allows remote troubleshooting, and the user interface can be tailored to address different customer needs. New features and functions can be also updated remotely.
By combining the new Metrics with its global service footprint, Metso Outotec and its distributor partners can support customers in making data-driven decisions that impact their crushing and screening operations.
safe distance. "Everything is set up practically and logically. For example, the display can be plugged in at different points on the machine. The user is always near the function currently being executed – a real advantage." With the new MOBISCREEN model, the blind operation of levers arranged remotely from the component to be folded is a thing of the past. Apart from the increased safety, this also simplifies operation during set-up and service. The numerous well-thought-out details all make the plant user-friendly and thus safer.
During a few months of practical testing, the MOBISCREEN MSS 802i EVO demonstrated its qualities. André continues: "One of the real challenges for us is, for example, gravel extraction. We have to deal with a lot of sand with a relatively small proportion of stone. This means that the fine-grain side discharge conveyor has a real tough job. Other screening plants would soon reach their limits. This is no problem for the new plant."
A further positive surprise for Ernst Krebs & Co. has been that the new MOBISCREEN's casing can be set over 20% steeper than many other screens for coarse elements. This guarantees a great cutting effect for separating fine material such as sand, and significantly higher output.
André is completely satisfied with the new acquisition, and he has already ordered another plant.
Metso Outotec has launched an upgraded
will significantly improve connectivity and optimisation benefits to aggregate customers' crushing processes. The solution has been developed with distributors and customers and offers several state-of-the-art features supporting customers to achieve their sustainability and operational targets.
The new Metrics features include C02 tracking for sustainability benefits, 24/7 access to real-time data, a maintenance module, critical dashboards for utilisation, and geolocation. Furthermore, the new
"We wanted to develop a next-generation solution that will bring quantifiable value and deliver more production hours and tons to our customers. The key to building sustainable operational efficiency is having the correct information to make decisions and select the right combination of services to lift the bar. Metso Outotec Metrics for aggregates connects mobile crushers and screens, providing increased real-time data visibility and analytics to improve availability, performance, reliability, and profitability," says Merja Tyyni, vice president, Standard Crushers, Metso Outotec.
The Metrics solution is part of Metso Outotec's Planet Positive portfolio.
In addition to the improved data transmission speed, new features will continually be developed. One currently in development is integrated mass flow
The MOBISCREEN MSS 802i EVO has impressed André Krebs with its ability to handle a challenging material processing brief
Sandvik's QA452 plant in action
SUSTAINABLE AND EFFICIENT
CUSTOM-MADE RECYCLING SOLUTIONS
The use of reclaimed asphalt, or recycling, is an absolute necessity of today. Ammann offers you custom-made solutions for using recycled products.
At the forefront of RA use is the Ammann ABP HRT asphalt mixing plant (High Recycling Technology). The HRT concept incorporates a high degree of technology and innovation, in particular the counter-current drying method of the RAH100 recycling drum.
LOW EMISSIONS
•Indirect heating
•Homogenous heat distribution
•Recycling rates of up to 100% possible
•Recipes are more flexible as there is no need to overheat the minerals
HIGH EFFICIENCY
•Low exhaust gas temperature
•High RA temperature
GENTLE BITUMEN PROCESSING
•No radiation heat
•Gentle heating of the RA material
measurement for tracking production and waste to help customers quantify their production performance.
Metso Outotec Metrics for aggregates generates a strong link between customer operations, product management, and product development.
"The new Metrics will enable us to take equipment features and customer experience to a new level by improving our customers' equipment's performance and increasing both uptime and the overall machine lifecycle," says Kimmo Anttila, vice president, Lokotrack solutions, Aggregates business area, Metso Outotec.
While newer Lokotrack machines come equipped with Metso Outotec Metrics, legacy equipment can, in most cases, be modernised and integrate digital connectivity equipment with a Retrofit Kit. In the initial launch phase, the Retrofit Kit is available for certain Lokotrack crushers and screens.
Sandvik Mobile Crushers & Screens (Sandvik) says its new QA452 mobile plant is the latest evolution of its QA Series products and three-deck Doublescreen technology. Doublescreen technology is said to typically outperform traditional screens by up to 30%, offering a tailored rock-processing solution for the quarrying, recycling & mining industries.
Featuring a host of innovations, Sandvik's new QA452 solution offers independent
LIPP-MUS TEST
Lippmann has entered the UK crushing and screening market.
The American company has teamed up with two distributors renowned for their high customerservice support levels. Stewart Plant Sales (SPS) and Aggregates Processing & Recycling Ltd (Agg Pro) will now be providing quality crushing and screening systems to aggregates suppliers throughout Scotland, England, and Wales.
With a legacy covering nearly 100 years in North America, commencing operations in Milwaukee, Wisconsin, USA, in 1923, Lippmann began with heavy-duty jaw crushers that have become world-renowned. Continuous development and innovation have seen the company grow into a premier aggregates-processing equipment manufacturer.
screen angle adjustment and hydraulic screen separation. The model also features two triple-deck inline screen boxes with equal-sized screen decks, each providing 9m³ of screening area.
Screen enhancements on the QA452 include an 11% longer bottom screen deck to extract more fines. Featuring independent screen angle adjustment, the primary screen can be independently adjusted from the secondary screen, allowing operators to optimise their throughput, screening efficiency, and product gradations. The primary screen performs as a fines extractor, while the secondary screen performs as a grader. Two processes on one plant, offering exceptional flexibility, excellent separation, accurate grading and massive throughput.
Sandvik offers a hybrid 'e' drive with electric plug-in, which means you can choose the most economical and efficient energy source for your materials-processing plant. The QA452 provides a lower environmental impact due to reduced fuel consumption, and the latest powerpack onboard offers less operating noise and low emissions. In addition, the hydraulic system has been enhanced to reduce energy wastage. Its hydraulic oil change intervals have been extended from 2000 to 4000 hours, meaning up to 50% less hydraulic oil is said to be consumed over 10,000 hours of machine usage (subject to oil sampling).
The QA452's primary screen can also be hydraulically separated to gain better access for maintenance and screen media changes. The addition of a new oversize cross conveyor means greater oversize material extraction. This cross conveyor can also be reversed to allow the plant to function like a two-deck screen with oversize and mid overs discharged together.
Each screen deck features end-tension screen media using Sandvik's unique mesh tensioning system. This means faster screen mesh tensioning and removal when you need uptime.
Sandvik's new range of WX rubber media combines the high accuracy of wire screens but with the durability of rubber, said to offer up to 10x longer wear life and up to 50% faster installation time than wire mesh. Having equal-sized panels also means the screen media is interchangeable between decks.
The QA452 comes with Sandvik's My Fleet telemetry system and seven-year data subscription as standard. This offers 24/7 fleet management, geo-fencing and remote support.
Sandvik says safety is its top priority, and the QA452 has several features as standard to improve operator and onsite protection. Dust-suppression spray bars, onboard water pump, safety pull cords and lighting mast are now fitted for extra peace of mind. AB
rich history in the heavy-equipment market in Scotland and Northern England, trading for over 50 years with over 17 locations," continues Kiesgen. "We are confident it will be a smooth and successful transition, bringing Lippmann crushing and screening equipment into their portfolio and to their customers."
The SPS booth at the ScotPlant tradeshow on 22-23 April in Edinburgh, Scotland, proudly presented a Lippmann jaw crusher for the first time in the UK. "It truly is a momentous day for Lippmann," said Kiesgen. "To see our growth solidified with a brand-new Lippmann 1200j-e tracked jaw crusher and its new UK distribution partners in place is amazing."
In recent years, Lippmann has seen opportunities for growth beyond its primary markets in the United States and Canada. The hard-rock processing requirements across the UK region are said to be well-suited to Lippmann crushing systems.
"Taking this first step into the UK is an exciting time for Lippmann,"
says Kevin Kiesgen, vice-president Lippmann. "We look forward to the next 100 years in this region and know that we have partnered with two strong and well-respected specialist distributors."
With the two new distributors, SPS & Agg Pro, Lippmann equipment sales and support will be efficiently covered throughout the entire UK region. Exclusive in each of their respective territories, SPS will be responsible for Scotland and Northern England (including
Lancashire and North Yorkshire). At the same time, Agg Pro will cover all remaining English counties in the South and Wales.
"Agg Pro's history of putting customers first and its extensive service department made it a clear choice as a dealer for Lippmann. Along with over 25 years in the crushing business, it has an extensive knowledge base for establishing products and brands in the UK.
"Meanwhile, SPS has a long and
Lippmann's new 1200j-e is a heavy-duty, mobile jaw crusher that can be powered via an electric line or onboard diesel generator. Its double-deck prescreen feeds the 48" x 34" high-inertia, single-toggle jaw and, at 75" deep, is suitable for the hardest rock applications. The 12" DSE control panel manages numerous built-in safety features as standard and, together with 365SiteConnex telematics, ensures maximum productivity and efficiency from any location.
Lippmann's 1200j-e tracked jaw crusher being showcased at ScotPlant 2022
Excavator sector hit by fall in Chinese demand
Sales of excavators in Europe, Africa and the Americas have been healthy in early 2022, but China’s huge market has been hit by price pressures and renewed COVID lockdowns across the country. Liam McLoughlin reports
Excavator and loader manufacturer
Volvo CE says that net sales of its equipment in the European market grew by 13% in the first two months of 2022, influenced by a large number of investments in infrastructure and housing, while North America increased by 20% thanks to the high levels of housing construction and manufacturing in the region. Due to the strong demand for commodities, Volvo CE says South America has continued its robust rise in market demand with a 45% increase on the same quarter last year.
The manufacturer adds, however, that all of this has been affected by a 33% decline in China (the world’s largest market), primarily due to a spike in COVID-19 cases that has led to restrictions and lockdowns across the country, but also due to a price pressure that remains primarily on excavators. Asia, outside of China, has also been negatively impacted by price increases on machines in India, related to new emission regulations, and has reported an 8% fall.
Volvo CE says it is “demonstrating a solid performance during challenging times, while also continuing its evolution as a sustainable leader, not just for the company but for the industry and society as a whole”. It adds that Q1 has seen the successful launch of its first fully electric machine in the Asian market
– the ECR25 Electric compact excavator –now available for customers to buy in South Korea and the introduction of a tailored CO2 Reduction Program aimed at helping customers realise their own unique goals towards carbon neutrality.
Volvo CE has recently unveiled its Connected Map solution, a positioning service which provides a visualised site overview for all machines - also non-Volvo machines - and vehicles on a site, accessible by personnel in the machines (via Volvo Co-Pilot or Android/iOS device) and in the office (via the Office Portal web platform).
Connected Map will visualise a host of typical jobsite features and landmarks, including roads to assist operators in navigating around the site, load zones, dump zones, speed zones as well as restricted zones. Points of interest such as offices, workshops and fuel stations can also be visualized, especially helpful for new or temporary operators. Single lane (narrow road) sections can be defined, notifying the operator if another machine is approaching within a single lane section helping to avoid traffic congestion.
Azadeh Fazl Mashhadi, service offer owner site solutions at Volvo CE, commented: “With Connected Map, users benefit from complete jobsite visibility. It gives them a visual overview in real time of
the position of every machine, every vehicle and every visitor on a site connected to the App, helping to make their operation more efficient and more productive.”
Elsewhere in the excavator and loader sector, Hyundai is adding to its A-series range by introducing a further two compliant crawler excavators, the 16-tonne HX160A L and 18-tonne HX180A L.
The mid-weight machines are powered by the latest Cummins diesel engines, achieving Stage V emissions standards without the need for exhaust gas recirculation (EGR).
Hyundai says the excavators offer improved fuel consumption, deliver improved operating speed and performance, in addition to increased visibility and safety.
Features include the Cummins EU Stage V B4.5 diesel engine that delivers a 13% increase in power and 27% more torque than previous models.
There is an up to 5% improvement in fuel consumption in levelling and truck-loading operations in P mode, plus particulate matter (PM) reduction of 60% with no requirement for EGR.
The new Lifting Mode improves fine hydraulic control, using engine rpm reduction, power boost action and pump flow control, while upgraded Electric Pump Independent Control (EPIC) optimises
Reduced demand in China for machines such as excavators has impacted Volvo CE’s results for Q1 2022
hydraulic pump flow rate and power to match the machine’s working conditions.
Hyundai says the HX A Series excavators benefit from a range of state-of-the-art digital connectivity technologies. This includes the proven standard Hi-MATE remotemanagement system, that delivers high levels of service connectivity and remote diagnostic ability. The Mobile Fleet App has been updated to allow fleet owners easy access to machine operating data, including economical usage, utilisation and fault code recognition.
That Wi-Fi connectivity, using Miracast, allows the operator to use many of the functions of their smartphone, directly through the machine’s 8” infotainment screen. Drivers can operate their phones hands-free, listen to music directly from their smartphone and use a number of internetbased applications through the Miracast system.
Optional Engine Connect Diagnostics (ECD), which is an integrated resource between Cummins and Hyundai, allows technicians and dealers to support customers with diagnostic reports and engine performance data. HCE-DT Air also allows the customer to connect wirelessly through a smartphone or laptop on site.
Hitachi has unveiled the largest model in its new Zaxis-7 wheeled excavator range, the ZX220W-7.
It features the HIOS III hydraulic system which is said to achieve higher levels of productivity with better fuel consumption than previous models, reducing running costs. Operators can also control the fuel efficiency and costs with the all-new ECO gauge, which is clearly visible on the large LCD monitor.
Owners can further boost their profits by working on a wider variety of projects thanks to the excellent versatility of the Zaxis-7 wheeled excavator. It can be used with a broad range of Hitachi attachments, such as tilt rotators and buckets, breakers and sorting grabs, to suit the application.
These are easily changed using the enhanced attachment support system and can be conveniently transported using the optional trailer support package. The new model can also be fine-tuned to suit the operator’s preference and jobsite requirements – for optimum productivity, while reducing fuel consumption.
The redesigned Zaxis-7 cab is designed to be ultra-spacious and comfortable, offering low noise levels and less vibration than the previous generation.
Hitachi says that operators will feel less tired at the end of their shift thanks to the synchronised motion of the seat and console. Easy operation also comes from: the new ergonomic design of the console and switches; convenient access to the controls; and features such as cruise control, automatic transmission and the optional ride control system that suppresses vibrations from the front attachment.
Added functionality to the easy-to-view screen and joysticks, and the auto working brake, has also been incorporated into the cab. The cab also offers a superior view of the jobsite to protect operators and the machine from potential hazards. Visibility is boosted by a 270-degree bird’s-eye view with the Aerial Angle camera system. Operators can choose from six image options on the
monitor to view the immediate environment. Their vision through the cab’s front window is also improved by the slim steering column (with wider adjustment angle) and smaller steering wheel.
Hitachi says that, to enable operators to work more confidently and productively, even in challenging conditions, the Zaxis-7 wheeled excavators are fitted with new features such as LED work lights, a windscreen wiper with an increased sweeping area, and larger mirrors. Heated mirrors are also available as an option. For additional safety, the upper structure and front attachment will lock in place when the machine is in the correct position, for driving on public roads.
A new innovation continuously monitors the quality of engine and hydraulic oil, 24/7. Data is transmitted daily via two oil sensors to Global e-Service. These detect if the oil quality has deteriorated, due to contamination or low viscosity. It reduces maintenance and unscheduled downtime, and gives owners peace of mind thanks to scheduled servicing and a higher resale value.
HCME excavator product manager Wilbert Blom commented on the new ZX220W-7: “It offers outstanding versatility for a wide range of applications when used with Hitachi attachments, and delivers an exceptional performance – allowing our customers to create their vision.”
Swedish manufacturer engcon is adding two new products to its range. The company is introducing a third-generation tiltrotator system for excavators, featuring technology based on a newly developed type of valve in combination with smart software that collaborates with the excavator's loadsensing hydraulic system. This optimises both the tiltrotator's functions and the excavator's movements, which engcon says leads to smoother digging with higher precision. At the same time, the excavator's wear and need for maintenance also decreases.
"To meet increased demands for electrification, digitalisation, security and sustainability, we have developed a solution adapted for the future of digging," says Stig Enöström, founder and owner of engcon and the leader of the company's product development. “Our new tiltrotator system
Volvo CE’s Connected Map solution provides a visualised site overview for all machines
Hyundai’s new HX180A L excavator
shows that engcon is at the forefront of innovative solutions that drive the development forward to reduce dependence on fossil fuels and thus the climate impact of excavators.”
With an app, the third-generation tiltrotator system also enables a higher degree of individual customisation in the form of improved possibilities for, amongst other things, connected remote diagnostics and mobile support.
In addition to the energy-efficient technology, the new series EC-Oil, the automatic quick-hitch system can easily and smoothly connect the tiltrotator and hydraulic gear automatically, without the driver having to leave the cab.
engcon is also launching a newly developed compactor plate for 12-24-tonne excavators, that it says is a further step forward in making the excavator an effective tool carrier. The company adds that the new PC6000 compactor plate has been adapted for use under a tiltrotator, increasing the excavator's efficiency whilst reducing risk of personal injury.
engcon says that combining a compactor plate with an excavator is becoming more common for soil compaction, reducing the number of machines or tools required for the task. Personal safety has also been increased by removing the need to have a person with a hand-operator compactor in a shaft
with the risk of walls collapsing because of vibrations or a chain or strap breaking whilst lifting equipment. engcon says that all of this significantly increases workplace safety and, in addition, the working area becomes larger as it is possible to rotate and angle the compactor plate so that it follows the lines of the ground.
Johan Johansson, engcon designer and project manager for the new compactor plate, says that it has increased the flexibility of the excavators so that the excavator operator can tilt and rotate the compactor plate. “Among other things it’s possible to compress around slopes and wells, without constantly having to change the position of the machine. This means that the excavator can perform more types of work,” he adds.
A production run of the PC6000 compactor plate is planned for autumn 2022.
An L975F wheeled loader from Chinese manufacturer SDLG is showing its efficiency
HCME STRIKES UKRAINE DEAL WITH MHM
Hitachi Construction Machinery (Europe) has appointed Mobile Heavy Machinery Ltd (MHM) – part of the Alwark Group – as its authorised dealer in Ukraine.
Based in the port city of Odessa on the Black Sea in the south of the country, MHM will offer a wide range of Hitachi machinery to the market.
The new Ukrainian Hitachi (HCME) dealer will be authorised to sell medium (from the ZX70LC-5 to ZX400LCH-5), large (ZX470LC-5 to ZX870H-3) and wheeled (ZX170W-5 to the ZX210W-5) excavators, and
medium (ZW180-5 to the ZW310-5) wheeled loaders.
As a consequence of the Russian invasion of Ukraine in February, the construction and related markets changed overnight and this has naturally had a huge impact on MHM’s strategy for the country.
Before the conflict, the construction industry had registered an annual growth of 23.9% in 2019 and 5.2% in 2020, and despite the pandemic this figure was also expected to increase in 2021 and beyond. This was scheduled to be supported by the government’s
in demanding conditions at a gravel quarry in the Oman desert.
High temperatures and dust make the working conditions in the area extremely tough. However, Volvo-owned SDLG says the harsh working environment is the best test ground to verify the performance of its equipment. The loader is mainly used for ore handling, site preparation, civil engineering and aggregate loading at the quarry, and has earned a good reputation for its overall performance, productivity and fuel efficiency.
The owner of the unnamed quarry said: "The SDLG machine works 14-15 hours a day. Its loading efficiency is pretty high. It saves me a lot of time, compared with other brands I used before.”
The owner adds that the L975F’s centralised lubrication system has been impressive, making it very convenient to perform maintenance.
SDLG says the efficiency of the L975F stems from its reliable configurations. It features a Volvo box-type chassis with 5.5m³ bucket capacity as standard, and is powered by a Weichai WP10 engine with a maximum traction force that reaches 229kN.
The loader has a HT200 heavy-duty automatic transmission, and the lifetime can reach more than 15,000 hours. Its 3550mm wheelbase is claimed to be longer than that of most competitors and makes the machine more stable. AB
investment in the development of transport infrastructure, energy and utilities, and industrial construction projects (due to be completed by 2030) with additional financial assistance from the EU.
MHM’s regional director Ukraine, Raivis Veckagans, says: “It is of course currently difficult to make any forecast on the future of the market, but we remain as optimistic as possible despite the war. There has been incredible damage to Ukraine’s infrastructure and one day there will be a huge requirement to rebuild it with the
supply and support of Hitachi construction machinery.”
Furthermore, MHM says it will embrace HCME’s value chain strategy to become the country’s first-choice solutions provider and help to build a better future. This will be achieved by providing the Ukrainian market with access to the Hitachi Premium Rental and Premium Used programmes, as well as remanufactured parts and the wide range of connective technologies available under the ConSite and Solutions Linkage banner.
engcon is introducing a third-generation tiltrotator system for excavators
An SDLG L975F wheeled loader is excelling at a gravel quarry in the Oman desert
The quarrying-suited engine evolution
Cutting-edge engines and linked technology well suited to powering aggregates production plant offer big financial and ecological returns for quarrying businesses globally. Guy Woodford reports
Cummins has been at the cutting edge of developing power solutions for over a hundred years and is continuing this leadership by developing a diverse range of sustainable drivetrains – from clean diesel to natural gas to battery and hydrogen power solutions. At the start of 2022, Cummins announced the expansion of its industryleading power portfolio with the launch of fuel-agnostic internal combustion powertrain solutions.
This is an industry first. These are the first engine platforms to be intentionally designed with commonality in mind for both the engine footprint and components across diesel, natural gas and hydrogen fuels.
This new approach will be applied across Cummins’ B, L, and X-Series engine portfolios, initially in on-road applications but with off-highway use coming soon.
For Cummins, this fuel-agnostic development, alongside its hydrogen fuel production activity, is crucial to achieving the company’s Destination Zero by 2050 commitments. This Cummins pledge will reduce emissions in duty cycles across markets via a range of solutions, as there is no one solution that will work for all application types or all end users and OEMs (original equipment manufacturers).
Creating a diverse power portfolio that can operate using different fuels, with minimal adjustments to engine architecture, enables greater flexibility to OEMs and therefore encourages the use of lower emission fuels.
The agnostic-fuel powertrain solutions will feature a series of engine versions that are derived from a common internal combustion engine, with up to 80% commonality compared to diesel engine counterparts. Below the head gasket of each engine will be largely similar components, and above these head gaskets will be different components matched for different fuel types. Each version will operate using a different, single fuel.
The fuel-agnostic platforms are designed and built following extensive trial and error research, resulting in Cummins' development
of millions of diesel and natural gas engines that are currently in use. By designing the three new engine platforms with inherent fuel-agnostic capabilities from the outset, Cummins can avoid performance limitations and efficiency compromise, problems that are often associated with converting existing engine designs.
Fuel-agnostic engine platforms offer a unique combination of benefits to OEMs and fleet owners interested in reducing vehicle emissions. The immediate reduction in carbon emissions, economic viability, and reliability are three of the most critical benefits of fuel-agnostic engines.
The choice between reliability and reduced emissions is not a trade-off. Using a fuel-agnostic engine with internal combustion engines offers a balance of reliability and reduced carbon emissions. In addition, technicians’ existing familiarity with the fuel-agnostic platforms strengthens the day-to-day reliability of these engines, as repairs do not have added layers of complexities from unfamiliar technologies.
Enabling internal combustion engines
to become fuel-agnostic brings important advantages for OEMs and fleets:
• Minimal vehicle redesign: Engines within a fuel-agnostic platform have a common product architecture. For OEMs, there is less need to alter vehicle design to accommodate different versions of the same engine family
• Limited manufacturing process changes: The need to re-tool production lines and create manufacturing processes to accommodate engines that are a part of a fuel-agnostic platform is lower than adopting a completely new power technology
• Reduced incremental technician training: Engines within a fuel-agnostic platform look and feel like the products technicians are already familiar with Annually, Cummins spends US$1 billion on research and technology to help its customers decarbonise. This research and development, supported with a string of acquisitions has identified a diverse range of solutions to decarbonise the power sector. A key focus of this recent Cummins activity and
the development of the fuel-agnostic engine platform has been supporting the future of hydrogen in the power sector.
There are three key areas when focusing on hydrogen:
• Production of green hydrogen
• Management and transportation of hydrogen
• Application of hydrogen in engines and fuel cells
As a fuel source, hydrogen is lightweight, easy to store, and capable of providing high energy per unit mass, with no CO2 emissions at the point of use. For hydrogen to be truly emission free, the production of the fuel needs to be “green” i.e., without direct emissions of air pollutants or greenhouse gases. Without hydrogen being green, it cannot be a meaningful part of the solution as we move toward carbon neutrality.
Green hydrogen is produced using electrolysis to turn sustainable power sources (wind, solar, hydro) into hydrogen with zero carbon dioxide emissions.
Companies like Cummins are investing in research to advance electrolyser technology so green hydrogen can be made in a more cost-effective manner, with reduced environmental impact. An example of this can be seen in the partnership between Cummins and Air Liquide to construct the world’s largest proton exchange membrane electrolyser, which is producing up to 8.2 tons per day of low-carbon hydrogen in Québec, Canada.
The use of hydrogen engines will be gradual over the next 10 to 20 years, as it becomes operationally and economically viable for OEMs and operators to transition power solutions. However, current generation diesel technology and other alternative fuel technologies can support this journey.
As a company committed to meeting the world’s sustainability challenges, Cummins continues to deliver a broad portfolio of power solutions that can support OEMs and customers transition to zero-carbon solutions. The firm is at the forefront of driving innovation in the areas of advanced fuel cells, alternative fuels and advanced energy solutions. Cummins continues to develop integrated engine system technologies and controls and is working with partners to integrate its products and services in the autonomous vehicles of the future.
Volvo Penta’s extensive quarryingsuited industrial engines’ portfolio ranges from five-to 16-litre solutions. Speaking to Aggregates Business, Riccardo Sardelli, the company’s industrial sales manager for UK & Ireland, says business is “extraordinarily busy” as the market continues to recover from prolonged COVID-19-induced disruption.
“There is big demand not just in Europe but globally,” he notes. “We are seeing particularly strong interest in our five- and eight-litre engines, and the generator
[engine] side of the industrial engines business is up 22-25% on last year. Demand is driven by emissions compliance - moving away from Stage IIIA engines to Stage V solutions is an 83% reduction in NOx [nitrogen oxides], [diesel] particulate and carbon.”
Sardelli says the biggest challenges faced by Volvo Penta and other off-highway machine engine manufacturers are the lack of semiconductor availability and shortages of raw material, such as copper. “A lot of raw material is processed in Russia, and [given the Russia-Ukraine crisis] new supply lines involving different countries are taking time to set up. A lot of shipping containers were also mothballed during the coronavirus pandemic and are in the process of being set back up.”
Commenting on key global regional market differences, Sardelli says smaller eight- and 11-litre engine-powered crushers tend to be preferred in the US quarrying market, with many European customers favouring larger crushers powered by 13- and 16-litre engines. Sardelli explains that these larger engines offer “significantly longer” life cycles.
He adds: “All our engines offer a highpower density for their cubic capacity. The 5-litre unit, for example, is a real torque animal. You don’t need to run it at a higher speed and are in the optimum area for lower fuel consumption.
“We have a dedicated industrial servicing network, so quarry customers are calling out top-tier Grade 3 and 4 technicians that
Volvo Penta’s Stage V 8-litre engine
know all about Volvo Penta products and how to diagnose them. That’s important with maintaining machine uptime.”
Sardelli highlights that Volvo Penta is part of the Volvo Group’s engine remanufacturing scheme where customer engines, along with transmissions and axles, can be rebuilt at a dedicated facility in Limoges, France. “A lot of regeneration work is carried out from reman injectors to carbon recovery from DPFs (diesel particulate filters) at the facility, with a lot of carbon recovered from the DPFs and sold back to the plastics industry for processing all kinds of polymers for use by the household appliance and automotive industries.”
Sardelli forecasts more hybridisation in quarrying machine engines, with a combustion engine combined with an electrical system. Furthermore, greater demand for energy-storage systems will allow for fully electric quarry machine operation. “You must be careful with crushing and screening applications as there can be huge plant vibrations, so electric components need to have great resilience. Large battery packs do not like shaking.”
Sardelli says Volvo Penta is working “very diligently” on its net-zero programme. “We are heavily focused on developing renewable technologies for the northern hemisphere, and we cannot ignore demands for the southern hemisphere with lower emission products.”
He notes the continued success of the Electric Quarry project involving Volvo Construction Equipment and Skanska that began five years ago. “Around 17 large, mostly 18-litre diesel engine-powered, rigid dump trucks, and other diesel enginepowered machines were replaced by fully
electric or hybrid-powered units powered by two generators. The wheeled loader, for example, was hybrid-powered with a small five-litre engine, and the crushers were electrically driven. The site also ran completely autonomous dump trucks, like skips on wheels. Environmentally, the carbon reduction was huge.”
Sardelli stresses how much he enjoys working as part of a “small, dynamic team” based in the UK. “We have Wendi Goodman looking after generators; Nick Styles working on variable speed; and Sam Thirlaway is our application engineer. We feed into our Service Market Team headed by Tim Barclay, who is supported by Chris Slevin, David Sherry and Jonathan Taylor. This group is very knowledgeable on hybridisation, electrical systems, and hydrogen-powered engines.”
Remaining with Volvo Penta, Morgan Blomgren, director Strategy & Business Development, and Prabhakaran Sundaramurthi, vice president - Product Management Industrial, have spoken to Aggregates Business in more detail about the company’s quarrying-suited industrial engine research and development work.
“In the short-term, the focus is still very much on diesel-powered engines. In this part of the business, we see continued strong demand for diesel engines, and we will continue our development in diesel moving forward, at least past a Stage VI regulation. However, we also see a rising interest in alternative fuels. Besides our engines being able to run on HVO and biodiesel already today, we are also looking into using both CNG, biogas and hydrogen as energy carriers for internal combustion engines.”
Asked about the challenges posed in
KOHLER TO USE HVO IN ALL EUROPE DIESEL ENGINES
Kohler Engines has approved the use of EN15940-compliant hydrotreated vegetable oils (HVOs) for all its diesel engines in Europe.
The manufacturer says the use of HVOs, either pure or as a blend with conventional diesel, is part of its commitment to lessen the environmental impact of its engines. The approval came after intensive laboratory and on-the-field testing by Kohler’s engineering team.
The group says its diesel engines do not require any kind of modification or specific upgrade to use HVO. However, use of exhaust gas after-treatment systems will still be necessary where already required.
HVO is a renewable paraffinic fuel, also known under the names 'synthetic diesel' and 'renewable diesel'. It is produced with plant or animal oils derived from the residues of the meat and fish industries.
Since it is obtained from organic material, HVO – unlike biodiesel – does not use agricultural resources or contribute to deforestation. It can be used wherever diesel fuel is used today.
Kohler says a reduction in overall CO2 emissions of up to 90% can be obtained depending on the raw material employed in HVO production. It adds that, compared to most conventional diesel fuels, HVO has an exceptionally low sulphur content and its use leads to lower vehicle exhaust emissions.
Synthetic diesel is widely available in service stations across northern Europe and Kohler says it is taking hold as the next-generation fuel. It is 100% fossil-fuel free and 100% recycled. HVO fuel can be distributed, handled, and stored just like any conventional fuel.
ensuring sustainability when engineering new off-highway engine solutions, the pair say: “Of course, new technologies always bring some challenges when it comes to engineering. But what we are seeing now is also a challenge in keeping on top of the different regulations when it comes to batteries and new types of fuel. A lot is happening across the globe when it comes to this and it’s extremely important to make sure that the solutions we put on the market are compliant with the various regulations. On the engineering side, we would say that some of the main challenges are to generate enough power to replace one of our bigger diesel engines today and still limit the size and weight of the solution, and also to reach a similar or better total cost of ownership.”
So, when can quarrying customers expect to see new Volvo Penta engines for
FRONT RIGHT TO LEFT: Sam Thirlaway, application engineer; Tim Barclay, head of service market industrial UK and Ireland; Riccardo Sardelli, head of industrial sales UK and Ireland; David Sherry, technical support engineer; and Nick Styles, OEM account manager VE BACK ROW RIGHT TO LEFT: Wendi Goodman, OEM account manager GE; Jonathan Taylor, business development manager; Chris Slevin, service engineer
their machines? “The second part of this decade is when the market can expect new solutions from Volvo Penta in this specific part of the business. We have already started our journey towards zero emissions within the battery-electric area. But we are, in parallel, looking at a wide range of solutions to support our full range of customers. This includes internal combustion engines powered by alternative fuel and hybridisation. These are most likely the transitioning solutions before reaching zero-emission solutions for this segment of the business.”
Commenting on how new quarryingsuited Volvo Penta industrial engines will stand out in a highly competitive marketplace, Blomgren and Sundaramurthi say the company always aims to give customers a solution they can rely on to perform. “To strengthen this even further we will soon provide several different services that maximise uptime and support efficient usage of the engine. This reduces fuel consumption even further.
“We have a solid foundation to stand on with our current diesel offering and together with the rest of the Volvo Group we are sure that we will continue to have strong customer testimonials moving into offerings beyond diesel as well.”
Asked about the feasibility of many future quarry sites being entirely powered by electric, hydrogen and other non-dieselpowered crushers, screeners, loaders and
haulers, Blomgren and Sundaramurthi add: “With a combination of the different alternatives mentioned it is quite feasible to see production sites like this in the future, but it will take a combination to achieve it. Electrification has its limits and so have other solutions but bringing them together in a site like this can offer a viable solution with less or even zero emissions.
“The big question is when it will be realistic to reach zero emissions. And that is most likely the million-dollar question here. One of the keys to making it happen is of course the availability of alternative fuels, like hydrogen, HVO, and biogas. This in combination with the electricity supply is what will determine the speed of transformation in the industry. There are ambitious plans for this across Europe and in other areas of the globe, but we are looking at the 2030 timeframe to reach sufficient levels of supply. Reaching a high enough supply is also a key to reaching a price level for the fuel that makes it a realistic option in a fuel-consuming business like this [quarrying].”
John Deere Power Systems (Deere) is constantly innovating ways to meet both market and customer demands to deliver new levels of reliability, durability, flexibility, and serviceability. The result is a comprehensive engine lineup for a wide array of heavy-duty applications. The newest addition to the next-generation Deere
industrial engines is the 18-litre JD18 engine. Featuring uptime-focused controls that offer improved diagnostic capabilities, users are able to quickly target the source of a performance issue and get back to work. The JD18 features a bedplate design, providing structural benefits for extreme durability, with the ability to be re-built two times. The engine also has Hydraulic Lash Adjustment (HLAs), which offers a maintenance-free valvetrain, eliminating the need to reset the lash.
New combustion technology means John Deere can offer an engine in the 522 – 676kW power range without aftertreatment, so users have one less fluid to manage. The highpressure common-rail fuel system in the JD18 allows the engine to deliver optimised fluid consumption. Plus, the DiamondLike Coating (DLC) improves bio-diesel compatibility and system robustness.
With the addition of the JD18, users can put John Deere power and performance into their entire line-up of equipment from 36kW to 676kW. OEMs are encouraged to contact their local John Deere engine distributor or dealer for more information on the JD18.
Building on its experience in integrating smart and sustainable technology innovations into powertrain systems, Deere has made strategic investments in two companies that are leveraging unique technologies for alternative fuel and electrification solutions.
In late 2021, Deere made an equity investment in ClearFlame Engine Technologies, a growing start-up dedicated to the development of clean engine technology. ClearFlame’s solution enables low-carbon fuels like ethanol to be easily integrated into compression ignition engines, offering a more sustainable solution without compromising engine performance.
In early 2022, Deere also acquired majority ownership in Kreisel Electric, Inc. (Kreisel), a battery-technology provider based in Rainbach im Mühlkreis, Austria. Kreisel develops high-density, highdurability electric-battery modules and packs. Additionally, Kreisel has developed a charging-infrastructure platform (CHIMERO) that utilises this patented battery technology.
This investment in Kreisel provides optimal integration for Deere to efficiently design vehicles and powertrains around superior immersion-cooled, high-density battery technology. Kreisel’s in-market experience combined with the global footprint of Deere is a powerful combination that will leave both companies better equipped to meet the growing demand for electrification.
Deere intends to continue to invest in and develop technologies to innovate, deliver value to customers, and work towards a future with zero-emissions propulsion systems.
Deere’s UK distributor, EP BARRUS, is due to showcase the company’s current Stage V engine range on stand G15 at Hillhead 2022 (21-23 June) near Buxton, England. AB
John Deere Power Systems’ JD18 engine
Crushing it in recycling
Companies are stepping up their recycling and sustainability efforts across a range of sectors including crushing & screening and off-road tyre retreading. Liam McLoughlin reports
German building materials recycling group Erdtrans has invested in a Kleemann MOBICONE MCO 90i EVO2 mobile cone crusher to enable cost-effective recycling and the production of high-quality ballast chips and high-grade flint.
Since summer 2021, the first plant of this type to be deployed worldwide has been recycling mainly railway ballast. Downstream of the cone crusher is a MOBISCREEN MS 953 EVO screening plant.
The MOBICONE MCO 90i EVO2 features the Kleemann continuous feed system (CFS) which uses ultrasonic probes to monitor the crusher level and other parameters. This optimises the utilisation of the crusher.
To guarantee fast and safe train travel, the ballast bed under railway tracks has to be regularly repaired. High demands are placed on the material because, in a high-quality ballast bed, the stones dig into one another with their sharp edges to form a stable base. Furthermore, only suitable material gives the track system the required elasticity and ensures the unrestricted downward flow of rainwater.
German Railways (DB) uses licences for the railway ballast suppliers to ensure that the material used meets the requirements.
Erdtrans, which has offices in Zossen and
Trebbin near Berlin, has had corresponding DB product qualification for years because "we recycle or process everything that's under the rails," explains company MD Michael Schwarzer.
Schwarzer adds that he is highly satisfied with the new Kleemann plant after its first six months in operation. Now he worries even more than before the purchase that "not enough recycling materials are used in ballast beds. The use of new material simply no longer meets contemporary standards. The
new crusher shows clearly that we can easily use modern machine technology to produce railway ballast and other high-quality products from recycling material."
Northern Ireland-based compact crushing and screening brand EvoQuip has launched the ‘Think Green, Think EvoQuip’ campaign to illustrate its commitment to developing increasingly sustainable equipment as part of global sustainability efforts.
Barry O'Hare, business line director for EvoQuip, says that sustainability is a strategic
EvoQuip says the ‘Think Green, Think EvoQuip’ campaign shows its commitment to developing sustainable equipment
priority for the company and consistently at the top of its agenda. “We see it as our responsibility to do what we can to be as sustainable a company as possible and to help to build a world that puts sustainability at the forefront of everything we do," O’Hare adds.
Terex-owned EvoQuip has also posted a sustainability responsibility statement on its website stating four key commitments.
These are: production of sustainable equipment that is as kind to the environment as possible whilst still being effective and eco-friendly in its use. This is both in the design stage of the products and in the physical processing of material; the use of sustainable materials where possible in the production of all equipment, parts, and packaging to help to ensure the products are sustainable from design to the finished product to operation; offering the best solution to customers to ensure their operation is as efficient and environmentally friendly as possible. They promise to comply with all legislation and health and safety requirements.
Recycling is an important industry for EvoQuip, with over 40% of equipment out in the field working in a recycling application. It is possible to process many types of waste, which can then be reused as product on site or sold. The entire EvoQuip range provides the ideal solution for generating profit from
to landfill will also help EvoQuip live up to the name of its campaign.
The campaign's economic contribution comes from reducing machine running costs, turning waste into profit and having a more measured approach to research and development. EvoQuip is also ensuring its training to operators is constantly and consistently updated to ensure that operators know the most economical way to operate
and service the machines.
Off-road tyre retread specialist Marangoni has won four categories at the Recircle Awards. The Italian company says this is a record for the awards event, which is dedicated to the circular economy in the tyre retreading and recycling sectors.
Marangoni has won four categories at the Recircle Awards, one through its TRM subsidiary
Marangoni made it to the highest podium in the Best Tread Rubber Supplier, Circular Economy Award, Best Tyre Retreader (for the second consecutive year), and Best Retreading Equipment Supplier (through its TRM subsidiary) categories.
Marangoni COO Matthias Leppert commented on the success: "We are extremely honoured by the recognition given to Marangoni: not by the excellent result itself, but rather by our customers, who with their votes have expressed their trust in the quality of our products and services.
"The categories in which our customers placed us on the podium, confirm how Marangoni supports in the finest way the retreader partners with a 360 degrees offering, ranging from machinery to retreading materials, and the fleets – especially in Italy –thanks to the retreaded tyre.”
Leppert concluded: “This result was achieved thanks to the extraordinary participation of our customers, partners and collaborators, which is an encouragement to renew Marangoni's commitment to further consolidate its leadership in the sector."
The Recircle Awards’ winners were announced at the ceremony broadcast online on 25 April. The trophies were delivered during The Tire (in Cologne, Germany, on 24 May) and Autopromotec (in Bologna, Italy, on 26 May) industry events. AB
Erdtrans is using a Kleemann cone crusher to recycle railway ballast
Nordic Bulk is taking care of the servicing and after-sales of a CDE waste recycling plant at Norwegian crushed stone, asphalt and concrete producer Velde
Enhancing after-sales service
Northern Ireland-based wet processing company CDE has joined forces with Norwegian firm Nordic Bulk to maximise customers’ productivity and minimise waste.
Nordic Bulk is a supplier of bulk material processing plants operating in the mining and aggregates industry in Nordic countries with 30 years of operational experience. It designs and delivers turnkey projects utilising advanced technology. The company supports its customers with a full warehouse of all needed parts and a service department with dedicated staff.
CDE and Nordic Bulk have worked together before on a number of projects in Iceland and Norway, resulting in a drive to enhance the after-sales care offered to new and potential customers across the Nordic region.
With the increased demand across Scandinavia, CDE says it recognises the requirement for more engineers on the ground and local holding of spare parts, to ensure a more timely delivery and reliable after-sales service. Having already established a good working relationship, CDE adds that it is confident in Nordic Bulk’s ability to deliver a high standard of aftercare on their behalf and thus the partnership was formed.
CDE’s CustomCare team supports customers in achieving and maintaining optimum efficiency in the running of their
plants and working collaboratively with customers to ensure maximum plant efficiency and uptime. CDE has worked alongside Nordic Bulk providing extensive and ongoing training to immerse them in CDE’s method of service and help the team gain a deeper understanding of the products, ensuring consistent aftercare for customers in Nordic markets.
Customers in Nordic markets can now expect a faster service turnaround and quicker delivery of plant equipment, as and when required. Part of this partnership sees Nordic Bulk taking care of servicing and after-sales of CDE’s largest waste recycling plant for Velde in Norway, operating at up to 300tph. CDE has integrated a new 220tph natural processing plant for Velde, which integrates feeding, screening, sand and aggregate washing and stockpiling on a single chassis and allows Velde to extract more fraction from its feed and produce a high-quality saleable aggregate. Nordic Bulk’s expertise and after-sales care will ensure the plant continues to work efficiently to ensure maximum profitability.
Martin Jackson, head of CustomCare at CDE, says the partnership will improve the service for Nordic customers.
“The collaboration with Nordic Bulk will not only benefit existing customers, but it will give reassurance to potential customers in the Nordic markets that we are dedicated to delivering first-class after-sales service in a timely manner,” Jackson adds.
Aggregates equipment manufacturers are putting more engineers on the ground to improve their after-sales service, and stressing the importance of using original OEM wear parts to ensure optimum performance. Liam McLoughlin reports
Eunan Kelly, CDE head of business development for North West Europe, says: “For us, this partnership was a no brainer. We’ve been working on projects with Nordic Bulk over the years and really admire how dedicated they have been to our customers and equally in their own rights. Over the years we have built a lot of trust with Nordic Bulk, and this partnership was a natural progression in our relationship.
“We recently hosted an event at Nordic Bulk’s headquarters to explain our new venture to our customers, which was followed by a tour at one of our flagship project sites, Velde, to showcase the positive outcomes of our working relationship.”
Nordic Bulk’s CEO Peder Egeland says that CDE is a key partner for his company to exceed its customers’ expectations delivering advanced and effective washing processing plants.
“Together we maximise customers’ resource yield and minimise waste,” Egeland adds. “CDE have provided us with comprehensive and detailed training into their products and also their delivery of service so that we can provide customers with top quality after-sales service. We have seen the support that CDE provide to their customers and their dedication in producing quality material, making it a straightforward decision to partner with them, and we are excited to work together to enhance the after-sales service.”
As well as the CustomCare partnership, CDE and Nordic Bulk state that they will continue to deliver projects across Nordic markets, which will include the installation of a new major waste recycling plant in Norway.
Weir Minerals has highlighted how buying original equipment manufacturer spare parts improves the performance of its Warman range of slurry pumps.
Simon Jones, pumps product manager at Weir Minerals Europe, comments: “When you buy genuine spares for Warman slurry pumps, you get so much more than just a volute liner, impeller or side liner. You’re
making an investment in a product that will receive expert lifetime support, achieve higher pump performance, last longer and reduce your process’ risk profile.”
He adds that Warman slurry pumps are designed to operate under demanding conditions that place every component in the pump under a significant amount of stress.
“Ensuring components meet such a challenge is an enormous task, requiring the highest quality construction materials, lengthy and precise design processes, stringent quality control in manufacturing and extensive safety testing,” Jones says.
A LONG WAY TOGETHER
Jones adds that replicators cut corners in design, manufacturing and transport, use inferior wear-resistant materials and do not supply safe lifting methods, which introduces significant risk to pump operations.
“Even tiny gaps between imperfectly replicated components can lead to leakage, vibration or excessive stress concentration which causes dangerous and unpredictable cracks in components - a problem that OEM parts don't have thanks to our strict quality control,” he says.
Jones says that failure of critical components can lead to high-pressure slurry spray, which is often toxic, corrosive or heated to very high temperatures. It can also cause high-energy brittle fracture projectiles which can travel dozens of metres. The risk of hitting other equipment or personnel is high in such situations.
He adds that a major advantage of buying genuine Warman spare parts is that the purchaser receives Weir Minerals’ cuttingedge wear-resistant materials.
“The products of our unique, advanced materials technology group are vital to achieving the legendary wear life of Warman pumps in harsh, abrasive and corrosive mining conditions,” says Jones. “For most situations, nothing compares with Ultrachrome A05, our near eutectic highchromium white-iron alloy that provides a great balance of hardness and toughness, without sacrificing corrosion resistance.”
CDE and Nordic Bulk staff visit Velde’s CDE recycling plant
He says that Weir Minerals does not rely on one alloy for every situation, and that its ever-expanding range of Ultrachrome and Hyperchrome chromium carbide alloys allow the company’s engineers to specify the optimum wear solution to fit the needs of the application.
According to Jones, the inferior alloys found in replicated Warman pumps are not only prone to failure, their lower, unpredictable lifespans also make it extremely challenging to efficiently align the pump’s maintenance needs to overall campaigns.
He adds that the complex manufacturing processes involved in producing its OEM parts are difficult to reverse engineer and are different for every size and component.
“Our cast alloy components require specific heat treatment, together with a variety of proprietary moulding, methoding and pouring techniques to achieve a high-quality casting with all the required mechanical properties,” he states.
Jones says that parts supplied by replicators either: produce a structurally inferior and possibly defective product, prone to cracking in the high-pressure environment of a Warman slurry pump; or modify the geometry component to suit their manufacturing process, which won’t achieve the fit required due to their poor tolerancing.
“Without the appropriate tolerances, replicated spares can fail to perform in any number of ways, ranging from high localised wear caused by gaps between liners, excessive vibration during operation, and fitment interference leading to an inability to thread the impeller or close the pump without cracking the volute liner,” he adds.
Aside from the rapid wear these issues
cause, any geometrical divergences from the OEM design will naturally interrupt the intended hydraulic performance of the pump, reducing throughput, total head and efficiency.
Aggregates and mining equipment does not last forever under the tremendous strain it is subjected to, and Jones says this is why the support that operators receive from their supplier is almost as important as the part itself.
“Genuine spare parts for Warman slurry pumps are backed up by our unique global support network, which includes dedicated service centres within 200km of almost all of the world’s major mining regions,” adds Jones. “That means Weir Minerals engineers, with decades of experience complemented by our unique skills working with mines across the world, are there to support you every step of the way, from installation to replacement or even decommissioning and disposal.”
Off-highway hydraulic component
manufacturer Danfoss Power Solutions has restarted its business activities in Ukraine. The Denmark-based multinational halted trading in the country after its war with Russia began, following the latter's invasion.
Danfoss's resumed business in Ukraine will focus on restoring critical infrastructure in damaged cities and towns.
Adam Jedrzejczak, president of Danfoss East Europe region, said: "It is key for us to continue supporting our customers in Ukraine. It is not only the right thing to do, but our products are also key components for the critical infrastructure which needs to be rebuilt. Thanks to Danfoss's products, residents in some of the most badly damaged areas of Ukraine will again have access to heating and hot domestic water."
Most Ukrainian employees decided to stay in Ukraine, but families were evacuated in February by the Danfoss crisis team. As safety levels in most parts of Ukraine are improving, employees are starting to move back. Currently, 40 Ukrainians – including eight Danfoss employees – are in Poland. Other colleagues and family members have been safely moved elsewhere. Currently, there are 16 Ukrainians in Germany, six in Denmark, four in Spain, three in Slovakia and two in Austria. All evacuated employees and their families are relatively well, and Danfoss continues to be in close contact with all families, both the evacuated families and those remaining in Ukraine.
Danfoss, a manufacturer whose varied industries' product portfolio includes hydraulic components for off-highway machinery such as excavators and bulldozers, says Ukraine remains an important Eastern European market for the firm.
According to The Kyiv School of Economics, the cost of direct damage to Ukraine's infrastructure has already reached the level of US$63bn. Therefore, solutions such as those provided by Danfoss are critical as they positively impact the rebuilding of district energy infrastructure, commercial and residential buildings, and water and wastewater treatment utilities.
A company spokesperson said the safety and security of the Danfoss team remain its key priority. Despite uncertainties, it has been key for Danfoss to resume business activities in the country as quickly as possible. For now, Ukrainian customers can pick up their products at a so-called crossdocking warehouse that the company has established in Lviv.
General manager in Danfoss Ukraine Andriy Berestyan, working out of Lviv, said: "Our team in Ukraine is eager to come back to their work. They want to play their part in rebuilding their home country. They are extremely motivated, and Danfoss's products are important to help rebuild our country's infrastructure." AB
Weir says buying original OEM wear parts improves equipment performance
IQSA conference reconnects the southern African quarrying industry
The Institute of Quarrying Southern Africa successfully held its annual conference in March this year following a two-year COVID-19-influenced hiatus. Held under the ‘IQSA Reconnect’ theme, the conference highlighted training and technology as areas of immediate attention. Munesu Shoko attended the event
In the past two years, the COVID-19 pandemic has undoubtedly decimated the conferences and exhibitions space, and the Institute of Quarrying Southern Africa (IQSA) conference, a staple on the quarrying industry’s annual calendar in southern Africa, was not spared. This year’s event – held on March 16–17 at the Kopanong Hotel & Conference Centre in Gauteng, South Africa, – was a platform for reconnection after the industry last congregated in 2019.
of championing skills development for our members,” says Hunter-Smith. “The programme will allow young professionals to gain CPD points along their journey to their required professional field within the industry. It is designed for all learning styles and members can learn at their own pace. Available courses include health and safety, blasting, geology, sustainability, environmental, processing, extraction and
to connect all the quarry processes and integrate their management in real time, to improve and optimise their operating regime. DIGIECOQUARRY’s ambition is to tap the full potential of ‘digital quarries’ through a significant breakthrough in process digitalisation and automation capabilities for the aggregates sector.
Through their exhibits, Loadtech Group, a specialist in load-weighing systems, and
The conference kicked off with Jeremy Hunter-Smith, CEO of KwaZulu-Natal based Blurock Quarries, officially taking the reins as the IQSA chairperson. Taking over from PPC’s Lazarus Meko, Hunter-Smith will be at the helm for the next two years.
Speaking during his inauguration, HunterSmith called on the quarrying industry to focus on skills development to respond to an ever-changing business and operational environment. To this end, IQSA used this year’s event to launch the IQ Academy Select. The online courses provide a fl and innovative approach to continuous professional development (CPD). The programme offers access to the latest bitesize eLearning modules and structured content, all of which can be undertaken based on each business’s needs.
According to Hunter-Smith, the Institute of Quarrying (IQ) has been supporting industry employers since 1949, developing high-quality training and raising standards to meet the needs of an ever-changing industry. The IQ’s training and qualifications are recognised globally with flexible learning formats available to meet the needs of both individuals and quarry operators.
“The IQ Academy Select is our way
“The IQ Academy Select is our way of championing skills development for our members”
Jeremy Hunter-Smith, IQSA chairperson
Electronic detonation technology has become more popular in the quarrying sector
“It is essential to adopt efficient and accurate on-board weighing solutions”
weighing intelligence and solid-state sensors for more accurate, precise and faster loading, says Webster. It also connects machines and devices for the collection and syncing of data via the built-in WiFi to the InsightHQ reporting portal. When using Trimble’s cloudbased InsightHQ quarry reporting portal, personnel can gain access to site production and operator performance KPIs on desktop or mobile devices.
“Fixed and mobile equipment are a major investment and efficient use of these assets is key to maximising profits. Given that the precise determination of the weight of products being carried at quarries is a crucial parameter in the daily functions of operations, it is essential to adopt efficient and accurate on-board weighing solutions,” says Webster.
BME sensed a positive tone at this year’s IQSA conference, and Tinus Brits, BME’s global product manager – AXXIS, says this is a clear indication that the region’s economy is recovering.
He notes that the presentations at the IQSA event provided an encouraging picture of emerging economic opportunities –especially in road construction, which relies on quarries for aggregates and other building materials. As plans are implemented to repair the South African national infrastructure and roll out new projects, contractors are expected to become much busier this year.
To provide context, the South African Roads Agency Limited (SANRAL) reiterated its commitment to roll out a total of 1,218
has become more popular in the quarrying sector, says Brits.
He sees more quarry managers moving towards newer blasting technology, for a couple of key reasons. As quarries age, areas to be blasted can become more challenging, requiring that blasting techniques and equipment become more accurate, flexible and controlled. There is also a cost factor related to energy consumption, where rising electricity prices are incentivising energy efficiency.
“Quarries want their primary blasted rock to be optimally fragmented, so that their crushers operate as productively and efficiently as possible,” says Brits. “A presentation at the IQSA conference estimated that the added cost of secondary blasting or breaking of large boulders could reach four times the cost of the initial blast.”
This is where electronic detonators – and the suite of digital tools that accompany this technology – allow quarries to achieve a higher quality of blasts, with better results. Conference visitors showed considerable interest in AXXIS Silver, he says, which is a slimmed-down version of BME’s flagship initiation system, AXXIS Titanium.
According to Bennie van Nieuwenhuizen, BME’s AXXIS quality manager, the company has already seen a massive interest in its AXXIS Silver system following its launch late last year.
“Our existing customers operating our AXXIS GII system are enthusiastic about moving up to AXXIS Silver – and we also
received considerable interest from potential customers who would like to see the new system demonstrated and tested on their sites,” says Van Nieuwenhuizen. “For those quarries still using non-electric detonation methods, the step to take them to AXXIS Silver is easily manageable.”
Van Nieuwenhuizen says there has been a steady annual conversion rate of quarries from non-electric to electronic detonators of about 12–14. Within the next five years, he says, it is likely that most quarries will have moved over to electronic detonation.
AXXIS Silver retains all the stringent safety features that have made AXXIS Titanium so popular, including an application-specific integrated circuit (ASIC) chip in the BME detonators. Among the added benefits of the ASIC is more internal safety gates against stray current and lightning – which enhances safety levels and allows for inherently safe logging and testing.
“The new system speeds up the blasting process, as the logging, testing and programming is done with one unit and requires only one visit to the blast hole,” he
The AXXIS Silver initiation system integrates with BME’s Blast Alliance suite of digital tools, including its BLASTMAP blast planning software, XPLOLOG data logger and online dashboard, and the Blasting Guide App for Android devices. This allows customised solutions that can be implemented with speed, accuracy and safety.
“There are also specific advantages for quarries that we have built into AXXIS Silver, such as the thinner wire which we’ve developed to suit small-diameter waterlogged blastholes. This results in a perfectly straight wire down the hole, so you know exactly where the booster is – without compromising on the line strength,” concludes Van Nieuwenhuizen. AB
“Quarries want their primary blasted rock to be optimally fragmented, so that their crushers operate as productively and efficiently as possible”
Tinus Brits, BME’s global product manager – AXXIS
Glen Webster, Sales director at Loadtech
Uganda’s sand-seeking challenges
Demand for sand is growing in Uganda amid a building boom in the East African country, but extraction and regulation challenges abound. Shem Oirere reports
In recent years, increased Ugandan government spending on roads, dams, bridges, and housing has boosted the country’s construction sector, creating a huge appetite for sand and other building materials to support infrastructure development. The growing number of major Ugandan public infrastructure projects either underway or approved for development include the Standard Gauge Railway, the oil pipeline from Hoima to Tanga, the expansion of Entebbe Airport, and energy projects such as the Isimba and Karuma hydropower facilities. Ugandan government spending on infrastructure increased by more than 120% between 2017 and 2020, with the administration allocating US$812mn, US$1.3bn, and US$1.8bn, respectively, to the works and transport sector between 2017 and 2019.
A recent Ugandan construction market report distributed by CISION PR Newswire said the average “input costs for the whole construction sector diminished by 2.85% for the year ending August 2020 compared to the 3.12% decrease recorded for July 2020 on account of COVID-19 restrictions and lockdowns.”
Although the budgetary allocation was reduced by 12% to US$1.6bn during 2020/21 on the back of the COVID-19 outbreak, Uganda has reaffirmed its determination to invest even more in a new and ambitious
sand-consuming US$5.3bn urbanisation and housing programme initially slated for completion between 2020 and 2025.
The Sustainable Urbanisation and Housing Programme includes a US$3bn housing component that, according to the Ugandan government, will see an increase in “home ownership through the preparation and development of low-cost and affordable housing projects, slum upgrading, promotion of condominium development and publicprivate partnership in housing development.”
The Ugandan government is providing US$2.9bn, an equivalent of 52% of the total cost, while the private sector, including the country’s development partners, should contribute US$2.7bn or 48% of the programme costs.
Uganda has a housing deficit of over 2,000,000 housing units. However, the sector is seen as having significant backward and forward linkages, such as opportunities in the production of building materials, construction, maintenance and related service industries.
“It is important to note that since housing depends on other sectors such as the building materials industry and accompanying supply chain, transport and other related services, labour-supply skilled, semi-skilled and unskilled we believe that this demand will, in turn, create a need for employment in these industries with a resultant growth in GDP,” says Dorcas Okalany, technical head
of a working group involved in the ambitious programme.
“With an estimated 300,000 housing units needed per year, commercial construction and residential construction in Uganda are booming,” says a report on Uganda’s construction industry investment opportunities by the US Department of Trade.
The housing construction boom is expected to grow as COVID-19 lockdowns and restrictions ease and projects are revived, increasing the extraction and consumption of sand.
According to Uganda’s National Environmental Authority (NEMA), there is now in Uganda “high demand for sand to support the construction sector and major infrastructural development projects such as roads, dams and bridges.”
A rebounding economy supports Uganda’s construction sector boom and corresponding sand consumption, with analysts predicting a 3.8% growth in 2022.
In early April 2022, Uganda’s Treasury Permanent Secretary Ramathan Ggoobi said the country’s economic rebound is driven by “continued recovery in production, consumption and employment and implementation of interventions to support households and business recovery.”
According to the Uganda Bureau of Statistics (UBOS), the country consumed an estimated 2,698,400 tonnes of cement in 2019 and another 3,240,000 tonnes in 2020.
Kidepo River in Uganda. Rivers are a popular sand source for miners
Of this consumed cement, 13,600 tonnes and 13,800 tonnes were imported in 2019 and 2020, respectively. With no latest official sand production and consumption data in Uganda, one can derive usage estimates from the volumes of cement consumed in the local market using the ‘old thumb rule’ of one cement, two sand, and three gravel. This assumption means sand consumption for 2019 and 2020 may have reached 5,238,070 tonnes and 6,289,994 tonnes, respectively.
Previously, UBOS estimated Uganda’s sand production for 2015/2016 at 3.49 million tonnes, with artisanal and small-scale miners (ASMs) accounting for more than 90% of the production. Medium and large sand miners produced an estimated 349,100 tonnes in 2015/16, according to UBOS.
The trends show a likelihood the consumption could have been higher in 2020 save for the impact of the COVID-19 outbreak when some of the infrastructure project contractors were forced to declare ‘Force Majeure’ due to the COVID-19 pandemic as there was a “general material shortage for most projects which had not stacked enough,” according to Amadenc Tarmac, a construction firm specialising in small and medium road paving projects using asphalt and other modern materials.
The company said although Uganda classified the construction sector as an essential service when the government announced lockdowns in Uganda, the sector was not fully banned but “instead construction companies that had material on-site could continue operating normally as long as they adhere to standing regulations as provided by the ministry of health.”
Uganda relies heavily on its abundant rivers to extract sand compared to a few other sand-producing countries in Africa, such as Kenya, where sand is sourced not only from riverbeds but also from the sea and hilly areas.
Sand extraction in Uganda, which is dominated by ASMs, was for decades informally done using basic tools such as hoes and shovels.
However, sand-mining technology has increasingly gained traction in Uganda, with recent studies showing an evolving industry where the deployment of heavy excavators and dredgers is becoming popular.
“From the year 2013, sand miners have been using sophisticated technology, particularly dredgers that extract massive volumes of sand in a short period of time,” says a recent report by a parliamentary committee on natural resources.
This technology upgrade, the committee found out, was largely driven by “increased demand for sand by the construction industry that has transformed sand mining into a commercial undertaking.”
The report cites the example of the sandrich Lwera wetland, where “sand mining has increased, and the use of advanced technology has been on the rise.”
The use of excavators and dredgers is mostly associated with medium-scale miners,
many of whom own or lease sand mines and can, therefore, carry out basic value addition such as sand selection and screening. Across Uganda, different sand types are priced differently.
While most of the Ugandan sand is used as fine-grained aggregate in the production of concrete, there are also deposits of glassquality silica sand along the shores of, and on the islands within Lake Victoria such as Bukakata, Dimu, Nyimu, Nyabu, Nakimuli, Kome Island, Kabugoga and Entebbe.
“The Lake Victoria Basin is endowed with alluvial deposits that contain sand, a material that is in high demand by the construction industry,” says a September 2021 statement by NEMA.
The deposits of sand, NEMA adds, are deeper on the western side of Lake Victoria, especially around the areas of Lwera and Bukatata.
“The deposits of sand in the basin are deeper in the west, especially around Lwera and Bukatata, and it is therefore not surprising that out of all permitted sandmining projects, over 80% of them are based in the west of the Lake Victoria basin, wholly in Lwera,” NEMA said.
With a negligible in-country glassmanufacturing capacity in Uganda, a large share of the sand extracted from these sites is used for construction purposes, mainly as the finer fraction of aggregate in cement production.
Various studies show the pricing of sand varying from region to region in Uganda,
although the final price is determined by sand’s grade and quality. Sand considered to be of the highest quality, with a silica (SiO2) content of 99.95%, ideal for glass manufacturing, is mostly mined from Kome Islands and exported.
In fact, according to the parliamentary committee report, since sand is not a restricted export in Uganda under the Minerals (Prohibition of Exportation) Act, which only prohibits exportation of copper, an estimated 63,380kgs were exported from the country between 2012 and 2016, earning the exporters UGX 11.5mn (US$3,220), a figure some consider too low and linked to the lack of reliable production data and systematic valuation of Uganda’s total commercial sand output. No recent data was immediately available from URA.
In a further show of disparity in Uganda’s commercial sand market trends, one report by the Pretoria, South Africa-based Institute for Security Studies (ISS) has estimated Uganda’s 2015 sand exports to neighbouring countries at 22 tonnes, worth UGX253mn (US$68,500). The exports dropped to 19 tonnes, worth UGX16mn (US$4,300) the following year.
“The lack of accurate export data shows the difficulty of tracking illicit flows that often take place on the black market,” the ISS report says.
The Institute says there is a “lack of formalisation, investment and adequate government oversight”, hence opening a gateway to illegal transactions in Uganda’s overall mining industry.
Meanwhile, the parliamentary committee report identified Kenya, Canada, France, Tanzania and USA as some of the destinations for Uganda’s sand. Rolax International (U) Ltd exported the highest export volume during the period (15,000kgs) in 2013 to Kenya. The lowest quantity (3kgs) was exported by Tullow Uganda Ltd to Great Britain. None of these exporters was involved in sand mining. The URA could not meet a request for the latest sand export data.
Uganda’s sand mining is done by a mixture of local and foreign firms, with Chinese entities leading the pack of international sand extractors.
However, the number of investors mining sand and their identity are unclear due to the lack of systematic registration of sand businesses and work permits given to foreigners eyeing Uganda’s sand-industry investment opportunities.
Furthermore, concerns have continued to emerge about Chinese nationals and companies easily accessing land titles for sand-rich lands in Uganda, a process considered too complex for the locals.
Despite the haphazard operations of Uganda’s sand industry, NEMA says it is determined to regulate the mining of the natural resource “to ensure sustainable extraction of the resource.”
The authority says only licensed entities that have been subjected to a full Environmental and Social Impact Assessment
A truck unloading sand in Uganda Pic - Lwera Sand Suppliers
Sand processing in Uganda. Pic - Lwera Sand Dealers
(ESIA) process are allowed to extract sand on a commercial scale. The permits to extract the natural resources have specifications on “the maximum permissible depth of the resultant pit, a clearly demarcated area from where the sand will be extracted, and a compulsory requirement to restore the area before moving to another.”
At the basic informal level, the sand is generally extracted and sold collectively by the ASMs under a small team of leaders who then sell the harvested sand. The income is distributed equally among the members.
In cases where individuals own sand extraction sites, the sand is extracted by a group of workers under a team leader or the site owner. Once the sand is sold, the workers are paid per individual production. Many of these small sand-mining sites are also points of sale.
Channels for distribution of the sand include dealers or buyers bringing their own or leased lorries to the sand mines where, in most cases, the sand is normally sold by the truckload. The sand may be used directly by the first-tier buyer or may be taken to an urban point-of-sale centre and sold to other consumers.
Although it is not easy to access comprehensive data on registered sandextracting companies in Uganda, previous records show a mixture of Ugandan and Chinese firms as the dominant players in the industry, with official records listing River Katonga Investments Ltd, Seroma Ltd, Parkson Hongkong Investments Ltd, Zhang Industries Ltd, Lukaya Sand Dealers, Tesco Industries, Capital Estates, Aqua World (U) Ltd, Mango Tree Group Ltd and He Sha Duo Co Ltd.
Currently, Uganda is pushing ahead with enacting a regulatory regime that would streamline the extraction, transportation, and trading in sand and safeguard the country’s wetlands from destruction through unsustainable sand extraction operations.
One of the recommendations of the parliamentary committee is the prioritisation
of the passing of legislation that prescribes how the exploitation of substances such as sand, which are not classified as minerals for commercial purposes, should be done.
Uganda’s constitution does not classify sand as a mineral but has instead left it to parliament to enact appropriate regulations to capture the commercialisation of the natural resource.
Uganda has been attempting to enact laws for regulating the country’s sand market but in a rather slow manner.
For example, it wasn’t until 2003 that parliament passed the Mining Act that classifies Uganda’s sand into two categories of building and industrial mineral. Yet, according to the ISS report, regulating the country’s sand market is hampered by “gaps in Uganda’s laws.”
“The new mining and minerals policy passed in 2018 gives only a basic legal framework [but] it doesn’t define smallscale artisanal sand miners who have often decried unclear licensing and regulating processes that target them rather than largescale operators,” the Institute says.
Although the policy mandates NEMA and respective local governments where the sand mines are located to regulate and enforce sand mining rules, the ISS says sand, being a unique natural resource, “should not be governed only by mining and minerals policy.”
“A holistic policy is needed that regulates the activity and commerce of sand mining, and also protects water and land bodies where extraction takes place,” it adds.
Uganda’s sand industry is facing claims that it is damaging fish breeding grounds, leading to a decline in fish stocks, especially in Lake Victoria. Another challenge for the industry is the higher cost incurred from the need to mine deeper to extract sand from certain lake waters.
Lack of capacity on the part of NEMA, fuelled by inadequate funding, has been blamed for illegal activities within Uganda’s sand industry.
For example, NEMA cannot effectively certify the increasing technology now being deployed to extract sand and, therefore, cannot determine the actual extractable sand volumes.
In addition, NEMA has difficulties obtaining data on the actual sand extracted from sand mines across Uganda due to a lack of appropriate measuring equipment, translating to a shortage of accurate data and valuation of Uganda’s commercial sand production.
Nevertheless, NEMA is the approved state agency for issuing sand extraction permits in Uganda to both local and foreign sand miners that previously used to pay UGX100,000 (US$28) in addition to signing a commitment to restore sand borrowed pits, not to sell the leased wetland, ensure the sand mine is 200 metres from major highways, and only to extract sand that is at least 200 metres from protected zones of water bodies, especially lakes.
But even with these licensing regulations, illegal sand mining persists in Uganda due to a weak enforcement regime.
“Unregulated sand mining has prevailed in these areas in spite of the negative impacts of the activity on the environment such as fragmentation of the landscape resulting in open pits that are habitats for invasive aquatic plants like the water hyacinth and the Kariba weed,” NEMA said in September 2021, referring to the sand-rich areas of Mpigi, Gomba, Butambala and Kasanje in Wakiso district.
“Sand mining is an activity that must be regulated in order to ensure sustainable extraction of the resource,” said NEMA.
The ongoing infrastructure development boom in Uganda is enhancing sand’s premium. However, the uncertainty around regulating this otherwise highly lucrative natural resource is not only fuelling the emergence of illegal sand cartels in this landlocked country but could lead to the devastation of the nation’s environment in the long run. AB
Boats at Lake Victoria. The lake is full of alluvial deposits that contain valuable sand for Ugandan construction works
CDE is now adding a larger thickener to its range in the shape of the A2500
Real-time tyre monitoring from Bridgestone Bridgestone is now offering IntelliTire, its real-time tyremonitoring solution, to construction and quarry customers for 49 inch or smaller applications. IntelliTire uses stem-mounted flow-through external sensors, in addition to internal sensors, to provide critical real-time data such as tyre inflation pressure and temperature to continually monitor the health of each tyre throughout its lifecycle. Transmitting sensor details through a cloud-based system, IntelliTire uses advanced and predictive algorithms to analyse data and issue alerts and customized reports to fleet operators.
With its smart fleet management technology, IntelliTire allows operators to proactively address tyre issues with automated task lists, increase technician productivity with digital inspections and reporting, and mitigate unplanned maintenance to help reduce downtime and improve driver safety.
“With the introduction of IntelliTire, we are equipping our construction and quarry customers with a connected TPMS offering,” said Brian Goldstine, president of mobility solutions, Bridgestone Americas. “As quarry, construction and rental customers continue to grow their businesses, it will be increasingly vital for fleets to effectively manage their growth and drive productivity, efficiency and sustainability.” www.bridgestoneamericas .com
CDE showcases water management efficiency
CDE has developed the new AquaCycle A2500 thickener, the latest addition to its top-of-the-line water management and recycling systems.
With a capacity of 41,640 litres, the new A2500 is CDE’s largest and most advanced water management system to date. The Cookstown, Northern Ireland-headquartered firm developed the AquaCycle A2500 due to demand from materials processors operating in high tonnage markets for water management solutions able to supply their operations while optimising production efficiency, minimising fines losses and maximising water recycling.
Darren Eastwood, business development director for the Americas at CDE, said: “It is increasingly important for materials processors to invest in an effective water management system that ensures a steady supply of clean water to their plants through cost-effective means.” He explained that the firm’s continued development of water management systems is helping operations overcome challenges of washing in areas where water is scarce.
The new A2500, showcased at WoA-AGG1 2022 in Nashville, Tennessee, expands the range to fit the requirements of sites processing high tonnages. The increased capacity also provides a lower rise rate, enabling operators to process challenging, harder-to-settle materials.
According to CDE, the A2500 is designed for
easy use and safe access for efficient maintenance. It boasts the first lattice bridge structure on any CDE thickener. An integrated monorail also provides access to the motorised rake, gearbox and motor.
The A2500 includes an adjustable rake-lifting mechanism and features passive torque control. Its automatic raise-and-start sequence protects rakes from surge pressure from dense sludges. The rake itself has been improved, with new spacing and redesigned blades for improved sludge conditioning.
Powered by the motorised rake arm, the introduction of a new floating scraper, independent of the rake’s height, allows for the easy removal of unwanted foam, oil and lightweight trash. And, creating even radial flow to all regions of the A2500, a redesigned volute feedwell optimises the incoming flow for improved flocculant performance.
Another key feature of the new A2500 is its feed height. Sitting at almost 6.7m, it simplifies upstream plant design complexity as it eliminates the need for costly installation works.
An alternative to water extraction from natural sources and the costly process of pumping water to the plant, CDE’s A2500, like the full AquaCycle range, significantly reduces costly water consumption by ensuring up to 90% of process water is recycled for immediate recirculation. www.cde.com
Martin unveils smart-tech belt cleaner system
Martin Engineering has developed a new belt cleaner system that can reduce maintenance costs and extend component life.
The solution features sensors that measure blade wear and also monitor belt tension. A spokesperson for the firm said: “The sensors fit on the end of the mainframe and measure wear against the belt. They can tell the life of the blade and also the belt tension.”
This can help to optimise belt life and makes a major reduction in maintenance costs. “It takes the guesswork out of maintaining the cleaners.”
The system means that service technicians only have to address scraper wear or blade tension when the sensors show maintenance is needed. This makes a significant saving in eliminating the need for maintenance teams to make periodic checks on conveyors to assess condition. The system also predicts wear so that replacement components can be ordered when they will be required, eliminating the need for stockholding. And as wear can be monitored, this also reduces the risk of unscheduled downtime and helps optimise uptime. www. martin-eng.com
Martin Engineering’s new belt cleaner system using wear sensors can reduce maintenance costs and optimise uptime
Superior upgrades Guardian screen offering
US-based Superior Industries has introduced several features to improve performance of its Guardian Horizontal Screen in stationary or static settings.
The company says that extra clearance between decks, a popular feature on inclined scenes, is now an optional feature for the Guardian Horizontal Screens. It adds that the extra headroom is appreciated by maintenance crews while working inside the screen.
Additionally, Superior has outfitted some of its screens with king-sized bearings, which greatly increase the capacity of the screen. One of the manufacturer’s largest models uses 200mm bearings.
“Historically, horizontal screens are most popular in port-
able or mobile applications,” said Ed Sauser, Superior’s product manager for the manufacturer’s vibratory solutions. “However, some static producers prefer horizontal over inclined screens, so we’ve designed a few features to improve performance for these customers.
“We also build one of the market’s only four-deck screens, which offers a five-product split (four end products and one oversize),” Sauser added. “This four-deck option is available in 6x20 and 8x20 models of our Guardian Horizontal Screen.”
Superior manufactures a dozen models of its Guardian Horizontal Screen in two-, threeor four-deck configurations for dry or wet applications.
www.superior-ind.com/
Cummins & Tierra connect for LiuGong
Cummins says it is working with telematics service provider Topcon/Tierra to support manufacturer LiuGong.
Cummins and Topcon/ Tierra are collaborating to enable advanced diagnostics and troubleshooting for major components on LiuGong construction equipment to come through a single interface. This solution will improve equipment availability and reduce the total cost of operation by providing actionable insights that enable component care, damage prevention and faster service response.
Telematics is used to improve operational efficiency of construction equipment at building sites, ports, distribution centres, logging sites and farms. Most of these environments have mixed fleets and need a compatible solution across all their machinery. Cummins is working to offer digital capabilities with existing telematics services providers to support customer needs in a flexible manner.
Cummins Connected Diagnostics wirelessly connects engines to enable continuous monitoring and diagnosis of system health and faults. Using telematics, this digital product
delivers valuable data to fleet managers via mobile app, email or web portal.
Ed Hopkins, Cummins digital partner management leader, explains the importance of connectivity to the future of supporting construction equipment: “With more information, end users can make more informed decisions. Site managers can use the data to determine whether to stop machine operation or continue to the end of the shift by understanding the suggested root causes. They can gain an understanding of how long they have before an issue is likely to
escalate to a breakdown or critical failure. This means that uptime can be maximised, with any potential fixes done more quickly. With the information provided in Connected Diagnostics, the correct parts, tools, and technician can be made available to resolve issues in an efficient manner.”
Sam Ternes, customer solutions director, LiuGong North America, commented: “LiuGong is proud of the collaboration with these important supplier partners and the achievement to deliver a technical solution to our dealers and customers that will directly impact machine availability. With
solution
this advancement in diagnostic information and communication through the TopCon telematics system, LiuGong will have a distinct advantage in minimising machine downtime and completing repairs on the first service call.
“Using the expertise and advanced capabilities of Cummins Connected Diagnostics, LiuGong customers will receive timely feedback in the event of an engine-related diagnostic code, allowing for continued operation where appropriate for scheduled repair or instruction to stop operation to minimise the risk of further damage to the equipment.”
Mohamed Abd El Salam, Tierra product management and business development senior manager, said: “Tierra adds new elements to its telematics solutions, offering a trusted and proven diagnostics service from Cummins: a system capable of adding even more value to our solutions and greater remote control of our customers’ assets, offering them higher autonomy, efficiency and a high ability to predict problems on the vehicle. This is just the first of a series of new, upcoming projects.”
www.cummins.com
Extra clearance between decks is now an option for Guardian Horizontal Screens
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