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Numbers stack up despite industry challenges
As you should expect, Aggregates Business International is always on the lookout for reliable and up-to-date data on the key regional aggregates markets of Asia, Africa and the Middle East. As such, I am delighted to be able to publish in this issue the latest GAIN (Global Aggregates Information Network) member country and regional perspective on global aggregates production.
Penned by GAIN convenor Jim O’Brien, the new report is based on GAIN country member estimates of aggregates production. Standout figures include Chinese GAIN member aggregates production tipped to fall by 1% in 2022, to 19.49 billion tonnes from 19.68 billion tonnes. A further 0.2% drop in production levels to 19.46 billion tonnes is forecast for 2023.
In contrast, GAIN India members are forecasting a 4% rise in their aggregates output to 5.33 billion in 2022, compared to 5.125 billion last year. Indian members are also predicting a 4.7% increase in aggregates production to 5.58 billion in 2023.
Other GAIN member country estimates include a 4.2% year-on-year drop (360mn to 345mn tonnes) in Japanese aggregates production in 2022, followed by a 1.4% rise to 350 million tonnes in 2023; a 2.1% rise to 398 million tonnes in South Korea’s 2022 aggregates volumes, with a further 0.5% rise to 400 million tonnes in 2023; and a welcome 6.5% rise in South African aggregates production to 165 million tonnes this year, followed by another 3% rise to 170 million tonnes next year. Finally, United Arab Emirates (UAE) aggregates output is estimated to reach 150 million tonnes in 2022 – a 3.4% rise on 145 million tonnes produced in 2021. UAE GAIN member companies forecast a further 3.3% uptick in aggregates volumes to 155 million tonnes in 2023.
Overall, the GAIN country member data indicates a global aggregates industry that has stood up incredibly well to the coronavirus pandemic and its linked severe disruption to
supply chains and the day-to-day work of large and small-to-medium aggregates enterprises.
What stood out to me in O’Brien’s astute analysis accompanying the GAIN country member figures were his largely positive observations on China, by far the world’s largest aggregates market, responsible for 46% of global production. He writes: “Growth in 2021 had been fuelled by its [China’s] 14th Five-Year Plan 2021-25. However, January to May 2022 saw a 12% decline on prior year, mainly because of renewed COVID-19 lockdowns and the weak real estate market.
The second half of the year is expected to see a recovery through the central government commitment to ongoing infrastructure investment, as well as stimulating real estate [spending] and introducing policies to help enterprises to stabilise growth.” O’Brien also notes that China is “massively” investing in coal to alleviate power shortages, with energy cost inflation hitting aggregates producers hard. “Overall, Chinese production may be declining somewhat from its 20 billion tonnes peak but continues to be very strong with Government support.”
O’Brien’s commentary on the world’s second-largest aggregates market, India, also made for very interesting reading. He notes that while India saw a coronavirus-induced 18% decline in aggregates production in 2020, major infrastructure projects including airports, roads, tunnels, and metro rail in Tier 1 and 2 cities are ensuring a steady recovery in output. “Aggregates industry sentiment remains positive, with huge potential for growth beyond its estimated 5.33 billion tonnes, particularly as its population is now overtaking that of China,” GAIN’s convener concludes.
Crucially, and documented in ABI’s recent coverage of the country’s increasingly impressive efforts to improve its national aggregates industry sustainability, any growth in India’s aggregates output does not have to come with an environmental cost. GW
CRUSHING & SCREENING
Crushing and screening plant versatility and innovation can generate impressive operating cost reductions
A top loading-model manufacturer has gone bigger than ever before in its hybrid excavator range
The hauling sector has seen several eyecatching recent announcements including a new machine made from fossil-free steel
All the key events in the
Top quarrying-machine tyre makers were due to exhibit their new and latest tyres at bauma 2022
Specials
08 INTERVIEW
Glen Webster: Loadtech is delivering savvy payload management for African quarries
12 MARKET REPORT India’s huge building materials and quarrying equipment markets are evolving
41 GAIN FEATURE Analysing why global aggregates demand is up despite strong headwinds
46 FEATURE Sand miners turn to ants and termites to help Kenya get better connected
49 QUARRY PROFILE Riding the winds of change at AfriSam’s Jukskei Quarry
CEMEX PROVIDES CEMENT FOR LONGEST BRIDGE IN THE PHILIPPINES
CEMEX has revealed that it is the sole supplier of cement for the construction of the longest bridge in the Philippines. The global building material giant has supplied nearly 70,000 tonnes of cement for the construction of the CebuCordova Link Expressway (CCLEX), a milestone project for the country. CCLEX connects Cebu City to the municipality of Cordova on Mactan Island and spans a total of 8.9kms, standing on twin tower pylons reaching 145m in height. The bridge, which opened to traffic in 2022, is expected to provide a safer and more efficient route for approximately 50,000 vehicles every day, seeking to improve the quality of life for residents of the area.
“CEMEX has been a proud contributor to the development of the Philippines for over a century, and our participation in CCLEX is further proof of our commitment to the country,” said Luis Franco, president of CEMEX in the Philippines. “Projects such as this modernize the country and foster the wellbeing of its residents. Improving the quality of life of the citizens of our communities sits at the core of our purpose: to build a better future.”
In the Philippines, CEMEX partners with over 20 public and private entities to support waste management efforts, using waste that would otherwise go to municipal landfills or water systems as an alternative to fossil fuels at its cement plants. Its Solid cement plant was recently recognized with the Award in Exemplary Operations in Small-Scale Waste-to-Energy Operations by the Department of Environment and Natural Resources.
Keestrack enters India joint venture
Quarrying, mining and construction equipment maker Keestrack Belgium has started a joint venture agreement with Indian manufacturing group Gujarat Apollo Industries.
The Goldoni Apollo Private JV, which Keestrack has entered into through its holding company PFH, aims to design, assemble and produce agricultural equipment for the Indian market as well as for certain export markets. The JV will use the Goldoni technology which was acquired by the Keestrack Group in 2021.
Headquartered in Ponzano Veneto, Goldoni is an Italian manufacturer of small- to medium-size agricultural equipment and was founded in 1927. From motoculti-
vators to specialised tractors like 4WD and Equal Wheels dedicated to orchards and vineyards, the Goldoni range is developed to help agricultural operators manage the entire agronomic cycle more effectively and sustainably.
Keestrack, headquartered at Bilzen in Belgium, is a familyowned global manufacturer and supplier of quarrying, mining, recycling and construction equipment. It produces equipment such as tracked crushers in Italy, Czech Republic, China and India with its parts, logistics and administrative headquarters in Belgium.
Keestrack started manufacturing in India in 2019 under the name eTrack Crushers, headquartered in New Delhi.
Gujarat Apollo Industries Group, founded in the 1970s, is a manufacturer of mining and construction equipment based in India. Gujarat Apollo has recently entered into the agriculture and farming machinery business.
Peter Hoogendoorn, CEO of PFH Holdings and president of Goldoni Italy, commented: “We see a great opportunity in the Indian market for high-quality localised agricultural equipment and believe that we can not only bring new technology to the Indian agricultural equipment market but also add value to the entire value chain, together with the expertise of our well-known and reputable Indian partner Group Gujarat Apollo Industries.”
Boral gains new CEO & MD
Vik Bansal has joined Australian building materials giant Boral as the company’s CEO and managing director.
Bansal, who took up his dual roles on 10 October 2022, is an accomplished CEO with deep leadership experience, managing industrial businesses through growth, transition, and improvement periods. He succeeds Zlatko Todorcevski, whose departure was announced in June this year.
Boral chairman Ryan Stokes said: “We are pleased to welcome Vik and look forward to working with him to lead Boral through
value for all stakeholders. We are confident that his operational and
performance-focused leadership will enable Boral and its people to realise the full and exciting potential of the company.
“On behalf of the Board, I would like to thank Zlatko for his contributions to the business over the past two years. Zlatko has led Boral through a successful transformation period, realigning the portfolio on Australian construction materials and refocusing the organisation.”
Todorcevski will remain active at Boral until Bansal’s arrival and is committed to supporting a smooth leadership transition.
Keestrack has been present in the Indian market manufacturing tracked crushers since 2019
Vik Bansal
Holcim India business sale
Holcim has closed the US$6.4 billion sale of its business in India, comprising its full stake in Ambuja Cement, to the Adani Group.
This transaction strengthens Holcim’s balance sheet and enables the company to continue its acquisition strategy, building on recent investments of more than CHF 5 billion ($5.2bn) in Solutions & Products.
Jan Jenisch, Holcim CEO, said: “I would like to thank our 10,700 Indian colleagues who have played
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 and our customers to
continue to thrive in the future.
“This divestment is another step in our transformation to become the global leader in innovative and sustainable building solutions, strengthening our balance sheet and giving us the firepower to continue our acquisition strategy.”
The deal comprises Holcim’s entire 63.11% stake in Ambuja Cement, which owns a 50.05% interest in ACC, and a 4.48% direct stake in ACC.
African cement sector to accelerate decarbonisation
continent.
The partners say the MoU, which was signed at Africa Climate Week 2022 in Gabon, will help build sustainable and resilient cities and communities in Africa.
The agreement sets out how both parties will work together to strengthen stakeholder advocacy towards net zero and encourage local governments to take policy action towards decarbonisation targets. A key target will be for cement industry association GCCA
on an initial first five pilot cities to scope out opportunities and challenges. The two parties will jointly organise events that strengthen advocacy for the involvement of local governments in decarbonisation.
The MoU also includes agreements on joint efforts to accelerate net zero across Africa and the cement and concrete industry. Both parties will aim to help make low-carbon cement manufacturing investable in Africa,
BIRLA REVENUE UP BUT PROFITABILITY HIT BY RISING INPUT COSTS
Birla Corporation posted a 25.2% increase in revenue in the first quarter of the 202223 financial year, despite tepid cement demand, as the company managed to ramp up like-for-like capacity utilisation to 101%.
The Kolkata, Indiabased flagship company of India’s M P Birla Group of companies, Birla Corporation’s consolidated revenue for the first quarter of FY22-23 was INR22.18 million against INR17.58 million in the same period last year. Sales in the first quarter of FY21-22 were disrupted by COVID-related outages and are not strictly comparable with the quarter under review.
as well as stimulate demand for low-carbon concrete products and to cultivate a fruitful environment for circular and net-zero manufacturing across Africa.
To reach these objectives, the parties say they will work to ensure African cities have more capacity to embrace innovative cement products and that these cities can be mobilised effectively to join the net-zero-by-2050 efforts. GCCA and UCLG Africa will also look to build stakeholder support for multi-level governance in urban planning and housing across Africa.
The MoU meets a key pillar of the GCCA’s 2050 Net Zero Roadmap, launched last year, which outlines the central role that policymakers must play for the industry to decarbonise and the wider net-zero ambitions of industry. GCCA chief executive Thomas Guillot commented: “Last year our industry made a milestone netzero global commitment to reduce our carbon footprint to zero by 2050. Crucial to this commitment is supporting and driving change across the African continent.”
Jean Pierre Elong Mbassi, UCLG Africa secretary general, said: “With the ever-growing need for greener construction methods, we’re excited to enter this agree ment with the GCCA to accelerate action towards a decarbonised cement and concrete industry.”
Profitability, however, was dented by escalating power, fuel and freight costs. Costs of optimising Birla Corporation subsidiary RCCPL Private Limited’s newly commissioned Mukutban plant in eastern Maharashtra also had a major impact on overall profitability, broadly in line with the management’s internal projections.
Commercial production at Mukutban started on 30 April 2022, and the management has drawn up a detailed plan to ramp up production over the next few quarters. It is expected that the Mukutban plant will break even at EBITDA level by the end of the current financial year.
HeidelbergMaterials’ Cimburkina cement grinding plant in Burkina Faso
Delivering savvy payload management for African quarries
To remain competitive in a cut-throat trading environment, African quarries are increasingly seeing value in digital systems. In a one-to-one with Aggregates Business International, Glen Webster, sales director at Loadtech, the authorised Loadrite distributor in sub-Sahara Africa, notes that the increased uptake of payload management systems is testimony to the industry’s insatiable appetite for digitalisation of operations. Munesu Shoko reports
In an environment where emphasis is fixed firmly on productivity at lower cost of operation, quarry managers are finding value in fleet-wide payload management systems that give them the ‘pulse’ of their loadout processes and the entire operation at large.
Modern load-weighing systems, says Webster, provide a networked, holistic view of operations, enabling quarry managers and operators to respond proactively with each load. Increased productivity goes beyond faster, more accurate loading; it now directly impacts the bottom line in each phase and across the entire operation.
Based on this understanding, aggregates producers are increasingly investing in these technologies to enable them to make informed decisions. Consequently, Loadtech has in recent years observed increased uptake of its Loadrite weighing systems in Africa. The company’s growth in the past three years, says Webster, is a clear indication that the market is fast maturing.
“We have recorded a substantial 15% business growth in the past three years,” confirms Webster. “COVID-19 has taken some of the competitors out of business and this has contributed to about 5% of our growth in the past two years. The remaining 10% is purely new business driven by the increased uptake of these solutions in the local market.”
Webster says new load-weighing systems, such as the Loadrite L3180 Smartscale provide much more than accurate payload weight. They add value with features that improve site safety, track stockpile inventory, empower operators with performance feedback, integrate with truck scales, and more.
Launched locally some three years ago, the Loadrite L3180 Smartscale is Loadtech’s best-selling solution in sub-Saharan Africa at the moment, with several big quarrying groups among the early adopters, says Webster.
“We sold about 90 units in the first year and about 200 the second year. There is an apparent mindset shift in the industry. Quarry owners are now aware that they can actively reduce their total cost of ownership by using load-weighing systems’ monitoring and alert features to set benchmarks and measure productivity,” he says.
By tracking the amount of material moved per hour to measure productivity and set benchmarks using load-weighing systems, operators can identify underperforming machines and make appropriate adjustments to ensure all assets on site are working at their optimum efficiency.
An on-board weighing system such as the Loadrite L3180 SmartScale can be used to calculate the weight of material in an excavator’s or loader’s bucket, relay this information to the operator and record the weight for later use. Being able to track the amount of material moved per hour can then be used internally as part of an overall business analysis to measure productivity and set benchmarks.
“Once you know your benchmark productivity rates, it’s also easy to identify equipment that is underperforming, which sets off a trigger for an investigation into the underlying causes. These causes can vary widely, from operator error to equipment failure.”
Once productivity benchmarks are set, fleet managers can customise their systems to capture a wide range of other data such
as cycle times, which can then be used to identify process bottlenecks and inefficiencies. By resolving these issues, quarry managers can improve productivity and reduce operating costs.
“This Loadrite system can also measure the cycle times between each loading event, which can show how efficiently material is being moved. Shorter cycle times generally point to a more efficient and therefore more profitable operation,” says Webster.
The system also actively helps reduce fuel usage. By using an accurate on-board weighing system, operators can ensure trucks are filled correctly the first time, with no productivity lost due to underloading or overloading.
“By loading trucks correctly from the outset, unnecessary truck movement is reduced as there is no need to turn around for either a refill or a removal of material once the trucks get to the weighbridge,” he says.
A major talking point on the Loadrite L3180 is the use of angle sensors instead of traditional rotary triggers. This maximises weighing accuracy, even in tough conditions. For example, the solution is able to adjust for rough terrain, technique and movement so new and skilled operators can load with greater accuracy, precision and speed.
The Loadrite L3180 SmartScale uses weighing intelligence and solid-state sensors for more accurate, precise and faster loading. It also connects machines and devices for the collection and syncing of data via the
“We have recorded a substantial 15% business growth in the past three years”
Modern load-weighing systems such as the Loadrite L3180 Smartscale provide much more than accurate payload weight
built-in WiFi to the InsightHQ reporting portal. When using Trimble’s cloud-based InsightHQ quarry-reporting portal, personnel can gain access to site production and operator key performance indicators (KPIs) on desktop or mobile devices.
“The L3180 now offers in-cab KPIs, including tonne/hour, tonnes and truck count to enable operators to monitor performance and achieve daily targets,” explains Webster. “Data is presented in dashboard or graphical formats, including a new loadoutperformance heatmap, powered by built-in GPS. The system caches data locally and then syncs it with InsightHQ.”
Amid this growing uptake of loadweighing systems in the sub-Saharan Africa market, Loadtech has just launched the Loadrite 360 payload management system in this part of the world. The company is currently trialling the first units at one of the leading aggregates providers’ quarries in South Africa.
The Loadrite 360 – a loadout-automation and -reporting system for quarry loadout activities – consists of a wheeled loader onboard scale, an automated communications connection and a performance-reporting tool. Jobs are entered in the office and selected in the loader, reducing data entry, eliminating mistakes and improving customer satisfaction.
The technology is designed to transform the way in which quarries have always conducted their loadout processes. Traditionally, operations have relied on weighbridges alone. These are known to be prone to product errors and weight challenges.
With the Loadrite 360, aggregates producers can turn their workflows around –literally. Instead of having a weighbridge at the exit, it could be moved to the entrance area, where information about the truck – including the registration, tonnage and product required – is captured and relayed to the loader. As soon as the truck drives in, the loader operator already knows the quantity and type of material to be loaded. This reduces loading, waiting and idle times.
“The Loadrite 360 can holistically improve loadout operation through performance metric tracking, job data automation and realtime 360° job visibility. It connects the loader and the weighbridge so as to provide data-sharing of loadout jobs, resulting in greater efficiency, improved visibility and higher product sales,” says Webster.
verbal communications and allows more time for loading.
With the InsightHQ reporting option, managers can monitor site production and performance anywhere, at any time, on any mobile device or web browser. InsightHQ also allows centralisation of data from excavator and belt scales.
“Although the Loadrite 360 is primarily a tool to improve the accuracy and speed of loadout operations, it can also reveal hidden
The two-way automated communication shows jobs requested at the weighbridge as a job list on the scale inside the loader cab and completed loadout data is fed directly into the weighbridge ticketing system. This reduces double-entry work and data-entry errors for both the operator and the weighbridge attendant. Accurate on-screen job data reduces error-prone
improvement opportunities. The system enables users to drill into production data to see individual trucks, loaders or even bucketby-bucket data and identify opportunities to improve,” concludes Webster. AB
The Loadrite L3180 SmartScale uses weighing intelligence and solid-state sensors for more accurate, precise and faster loading
To support the growing customer base, Loadtech has grown its technical team by almost 100% in the past two years
The Loadrite 360 can holistically improve loadout operation through performance metric tracking, job data automation and real-time 360° job visibility
Komatsu HB365LC-3
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Komatsu
KOMATSU IN HALL C6 AND DEMO AREA
A 25-strong batch of special variants of L&T’s 9020 wheeled loaders being dispatched for delivery to the Border Roads Organisation of India
Indian market evolution
For several reasons and despite robust aggregates demand, sales of many machines deployed in Indian quarries and on the country’s many major infrastructure projects have been sluggish for much of 2022. However, new emerging factors are helping to improve the country’s off-highway unit trading landscape. Partha Pratim Basistha reports
Demand for aggregates continues to remain strong, led by the ongoing large-scale expansion of India’s road construction sector. It is also buoyant due to the major ongoing extension of India’s railway network, with the laying of new lines, and the doubling and tripling of existing lines, requiring vast volumes of aggregates ballast.
One important rail capacity expansion project led by Indian Railways is the doubling of the line between Bondamunda in Odisha and Ranchi in Jharkhand state in Eastern India. This includes the laying of 158.5 kilometres of new track. Another major works is the laying of a third line, stretching 155.5 kilometres between Narayangarh in Madhya Pradesh, Central India and Bhadrak in Odisha to allow increased movement of freight trains with higher parcel loads.
Despite the health of the Indian transport infrastructure development sector, paradoxically, demand for vital off-highway equipment used in quarry-crushing-supporting activities and road and rail construction works including backhoe loaders, wheeled loaders, rigid dump trucks (RDT’s), and compactors has been suppressed for much of this year. Commercial quarry owners, main contractors, subcontractors and renting agencies have been putting into abeyance acquisition of new equipment for some time, partly due to the higher initial cost of equipment featuring
engines conforming to new CEV-IV emission norms. Rising diesel fuel costs have also reduced equipment purchases, as have increased product support and services costs accompanying newer-range off-highway machines.
Research by Aggregates Business International has found that while big Indian transport works contractors with large order books have been acquiring some new equipment, the pace of acquisition has been slower in 2022 compared to 2021. Big road contractors like Dilip Buildcon, G.R. Infra, H.G. Infra, APCO, Gawar Construction, Patel Infra, Monte Carlo, Ashoka Buildcon, and KCC have been acquiring 10-20 excavators this year. However, there has been greater purchasing activity by medium and smaller-sized road contractors like Mundan Construction, Saran Construction, and Ravi Infra who have been purchasing many excavators. The bulk of the demand has been for the 20-ton class machines, with the market size hovering around 20,000+ units this year. The Indian excavator market overall is projected to reach 25,000 units a year by the close of the final year on 31 March 2023.
While wheeled loader demand has been lower in 2022, manufacturers remain optimistic about sales growth potential given the backdrop of firm demand fundamentals. Some of this stems from a focus on urban mass rapid transport infrastructure that will
necessitate larger volumes of aggregates, sand, cement and ready-mix concrete plants and the machines that enable it. “Demand will continue to be there for three-ton class loaders. However, we see demand for five-ton class machines catching up,” says B.K.R Prasad, head of marketing & product development, Tata Hitachi Construction Machinery Company.
Wheeled loader manufacturers are unanimous, though, that it will be some time for unit demand to become fully ignited. Dimitrov Krishnan, managing director, Volvo CE India, said: “Subcontractors and hiring segments continue to be in wait-and-watch mode as hiring rates continue to remain soft. Noticeably, significant price increases arising from the transition to CEV-IV-compliant wheeled equipment and a steep rise in steel prices continue to have its impact on keeping purchase decisions at abeyance.”
Interestingly, wheeled loaders are being used in a more diverse range of quarrying applications, as Subhash Sharma, regional manager, key accounts at Volvo CE India, explains: “Quarry owners that have been traditionally using excavators for hopper feeding, handling stockpiles and loading crushed aggregates into rigid dump trucks are now migrating to wheeled loaders to do those jobs. Three-ton class loaders are now also being acquired by small-size quarry owners.
“There is also a rising use of wheeled
loaders for handling manufactured sand as a sizeable number of quarry owners are setting up multiple trains for higher aggregates production. They are also setting up manufactured sand plants to attain higher levels of optimisation and profitability in their operations.”
An interesting evolving trend is using eight to 10-ton and 13-14-ton class excavators fitted with multiple attachments in bigger transport contract works requiring higher productivity. The excavators are replacing backhoe loaders that had been doing most of this work.
Due to higher initial new machine acquisition costs, customers have been preferring to extend the use of their existing equipment fleets, while also looking to minimise operating costs. However, big and middle-level road construction sector customers and commercial quarry owners are showing rising interest in machines featuring advanced technologies through which they can lower their operating costs.
Saurabh Agarwal, director of LSC Infratech, one of the biggest quarry owners in Northern India, says “We have found the Tata Hitachi, TL 340 H prime, 3.4-ton wheeled loaders extremely beneficial, enabling us to curtail our operating costs. We have deployed the loaders at our main Haldwani operations in Uttarakhand and in our new facility at Bharatpur in Rajasthan to handle aggregates and silica sand. Inculcation of advanced hydrostatic technology in the wheeled loaders has eliminated the use of conventional
transmission. It handles the same payload while maintaining the lowest deadweight of the machine. This technology also increases efficiency by minimising mechanical losses, making it the most fuel-efficient wheeled loader in its class.”
Ram Kripal Singh, director of North Indiabased R.K. Singh Constructions, says his company owns more than 100 Volvo FM 460 rigid dump trucks (RDTs) and 60 Scania RDTs. The firm has also recently placed orders for new Volvo FMX 550 RDTs. “The Volvo 460 rigid dump trucks have proven highly useful to us for transporting overburden materials from 50-to-70-metre-deep opencast mines at Northern Coal Fields of Coal India Limited at Dudhichua Mines Singrauli in Central India. The 22 cubic metre-bodied trucks are being used 18-20 hours daily for covering distances of between 6-10 kilometres in dumping overburden materials. Despite their very higher usage, we have found that the per cubic metre of load hauled is more with lower/per unit diesel consumption. This has enabled us to derive right levels on return of investments. Further, there is very minimal truck breakdown due to very high levels of proactive onsite parts and maintenance support. This is making our operations profitable.”
Rajesh Singh Gurjar, managing director at RGS Infratech, the dealer for Terex equipment, Chicago Pnuematic compressors, and Dynapac road construction machines in Rajasthan, says that new and existing quarry owners and road contractors have been
preferring to acquire hybrid, track-mounted crushing and screening equipment due to its lower maintenance costs. He has sold three Terex Finlay Hybrid plants since October 2021. He continues: “Quarry owners operating across all important crushing clusters in Rajasthan are also seeking newer levels of services and readily available parts support. This is because utilisation levels of plants have been going up, crushing high abrasive rocks to cater for the aggregates demand of ongoing, large-scale road construction projects going on across North India. To have higher availability of plants, crusher owners are now looking for companies who are able to provide annual maintenance contracts for a stretch of two to three years. Over this time, the OEM [original equipment manufacturer] will completely maintain and operate the plants giving the required agreed throughput.”
To attain higher throughput, operators in important crushing clusters in Rajasthan involving Kotputli, Sikar, Bharatpur, Rupbas, Bikaner, and Nangal Pahadi (prominent for meeting the aggregates demand for Delhi’s National Capital Region) are preferring 300-350tph stationary plants, rather than their traditional 250tph plant choice. Trackmounted plants offering a 200-250 tph throughput are also proving popular. The Rajasthan crushing clusters are also home to strong demand for 450-500 CFM (cubic feet per minute) pneumatic compressors for operating jack drill and track-mounted drills to drill into rock boulders to enable blasting and breaking.
“These sturdy machines are fitted with cold starting kits, enabling them to operate in sub-zero temperatures”
Vivek Hajela, vice president & head, CEB, L&T Construction & Mining Machinery
Furthermore, demand for wheeled loader block handlers is expected to increase in Rajasthan from new crushing clusters including Diggi Malpura and Chitamba Mines. Demand for block handlers has been stable from existing clusters like Jaipur, Jalore, Barmer and Dev Garh in Rajasthan. Granite mine owners have been showing interest in wheeled loader block handlers due to their higher utility in pushing marble blocks compared to excavators.
To cater for the demand for higher productivity and reduced owning and operating costs, Indian equipment manufacturers have been introducing new solutions and improving the capabilities of existing machines.
Vivek Hajela, vice president & head, CEB, L&T Construction & Mining Machinery (L&T), says: “Considering the requirements of the large crushing and screening plants, we have made suitable changes in the arm, linkage and bucket designs of the L&T 9020 wheeled loader – CEV-IV. These changes enable better material retention during carrying and effective loading onto carriers. In addition, rollout forces have been increased to allow for faster loading. The horizontal reach has been improved to enable levelling of the heaped material inside Hyva body RDTs. The engine power of our L&T 9020 model has been enhanced to 140hp from 133hp to ensure extra power availability. All these changes have improved productivity by 20-25%.”
Hajela says L&T recently dispatched the first batch of 25 special variants of L&T 9020 wheeled loaders suitable for operation in harsh terrains, high altitudes and extreme weather conditions for use by the Border Roads Organisation of India (BRO), which is engaged in serving strategic national requirements.
“These sturdy machines are fitted with cold starting kits, enabling them to operate in sub-zero temperatures of up to minus 20 degrees,” he explains. “BRO will deploy them to strengthen road infrastructure in Northeast,
North and Northwest India. LTCEL bagged the prestigious contract for supplying seventy L&T 9020 wheeled loaders, its single largest order, against stiff competition from domestic and multinational companies.”
To counter rising fuel and material costs to keep overall project costs down, the Indian Government has been insisting that construction equipment manufacturers develop more efficient technology solutions.
Addressing a recent gathering of representatives from top equipment manufacturers such as JCB India, Volvo CE, L&T, that was also attended by Aggregates Business International, Nitin Gadkari, India’s Union Minister of Road Transport & Highways, Government of India, said: “There is a huge scope for bringing innovative construction technologies. This will not only increase the pace of road construction, but also enable contractors to make more profits. Some of the key breakthroughs have been the newer soil stabilisation technologies in the construction of bridges and tunnels.”
Emphasising the need to use alternative fuels, he continued: “The scope of construction is immense in India given the large government roadmap. Despite adequate funding, the cost of construction needs to be minimised to make projects financially viable. This can be achieved by introducing innovative technologies, including alternative fuels. Use of alternative fuels like biofuel, methanol, and other bio-products will negate the impact of the spiralling crude oil prices.”
Gadkari suggested that stakeholders in the construction industry should focus
Newly commissioned Schwing Stetter (India) global manufacturing hub in Cheyyar, Tamil Nadu, South India
strongly on research and development and gave the example of the initiative taken in the Northeast India construction market where diesel and methanol were mixed in a 50:50 ratio. To make alternative fuels available on a larger scale, the government is experimenting with ethanol to derive higher calorific value at par with diesel and is also working on developing bio CNG sourced from the Indian Oil refinery plant at Panipat, Haryana, North India.
“OEMs should consider developing machines in which their petrol engines can be converted to flex engines that can use biofuel, methanol, and other bio-products. This will not only check pollution in a big way but will also reduce the cost of operations and thereby minimise the overall cost of the projects,” said Gadkari.
Taking onboard the Indian government’s directive, OEMs have been developing machines running on alternate fuel hybrid technologies. This was seen in some of the machines showcased at the recent Excon exhibition in Bangalore, India’s mega construction equipment event featuring a large array of prominent manufacturers including JCB, Cummins, L&T, BKT, CDE Asia, Volvo Trucks, Tata Hitachi and Komatsu.
Blue Energy Motors recently launched India’s first liquified natural gas (LNG)-fuelled green truck at its newly inaugurated plant in Chakan, Pune, Western India, in the presence of Anirudh Bhuwalka, CEO of Blue Energy Motors; Gerrit Marx, CEO of Iveco Group; and Sylvain Blaise, president of Iveco Group’s Powertrain Business Unit.
Speaking at the event, Bhuwalka said: “With a keen focus on developing LNG as an alternate fuel, Blue Energy Motors’ heavy-duty and long-haul trucks powered by LNG are set to pioneer the green trucking revolution in India. The market entry of the LNG-fuelled trucks is starting with the introduction of the 5528 4x2 truck as the first model. Blue Energy Motors’ trucks are created and tested to meet the rigorous duty cycles of the Indian transportation sector. Through the FPT Industrial cuttingedge technology in the field of natural gas, these trucks provide best-in-class TCO with unparalleled riding comfort and safety for drivers throughout lengthy hauls.”
Iveco Group’s Blaise said: “India is one of the largest vehicle markets in the world and our cutting-edge technology and natural gas engines are key enablers of the ecological transformation and generating value for the transport operators.”
Bhuwalka added: “The Blue Energy Motors’ 5528 truck uses an FPT Industrial multipoint stoichio metric combustion engine to ensure best-in-class fuel consumption and lower noise than diesel engines. With 280hp power and 1000Nm torque, it is one of the most powerful natural gas trucks on the Indian market and is compatible with CNG, LNG, and bio methane. The 5528 4x2 truck has the industry’s first 1000-lt fuel tank which provides the range of up to 1400 km in a single fill. Given this long range, issues pertaining to range anxiety are well taken care of and with the upcoming LNG dispensing network, sufficient coverage across key routes in India will be available without need of frequent refilling.”
Blue Energy has installed capacity to produce 10,000 trucks per year, which can be augmented further as demand picks up. With Indian market demand prospects continuing to remain firm in the medium and long term, off-highway equipment manufacturers are going in for capacity expansion by opening
new facilities. The facilities will also cater for healthy export as well as domestic unit demand.
Schwing Stetter (India) has recently commissioned a new global manufacturing hub in Cheyyar, Tamil Nadu, to cater for national and export customers. There will be a focus on localisation at the new site to lower initial costs.
V.G. Sakthikumar, the company’s managing director, says: “The new facility will be promoting XCMG products, helping Schwing Stetter (India) to expand and strengthen its business presence in India. The XCMG products score high on technology and services and deliver a high level of performance with low operating costs.
“We will use our state-of-the-art production and testing technologies to further align the new solutions to meet customer expectations in segments like road and metro railway construction, the latter catering for upcoming Indian high-speed rail projects.
“We have appointed close to 28 dealers and have put together an expert sales team for both pre- and post-machine sales of models produced at the new facility, notably mobile and crawler cranes, piling rigs and motor graders.”
Sakthikumar says sales of XCMG 20-ton excavators have been “highly encouraging” since their launch a few years ago, with XCMG excavators achieving the largest single brand sales in India in 2021, “even when the segment was depressed”.
He adds: “Based on customer requirements in both the track and stationary crushing segment, we will be introducing required solutions. Currently, we have a strong presence in niche demolition waste recycling with our Rubble Master plants. We plan to position ourselves more strongly with
Anirudh Bhuwalka (left), CEO of Blue Energy Motors, and Gerrit Marx, CEO of Iveco Group, launching Blue Energy Motors’ 5528 4x2 LNG truck at the company’s Pune facility
V.G. Sakthikumar at the inauguration of the new state-of-the-art Schwing Stetter (India) Cheyyar facility
solutions that will enable commercial quarry owners to optimise their crushing plants and be more profitable. Our key initiative will be to provide solutions for producing manufactured sand. We will support the mineral processing plants with our wide range of high-performing wheeled loaders, as we did successfully for ready-mixed concrete plants.”
Indian off-highway machine companies are also working hard to create products and services closely attuned to customers’ needs.
According to R.B. Patel, managing director of Electro Magnetic Industries, a Gujarat-based manufacturer of vibratory screens, circular vibratory screens, vibratory conveyors, vibrating grizzly feeder, vibratory motors, demand for quality components is also growing due to crushing and screening OEMs offering ever-higher product standards to deliver higher plant availability alongside greater production volumes.
“We are working proactively with customers in our production of mobile, stationary and tracked plants. Our work is supported by our integrated manufacturing facility involving our own foundry, fabrication and performance test facilities.” Electro Magnetic Industries’ (EMI) clients include Sandvik, Metso and prominent Indian crushing and screening manufacturers like Puzzolana Machinery Fabricators, and Marshman.
An interesting novel EMI product is dump body vibrators for rigid dump trucks. The 12-volt DC vibrator mounted on the tipper trucks will discharge sticky wet and frozen materials quickly and safely. Patel said: “With the solution, tipper truck operators do not need to bang tailgates, jam brakes or pop clutches. The vibrators give a quicker and cleaner dump every time, reducing the risk of vehicle damage. The vibrators will also facilitate discharge of compacted materials at lower dumping angles to avoid possible vehicle tip-over.”
Another Gujarati company, Dynemix India, has launched concrete reclaimer solutions for aggregates and concrete slurry reuse and concrete bucket attachments.
Jignesh Patel, Dynemix India’s managing partner, says: “The concrete reclaimer is meant for the ready-mixed concrete industry, where there is rising requirements of contractors for higher levels of plant optimisation. It arrests the concrete from spillage while being transferred from transit mixers.”
With Indian national and state governments continuing their commitment to develop India’s infrastructure for the long term, building materials and building materials production machinery demand is expected to gain further momentum in Q4 2022 into Q1 2023. Several major infrastructure projects are approaching completion with large new projects set to begin before India’s next general election in spring 2024. However, some industry analysts anticipate that product and machinery demand could dip in 2025. AB
Nitin Gadkari, India’s Union Minister of Road Transport & Highways (pictured centre), recently addressed an Indian off-highway equipment industry gathering, discussing greener technologies
Dynemix India’s new concrete reclaimer for the ready-mixed concrete industry
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Due to Rubble Master’s efficient drive solutions, the company’s mobile crushers and screens are increasingly used globally for large infrastructure projects
Plant versatility & innovation
Crushing and screening plant versatility and innovation can generate impressive operating cost reductions. Guy Woodford reports
Electrified quarry mobile processing plant manufacturer Rubble Master is highlighting at bauma 2022 Munich (24-30 October) how its innovative machines can ensure customers up to 25% operating savings.
The Austrian company has been powering its mobile processing plants with electricity for decades. Using this expertise, Rubble Master says it is continuously setting standards in the energy efficiency and costeffectiveness of its machines.
With the claimed revolutionary new development of the bauma-showcased RM H50X hybrid screen and the RM J110x jaw crusher, customers are said to be saving even more fuel costs. In addition, the RM XSMART software solution and other new digital innovations demonstrate how operators and machines can network intelligently to get even higher output. As a result, mobile RM crushers and screens can be combined in a versatile, flexible and efficient way.
Even at a time before steadily rising fuel prices, the electrification of Rubble Master machines was said by the company to be a "key economic as well as ecological argument". As part of the RM NEXT philosophy, the RM Group says it is consistently supporting electrification and offers all its crushers and screens as hybrid versions as a matter of principle. These machines can also be operated fully electrically. A special focus is on combining machines to form crushing and screening trains so they can be operated together. This
means, for example, that the crusher can also power the screen. That is how customers can save time and money because they only need to refuel and service one engine.
Rubble Master hybrid machines are said by the manufacturer to consume up to 25% less fuel than diesel-direct systems. If a crusher equipped with a hybrid drive system also powers an electric screen - a standard set-up with RM - even greater savings are said to be achievable. With this technology, the savings are said to be much higher than with conventional diesel-hydraulic systems. Another advantage, in addition to lower operating costs, is that the machines can be used in emissions-sensitive areas.
Digital solutions and networked machines increase efficiency in addition to electrification, and Rubble Master is focusing intensively on digitalisation to give customers a full overview of their machines while operating even more efficiently. Using the RM XSMART app, machine operators can network with their machines either using an app on their mobile devices or by using the browser app. Fleet management, condition monitoring, end-to-end reporting, and troubleshooting support make everyday life much easier and, at the same time, increase productivity. Rubble Master, however, says it goes one step further by networking the machines with each other.
In a networked crushing and screening train, the machines can communicate with each other to adjust their output to optimise the utilisation of the upstream and downstream units or react to an event
such as one of the machines in the train switching off. This means that machines are not overloaded, nor do they run idle. Rubble Master says autonomous crushing and screening is the next logical step the group will be presenting soon.
Astec Industries has launched its newest mobile high-frequency screening plant, the GT2612V. The plant features a 2612V VariVibe high-frequency screen. The two-deck, 6’x 12’ (1.8m x 3.7m) screen uses a unique rotary tensioning system that allows for some of the quickest screen media changes on the market, giving producers more uptime. The 2612V also has deck-mounted, variablespeed hydraulic vibrators, a hydraulic mechanism for varying operating angles, a fines-collecting hopper, top- and bottom-deck discharge chutes and an aggregates spreader. The high-frequency screen can quickly and efficiently size crushed stone, recycled asphalt pavement, sand, gravel, coal and a variety of other materials.
The mobile GT2612V is manufactured on a heavy-duty, welded-steel mainframe with a channel cross-section. A walkway around the screen and remote grease lubrication for ground-level access make maintenance simple.
The plant includes a large hopper with a capacity of eight cubic yards that is equipped with six-inch (15.2cm) sloped grizzly openings and a remote tipping grid. The hopper also includes foldable wings and hydraulic support legs. The variable-speed, 48-inch (122 cm) wide belt feeder features a high-torque hydraulic drive, full-length
impact bed, rubber lagged head pulley and self-cleaning wing tail pulley.
The screen plant is equipped with four conveyors: a delivery conveyor, two side conveyors and a fines conveyor. All conveyors feature a variable-speed hydraulic drive and easily fold for transport.
The GT2612V is powered by a Caterpillar Tier 4 Final, 136 hp (101.4 kW) engine, while engine-mounted hydraulic pumps operate all plant functions. The plant includes a PLC control system with pendant remote controls for the tracks.
Additional options for the GT2612V mobile plant include engine alternatives (Caterpillar Tier 3 and Stage V) 15-foot (4.6m) hopper/feeder in lieu of standard for additional capacity, heavier-duty grizzly section with replaceable grouser bar cartridge, vibrating grid, bridge breaker,
vinyl dust cover, standard steel screen cloth, engine-enclosure filter kit, engine block heater, immersion heater, wireless track remote, and telematics and auto-grease systems.
Kleemann’s mobile cone crusher MOBICONE MCO 90(i) EVO2 and its mobile impact crusher MOBIREX MR 110(i) EVO2 can now be fitted with a double-deck post screening unit as an option. Cone crushers are mainly used in hard stone, impact crushers in soft to medium-hard stone and in recycling. A very high product quality is expected from both plant types. Thanks to the new optional double-deck post screening unit, it is now also possible, with a single machine – without the use of an additional screening plant – to produce two classified final grain sizes.
The large screening surface makes effective screening possible even for grain
sizes below 20mm. The discharge height of the fine grain conveyor is designed for a maximum stockpile volume. Oversize grain can be processed in a closed material circuit via a return conveyor. As an option, the conveyor can be swivelled hydraulically by up to 100°, which also makes side discharge possible. A kidney-shaped stockpile can thus be created manually.
If an application is only to produce one classified final grain size, the post screening unit can simply be used as a single-deck version.
As the MOBIREX MR 110(i) EVO2 is frequently used in recycling applications, wind sifters are used here as an option. They are said by the German manufacturer to guarantee increased material quality because potential light-material contaminants like wood and plastic are removed. The air flow can then be controlled precisely depending on the material. This is also said to reduce manual and sorting work. The wind sifter can only be used in conjunction with the post screening unit. With the double-deck post screening unit, a second wind sifter can be used as an option for cleaning the medium grain. AB
The GT2612V is Astec Industries’ newest mobile high-frequency screening plant
Kleemann’s MOBICONE MCO 90(i) EVO2 and MOBIREX MR 110(i) EVO2 can now be equipped with an optional double-deck post screening unit
POUNDS LIKE A HAMMER, FLOATS LIKE A FEATHER
STEER-BY-WIRE MACHINE CONTROL
Question: How can an operator easily control a multi-tonne asphalt roller? The answer: With innovative steer-by-wire machine control. This highly advanced system makes machine operation smooth and comfortable.
Advanced steer-by-wire is the hallmark of the Ammann ARP 75 Pivot-Steer Roller. The machine also sets a new market standard with an advanced driver lever with intelligent functions and a 10-inch multifunctional touchable display.
Soil and Asphalt Compactors
Bigger & better loading
A top loading model manufacturer has gone bigger than ever before in its hybrid excavator range while another major brand was due to unveil eye-catching quarrying-suited machines and linked technology at bauma 2022 Munich. Guy Woodford reports
Volvo Construction Equipment (Volvo CE) is introducing the EC380E Hybrid - the largest model so far in the Swedish quarrying, construction and mining machine manufacturer’s hybrid excavator range.
In addition to helping enable increased fuel efficiency of up to 17%, Volvo CE says the new 38-tonne class EC380E Hybrid also offers a reduction in CO2 emissions of up to 15%.
The new machine utilises Volvo's hydraulic hybrid technology and builds on the EC300E Hybrid excavator that the company launched in 2019. Since its launch, Volvo CE says the EC300E Hybrid has proven itself as a reliable partner on the jobsite and has been recently upgraded with an all-new powertrain. Two new hybrid machines have recently joined the family – the 25-tonne class EC250E Hybrid and 35-tonne class EC350E Hybrid.
Kangwook Kim, Volvo CE global product manager, said: “We knew when we launched the EC300E Hybrid two years ago that we were only at the beginning of our hybrid journey. Our unique hybrid hydraulic technology has proved it has the potential to work across a range of excavators, no matter the size, and we will continue to build on our offering to provide the most efficient, flexible and environmentally responsible solutions for our customers.”
Volvo’s hydraulic-hybrid technology is
designed to harvest ‘free’ energy generated by the down motion of the excavator’s boom. The powerful and regular boom-down motions charge a hydraulic accumulator, which then stores and delivers energy, when needed, to drive the hydraulic-assist motor that helps power the engine system. Volvo CE says the Hybrid models involve no compromise in ability, with these excavators offering the same levels of controllability and performance as non-hybrid machines.
The manufacturer says that the biggest difference between its own hybrid concept and those of its competitors is that it uses the up and down motion of the boom to capture free energy.
"Other systems typically use the swing motion and capture energy that way," the manufacturer states. "With Volvo CE, customers are able to capture the energy of a typical loading cycle, which is really how the system is able to optimise workflow."
It adds that the hybrid solution is easy to maintain and consists of just a handful of add-on components, meaning no disruption or complication to how the 38-tonne class excavator works.
With this latest machine added to the hybrid range, Volvo CE is committed to a more sustainable operation and a reduced environmental footprint.
Doosan was due to present a claimed industry-leading display of new state-of-theart machine and digital technologies on the
company’s stand at bauma 2022 Munich (24-30 October 2022), the world’s largest exhibition for the construction, quarrying and recycling machine industries. The Doosan stand is centred around a dedicated Innovation Centre and, under the theme of Powered by Innovation, will present the latest developments in the company’s leading-edge Concept-X, Xitecloud and DoosanCONNECT systems, together with other unique products such as the world’s first Transparent Bucket and the new DX225LC-7X, Doosan’s first ‘Smart’ Crawler Excavator.
As well as the new DX225LC-7X, the array of products on the Doosan stand will show the increasing expansion at both ends of the product range for the first time at bauma. At the top of the range, these will include the new DX1000LC-7 100-tonne crawler excavator and the award-winning DL580-7 wheeled loader.
Being shown for the first time in the world at bauma, the new DX225LC-7X - Doosan’s first ‘Smart’ crawler excavator - is designed to help operators work faster and more efficiently. To facilitate this, the DX225LC-7X offers several exciting new features as standard, including full electric hydraulic (FEH) technology. As well as the FEH system, other standard features of the DX225LC-7X include integrated 2D machine guidance and machine control systems, as well as an E-Fence Virtual Wall.
Volvo CE’s new 38-tonne class EC380E Hybrid at work on a quarry site
At bauma, Doosan is premiering the new DX1000LC-7 Stage V-compliant 100-tonne crawler excavator, the largest excavator model ever manufactured by the company.
Driven by the most powerful engine in the 100-tonne class, the DX1000LC-7 also has the highest hydraulic flow for this size of machine, providing claimed best-in-class performance, with higher productivity, lower fuel consumption and smoother controls.
ZF has started prototype assembly of its new eTRAC eCD160 electric drive system for wheeled loaders.
The Germany-headquartered automotive manufacturer produced the prototypes at its facility in Patriching, Passau.
While the eTRAC eCD20-40 for compact vehicles is already being produced in volume production and the fi are underway for the next larger eCD 50-90 series, the newly developed system supplements the existing range with
construction machinery
and power management completes the system. With a 650 V operating voltage, the system can be scaled up to 120kW continuous power. The ePTO ranges from 30-to-70kW continuous power.
All components are thoroughly matched to a comprehensive system consisting of an electro-mechanical powershift transmission and one e-motor for traction and ePTO each. An electric drive control unit for overall system performance
Based on the established ERGOPOWER powershift technology, the eTRAC system is not intended to replace the conventional driveline technology. Rather, it is precisely this modular design that allows many drive concepts to be covered and thus to react even more flexibly to customer requirements in the future.
The newly developed solution can therefore be integrated into battery-electric vehicles as well as vehicles with fuel cells. At the same time, conventional drives with powershift and power-split transmissions will remain the backbone of the vehicle´s system architecture; even for alternative fuels such as hydrogen, eFuels, or biodiesel.
After a successful prototype phase, series production is intended to start in 2025. AB
READY FOR ACTION: THE NEW IMPROVED HEAVY-DUTY VOLVO L350H
Built to tackle the toughest of jobs, the upgraded L350H wheeled loader from Volvo Construction Equipment (Volvo CE) is ready to address a range of applications, from mining and quarrying to heavy infrastructure - with greater productivity and fuel efficiency and lower service costs.
Stronger and smarter, the new Volvo L350H comes with a few notable improvements to boost productivity, increase fuel efficiency and reduce costs, whilst ensuring operator comfort and safety.
Upgraded with the latest innovative technology, including a more responsive
hydraulics system featuring new lift and tilt cylinders, upgraded driveline and all-new Volvo transmission, as well as telematics connectivity and features such as LoadAssist and OnBoard Weighing, the L350H is ready to tackle a range of heavy-duty applications.
And with extended service intervals and durable design, the Volvo L350H can keep working for longer – increasing productivity and reducing downtime.
• This article was produced in association with Volvo CE
Doosan’s DX1000LC-7 Stage V crawler excavator was due to premiere at bauma 2022 Munich
The ZF eTRAC drive system enables emission-free operation of medium-sized wheeled loaders
Hauling with fossil-free steel
The hauling sector has seen a number of eye-catching recent announcements including a new machine made from fossil-free steel, details of upcoming bauma launches, and the inside story on Rokbak’s rebrand. Liam McLoughlin reports
Volvo Construction Equipment (Volvo CE) has become the first manufacturer to deliver a construction machine built using fossil-free steel to a customer. The Sweden-based manufacturer says the move demonstrates the fast-tracking of innovation to real-world solutions as companies across the value chain come together to drive change.
The A30G articulated hauler built using fossil-free steel was handed over by president of Volvo CE Melker Jernberg to long-standing customer NCC on June 1, at a ceremony hosted by LeadIt – the Leadership Group for Industry Transition – in conjunction with the United Nations environmental meeting Stockholm +50. It was attended by John Kerry, US Special Presidential Envoy for Climate (pictured third from left) and Annika Strandhäll, Swedish Minister for Climate.
The move comes just nine months after the company unveiled the world’s first vehicle concept using fossil-free steel, as part of the testing of the implementation in an ordinary production setup. While commercial introduction is expected to be gradual with selected customers, this speedy first handover is an important milestone in the group’s ambition to drive industry transformation towards global climate goals. The A30G is produced at Volvo CE’s Braås facility in Sweden, using the existing manufacturing process, with fossil-free steel from Swedish steel company SSAB.
“We are sure that to succeed in decarbonising the construction industry, actors in the value chain will need to collaborate and act,” Jernberg commented. “Thanks to our strong partnerships with other driven and forward-thinking companies, we are now able to lead the change towards
fossil-free construction and be the first to deliver a machine built using fossil-free steel to a customer. Turning commitments into actions is key to building the world we want to live in.”
Tomas Carlsson, CEO and president of NCC, said: "NCC has a firm commitment to contribute to sustainable development. We are working determinedly and systematically to reach that target, which includes selecting machines that live up to our high demands. As demonstrated in this great example, it takes strong and proactive partnerships between several players to make the sustainable shift possible."
As part of its Science-Based Targets commitment, Volvo CE is set to achieve
raw materials used in its products, of which steel is a major component. The production using fossil-free steel in Volvo CE’s machines and components will be gradual and depend on aspects such as steel availability.
Employees at Motherwell, Scotland-based Rokbak have been celebrating the articulated haul truck brand’s one-year anniversary. Marking the occasion, managing director Paul Douglas has revealed the full story behind the rebrand. Keeping one of the biggest construction equipment stories of 2021 under wraps was not an easy task, so how did Douglas and his team keep the rebranding of Terex Trucks a surprise for so long? The answer lies in good old-fashioned hard work from a dedicated and highly skilled team.
Volvo CE’s A30G is made from fossil-free steel provided by partner SSAB
The Rokbak brand was finally revealed on September 1st 2021 – gratifyingly taking the media, customers, and the competition by surprise – and the public reaction was music to Douglas’ ears.
“The momentum built quickly, with customers and dealers alike eager to get their hands on Rokbak-branded products, whether that was haulers, work wear or coffee mugs,” he said. “Seeing the news bouncing around social media was great, too, perhaps the best feedback you can get.
“When people see the new Sand paint job in real life, they are blown away – it looks incredible on the iron. We’ve been out at a few trade shows and open days this year – including Hillhead, Balmoral Show and ScotPlant – and the feedback has been that our haulers were the best-looking pieces of equipment on site!”
function in the business that didn’t have to get involved.
“For instance, we had to try the new colour scheme out in the paint shop, and we said it was a customer-specific colour – which is something we’ve done for our customers before. Then, before the launch, we had to take the RA30 and RA40 to a quarry to take photos for the marketing materials. It was incredible how everyone in our team, the dealers and our external partners worked together to ensure it remained confidential.”
The COVID-19 pandemic and the essential lockdowns that came with it caused difficulty but ironically the pandemic actually helped to keep the news under wraps. With no events or exhibitions to attend, and no customers or journalists visiting the Motherwell factory, the risk of anyone finding out was greatly diminished.
“We didn’t have to drop the Terex Trucks name, but we had overrun on the initial agreement,” Douglas explained. “For the first few years changing our name wasn’t a high priority, as we focused on stabilising the business and investing in the product, manufacturing and our people. But after we’d made such significant performance improvements to our articulated haulers, it was a natural progression to rebrand – the Terex Trucks name was holding us back. Our customers and dealers also expected and supported a name change to reflect the new machines, so the rebrand was set in motion about four years ago.
“The Volvo Group is extremely brand aware. Originally, we investigated whether there would be any mileage in resurrecting one of the group’s sleeping legacy brands, until the practicalities and legalities outweighed the benefits. This was the first time Volvo had created a new global brand
from scratch, so they were heavily invested in its development and success. We got a lot of help and support from the Volvo Group and Volvo Construction Equipment in particular. On top of the significant investment they made in the Rokbak brand, we also benefitted from shared resources and support when it came to things like design, branding, marketing and legal work – they really helped us bring the brand to life.”
With a small focus group put together from marketing, branding, commercial, sales, and dealer-development backgrounds, the task of selecting a new name could begin. “Some of our original shortlist names turned out to be similar to those used elsewhere, but the team came up with one that we all loved and was truly unique and impactful,” explains Paul. “We were told by Legal that they had never seen anything as clean as it, and that we should grab it with both hands!”
The team then consulted a handful of select dealers across Asia, Europe, the Americas and Oceania in an attempt to understand how different cultures would perceive the most critical aspects of the new brand.
“One piece of dealer feedback was that it was important to ensure our eight decades of hauling heritage was embedded in the new brand, which was essential for us too,” explains Paul. “One way we incorporated this is through a ‘Made in Britain’ element within our machine branding for certain markets.
“Of all the dealers we initially tested the Rokbak name and new colour on, the majority were immediately enthusiastic, leaving just a couple of individuals who needed to see a little bit more to be convinced. I wasn’t remotely surprised at how quickly they changed their minds at the launch.”
The success of the entire rebranding project was also recognised by a wider audience when the company walked away from the Star Awards 2022 with five accolades from the Marketing Society, as well as a CeeD Industry Award at the start of the year.
One of several world premieres from Doosan at bauma 2022 is the launch of the company’s new 4x4 articulated dump truck (ADT).
Complementing the company’s standard range of 6x6 ADT models, the new 4x4 version of the DA45-7 ADT is intended to compete with rigid dump trucks (RDTs) in the 40-tonne class.
The new 4x4 DA45-7 ADT complements the manufacturer’s current range of Stage V-compliant 6x6 ADTs, which includes the DA30-7 and DA45-7 models with payloads of 28 and 41 tonnes, respectively.
In the new 4x4 ADT, the front truck and cab unit is the same as in the original 6x6 model, with modifications being made on the rear dumper unit only. Featuring a ZF EP8-420 transmission, the 4x4 DA45-7 is a two-axle ADT with twin wheels at the rear, and with a dumper section similar to that on RDTs in the 40-tonne class.
“With superior operation on poorer roads, smoother surfaces and steeper terrain, the aim of our new 4x4 machine is to challenge RDTs in the 40-tonne class, by providing a dumper product that delivers much more than RDTs,” said Beka Nemstsveridze, ADT product manager at Doosan.
As well as performing better in conditions that are tough for RDTs, the new 4x4 DA45-7 ADT has a width of less than 4m to avoid the need for special transportation and offers a better turning radius than a comparable RDT. The shorter turning radius and the design of the rear dumper unit, which is more suited to carrying flat and heavy rocks, provide particular advantages in the mining and tunnelling industries.
The latter are growing markets for ADTs, and include pioneering, short-term mining projects, quarrying and contract mining industries, especially those in southern Africa, the UK and Australia. AB
Rokbak MD Paul Douglas with a hauler in the new ‘Sand’ livery
Continental’s new LD-Master L5
Traction radial tyre is well suited to rigid dump trucks in quarries
Impressive tyre tracks
Two major quarrying- and construction machine tyre makers were due to exhibit their new and latest tyres and linked technology at bauma 2022. Guy Woodford reports
Three Giant BKT tyres with a host of standout features were set to be eye-catching sights for visitors to the bauma 2022 construction, quarrying and recycling equipment industries exhibition in Munich, Germany (24-30 October 2022).
Launched last year, the EARTHMAX SR 468 is the largest tyre ever made by BKT. It is designed for rigid dump trucks (RDTs) and exhibited in size 40.00 R 57 corresponding to a height of 3.5 metres, a width of 1.13 metres and a weight of 3,800kg.
The second Giant tyre is the EARTHMAX SR 46, displayed in the sizes 27.00 R 49 and 33.00 R 51, also designed for RDTs. The 33.00 R 51 size is equivalent to a diameter of over three metres or precisely 3,061mm, a width of 905mm and a weight of 2,400kg, while the 27.00 R 49 has a diameter of exactly 2,688mm and a width of 746mm.
Suitable for operations on rocky and harsh terrains, both these tyres are particularly resistant to impacts and punctures thanks to their all-steel structure that provides resistance to the casing. In addition, the E-4 tread depth offers extreme resistance in severe conditions. Finally, the tyres’ specially designed tread pattern and the tread compound have been developed to reduce the heat generation during extreme applications.
The tyre duo is part of EARTHMAX, the BKT range designed for a better weight distribution on the ground for dumpers, wheeled loaders, dozers, graders and some multi-purpose vehicles. Today, the EARTHMAX range includes 40 different tyres for the earthmoving, construction, quarry and mining sectors and is available in many sizes and different compounds.
BKT says it is working on many fronts in
BKT’s largest off-the-road tyre to date, the EARTHMAX SR 468, was due to be showcased at bauma 2022
the off-the-road (OTR) tyre sector, with a particular focus on new compounds that are highly cut-and-chip resistant, as well as on ultra-heat-resistant compounds that are able to carry heavy loads maintaining, at the same time, an excellent TKPH (the average ratio between the transported weight by the equipment and the speed in km/h).
Continental was also due to play a prominent role at bauma 2022 with the German OTR maker launching its innovative LD-Master L5 Traction radial tyre.
Expanding the ContiEarth range and initially in size 35/65 R33, the new LD-Master L5 Traction radial tyre is said to be ideal for demanding conditions and is also fitted with tyre sensors ex-factory.
Construction and quarrying machines usually operate with heavy payloads and are exposed to a variety of harsh ground conditions, such as rock, gravel or rubble. The LD-Master L5 Traction is specifically designed for loaders operating on abrasive surfaces and in-face working jobs where high productivity and assured vehicle uptime are of the upmost importance.
The reinforced 3* carcass is said by Continental to satisfy the highest loadcarrying capacity requirements, even under extensive production cycles. The L5 traction-tread pattern protects the carcass and ensures smooth and safe operation on the construction or quarry site. The solid tread block design always provides secure traction. The extra deep tread and sidewall protection also make the tyre more robust and ensure long-term productivity.
To minimise idle time and ensure serviceability even under harsh conditions, the special tyres fitted to construction machinery should be controlled as precisely
Tyre-retread manufacturer Marangoni has issued a message of condolence after the sudden death of former group CEO Massimo De Alessandri.
The Italian company said its board of directors, the management, and all employees and collaborators of Marangoni participate in the mourning for Mr De Alessandri's untimely death on 19th July 2022 and extend their condolences to his family.
De Alessandri joined the Marangoni Group in 1987 and was the long-time CEO of the parent company, ending a 30-year career in 2017.
During this time, he was also chairman of Marangoni Group subsidiaries such as Eurorubber (20112016), Pneusmarket (2001-2016) and Marangoni Tread (2003-2009), managing director of Marangoni Tyre (2004-2017) and director of Marangoni Meccanica (2008-2017).
In addition to holding top roles
as possible. The LD-Master L5 Traction is fitted with an integrated tyre sensor ex-factory, making monitoring possible in real time. The sensor monitors temperature and tyre pressure, always assuring the most efficient operation mode for a long tyre life.
At bauma 2022, Continental was also presenting a new generation of its ContiConnect tyre-management system. Version 2.0 is said to put in place the necessary infrastructure for the all-encompassing, digital tyre management
of the future. To this end, the company has refined its system environment to keep it “perfectly in line with the specific requirements of fleet customers around the world.”
PSH Environmental is said to have eliminated all instances of punctures across its fleet of Volvo Construction Equipment (Volvo) wheeled loaders by utilising Michelin’s ultra-durable X Mine D2 Pro tyres. The Norwich, England-based skip hire, recycling and aggregates business specifies
FORMER MARANGONI GROUP CEO PASSES AWAY
within the group, he has held positions in other industry bodies such as the Plastic Rubber Federation, ETRMA (European Tyre & Rubber Manufacturers Association) and Ecopneus Scpa (of which he was also President in 2014).
His contribution has deeply marked the history of the Marangoni Group and will remain rooted in the company's memory.
Vittorio Marangoni, chairman of the Marangoni Group, said: "The news has shocked the company as well as the family. There are no words for such a circumstance; we all join in the grief."
In a statement, Marangoni said that the entire company expresses its deepest and most heartfelt condolences for the passing of a competent, conscientious person always committed to his work with great seriousness and passion.
At bauma 2022, Continental was also presenting Version 2.0 of its ContiConnect tyre-management system
Massimo De Alessandri (left)
all new machines with the Michelin fitments, having found them to be more durable than any other rubber tyre on the market, while offering a much-improved level of comfort and performance over a solid waste tyre.
Nigel Parker, who runs PSH Environmental alongside his brother Martyn, says: “We fit the Michelin product because it is by far the best option for our wheeled loaders. The Volvos are fantastic machines, working in a very tough environment and we use a premium tyre to ensure we get the best out of them and avoid costly downtime.
“Unless you are very, very careless you really cannot puncture these tyres. The only other option for us would be to run solid tyres, but we have avoided that as the ride quality is so poor and, working on concrete, you can end up damaging the machine.”
PSH Environmental runs three Volvo loading shovels – one older L60H and two new L90H machines, all supplied by SMT GB. The L90H is the latest addition to Volvo’s H-Series, offering a higher load capacity and greater lifting height than any of its predecessors.
The business uses the loaders to move materials onto walking floor trailers, shifting waste into shredders and loading plant machinery at its depot in Norwich.
“The older L60H we have had for more than four years now, and it has the same set of tyres on as when we got it. It’s done in excess of 7,500 hours,” says Parker. “With the
two new L90s I think they’ll last even longer –they’re fantastic machines. We can put about 26 tonnes of black bag waste on a walking floor trailer in around eight minutes.”
Designed specifically for operation in demanding environments, the X Mine D2 Pro is built with optimised rubber compounds to help withstand hard conditions and slow tyre wear. The range features a reinforced, resilient casing and an innovative, robust tread design to improve resistance to cuts and punctures.
Michelin’s NRF Technology – two extra plies added to the tyre construction, which
contain crossed cords encased in rubber for greater resistance and toughness – helps to reduce downtime and increase load capacity.
“We’re running a busy operation and we can’t afford to have machines that are out of action with a damaged tyre,” adds Parker. “You know you’re not going to get that from Michelin. The tread pattern is bang on for the work we’re doing as well.
“We have tried other tyres in the past, but they are like chalk and cheese really. They just don’t stand up to what the Michelin’s can offer.” AB
PSH Environmental runs three Michelin X Mine D2 Pro-tyre-fitted Volvo loading shovels, all supplied by SMT GB
A LONG WAY TOGETHER
EARTHMAX SR 41
No matter how challenging your needs, EARTHMAX SR 41 is your best ally when it comes to operations that require extraordinary traction. Thanks to its All Steel radial structure and the special block pattern, EARTHMAX SR 41 provides excellent resistance against punctures and an extended service life. In addition to long working hours without downtime, the tyre ensures extraordinary comfort.
EARTHMAX SR 41 is BKT’s response to withstand the toughest operating conditions in haulage, loading and dozing applications.
Epiroc's new SmartROC T35 E battery-electric tophammer drill rig is designed to enhance the environmental standards of quarries and larger construction sites
Testing the ‘world’s first’ battery-electric tophammer drill rig
The drill rigs, hammers and breakers sector has seen some significant product, market and people news as manufacturers gear up for the bauma equipment show in Munich. Liam McLoughlin reports
Epiroc, the Sweden-based drill rig and hydraulic breaker manufacturer operating in the global quarrying and mining industries, has partnered with Skanska Industrial Solutions to trial what is claimed to be the world's fi battery-electric tophammer drill rig.
The Swedish quarry-based trial is said to mark a significant milestone in the journey towards zero- emissions drilling in surface mines and quarries worldwide.
"This is a proud day. For many years we have been leading the development in lowering fuel consumption within tophammer drilling, "says Ulf Gyllander, product manager tophammer drill rigs, Epiroc surface division. “With this new solution, we are taking a giant leap in the low-emissions field – we are practically removing emissions from the actual drilling process.”
The design of the rig is based on the well-proven SmartROC T35 surface drill rig. In combination with invaluable experience gained from the development of Epiroc underground battery rigs, this SmartROC T35 E is designed to enhance the environmental standards of quarries and larger construction sites. Besides the low emissions, this rig comes with a range of smart features, options and enhanced automation solutions for high safety, reliability, and performance.
"With this achievement, we show that the innovations of Epiroc will play a significant role in the shift to low-carbon operations within quarries and large construction applications," says Jose Sanchez, president of Epiroc Surface division. "As our sustainability agenda goes hand in hand with those
of our customers, we are very pleased to be collaborating with Skanska Industrial Solutions AB in the trials of this important solution."
The tests commenced in September 2022 in one of Skanska Industrial Solutions' quarries in the Stockholm area.
Epiroc has also won a large order for surface mining equipment from Société Nationale Industrielle et Minière in Mauritania.
Société Nationale Industrielle et Minière, known as SNIM, is one of Africa’s largest iron ore producers. The mining company has ordered a package of Epiroc Pit Viper 351 drill rigs with advanced automation solutions that will be used at the new F’Derick mining site.
Epiroc will also provide service supervision and spare parts. The equipment order is valued at around SEK150m (US$14.67m) and was booked in the second quarter 2022.
“Epiroc has a long-term relationship with SNIM, and we look forward to continue supporting the customer with optimal productivity and safety at the new mine site,” said Helena Hedblom, Epiroc president and
The Pit Viper 351 rigs are manufactured in Texas, United States. They will be installed with automation features including AutoDrill, which allows for up to 100% of the holedrilling cycle to be in automatic mode with high consistency and reliability of operations, and with AutoLevel, which minimises the time it takes to level and de-level and hence provides more time drilling.
The rigs will also be equipped with Epiroc’s telematics system, which allows for intelligent monitoring of machine performance and productivity in real time .
Epiroc celebrated its best-ever quarter for electrification-linked orders and welcomed rises in operating profit, revenues and overall orders in the second quarter of 2022.
The company's orders increased 21% to SEK13,377m (€1.273m) (SEK11,070m Q2 2021), an organic increase of 6%. Excluding Russia, the organic order growth was 18%.
Epiroc revenues increased 22% to SEK11,868m (SEK9,733m), an organic increase of 9%.
The company's operating profit increased 9% to SEK2,381m (SEK2,182m), corresponding to a margin of 20.1% (22.4% organically).
Skanska's Johan Eliasson (left) and Jonas Albertson, Epiroc CTO, mark the agreement to trial Sweden's first-ever battery-electric tophammer rig
Targeting your requirements to come up with a ground-breaking solution.
That’s what we’ve been doing for over 45 years. Targeting your specific needs on your jobsites, delivering the best solution in terms of reliability, efficiency and productivity. Discover how, by scanning the QR code on this page. You will get an overview of the wide range of Indeco hydraulic hammers, to help you choose the model best suited to your needs, to your carrier and to the job at hand. Bauma 2022 October 24-30 Munich Open Air Area FM 709/8
Commenting on Epiroc's Q2 2022 trading performance, Hedblom said: "Several large equipment orders were won, of which many included battery-electric and automation solutions. Also, the service business performed strongly. We expect that the underlying demand, both for equipment and aftermarket, will remain at a high level in the near term."
Hedblom described the ongoing war in Ukraine as "truly horrifying" and stressed that Epiroc continued to take measures to protect colleagues and manage the complex situation in Ukraine and Russia.
"We also continue to face higher input costs and supply-chain challenges. However, our agile organisation can adapt quickly to changes and challenges, and our large aftermarket business provides resilience."
Hedblom said Epiroc offered "marketleading solutions within automation, digitalisation, and electrification" and noted that the second quarter was the company's best quarter ever for electrification.
"We won several orders for battery-electric equipment, also for greenfield projects, as well as for battery retrofits and electrical infrastructure solutions. And, shortly a customer will be testing our first batteryelectric surface drill rig. We are excited to help our customers reach their sustainability goals."
Hedblom noted that in June Epiroc celebrated four years as a listed company. "It has been an exciting time. We drive the productivity and sustainability transformation in our industry and will continue doing this by investing in innovation, aftermarket, and options for the future. Some examples are the acquisitions of a provider of electrical infrastructure solutions and of a manufacturer of rock drills.”
In August, Epiroc announced that it has completed the acquisition of RNP México, a manufacturer of rock drills and related spare parts.
RNP México is based in San Luis Potosi state, and has branches in Chile and Peru. The company develops, manufactures, and sells rock drills and related components, serving mining and construction customers mainly in Latin America.
The transaction is not subject to a disclosure obligation pursuant to the EU Market Abuse Regulation.
Italy-based hydraulic hammer manufacturer Indeco that serves industries including quarrying, says that the company has invested in a new €7m metal-casing fabrication plant in the Bari area.
Speaking to Aggregates Business at the Hillhead 2022 exhibition near Buxton, in Derbyshire, England, Michele Vitulano, commercial & marketing director at Indeco, said the new Bari facility was required to meet rising global hydraulic hammer demand.
In July Vitulano was elected as the new chairman of the board at UNACEA, the Italian Construction Machinery Union. He will serve a two-year period as chairman from 2022 to 2024.
Vitulano commented on the market situation as he takes up his new industry role: “Although the market results remain positive, the construction Italian machinery and equipment sector is going through a complex period due to the effects of the war in Ukraine, the rising inflation and the outbreak of the Italian government crisis.
“However, I remain optimistic about the future: Italian companies are used to work[ing] in complicated contexts and, on the other hand, post-COVID public investments in infrastructural works should ensure stability to the construction sector .”
UNACEA was founded in 2010 and represents the manufacturing and commercial sector, which has a total turnover of €3.5bn and an employment volume of 50,000 workers, including related activities. The association also represents the Italian industry in the European construction equipment manufacturing association CECE. Sweden-based rock-drilling-equipment company Sandvik has appointed Mats Eriksson as president of business area Sandvik Mining and Rock Solutions (SMR) and as a new member of the Sandvik Group Executive Management, effective October 1, 2022. He was previously president of Load and Haul, a division within Sandvik Mining and Rock Solutions.
Helena Hedblom Epiroc CEO and president
“We are excited to help our customers reach their sustainability goal”
“Mats Eriksson is an experienced international leader who has successfully delivered strong results and growth for the Load and Haul division,” says Stefan Widing, president and CEO of Sandvik. “He has also been instrumental in the development of our world-leading offering of battery-electric vehicles.”
Mats Eriksson was born in 1962 and is a Finnish national. He joined Sandvik in 2016, when he assumed the position as president of the Load and Haul division. His previous experience includes being president and CEO of two listed companies, Cencorp Oyj and Salcomp Oyj. Additionally, he has held leading positions for several other companies, building businesses and operations in countries such as Singapore, Malaysia, China, India, US, Brazil and South Korea.
Sandvik has also appointed Richard Harris as president of its Sandvik Rock Processing Solutions (SRP) business area and as a new member of the Sandvik Group Executive Management, effective 1 October 2022.
He succeeds Anders Svensson, who, as previously announced, is leaving Sandvik to become president and CEO of Konecranes.
Harris is currently president of Walter, a division within the business area Sandvik Manufacturing and Machining Solutions.
“Richard Harris is an experienced international leader with a very strong operational background who has proven great performance management and execution skills during his years at Sandvik,” said Stefan Widing, president and CEO of Sandvik. “In addition, he has successfully driven an active growth and acquisition agenda. I am convinced that he will be a very good fit as business area president for SRP and a great addition to the group executive management.”
Born in 1970 and a British national, Harris has been with the Sandvik Group since 2002 in various senior positions within Sandvik Machining Solutions (SMS). Before becoming president of Walter in 2019, he was president of the Wolfram division. Previous positions also include several different supply and production director roles within SMS.
Svensson leaves Sandvik on 14 October 2022, after completing the report for the third quarter. AB
Michele Vitulano of Indeco, has become chairman of the board at UNACEA
SHAFT SCREENER
Sorting bucket with interchangeable shafts for excavators. When installed on your excavator it selects large volumes of material directly on-site wherever it is.
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Showcasing greener and efficient washing solutions
Major wet-processing industry players are highlighting more advanced and sustainable solutions. Manufacturers in the sector are also emphasising the benefits to operators of decanter centrifuges and coarse washers. Liam McLoughlin reports
CDE, the global provider of sand and aggregate wet-processing solutions for the natural processing and waste-recycling sectors, will highlight the role of its technology in supporting the circular economy and zero-waste agenda at this year's bauma exhibition in Munich, Germany (24-30 October).
As the construction sector continues to cope with the availability and cost of raw materials, CDE says it will demonstrate the potential of construction, demolition and excavation (CD&E) waste to address the challenges facing the sector.
On October 26 and 27, it will be joined on stand by a number of its European customers for a series of round table discussions on the future of recycling, and, as part of the bauma exhibitor forum on 24 October, will deliver a lecture on the topic of Creating valuable in-spec products from CD&E waste
CDE's head of business development for North West Europe, Eunan Kelly, comments: "In the current economic and social climate, with materials costs rising, resources depleting, and regulations calling for the adoption of sustainable solutions, we should look to the technology of today to produce the sustainable construction materials of tomorrow; how CDE's waste-recycling solutions in their trademark blue can support the industry to transform CD&E waste into certified, in-spec sand and aggregates."
Earlier this year, a package of European Green Deal proposals was presented with a view to making sustainable products the norm within the EU internal market. The revised Construction Products Regulation (CPR) emphasises the value of construction to the EU as a key employer and economic contributor. However, it also highlights the adverse impacts the sector has on the
environment, as one generating some 30% of the EU's annual waste and contributing significantly to its domestic carbon footprint and emissions.
The construction industry is a major economic driver; in the EU alone, 25 million people are employed across five million companies, according to data from the revised CPR. So, when the COVID-19 crisis gripped economies and construction output fell to some of its lowest-ever levels, it was no surprise that robust recovery plans with a clear focus on investments in infrastructure were announced by nations around the world to rebound and stimulate economic growth.
However, the cost of raw materials and their availability remains a deepening challenge for the sector.
Materials shortages and their rising costs are not entirely symptoms of the pandemic but they have been exacerbated by it and have become more acute,
Sweden-based DA Mattsson diverts almost 100% of its incoming CD&E waste from landfill through a wet-processing operation provided by
CDE's business development manager for the DACH region, Christoph Baier, explains: "Every day we continue to extract our fastdepleting natural resources to support rapid urbanisation and our modern, technological lifestyles. Essential to this is sand, the secondmost consumed natural resource after water and the most-consumed solid material on earth.”
In April, the UN Environment Programme (UNEP) published 10 recommendations to avert the impending sand crisis. It referenced how the use of sand, gravel, crushed stone and aggregates has tripled in the last two decades, reaching an estimated 40-50 billion metric tons per year (UNEP 2019).
"This, in the context of projected increases in global populations and urban living," Baier continues, "demonstrates how demand will only rise, while resources will only deplete, unless we adopt long-term attitudinal, regulatory and technological change to ensure not only the sustainability of companies within the construction sector –and with it the livelihoods of those employed within it – but also the sustainability of the very planet.”
While COVID-19 economic recovery packages may help to stimulate growth, they must be conditional on building back greener, more sustainably, Baier adds.
A circular approach is the only answer, Kelly corroborates: "It can be the means to equip us with the resources needed to supply a sector charged with a key role in the economic recovery while addressing our collective environmental footprint by reducing waste-to-landfill volumes and extending the lifespan of precious natural materials.”
He says the technology needed to extract recycled sand and aggregate resources from CD&E waste that are equivalent to their virgin quarried counterparts is already in operation throughout Europe.
To date, CDE solutions have supported companies around the world to divert over 100 million tonnes from landfill.
Kelly says: "Many material processors utilising CDE technology are successfully producing CE- and BSI-certified concrete products, including competitive concrete for non-structural – but still high-value –construction projects, with some applications successfully achieving beyond C45 spec."
DA Mattsson, based near Stockholm in Sweden, diverts almost 100% of its incoming CD&E waste from landfill through its CDE wet-processing operation. The company produces high-quality sand and aggregates that meet EN 12620 specification, and it supplies these concrete materials to the Stockholm construction market.
McLanahan – the US-headquartered dry and wet materials processing solutions manufacturer for quarry and mining customers - says that aggregates producers have several mechanical options to choose from when it comes to dewatering tailings for improved handling, settling pond elimination, water recovery or meeting environmental regulations.
One of these options is a decanter centrifuge, which is used to separate solids from liquid in a variety of applications. In agregates processes, one use for decanter centrifuges is to handle the tailings in the waste stream. With high centrifugal forces to induce sedimentation, decanter centrifuges separate the solid particles from the liquid in a typical waste stream coming from a wet-processing plant.
Decanter centrifuges discharge two products: a liquid that can be reused as process water upstream, and a solids cake that is suitable for mechanical handling. McLanahan says that their main benefit for processing tailings in aggregate applications is that they make handling the waste stream easier and more efficient. Processing the waste stream through a decanter centrifuge has even allowed some sites to eliminate their settling ponds or lagoons, which can be costly and time-consuming to maintain as well as taking up valuable land space.
Decanter centrifuges consist of a feed pipe that goes inside a helical screw conveyor that is surrounded by a bowl assembly. These components are then enclosed in a casing, which helps improve housekeeping and reduce noise. Discharge chutes at the bottom of the casing collect the discharged materials
Decanter centrifuges are supported on a heavy-duty base frame mounted on vibration isolators to minimise vibration and maintain balance. Other main features include the motors and gearbox, which impart the rotation of the conveyor and bowl assembly necessary for liquid-solid separation.
“A decanter centrifuge uses centrifugal forces to separate solids from liquids at high Gs ,” McLanahan comments. “The waste stream in the form of a slurry enters the
inside of the helical conveyor through the feed pipe. The slurry is then released into the space between the rotating conveyor and the bowl, which is rotating at a higher speed than the conveyor. The solids in the slurry are forced to the wall of the bowl, while the liquid moves freely toward the liquiddischarge end of the machine.”
The conveyor moves the solids toward the solids discharge at the opposite end of the machine. The conveyor and bowl are tapered conically at this end to further dewater the solids before they are discharged. The solid cakes are low moisture, and they can be handled with a loader and transported via a truck to a final resting place.
A decanter centrifuge operates in a continuous process, meaning material is continuously being fed into it and material is continuously being discharged from it.
Decanter centrifuges come in a variety of sizes to handle a range of capacities. Like many aggregates- and mineral-processing machines, Decanter centrifuges are sized based on the feed and process requirements. The larger the centrifuge, the higher capacity of feed material it can handle and the more tons per hour it will discharge.
Other factors that affect sizing include the speed of the conveyor, the speed of the bowl, the angle of the tapered beach area and the pitch of the conveyor.
McLanahan states that, because of the range of sizes and capacities they come in, the cost of a decanter centrifuge can vary enormously depending on the type needed to fit the application requirements. Once a duty is determined, the manufacturer will be able to select a suitable model and provide cost and cost-benefit information accordingly.
A McLanahan decanter centrifuge
The operational costs can vary depending on the size of the machine and how much power is necessary to process the material to the desired outcome. Power costs, too, can vary depending on location and energy supplier.
Depending on the material being processed and the goals of the site, chemicals may need to be added to the feed to aid sedimentation.
Decanter centrifuges are fully automated, meaning they require minimal operator intervention, so labour costs will be less with these machines compared to other mechanical dewatering devices such as belt presses. They are relatively low-maintenance machines. For the most efficient operation, McLanahan states that they should be regularly inspected and maintained according to the manual.
Inspections should be carried out before the centrifuge is started up every day, and more in-depth inspections should take place every 2,000, 4,000, 8,000, 16,000 and 40,000 hours of operation (or every three months, six months, year, two years and five years, respectively).
If inspections reveal components need to be repaired or replaced, do so immediately by following the replacement procedures listed in the manual. Be sure to follow all safety guidelines outlined in the manual and to heed all machine warning labels and sitespecific safety measures.
“Also, be sure to keep a stock of spare parts at your facility to minimize downtime when replacement of a component is necessary,” McLanahan comments.
“Decanter centrifuges are a great option for dewatering tailings in aggregate applications to a low-moisture content suitable for mechanical handling. They are fully automated, low-maintenance, compact
saleable product. The design of the Trio TCW coarse material washer allows the deleterious material from the overflow to be floated off and removed, thus improving the quality of the product and efficiency of the process. In addition to supply, Weir Minerals supported in the removal of the old barrel washer and installation and commissioning of the new Trio TCW coarse material washer.
machines that can be adjusted to improve the solids dryness or liquid clarity, depending on the goals of the site.”
Washing plant manufacturer Weir Minerals says that its Trio coarse washer has unlocked a 12% increase in production at the Tudor Griffiths Group, a leading UK independent supplier of construction materials, building supplies and most recently, waste management and recycling services.
Established in 1874, the Tudor Griffiths Group utilised steam engines to increase production and continues to innovate, evolve and grow to enhance its operations for a sustainable future. During a regular site visit, the Tudor Griffiths’ team discussed its need to improve plant reliability, availability and product quality.
Tudor Griffiths’ process included a barrel washer. This ageing technology was inhibiting the plant’s overall production by around 30,000 tonnes (when compared with the production achieved in the previous year). Breakdowns became more frequent, occurring at least once per week over a period of six months, which had a negative impact on the plant’s availability and the costs incurred.
Using the incumbent barrel washer, Tudor Griffiths experienced the equivalent of a months’ downtime over the period of a year. In addition, there was limited access for the Weir Minerals Europe team to install the Trio coarse washer. There was limited space available for the new equipment to fit in and the Trio was a perfect fit, while at the same time removing any contaminants from the aggregates.
The team at Weir Minerals specified a Trio TCW3618 coarse material washer to help Tudor Griffiths achieve its required operating parameters and increase the amount of
The TCW3618 reduced power consumption by around a third, from an estimated 55kW to 22kW at the same time as maximising plant availability. A potential of 170 TPH of mixed sand and gravel are produced and approximately 40 to 80 TPH of stone are washed, depending on the dig. A paddle change was undertaken after six months of use, achieving a total of 1,200 hours of wear life.
Following the installation of the Trio TCW3618 coarse washer, Tudor Griffiths saw production increase by 50,000 tonnes per year (12%) and a reduction in downtime of around 26 days per year.
Jason Pritchard, quarry manager at Tudor Griffiths said: “The Weir Minerals team worked with us to understand our objectives and proposed a solution which was capable of meeting our needs. The Trio washer has not only increased our plant capacity but also improved the overall cleanliness of our end product. We have been thoroughly impressed by the quality of the equipment provided by the Weir Minerals’ team, who have been proactive in proposing further adjustments and optimising our washer’s performance.”
The Trio coarse washer cleans coarse material containing very water-soluble silts and soft clay. Material rolls and tumbles while carried up the spiral shaft. Cast paddles abrade and separate aggregate from dust and soluble clay. The waste material absorbed by the water is discharged over the adjustable weirs at the back of the machine. Classifying is accomplished when material containing deleterious matter that has a specific gravity less than the coarse material is floated upwards and carried over the adjustable weirs. The water velocity to float the deleterious materials comes from the manifold on the bottom of the tub. The cleaned product is discharged at the inclined section of the machine. AB
The Trio TCW3618 coarse washer from Weir Minerals
Having an optimised blast
There are a lot of exciting technological developments in the quarries and mines blasting sector. Guy Woodford reports
As one of the world's leading mining, quarrying and infrastructure solutions companies, Orica’s digital strategy is maturing beyond the range of technologies it offers today, aiming to deliver a suite of digitally integrated workflow tools to enable the corporate vision of sustainably mobilising the Earth's resources.
Traditional digital solutions including software and IoT devices are typically focused on delivering data and insights specific to a discrete product. Through the digital integration of workflows, customers can now gain a deep understanding of how geology within the ore body intelligence space informs the optimisation of energy required for blasting in real time, and the subsequent benefits on downstream processes.
One example of this is Orica’s FRAGTrack suite of automated fragmentation and analysis technologies that has proven to deliver operational continuity for quarrying and mining operations, enabling downstream process efficiency by providing insights to optimise fragmentation.
The award-winning fragmentation monitoring solution leverages deep neural network artificial intelligence, along with industry-proven hybrid 2D and 3D particle-size distribution (PSD) processing methods. The system now includes a new variant, FRAGTrack Crusher, specifically designed for the quarry and construction market, providing automated, near realtime fragmentation monitoring at the crusher dump pocket.
Raj Mathiravedu, vice president for Digital Solutions at Orica, said: “Delivering unmatched measurement accuracy of material on trucks during the tipping operations, FRAGTrack Crusher is our latest addition that autonomously delivers constant and accurate performance tracking of particle-size distribution to drive continuous end-to-end improvements
for quarrying and mining operations. Our technology roadmap is to leapfrog from measurement as a tool to measurement as an outcome, and it is great to see the value that this is unlocking for our customers.”
Stevenson Aggregates, a longestablished concrete and aggregates provider recently embarked on a project to improve crusher throughput and reduce carbon footprint at Drury Quarry in New Zealand. Among the challenges faced were irregularities of scalping yield and inconsistent crusher throughput. Manual interventions and in-pit sampling for improvements had been time-consuming and unsustainable.
In response, Orica installed FRAGTrack Crusher, enabled with machine vision at the primary crusher feed, providing PSD analysis during tipping without interfering with the haulage operation. Smart trigger settings captured true samples and insights are fed to the FRAGTrack portal that enabled a direct feedback loop to managers and engineers for assessing blast fragmentation performance, as well as production rates, blockages, and the amount of primary crushing versus secondary crushing.
Daniel Topp, performance manager at Stevenson Aggregates, said: “FRAGTrack is allowing us to obtain information that we've never
typically had. What we're getting out of it so far is huge information to understand our rock and resource better. This is actually data that we can feedback and analyse and that's pretty revolutionary.”
Since the installation of FRAGTrack Crusher in May 2022, Drury Quarry has been equipped with more than 10,000 fragmentation images and PSD data, generating unbiased data that matches blast PSD to crusher performance metrics through time-stamped samples. A critical insight revealed that a large percentage of blasted rock bypassed the primary crusher and went straight to the secondary feed. This led to the calibration of the fragmentation prediction model to optimise blast design and the opportunity for pattern expansion to increase coarse rock fragments.
The application of FRAGTrack has saved Drury Quarry over 800 hours of manual processing, of which a fraction of the time is now given to data analysis and correlation, and continual optimisation of its operations. More importantly, FRAGTrack has allowed Drury to develop an accurate and unbiased PSD baseline for the optimum range of sizes to maximise crusher performance and reduce scalp yield.
FRAGTrack Crusher capturing samples during tipping
Recognising the value of the partnership, Stevenson Aggregates’ general manager, Kurt Hine, said: “Having a partner like Orica is great for us. We love our supply partners coming to us so that we can continue to innovate, improving our processes and deliver a quality product to our customers in a more sustainable way."
Today, Drury Quarry continues to leverage the FRAGTrack Crusher to reduce overall cost per tonne of aggregate, provide critical data for specific drill and blast optimisation and reduce overall carbon footprint as the demand for aggregate production in the region rises.
Orica’s leading blasting technologies undergo continuous improvements –among them is the uni tronic electronic blasting system designed for quarrying and construction. The current variant and its predecessor have long been the leading blasting systems in the category since 2004. Widely adopted globally, the current uni tronic 600 is hailed for its inherent safety features, reliability and cost-effectiveness in addition to its remote firing capability. Trials are underway for the next generation uni tronic. Details are yet to be revealed but Aggregates Business understands that enhancements are being made to the system to deliver greater precision timing, increased firing capacity, more flexible timing delays and a new user interface to speed up operations.
Joel Guenther, global senior manager for marketing (EBS), said: “As uni tronic continues to see increased adoption, we continue to look for opportunities to improve its features and usability to better support our customers. The upcoming release of our next-generation electronic blasting system will be easier to learn and use, with an improved user interface to enable faster field
implementation and troubleshooting.”
The upgraded version looks set to enter the market globally in the first half of 2023.
Experienced engineer Scott Britton, of leading global quarrying and mining technology provider Maptek, has observed a growing appetite to embrace new drill and blast technology solutions in the quarrying sector.
Quarry operators are starting to consider more advanced software solutions as operations face ever-higher demands to perform efficiently and comply with more stringent environmental and permitting constraints. Historically, the comparatively small size of quarries, and the perception of a lengthy return on investment, has contributed to a lack of focus on best-available technology when it comes to detailed analysis, modelling and design for drill & blast activities.
Production improvements have been introduced through more efficient fleet vehicles, automated systems and better utilisation of hardware, but when it comes to specialised software for design and modelling there has been a lack of real technical innovation.
Many quarries use CAD software, which is often lacking in sophistication or current techniques, meaning operations miss out on the opportunity to access ongoing improvement in their drill and blast practice.
As operations grapple with industry-wide skills shortages and large companies look to acquire quarries, there is growing enthusiasm to explore better design, execution and reconciliation methods.
Maptek’s sales manager: Europe, MENA & West Africa, Britton says one of the biggest drill and blast challenges for the quarrying sector is the lack of technical resources available to help make efficiency gains and push for change.
For various reasons, profit margins on the majority of projects are so small that, in addition to the expertise shortage, there is limited revenue for investing in the latest technology.
As most quarry operations are fairly small in comparison to bulk mining projects, it can be challenging to incorporate changes that typically deliver relatively small improvements, as the payback period can be much longer.
The quarrying sector has also struggled to retain skilled technical staff, with increased competition coming from construction and civil engineering, accelerating the need to embrace automation.
Some operators recognise that this change is coming and are starting to make appropriate changes, but due to the lack of investment and resources, companies that fail to streamline their operations are likely to struggle.
In addition to issues relating to technical resources, productivity and efficiencies, more stringent legislation and permitting is now required to exploit new resources. This has increasingly resulted in higher project startup costs and further reliance on specialist consultants to support new planning applications.
FRAGTrack Crusher’s autonomous adaptive fragmentation monitoring at the crusher dump pocket
Blast Box 310R with remote firing at Drury Quarry with the current uni tronic 600
"Ultimately it means that companies are at risk of being uncompetitive if they fail to adapt," Britton says.
"They know this, and demand for Maptek solutions and technical support is on the rise within the quarrying sector. We are beginning to see a higher level of interest and engagement at technical events with more companies approaching us for help."
While Maptek has more customers in the mining sector, its solutions can be found in a wide range of quarry operations across Europe. One long-standing customer has used Maptek Vulcan geological modelling and mine-planning tools routinely for their mainland Europe projects over the past 20 years and recently started to implement a similar approach for their operations in North America.
In a large operation, different (survey, modelling, design) tasks are performed by dedicated teams. In quarry operations, a smaller technical team requires individuals to carry out multiple tasks to keep projects moving.
These range from the extrapolation of existing resources, reconciliation of the current ‘mined’ topography and stockpiles against the remaining reserves or preparing new excavation designs and production schedules to satisfy key strategic objectives.
rock fragmentation or help to best mitigate environmental effects as these key parameters often differ from blast to blast.
CAD-based software in current use by the quarrying industry is often not up to the task. Even minor modification to excavation or blast designs requires significant time and effort, meaning it simply does not get done, or only gets done once. There is seldom time available to consider alternative scenarios, which is how mine planners and drill and blast teams can pre-empt issues before they occur.
This is where Maptek comes in. Vulcan QuarryModeller, Vulcan Drilling Designer and BlastLogic products have been configured to efficiently perform routine tasks. These products employ cutting-edge visualisation, geological domaining and modelling capabilities, as well as easy-to-use design and planning tools in a single software environment.
Vulcan QuarryModeller is tailored for modelling and analysing deposit geology and designing quarry operations. Different scenarios can be tested to maximise output, and production reports can be generated to
guide daily operations. Adding the Vulcan Drill and Blast Design module brings in tools for previewing a drill and blast pattern before it is set, ensuring potential layout issues are solved early, saving time on the ground.
Benefits of the advanced approach allow quarry operators to:
• Test blast patterns quickly and efficiently to identify the optimal design
• Reduce consumable costs and increase production by maximising equipment efficiency
• Save time and reduce errors with automated editing of multiple holes
• Ensure accurate blast designs with up-todate information
Complementary solutions include the Maptek open-pit scheduler Evolution, GeoSpatial Manager for managing survey surfaces and PointModeller for modelling point cloud data. Working with the Maptek suite of tools allows the majority of work for a quarry project to be handled in one system, with single-vendor technical support and services.
From a drill and blast perspective, it is common for quarries to apply standardised burden/spacing patterns and hole-charge plans. This approach does not optimise
The right software is fast and intuitive, providing efficiency gains that give opportunities for deeper analysis
Rich 3D environments handle large datasets from multiple sources
As quarry staff need to be multi-skilled, Maptek understands software solutions need to be intuitive.
“Multi-tasking may see an individual running some geological modelling, creating a blast pattern and changing the excavation design,” Britton says.
“Tools that interact with the pit design and the geology as well as the spatial technical data, provide a seamless data flow.
“Software that is quick and easy to learn and that does all of those tasks becomes an important asset for quarry operators and managers.”
The efficiency gain leaves time to run alternative scenarios, adjust to changes in rock type, consider infrastructure and ESG concerns and experiment with different designs.
“If users are not able to explore scenarios virtually on the desktop, they’re not getting the opportunity or the data to drive for these efficiencies.
“Holes are easily manipulated in Vulcan, allowing users to quickly make adjustments. This is a huge benefit, because with inefficient, older packages it's almost impossible.
“Changing drill-pattern design or hole loading or charge plan for a blast could take half a day with CAD packages, whereas
Vulcan can do it in a matter of minutes.
“The tools all tie into each other and the data flows, so you make the right decisions.”
The enterprise nature of drill and blast management and reconciliation package BlastLogic may be beyond the scope of individual quarries. However, it is ideal for large organisations operating multiple satellite quarries, which Britton notes is a growing trend in the UK and beyond.
“Each quarry may only blast a small number of holes weekly or monthly, with the same blast team moving from site to site to carry out the work. BlastLogic supports the drill and blast design and inventory control in a centralised, audited system so there's definite benefits,” Britton says.
Maptek understands the issues that quarry operations and industrial minerals companies face - the global mining sector faces a similar dilemma - and has applied insights garnered from its 40-year foundation in the mining industry to deliver solutions that support safe, productive extraction.
Britton, a chartered engineer with a background of more than 25 years in mining and who obtained EPC shotfiring & blast design certification in the mid-1990s and a DAPS Quarry Manager’s Qualification more than 20 years ago, says experience and technical expertise set Maptek apart.
“We employ skilled technical teams who understand these types of problems and can draw on our global pool of experts,” he says.
“Our technical team includes people who have worked at mining operations, and I do think it's an important differentiator that means Maptek is better placed to understand customer problems and identify how we can help.”
Post-COVID, as in-person events such as trade shows return, he has noticed a growing appetite for change.
“When we attend these events, we're getting an uptick in activity around what Maptek solutions offer.
“There’s definitely a positive charge in the industry and a willingness to look at all the solutions available.”
A company philosophy which includes walking in the shoes of customers has helped Maptek reposition its offerings to quarries, led by dedicated packages at more attractive prices, flexible licensing and web-based applications.
The Maptek Account licensing system is designed to facilitate software uptake and usage between users and teams. Scalable configurations can facilitate short-term campaign access to advanced, industryleading optimisation features.
The technical support and services staff come from diverse industry backgrounds and are always eager to get involved with unique, challenging projects and find innovative solutions.
“Maptek’s varied customer base ranges from some of the largest global mining companies to individual operations with a handful of staff. This means that our local service team can draw on a global network of expertise to ensure our customers get the support they need.”
As automation becomes more prevalent, operations need to become better equipped to handle the demands of the systems collecting and delivering the data stream.
The capability to quickly update designs and planned sequences in a digital workflow that takes into account changing geological conditions is critical for allowing the latest data to flow through from the resource model to production, ensuring that ore body knowledge informs all activities.
Interoperability and integration of tools in the modelling and design process enable block models and scheduling plans to be updated as new data becomes available.
Maptek says it is the perfect technology partner to help quarries adapt and thrive through this evolution of mining and quarrying practices.
Global aggregates demand up despite strong headwinds
The Global Aggregates Information Network (GAIN) continues to be a key voice within the world’s aggregates industry. Below, GAIN convenor Jim O’Brien analyses GAIN member association aggregates production data, which offers a further indication of the robust nature of the industry and its essential importance to global infrastructure development
Introduction to the Global Aggregates Information Network (GAIN)
Many readers will already know that the Global Aggregates Information Network (GAIN) is a unique voluntary coalition of aggregates associations with the express purpose of openly sharing best practices for the greater good and sustainability of the industry globally. GAIN members share valuable experiences in quarterly conference calls and meet physically every few years, the next such meeting being planned for New Zealand in July 2023.
An update on global production
Recently, GAIN members kindly provided updated estimates of aggregates production in their respective regions, as shown in Figure 1. For the pre-pandemic year of 2019, the GAIN total was just on 34 billion tonnes (bnt). Quite surprisingly, the year 2020 showed only a 3% decline, thanks to great industry resilience throughout the pandemic lockdowns. The year 2021 saw modest recovery, which is continuing into 2022. If the momentum can be maintained into 2023, GAIN member production will surpass the 2019 level of 34bnt. Adding in the figures for the rest of the world (estimated from populations by tonnes/capita ) shows that the 2019 global total was just on 44bnt; it will probably be 2024 before this total is achieved again, as these typically less-developed countries are having a slower recovery.
The regional breakdown clearly depicts China continuing as world leader, with 46% of global aggregates production. India follows in second place with just 12% of global production for a population soon to be greater than that of China, hinting at enormous growth potential for India. Europe and the US follow with 7% and 6% of global production respectively, with these top four locations together representing some 71% of global production.
At 14.5t/c (boosted by its exports), the UAE leads for 2021 aggregates production tonnes per capita (t/c) for the various GAIN countries. Next is China at 13.6t/c, with the
smallest being Argentina at only 1.6t/c. The GAIN average was 7.4t/c, while the global average was 5.3t/c. Clearly the developing world has enormous growth potential.
Commentaries on country trends
It is interesting to view the data in Figure 1 in terms of the trend by region compared to 2019.
CHINA:
In China, the world’s largest aggregates market, growth in 2021 had been fuelled by its 14th Five-Year Plan 2021-25. However, January to May 2022 saw a 12% decline on prior year, mainly because of renewed COVID-19 lockdowns and the weak real estate market. The second half of the year is expected to see a recovery through the central government commitment to ongoing infrastructure investment, as well as stimulating real estate and introducing policies to help enterprises to stabilize growth. China is massively investing in coal to alleviate power shortages, and energy cost inflation has hit aggregates producers. Overall Chinese production may be declining somewhat from its 20bnt peak but continues to be very strong with government support.
INDIA:
India, the world’s second-largest aggregates market, suffered a significant decline of over 18% in 2020, due to the COVID-19 pandemic, with steady recovery envisaged in 2021 and 2022, driven by its major infrastructural projects including airports, roads, tunnels, and metro rail in both Tier 1 and Tier 2 cities. However, aggregates demand for residential/commercial complexes is slow, and development has also been stalled by electricity power disruptions in some states, due to low stocks of coal at many thermal power plants. There is also some disruption in the supply chain of imported spare parts, compounded by soaring energy costs and weakening of the Indian rupee . Despite these headwinds, aggregates industry sentiment remains positive, with huge potential
for growth beyond its estimated 5.3bnt, particularly as its population size is now overtaking that of China.
SOUTH KOREA:
Aggregates demand remains strong in Korea, driven mainly by new housing needs. COVID restrictions have been lifted, and there is a determination in the new administration to drive the economy forward. Access to aggregates resources is an ongoing challenge and marine aggregates are seen as a significant opportunity.
MALAYSIA:
Aggregates demand fell by over 40% in 2020, and the continuing difficult economic situation has led to a severe recession in the building sector, with both existing and new projects curtailed. Other challenges include ongoing COVID cases, power deficits due to coal shortages, a shortage of overseas labour and surging diesel costs for aggregates producers. Despite all this, the outlook still remains positive because of the nation’s infrastructural needs.
SOUTH AFRICA:
The economic situation remains very difficult, exacerbated by continuing impacts of the pandemic, frequent power outages and high unemployment. However, it is hoped that the government will re-focus on much-needed infrastructural spend to stimulate the economy and thereby assist the medium - to longerterm growth of the aggregates industry. Very little data is available for the rest of Africa, the “forgotten continent”, with its growing population of 1.3bn.
EUROPE:
The year 2021 saw continued growth in aggregates markets, which has continued into H1/2022. However, the outlook is somewhat challenged by the wider impacts of the war in Ukraine. Strong inflation in energy and other costs are now compounded by security-of-supply concerns about natural gas in the coming winter. The geopolitical
situation has had a positive effect in putting a strong new focus on independence in the supply of all resources, as well as on upgrades in infrastructural spend from both security and climate adaptation perspectives. Consequently, the overall outlook, despite these headwinds, remains positive in Europe.
USA:
The US aggregates market has moved ahead positively in H1/2022, thanks to the implementation of the first phase of the 2021 Infrastructure Investment Bill. There are some concerns about labour shortages and energy futures, which later can be resolved provided the current Administration awards new drilling permits. While the midterm elections later this year may see a political shift in power, it is hoped that bipartisan cooperation will continue to provide infrastructural funding authorisation. The construction outlook and aggregates demand both, therefore, look set to remain positive through to 2026.
CANADA:
Aggregates demand in H1/2022 continued in positive territory, despite labour shortages, fuel price hikes, some supply chain disruption and a new COVID wave in the Eastern Provinces. There were also some challenges from an unusually cold winter and high rainfall in some provinces, compounded by unusually hot summer weather in others. However, overall industry sentiment remains positive.
MEXICO:
The H1/2022 recovery has been tempered by very high energy inflation, supply chain delivery and cost challenges, compounded
by a COVID resurgence. However, it is hoped that the strong US market may also help stimulate the Mexican aggregates sector.
CENTRAL AND SOUTH AMERICA:
Colombia is the shining star, anticipating that double-digit growth in aggregates demand will continue to be driven by major infrastructural investment in railways, tunnels, and roads. It is also hoped that the recent presidential election result will positively stimulate the Colombian economy. Argentina continues to suffer from severe economic turbulence, having experienced a precipitous decline in aggregates demand of almost 50% in 2020 . However, it is hoped that presidential elections next year will provide a growth stimulus. The Brazilian economy continues to move in positive territory. Reports from Chile, Peru and Ecuador unfortunately indicate slowing economies due to social unrest, with the exception of Costa Rica, which is benefitting from the exports from its mining sector. More general regional challenges have been unusual weather patterns and a marked deterioration in local exchange rates versus the US dollar. However, the potential for growth in demand for aggregates in Latin America remains huge with its rapidly growing 500 million population.
OCEANIA:
In Australia, there continues to be a strong pipeline of public infrastructure projects which is supporting aggregates demand. However, there are significant labour shortages and supply chain challenges. Despite an unusually cold winter which has fostered continued COVID and influenza outbreaks, the overall construction industry
outlook remains very positive. Likewise in New Zealand, the outlook remains very positive, the main challenges being a post-pandemic lack of immigrant labour. Aggregates producers there are currently unable to meet the pent-up construction demand, exacerbated by delays in permitting consents for new quarries. Variable weather patterns across Oceania have presented both challenges and opportunities to the aggregates industry.
Conclusions
The global aggregates industry has proven itself amazingly resilient in overcoming challenges that would have been unthinkable only three years ago. Developed economies have now come through the COVID pandemic successfully, with their governments having the resources to stimulate economic recovery. However, the pandemic and post-pandemic impacts still linger in many developing countries, slowing their economic recovery. Other headwinds include severe energy shortages, price hikes, supply chain challenges and post-pandemic labour dislocations, compounded by unusual weather patterns in both the northern and southern hemispheres.
Despite all these challenges, the medium- and longer-term demand for the aggregates industry remains fundamentally strong, driven by a growing global population, increasing urbanization, varying levels of economic growth and climate adaptation measures. Consequently, global aggregates demand is anticipated to recover to the 2019 level of 44bnt by 2024, likely climbing towards 50bnt by 2030, assuming continued current patterns of global economic growth. AB
Figure 1: GAIN and global aggregates production estimates for the years 2019-2023
RIDING THE WINDS OF CHANGE
Given the extraordinary shift in the aggregates market, adaptability and flexibility are key to riding the winds of change. This was the overarching reflection from Munesu Shoko’s recent visit to AfriSam Jukskei Quarry, where several initiatives have established resilience in the face of a rapidly changing business landscape
Having enjoyed a thriving construction materials market for the better part of the last decade, AfriSam’s Jukskei Quarry has had to contend with a drastic dip in demand in recent years. When first established in the late 1950s, the quarry was considered to be far-flung from any meaningful construction development at the time.
However, due to rapid urbanisation in its vicinity in recent years, anchored by the ZAR16 billion (US$885.7 million) Waterfall City mixed-use development, Jukskei became one of AfriSam’s busiest quarries between 2015 and 2018. Apart from the thriving commercial development activity in the area, the quarry was at one point the principle
construction materials supplier for major infrastructure projects in the area, including highways and bridges.
Mohamed Docrat, works manager at AfriSam Jukskei, says the market has changed significantly in the past four years. While the post-COVID volumes have started picking up slightly, they are still nowhere near the 2015-2018 levels.
One of the major trends, notes Docrat, is the noticeable increase in small and medium enterprises (SMEs) being contracted to execute government infrastructure projects. To provide context, a 40-km road project that would traditionally be undertaken by a single large contractor is now allocated to about four emerging contractors.
One of the emerging contractors’ operating models is to shop around for
“cheaper” construction materials, resulting in what Docrat calls a “price war” in the market. Due to affordability, emerging contractors are also ‘buying down’ on quality of aggregates. In fact, this trend is prevalent across both public and private construction projects.
“The dynamics of the market have changed completely,” says Docrat. “High-spec material such as G1 is now being replaced with lower-spec products like G2. This approach is not only driven by contractors, but the concept is even being embraced by developers and consultants. While we have adapted to these new realities, the challenge is that our production processes for either high- or lower-spec material remain the same, which impacts our bottom line.”
Another major trend, notes Docrat, is the emergence of resellers. Previously, he says,
An aerial view of AfriSam Jukskei Quarry
resellers were largely suppliers of sand, but in the past two years, they have spread their wings to other areas of the market.
“This is traditionally common in Cape Town, but in the past two years we have seen it taking root in our market as well. The emergence of resellers has to some extent resulted in the price war. Armed with large fleets of trucks, they are able to shop around and influence prices. The rules of the game have therefore changed significantly. We believe it’s a buyer’s market at the moment, with customers dictating the price of aggregates,” says Docrat.
In such an ever-changing market, Docrat believes it is imperative to grasp the new trends, understand their implications and act accordingly. Adaptability and flexibility, he says, are the most essential skills to respond to such an evolving and cut-throat trading environment.
As part of the company’s response to a low-volume market, Jukskei has adopted a demand-driven strategy, where production is based – as far as possible – on actual customer orders rather than market projections. In fact, this strategy has been adopted across all AfriSam operations.
In addition, recycling, especially readymix concrete waste, continues to grow in importance at Jukskei. This not only addresses environmental issues, but also allows the quarry to meet the growing demand for lower-spec material at a lower cost of production.
“As part of our contribution to the circular economy, we take all the waste material, mainly return concrete from the readymix trucks, and stockpile it to dry. We then employ a hydraulic hammer to break down some of the big blocks of concrete into smaller, manageable sizes that can be fed into the processing plant. The recycled concrete is blended with some of the virgin
material to produce lower-spec subbase products such as G5, G6 and G7,” says Docrat.
Key to the ability to produce some of the new material specs is the flexibility of both the plant and personnel. “We have good flexibility at our Plant B, which allows us to switch between products. For example, within two days, we can change over to either aggregate or G-mode, which is crucial, especially in the current market conditions,” says Docrat.
Key to realising the flexibility of the plant is a team of experienced personnel willing to adapt to meeting the ever-changing market requirements, says Zielas du Preez, regional manager Gauteng and Cape Operations at AfriSam.
“One of the key trends in the market is the constant request for new material sizes, especially specific sand-grading envelopes with reduced fines on the -75 micron envelope to assist clients with water demands on mix designs. Thanks to our experienced team, we have successfully managed to trial different types of sands without incurring huge costs. The flexibility of our plants, matched by that of our team on the ground, gives us the edge to address any special requests,” says du Preez.
Contractor partners working on site have also heeded the call for agility and flexible operation, adds du Preez. “Despite all the
changes we experience in our business, our service providers have been understanding and accommodative. We have, for example, agreed to remodel our contract with the load and haul contractor to accommodate our demand-driven production model. The contractor is willing to make changes to the fleet at short notice,” he says.
The same flexible and cooperative approach has been adopted by the drill and blast contractor. “With all the uncertainty in the market, sizes and frequency of blasts vary significantly. We have therefore remodelled our contracts to be able to navigate the market uncertainty. Our contractor partners have been supportive and have assisted us in finding our way through the ups and downs of the market,” says du Preez.
While the rapid urbanisation in the Midrand area has previously boosted the quarry’s business, it has also meant that the operation now finds itself bordered by communities – a business park to the north and a residential area to the south. With some of the buildings as close as just over 100m away, it is therefore important to forge strong community relations.
“In such a highly developed area, the ability to adapt is crucial,” says Docrat. “About four years ago, we started visiting all our neighbours to acquaint them with the activities of the quarry. We also have quarterly community meetings to keep them
The recycled concrete is blended with some of the virgin material to produce lower-spec subbase products such as G5, G6 and G7
informed of some of the developments and changes at our operation,” says Docrat.
Docrat says the Varistem stemming plugs have proven to be key to good blast outcomes. On the health and safety side, there has been a reduction in flyrock, noise and airblast. From a productivity point of view, there has been a marked improvement in fragmentation.
Apart from these blast improvements, three fixed vibration recorders have been installed at some of the closest neighbours’ premises to monitor the impact of blasts. Two portable recorders are also planted at different locations to monitor issues such as airblast and ground vibrations. These are monitored by a third party, Blast Analysis Africa, which provides an independent report every month.
A strong focus on safety is paying dividends, with no lost-time injury (LTI) recorded in the past four years, confirms Docrat.
The closest development is only 110m away from the northern face of the quarry. Here, AfriSam has entered into a special agreement to finalise mining on this face and change the mining footprint. The mining team has already sterilised three benches, with the fourth one almost complete.
for safety, we have tweaked a number of parameters such as burden, spacing, powder factor, timing, design and stemming, among others,” says Docrat.
For an operation that is close to communities, blasting poses major challenges. “We have over the years adapted our blasting practices. In our quest to blast
To further improve its blasting practices, Jukskei was one of the early adopters of the Varistem stemming plugs in the local quarrying industry. Docrat says the most important factor in achieving a safe and efficient blast is to contain energy in the hole, and good stemming creates more resistance at the top of the blast hole and directs the energy to where it’s needed – the rock mass.
“Safety is one of the main drivers on site. Our Competence Based Safety programme is at the heart of our safety achievements. This is an employee-driven safety programme, where they are allowed to take ownership of safety on site. Good safety behaviour is recognised, while unsafe behaviour is quickly addressed through coaching,” concludes Docrat. AB
• This article first appeared in Quarrying Africa magazine
Specific sand-grading envelopes with reduced fines are popular among customers
As part of contribution to the circular economy, AfriSam Jukskei recycles return concrete from the readymix trucks
Ants & termites help Kenya get better connected
High population growth and rapid urbansation in Kenya’s capital city, Nairobi, and other major towns has increased demand for housing and business outlets, resulting in a national construction boom. An annual target of 500,000 housing units is driving Kenyan demand for sand to unprecedented levels as both the private and public sector scramble to meet the high need for new housing units, shopping malls, offices and urban infrastructure.
Alex Kimeu, a father of two children, aged 8 and 14 years, is a veteran sand harvester who has plied the trade for more than a decade, thanks to plenty of seasonal rivers and riverbed sand in counties that border the capital, Nairobi.
Over the years, Kimeu has always ensured he has a huge stockpile of tons of sand, enough to supply his ever-increasing customers. However, with rapid urbanisation that has driven the need for new housing units and mega infrastructural projects being undertaken by the government, NGOs and the private sector, demand for sand has reached unprecedented levels.
In the recent past, Kenya, like its neighbouring countries, has rolled out several mega infrastructure projects such as roads, railways and housing units to meet high demand for good housing and ease transportation in a region whose population
Soaring sand demand has left major sources of sand harvesting depleted at a faster rate than they can be naturally replenished, with sand miners crafting an ingenious and unique sand-prospecting method to fill the supply gap. Shadrack Kavilu reports
is projected to reach 400 million by 2030. These projects have contributed to the growth of the construction sector while also putting pressure on construction materials such as sand and gravel.
The high demand for sand to implement these projects, coupled with perennial rainfall, is putting pressure on riverbed sand which is being extracted at a faster rate than it can be naturally replenished.
The increasing scarcity of this rare commodity has prompted sand miners to look for alternative sources of sand to fill the supply gap. Given limited resources and lack of funds to undertake research and development, the local people have resulted to using natural methods of determining sand-mining locations.
In the plains of Katani, Machakos County, some 30 kilometres southeast of Nairobi, sand miners have devised an ingenious method of prospecting for sand deposits on land.
Here, sand miners are relying on ants and termites as a sophisticated, yet low-tech, method to prospect for sand deposits beneath the ground.
They believe the dome-shaped ant mounds that are walled by tiny spectacles of sand deposits burrowed deep underground hold the key to thousands of tons of underground sand reserves.
Ants and termites push to the surface tiny sand deposits once burrowed deep
underground. It’s these ant mounds that are helping miners strike the increasingly rare but vital construction commodity.
To maintain a constant supply of sand to the country’s booming construction industry, Kimeu is among hundreds of young men who wander the plains of Katani in search of the ant mounds.
“By keenly sampling and analyzing the type of sand on these mounds, we can tell with precision the depth of the sand deposits and the quantity of sand we are likely to get from a given location,” Kimeu told Aggregates Business International
Kimeu says searching for underground sand deposits could be an excruciating exercise, sometimes leading to empty pits. But for these miners, relying on ants to prospect for sand is a sure bet since they provide an accurate location of sand deposits.
“Ants never disappoint, with their help we are able to locate accurately an ideal mining field within the shortest time possible, thus saving us time and money that would have been spent chasing ‘wild goose’ sand deposits,” said Kimeu.
Sampling of soil from ants’ mounds is a daily routine in these vast Katani sand mines. The dome- shaped ant mounds that are walled with tiny sand spectacles have become a toolkit for hundreds of sand miners.
“To ensure you have enough stockpile of
An ant mound in Katani, which sand harvesters use to prospect for sand underground
sand to meet your customer’s daily demand, you have to trust these ants, for sure. They carry load of sand to the surface while building their empires and through this we are able to determine which type of soil lie underground,” said Joseph Mumo, a seasoned sand harvester in Katani.
Mumo, however, warns that over-reliance on ants can sometimes be misleading. “There are cases where we have ended up discovering shallow sand deposits that can hardly fill up a 70-kilogram wheelbarrow. We have to be very careful when following these leads because ants
Given the huge infrastructure projects being undertaken across the region, demand for sand is projected to keep on rising, especially in East Africa as governments continue improving major infrastructure such as roads, railways, housing units and manufacturing plants.
Kenya, like other east African nations, is witnessing a rapid rate of urbanisation. A report by The World Bank estimates that 15 million people live in cities and towns, and it’s projected that more than 50 percent will live in urban areas by 2030, according to its collection of World Development Indicators 2021.
don’t follow a straight line when burrowing this sand,” he said.
According to several studies, scientists have confirmed the economic importance of termites which they say extends to mineral exploration.
“Termites burrow materials from depth to the surface environment. It carries with them the encountered materials. If the substrate is dominated by sand, the particle-size analysis of a sample taken from the mound will indicate so and if it is clayey it will show,” says Professor Emmanuel Arhin, professor of applied geology, University of Energy and Natural Resources, Navrongo Ghana.
He notes that based on the particle-size analysis results, the sand miners will have an idea of the material beneath the area. “This is a mere physical property of the mound that is used. It differs from how termite mounds are used in mineral exploration, particularly for gold.”
This high rate of urbanisation is set to put more pressure on housing and urban infrastructure as well as stretch demand for construction aggregates materials.
Though the country lacks reliable data on the volume of sand extracted or consumed annually, cement consumption is estimated to have grown by 23.4 percent from 7.3 million tons in 2020 to 9.1 million tons in 2021, according to data from the Kenya Bureau of Statistics Economic Survey 2022.
A recent study by the United Nations Environment Programme (UNEP) shows that sand is the second-most used resource after water. The report estimates that 50 billion tons of sand and gravel are used every year, which is enough to build a square wall that is 27 metres long.
However, despite being the second-most used resource, the report warns that its extraction, sourcing, use and management remain largely ungoverned in many regions of the world.
In Kenya for instance, years of uncontrolled mining of sand mines in riverbeds have depleted sand deposits in counties that border the capital city, Nairobi.
Despite the country enacting some progressive legislation over the years to regulate sand harvesting at the national and county level, illegal and crude sand harvesting techniques continue to be administered unabated in most parts of the country.
According to the National Environment Management Authority (NEMA), legislation
John Mwanzi, a sand harvester, demonstrates how they analyse ant mounds for possible sand prospects underground
A group of youths loading sand on to a truck to be supplied to construction sites in the capital, Nairobi
on sand harvesting has greatly reduced cases of unregulated and illegal sand harvesting across the country.
“We conduct an environmental impact assessment before awarding a permit to sand harvesters. However, there are a few cases of illegal sand miners who don’t adhere to the set guidelines of sustainable sand harvesting,” said Parnwell Simitu, NEMA county director for Machakos.
Simitu attributes the increasing cases of illegal sand harvesting to miners’ ignorance of the environmental impact of the procedure.
“Some of these miners will even mine sand outside their houses, oblivious of dangers that lurk in these pits,” said Simitu.
Many of these unemployed young men are trapped in a vicious cycle of poverty and family responsibility which lures them into illegal sand harvesting to earn income to support their families.
“Sand harvesting is also a source of ready and direct income for many unemployed youths in these mining fields and the majority of them would rather risk their lives mining in these illegal mines to eke a living and this poses one of the biggest challenges in effectively regulating these mines,” said Simitu.
At the root cause of illegal sand harvesting across the country is a network of powerful cartels and middlemen who have invested heavily to supply sand to construction companies.
“Most of these illegal sand mines are operated by groups of powerful shadowy cartels who are faceless, thus making arrests and prosecution by authorities difficult.”
Simitu says that a few culprits at at the bottom of the pyramid have been arrested and taken to court and charged with engaging in illegal sand harvesting. “We
“Currently, 20 tons of sand is being sold at $400 (Ksh 40,000) up from $300 (Ksh 30,000) a month ago, the highest in a decade”
have arrested and sued some of the illegal miners and their cases are pending hearing at the Machakos Environment Law Court,” he added.
Experts in the industry say over-extraction of river sand in counties that border Nairobi, coupled with years of perennial rainfalls, have significantly affected the availability of this rare commodity in the East Africa’s largest economy.
Tough regulatory interventions by neighbouring counties that supply sand to the capital have exacerbated the scarcity of sand, making the price of sand surge over the past two years.
The stringent measures have seen the cost of sand increase by 30%. Currently, 20 tons of sand is being sold at $400 (Ksh 40,000) up from $300 (Ksh 30,000) a month ago, the highest in a decade.
The scarcity of sand has seen developers increasingly embrace alternative sources of sand such as rock sand and black volcanic sand which is relatively cheaper compared to river sand.
Last year, due to unreliable sand supplies, price fluctuations and inconsistent quality, a Chinese construction company that was constructing phase two of the standard gauge railway abandoned use of river sand and improvised to use its own sand from volcanic rock sand.
“We have tested the rocks and found that they produce high-standard sand that bonds well with the other materials. The concrete mix is much better than what you get from river sand,” said a senior Chinese contractor who was quoted in one of the local dailies.
With several mega construction projects underway across the country, demand for sand is projected to increase.
According to statistics by Kenya National Bureau of Statistics (KNBS) in its economic survey 2022, the construction sector grew by 6.6 percent in 2021, defying major challenges brought about by the global COVID-19 pandemic. AB
Trucks loaded with sand in Ruai trading centre, awaiting customers
A section of a river showing bare rocks after sand harvesting from the river bed
Two new high-frequency screen plants from Astec
Astec Industries’ Materials Solutions Group has designed and launched two new highfrequency screen plants.
The US-based manufacturer says the portable PTSC2818VM plant features an innovative design and size and is the first of its kind for the industry, featuring an 8-foot-wide high -frequency screen.
Astec’s newest PTSC plant is equipped with an 8’ x 18’ (2.4 x 5.5 m) top deck and an 8’ x 12’ (2.4 x 3.7 m) bottom deck. The patent-pending screen design features externally-mounted vibrators at the ends of the tappets for a more aggressive screening action. This unique design creates a higher G-force and reduces heat load from material to motors as compared to single, centre-mounted vibrators. It also allows for easier maintenance and adjustments. The screen is equipped with hydraulic-operating angle adjustment, a fines-collection hopper, top-and bottom-deck discharge chutes and an aggregates spreader.
Similar to other PTSC plants, the 2818VM features a nominal 54” x 38’ (137.16 x 1,158.2 cm) delivery conveyor with hydraulic drive and full-length skirtboards. The chassis is fitted with manually-operating support legs, outriggers for additional support and folding walkways along the screen.
The PTSC2818VM features an 8-foot-wide high-frequency screen
The new portable plant is available with a variety of options, including: steel screen cloth, vinyl dust cover, hydraulic levelling jacks, immersion heaters for hydraulic reservoirs, starters for three off-plant conveyors and more.
Astec Industries has also just launched its newest mobile highfrequency screening plant, the GT2612V.
The plant features a 2612V Vari-Vibe high-frequency screen.
The two-deck, 6’x 12’ (1.8 x 3.7m) screen uses an innovative rotary tensioning system that allows for some of the quickest screen media changes on the market, giving producers more uptime.
The 2612V also has deckmounted, variable-speed
hydraulic vibrators, a hydraulic mechanism for varying operating angles, a fines-collecting hopper, top- and bottom-deck discharge chutes and an aggregates spreader. The high-frequency screen can quickly and efficiently size crushed stone, recycled asphalt pavement, sand, gravel, coal and a variety of other materials.
The mobile GT2612V is manufactured on a heavy-duty, welded-steel main frame with a channel cross-section. A walkway around the screen and remote grease lubrication for ground-level access make maintenance simple.
The Astec plant includes a large hopper with a capacity of eight cubic yards that is equipped with 6-inch (15.2cm)
sloped grizzly openings and a remote tipping grid. The hopper also includes foldable wings and hydraulic support legs.
The variable-speed, 48-inch (122cm)-wide belt feeder features a high-torque hydraulic drive, full-length impact bed, rubber lagged head pulley and self-cleaning wing tail pulley.
The screen plant is equipped with four conveyors: a delivery conveyor, two side conveyors and a fines conveyor. All conveyors feature a variable-speed hydraulic drive and easily fold for transport.
The GT2612V is powered by a Caterpillar Tier 4 Final, 136 hp (101.4 kW) engine, while enginemounted hydraulic pumps operate all plant functions. The plant includes a PLC control system with pendant remote controls for the tracks.
Additional options for the GT2612V mobile plant include engine alternatives (Caterpillar Tier 3 and Stage V), 15-foot (4.6m) hopper/feeder in lieu of standard for additional capacity, heavier-duty grizzly section with replaceable grouser bar cartridge, vibrating grid, bridge breaker, vinyl dust cover, standard steel screen cloth, engine enclosure filter kit, engine block heater, immersion heater, wireless track remote, telematics system, auto-grease system and more.
www.astecindustries.com
CEMEX expands zero-emission concrete mixer trial
Building materials supplier CEMEX is to further develop its global pilot of zero-emission electric concrete mixers. The European aspect of the pilot was organised in Germany, France and Poland, testing the Putzmeister iONTRON e-Mixer which is powered solely by electricity.
CEMEX says that Putzmeister provided a mobile charging station for use during the successful trials, enabling the concrete mixer to be charged overnight from 20 to 100% in eight hours. Craig Hooper, mobile equipment fleet & category manager - Europe at CEMEX, commented: “Transport is one of the key areas where CEMEX is striving to reduce carbon emissions. Our company is constantly looking for new, more environmentally friendly transport solutions, hence the decision to conduct extensive pilot studies to verify the possibilities offered by electric concrete mixers.
CEMEX says transport is a key area for reducing its emissions
“The positive results of the trials in Europe now allow us to think positively about the potential implementation of these vehicles, which will bring CEMEX closer to achieving its climate goals.”
In 2021 CEMEX joined the First Movers Coalition. As part of this, it has committed to accelerate innovation and development of decarbonisation technologies in heavy road transport services. www.cemex.com
Makin Teguh Sdn Bhd (MTSB) has completed the construction of an integrated clinker and cement manufacturing plant (ILPP) in Lahad Datu on the Malaysian island of Borneo.
It is the first integrated cement plant in Malaysia which uses renewable fuels such as heavy fuel oil derived from refined recovered oils, palm kernel shells and bio char.
The Borneo Post reported that the work on the project started in 2017, following detailed feasibility studies and considering the various infrastructure challenges.
MTSB, which is 30%-owned by BornOil, says the integrated clinker and cement manufacturing plant is designed with great emphasis on environmental protection and efficient energy use. It is located near to a limestone and marble quarry in the state of Sabah, north Borneo.
The plant utilises a heat-recovery system that is able to generate part of its energy requirements and recycles all of its water, relying heavily on rainwater collection which is stored and treated internally. The plant is part of an integrated limestone processing complex (ILPP) which aims to create an economic value chain utilising natural resources to produce a range of limestone-derived products such as crushed limestone powder, aggregates, hydrated lime, clinker, cement, concrete and other related products for local use as well as export.
The ILPP will employ up to 250 people on-site and will train employees in all aspects of the limestone and cement manufacturing business.
www.borneo-oil.com.my
Komatsu updates HD1500-8E0 hauler
Komatsu has introduced an upgraded version of its HD1500-8E0 rigid-frame off-highway haul truck.
The 150-tonne HD1500-8E0 is purpose-built for mining, quarrying and aggregates applications.
It delivers 1,580 gross horsepower (1180 kW) and features a Tier 4 final Komatsu SDA16V159E-3 engine to drive high levels of productivity. The redesigned cab, combined with a MacPherson struttype and hydropneumatic suspension, is intended to give operators the smooth and comfortable ride they need for long shifts.
In addition to speed on grade, the HD1500-8E0 is equipped with hydraulic, wet multiple-disc brakes on all four corners. The continuously cooled, largecapacity brakes also act as a highly responsive retarder, providing operators with confidence at higher speeds when travelling downhill. Downhill descent can also be controlled by setting a desired
travel speed with the automatic retard speed control (ARSC), which applies the brake retarder to maintain the desired setting and descend the road with confidence.
With a tight turning radius (11.2 m), Komatsu says that HD1500-8E0 operators can easily manoeuvre in and out of tight spaces when spotting to be loaded or positioning to dump. The MacPherson strut-type independent front suspension features an A-arm wheel-to-mainframe design for wide spacing and easy access to the engine bay. Komatsu’s Traction Control System (KTCS) is designed to provide excellent control in loose or slippery haul-road conditions by monitoring the rear wheels for slippage and automatically applying pressure to the independent wheel-brake assemblies.
www.komatsu.jp
Volvo CE launches EC550E T3 excavator in Asia
Volvo Construction Equipment has rolled out its new EC550E T3 excavator in the Asia region.
The manufacturer says the EC550E T3 excavator breaks the link between operating weight and productivity, offering tonnes -per-hour production close to a 70-tonne class machine but with lower fuel consumption.
Thanks to its buckets and fast cycle times, the EC550E is said to deliver 35% greater production than the 50-tonne class EC480D in typical dig and dump applications, and its production levels approach those of a 70-tonne class machine.
The larger bucket is enabled through the increased undercarriage dimensions (for greater stability), as well as upgrades to the frame, boom and arm. The fast cycle times result from the engine’s high torque at a remarkably low rpm combined
with the large displacement pumps. Volvo CE says the EC550E excavator’s dimensions, lifting capacity and engine are well in line with some competitor 70-tonne models, but it consumes considerably less fuel.
Besides the efficient engine and electrohydraulic joystick commands, the manufacturer adds that the EC550E has the industry’s most high-performing hydraulics. The EC550E is the first excavator to use Volvo’s
independent metering valve technology (IMVT). Instead of a conventional spool-type main control valve (MCV), the EC550E uses dedicated valves – for feed and return for each actuator.
Oil is pumped exactly according to demand at any given moment to eliminate hydraulic losses and deliver an extreme level of fuel efficiency with astonishing controllability.
Volvo CE says that matching the size and capacity of your loading machine to your hauler also impacts productivity and efficiency. The EC550E can fill an A35G or A40G hauler with four to six buckets meaning that Volvo now offers two perfect match excavators for A35G or A40G haulers in Asia – the EC750D and the EC550E according to the operator’s productivity and efficiency needs.
www.volvoce.com
The HD1500-8E0 is purpose-built for mining and quarrying
The EC550E T3 excavator
The integrated clinker and cement manufacturing plant in Lahad Datu
Aggregates Business travels the globe attending conferences, events and equipment shows, keeping you informed of the latest offerings. Come and join us for a chat at any of the events below.
OCTOBER 2022
24-30: bauma Munich, Germany
MARCH 2023
14-18: CONEXPO-CON/ AGG
These dates were correct at the time of going to press, but please note that the COVID-19 pandemic means some events may be rescheduled with little advance notice
