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WGigatonnes of concrete concern
ithout abatement, the world’s concrete industry will likely emit 3.8 gigatonnes of CO2 by 2050. That is one of the chief findings in new research from the global management consultants Boston Consulting Group (BCG).
The research states that to meet the industry’s net-zero commitments, more than a third of these emissions—1.4 gigatonnes— will need to be reduced by scaling up carbon capture and storage (CCS) technology.
BCG adds that carbon capture and storage capacity is currently at just 19 million tonnes per year but will need a 74-fold increase to reach an estimated 1.4 gigatonnes by 2050 just to meet demand from the concrete industry.
The report predicts that the cost of carbon capture and storage will increase cement prices from US$90 to US$130/tonne now to at least US$160 to US$240/tonne by 2050.
The report’s authors state: “The only realistic way to fully abate those emissions and meet the industry’s 2050 net zero goals involves scaling carbon capture and storage (CCS) to an industrial level. Industry experts expect this effort to require more than $1 trillion of capital deployment over the next 25 years.
“For the industry to reach net zero in 2050, sufficient CCS capacity must be available to abate more than 35% of its GHG emissions— and its implementation will transform the industry’s cost structure and traditional sources of competitive advantage.”
As BCG explains, today, most cement is consumed within 200km of where it was produced since the most cost-effective way to supply it is by serving local demand, thus minimising transport costs. The report states that only around 5% of the world’s cement production is traded across country borders. It says the cost of CCS technology “will change all that”.
BCG says cement production costs will vary considerably depending on local access to CO2 storage capacity, proximity to industrial CCS hubs, and the cost and availability of the green energy needed to produce cement. This, in turn, will transform the industry’s global geographical footprint from an almost entirely local industry to one where the advantage goes to low-cost producers, wherever they are.
The highly insightful BCG report also examines issues like the impact of rising energy, transport and infrastructure costs and areas like the Middle East, which will likely become hubs for carbon capture and storage sites. Many parts of Europe face competitive challenges due to far higher energy costs and further locations from suitable CO2 storage sites.
Meanwhile, linked to other big building materials industry carbon emissions news, the World Cement Association’s CEO, Ian Riley, has welcomed China’s recent announcement to expand its national carbon trading market to include the cement industry, among other hardto-abate sectors, by the end of this year.
China’s Minister of Ecology and Environment, Huang Runqiu, revealed the ambitious national carbon trading market change last month (September), marking a significant step in China’s environmental plans.
Riley commented: “The inclusion of cement in the Chinese ETS [emissions trading scheme] is a critical and long-awaited step. As we have seen in Europe, a well-implemented carbon ETS can be beneficial by not only curbing emissions but also catalysing industry restructuring that favours the most efficient and lowest-emitting producers. This move signals China’s intent to prioritise sustainability in high-emission sectors, a move welcomed by the World Cement Association.
“In addition to the ETS, China has also successfully used energy efficiency standards to encourage widespread adoption of the latest low-energy technology. This approach is essential for meaningful climate action.” GW
“Powerscreen
Gigatonnes of concrete concern
Heidelberg Materials strikes Moroccan deal with Vorantim Cimentos; XCMG Group chairman eyes growth; Epiroc to expand Indian output; BKT appoints new global president OEM
All the key events in the quarrying & aggregates world
Why Feiring Bruk’s Tanje Gjerde is ‘born to rock’
Crushing and screening solutions making tracks in Africa and America
Searching for a more productive & efficient haul
Electrifying the
Big
amid strong tyre
Specials
08
12 KENYAN QUARRYING
Road development boon for the Kenyan quarrying sector
14 WIRTGEN GROUP
New cutting-edge machines from Kleemann and Hamm
16 QUARRY PROFILE
Portland Group is on a growth path
ROKBAK APPOINTS
MACHINERY EXCHANGE AS ZIMBABWEAN DEALER
A subsidiary of the larger Industrial Exchange Group (IEG) network of companies, Harare-headquartered Machinery Exchange will provide full sales and service support for Rokbak trucks in Zimbabwe. Interest is already high, thanks to ongoing growth in the country’s infrastructure and mining sectors. “The partnership with Rokbak will help us meet the growing demands of our customers in the mining and construction industry and further solidify our position as a leading earthmoving equipment supplier in the region,” says Irene Khumalo, IEG Head of Marketing and PR. “We’ve been keen to develop our presence in Zimbabwe and foster relationships with customers through an established dealer,” says Paul Culliford, Rokbak Regional Sales Manager EMEA.
“Partnering with Machinery Exchange makes perfect sense. It’s a company that shares our commitment to quality and customer satisfaction and benefits from the support of IEG’s extensive expertise and service network.”
Heidelberg Materials strikes Moroccan deal
Heidelberg Materials has signed a strategic agreement to acquire Votorantim Cimentos’s Moroccan assets.
Expanding an existing minority stake of Heidelberg Materials in Asment de Témara, the transaction ultimately results in the acquisition of 63% of the shares in Asment de Témara, a cement and ready-mixed concrete producer, and 100% of the shares in Grabemaro, a supplier of aggregates, by Ciments du Maroc, Heidelberg Materials’ subsidiary in Morocco.
With this investment, Heidelberg Materials via its subsidiary Ciments du Maroc further strengthens its positioning in one of the company’s core growth markets in Africa. By taking control of Asment de Témara and Grabemaro, Ciments du Maroc will expand its operations in the attractive Northern region of Morocco to include a cement plant with an annual capacity of
1.4 million tonnes of cement, two aggregates sites, and eight readymixed concrete plants.
“Our latest investment marks an important step as part of our ongoing portfolio optimisation to strengthen our core markets,” said Dr Dominik von Achten, chairman of the managing board of Heidelberg Materials.
“Expanding our presence in the attractive Moroccan market while increasing our use of alternative fuels will generate substantial financial synergies and thus help us accelerate our ambitious decarbonisation efforts throughout our sites in the country and grow our local offering of sustainable solutions.”
XCMG Group chairman eyes growth
Yang Dongsheng, chairman of XCMG Group, has discussed the difficulty of sustaining high growth in both corporate and national market levels for the long term as the industry enters a new adjustment period. He has also made observations on changes in the Chinese market, along with the export plans, the corporate strategic standing on electric equipment, and heavy construction robots.
In the latest Yellow Table 2024, XCMG is ranked as China’s largest construction machinery manufacturer and the fourth largest globally, marking rapid growth since 2014, when the company ranked 11th globally. This high growth at both the national and corporate levels is difficult to sustain in the long term.
Yang admitted that the industry is entering a new adjustment period, partly due to fluctuations in China’s real estate market and the completion of multiple large infrastructure projects.
Yang said that China’s construction market has undergone major changes in recent years and is now gradually carrying out some
reconstruction and adjustments that are moving towards higherquality development, which initially will be reflected in construction machinery sales. In 2022, China’s construction machinery market entered a new adjustment period. Yang said he thinks the entire market will now grow steadily and more sustainably. He believes there will no longer be a price war, with instead a focus on value creation, technological improvement, capability improvement, and the aftersales market.
XCMG has set sales targets
for regions including Europe and North America, aiming for these markets to account for 25-30% of total export revenue by 2027. By then, exports will make up more than 50% of XCMG’s total revenue, presenting opportunities and challenges. Yang emphasised the importance of building a strong system to support global operations, including a global risk control centre to navigate varying laws, taxes, and regulations. He also highlighted the need to understand cultural and business practices across countries.
Machinery Exchange will provide full sales and service support for Rokbak trucks in Zimbabwe. Pic: Rokbak
Yang Dongsheng, chairman of XCMG Group, and colleagues at a group event. Pic: XCMG
Dr Dominic von Achten (seated right) has welcomed Heidelberg Materials’ strategic agreement to acquire Votorantim Cimentos’s Moroccan assets. Pic: Norsk-Tysk Handelskammer
Epiroc to expand Indian output
Epiroc, the Swedish global market manufacturer of drill rigs and hydraulic breakers for the quarrying, mining and construction industries, has staged a groundbreaking ceremony in Hyderabad, India, to expand its manufacturing facility for rock drilling tools.
Epiroc has also inaugurated an innovation and technology centre in Hyderabad. The investment is part of Epiroc’s growing focus on India as a key hub for manufacturing, research, and development to support customers throughout the region.
buildings, and state-of-the-art machines.
Epiroc’s investment covers the expansion of land, new
“India is a key growth market and an important manufacturing and innovation hub for the Epiroc Group,” says Helena Hedblom, Epiroc’s President and CEO. “It’s been great to see
the growth in the Hyderabad product company in recent years, and this investment shows our trust in India’s future potential.”
Epiroc has maintained a strong presence in India for more than 60 years, with
BKT appoints new global president OEM
BKT, the major off-highway tyre manufacturer for the quarrying, construction, agriculture, and industrial sectors, has appointed Ludovic Revel as president global OEM.
This strategic choice reflects the Indian multinational’s commitment to pursuing its ambitious business goals, starting with strengthening its growth strategy in the OEM channel for original equipment and consolidating BKT’s brand visibility among the major global players. With nearly thirty years of experience in
the off-highway tyre market gained at world-renowned companies, Revel brings a sound knowledge of the industry. He has successfully implemented business development plans and accomplished medium-and longterm financial goals.
As BKT’s president of global OEM, Revel will lead a dedicated team whose members will contribute to the company’s expansion in the OEM channel. They will leverage a well-defined plan to explore new markets, new businesses, and development opportunities.
Revel said: “I am greatly impressed by the remarkable growth path BKT has made over the years, taking the company to a worldwide leadership position in the specialty tyre industry. It is an honour for me to join a company deeply rooted in sound traditional values but with a strong international perspective, a clear strategy, and strong ambitions for the years to come. We have the right resources, skills, know-how, and production capabilities to convert any business opportunity into reality.”
manufacturing locations in Hyderabad and Nashik, an innovation and technology centre in Bangalore, and a sales and marketing presence in all major regions of the country. The company employs around 1,600 people and has its head office in Pune.
The Hyderabad factory produces rock drilling tools such as rotary bits and downthe-hole products. Epiroc doubled the facility’s capacity in 2017 and is now expanding further. The investment will create employment for around 30 additional people. Production in the expanded area is expected to begin around April 2025.
Powerscreen partners with PICO in Egypt
Powerscreen has appointed PICO Engineering Group (PICO) as its new authorised distributor for Egypt. This strategic collaboration aims to strengthen the major crushing and screening plant and linked technology solution brand’s presence in the region and provide enhanced customer support through PICO’s extensive network and industry expertise. Renowned for its robust distribution of construction equipment and exceptional customer service, PICO will now offer Powerscreen’s full range of innovative crushing and screening solutions. This collaboration will provide
customers in Egypt with direct, unfiltered access to Powerscreen’s state-of-the-art equipment.
“We are thrilled to welcome PICO into the Powerscreen family as our authorised distributor in
Egypt,” said Imran Kazi, regional sales manager at Powerscreen. “Their deep understanding of the local market and their commitment to excellence make them the ideal choice to represent the Powerscreen
brand. We are confident that PICO will provide unparalleled support to our customers, helping them to maximise productivity and efficiency with our industry-leading equipment.”
As an authorised Powerscreen distributor, PICO will offer a comprehensive range of services, including sales, technical support, spare parts, and maintenance, providing Powerscreen customers with the highest level of service throughout the lifecycle of their equipment. “We are honoured to be appointed as the Powerscreen distributor for Egypt,” said Shahir El Essawy, CEO of PICO Engineering Group.
Artist impression of expanded Epiroc facility in Hyderabad. Pic: Epiroc
Pic: Powerscreen
Indonesia in construction mode
Indonesia is well and truly in construction mode, creating a wealth of commercial opportunities for the country’s building material suppliers. VL Srinivasan reports
On 12 August this year, Indonesia’s President Joko Widodo captured the growth of the archipelago nation's construction sector by laying the foundation for three flagship projects. These will be undertaken by the leading property developer PT Intiland Development Tbk through its subsidiary PT Adiwarna Harapan Nusantara in the new capital city, Nusantara.
Besides Intiland, seven more companies announced plans to start construction of their projects at Nusantara in September. Some of these projects are in the hotel and education sectors, Indonesia’s Public Works Minister Basuki Hadimuljono told reporters in Jakarta on August 22.
“We will be witnessing the groundbreaking of new projects in the education, hotel, and property sectors. A sports centre project will also begin its construction in September,” Basuki Hadimuljono said.
All this indicates that besides tourism and oil & gas, the construction sector is
playing a major role in the development of Indonesia’s economy. The construction industry has been accorded top priority by the government which has taken up several projects including development of the $35 billion new capital IKN Nusantara on the island of Kalimantan (Borneo).
With Indonesia's construction sector witnessing a rapid growth, the demand for construction aggregates, particularly cement, silica sand, crushed stones, and clinker, too are in great demand and expected to reach pre-COVID levels in the next few years.
In order to meet the growing demand for construction aggregates, the government has urged the project developers to use materials made in Indonesia instead of importing them in an optimal manner to maximise the economic impact on the people.
Cement production in Indonesia rose 6.4% y-o-y to 6.457 million tons (MT) last month compared with 6.067 MT in August 2023. Clinker production also increased 3.3% YoY to 5.296 MT, up from 5.125 MT in August 2023.
Besides IKN Nusantara, the government also launched several infrastructure projects such as laying new toll roads linking main regions of the country. The construction of seaports, airports and housing has helped Indonesia’s growth.
The government is also encouraging private sector involvement and foreign investment in the construction of these infrastructure projects.
In fact, a total of 2,700 km of toll roads were built by Joko Widodo government in the last 10 years, and only 780 km toll roads existed before he assumed charge in 2014.
According to Business-Indonesia, which aims to promote business within the country, Widodo’s government has been relatively positive for the construction industry – which accounted for 9.86% of the nation’s Gross Domestic Product in 2023, making it the fifth-largest contributor of the national economy. This was evident from the continuous increase in the state budget allocation to infrastructure projects year after year, from around $24.3 billion in 2017 to $27 billion in 2024.
Indonesian President Joko Widodo taking part in the ground-breaking ceremony of three projects of PT Intiland Development Tbk (Image courtesy – PT Intiland Development Tbk).
While the projects are being executed at breakneck speed, the country’s aggregate market is witnessing a phenomenal growth as it throws open a wide array of opportunities in the infrastructure, residential, and non-residential construction industries.
“In 2019, the Indonesian construction industry registered an annual growth rate of 5.8% in real terms. The overall trend has led most other institutions to forecast an annual growth rate of between 4% and 7% all the way from 2024 through to 2029,” BusinessIndonesia said.
Demand set to rise
On the basis of a comprehensive research, the US-headquartered Lucintel, the premier global market research and management consulting firm, said that the future of the construction aggregate market in Indonesia looks good with opportunities in the infrastructure, residential, and non-residential construction industries.
The major growth drivers for this market are growth in residential and non-residential construction activities, increasing urbanisation, and rising per capita income. Emerging trends which have a direct impact on the dynamics of the construction aggregate market include increasing adoption of pea gravel and the growing use of recycled stone.
In its reports entitled Opportunities for the Construction Aggregate Market in Indonesia 2014-2025: Trends, Forecast and Competitive Analysis, Lucintel has forecast crushed stone will remain the largest product type over the forecast period due to its high durability between 2024 and 2028.
The firm also predicted that sand and gravel will witness the highest growth during the forecast period due to its easy availability and low price. The growth for the sand and gravel segment will also be driven due to
“We will be witnessing the ground-breaking of new projects in the education, hotel, and property sectors. A sports centre project will also begin its construction in September.”
Basuki Hadimuljono
increasing demand in the residential industry. Within the construction aggregate market, infrastructure will remain the largest end use market during the forecast period due to increasing infrastructure development especially in emerging countries and growing government focus on infrastructure projects. Residential construction is expected to witness the highest growth during the forecast period, the report said.
Demand for Housing
In Indonesia, which has a population of around 280 million spread over 18,000 islands, the demand for housing has been on the rise in the last decade due to rapid urbanisation coupled with infrastructure development. The need for major
construction materials like gravel, concrete, sand and others has grown accordingly.
According to Bank Indonesia, the country’s federal bank, the demand for residential units rose modestly and in the last quarter of 2023, the sales increased by 3.27% compared to the previous year.
Even Fitch Ratings, an American credit rating agency, expects steady sales in Indonesia’s residential market in 2024 for most of its rated Indonesian homebuilders – and its presales projections to be met – as the year started on a positive note and the presales in the first quarter of 2024 registered neutral-to-positive growth q-o-q as well as y-o-y.
“We expect inflation and interest rates to remain benign in the next 12 months, and to drive steady GDP growth. We also expect domestic banks to remain supportive of mortgage loan growth, despite a modest rise in home-loan rates in Q1 of 2024 at many major lenders,” the ratings agency said.
However, the value added tax (VAT) rebate, which was unveiled by Joko Widodo in November 2023, drove some purchasing demand, and will be raised from the existing 5.5% to 12% in January 2025. This should be so for the developers with ready-completed inventory for sale, or those able to fast-track construction, Fitch Ratings said in its market update on Indonesia’s property market for Q2 of 2024.
Besides VAT, the government enacted Omnibus Law, which aims to attract foreign investors who can buy and possess real estate properties. These properties were earlier re-categorised as ‘Right to Use’ to the more flexible ‘Right to Build.’
Cement Consumption
Indonesia is the sixth-largest producer of cement globally and the Indonesian Cement Association - Asosiasi Semen Indonesia
Image courtesy – Cemindo Gemilang
(ASI) - has forecast the volume of cement to be used in the construction of Nusantara, as 1 million tonnes per year (MTPA), which is 1.5% of the current domestic demand of 65.6 MTPA. The domestic cement consumption is expected to grow 3% in 2024, ASI said.
However, the first half of 2024 saw a 1.4% year-on-year increase due to various factors, such as escalating tensions in the Middle East, stringent global monetary policies, and fluctuating coal prices.
This placed substantial pressure on the sector, said Indonesian cement major PT Cemindo Gemilang Tbk in August 2024, on receiving a Special Recognition Award from the World Cement Association for continuing its progress in climate action.
Though the latest data from BPS-Statistics, Indonesia's official statistics office, showed a decline in the country's cement demand, it is set to grow to 1.94 MTPA by 2024 due to the development of various projects in the new capital city, according to a report in Global Cement magazine.
The Bandung Institute of Technology (BIT), which published a report in 2022, said that the Nusantara project would increase Indonesia’s cement demand by 33% to 84 MTPA for 20 years from the start of its construction.
Cement decarbonisation
For its part, ASI has drawn a low-carbon cement roadmap, in collaboration with the Indonesian Ministry of Industry and the plan, with a two-scope approach to reducing GHG emissions, suggests increasing the use of alternative fuels and biomass substitution rates, reducing the clinker factor by advocating for a performance-based cement standard with a lower clinker factor, and reducing fuel usage by optimising pyroprocessing systems.
“Scope two of the plan consists of reducing the need for electrical energy. This will be achieved through digitalisation/
automation, solar panel installation and other renewable energy systems such as waste heat recovery systems,” ASI Chairman Lilik Unggul Raharjo said in his remarks at CEMTEC Asia 2024 held in Jakarta in June.
Climate goals
Indonesia plans to bring down greenhouse gas emissions by around 32% through its own efforts and above 43% with international support by 2030, based on the Enhanced Nationally Determined Contributions (ENDCs) document.
Indonesia has also pledged to achieve net zero emissions by 2060 and sustainability is one of the main challenges facing the construction industry in Indonesia. As the demand for environmentally friendly construction is being voiced by environmentalists, there is an urgent need for the construction industry to adopt green technologies, eco-friendly building materials and sustainable building practices.
“The launch of L120 Electric is a continuation of our electrification journey. I hope our customers can benefit greatly from this product to build up a sustainable Indonesia.”
Tomas Kuta
Coal mining in Indonesia: Image Source - Business Indonesia
Volvo L120 Electric wheeled loader being exhibited at Mining Indonesia. Image courtesy – Volvo CE
Citing two experts in a report published in August, Mongabay, an independent media organisation reporting on Nature and planetary challenges, said that construction of the new capital city is likely to lead to a surge in carbon emissions putting the country’s climate goals at risk. Coal is the major fuel consumed in cement and steel production.
Quoting Firly Rachmaditya Baskoro of BIT, the report said that construction of Nusantara might increase demand for cement by one-third, or about 21 million metric tons per year for the next 20 years.
“For this, the government has increased the coal domestic market obligation (DMO) for cement manufacturing from 4.5 million metric tons in 2021 to 15 million metric tons in 2022-2025, just to ensure coal supply for the growth in cement industry,” Firly said.
This represents an additional 9% of the total coal consumption in the country, which currently stands at about 115 million metric tons per year. The trend will likely continue depending on the design of the city and the population it will accommodate, the report said.
Shaohui Zhang, an Associate Professor at Beihang University in China, and an expert in cement and steel manufacturing, said that coal will be the key energy source used in manufacturing building materials for Nusantara, particularly given the city’s
proximity to coal resources.
Zhang estimates that for a new city with 10 million residents, the demand for cement in residential housing could be as high as 60 million metric tons. The amount of cement needed will be much higher when non-residential buildings and other infrastructure are included, the report said.
Government’s response
It is not that the government is unaware of the ecological issues as companies including construction equipment suppliers are taking adequate steps in this regard.
Indonesia’s FMCG firm Bina Karya has signed a Memorandum of Understanding (MOU) with Nusantara’s officials in providing construction material solutions for the new capital city in May this year.
The purpose of this collaboration is to provide building material solutions that include cement-based products including green cement (environmentally friendly cement) such as hydraulics, cementderivative products including concrete and porous paving, as well as construction solutions such as SpeedCrete (quick-drying concrete), soil stabilisers, and other building materials.
President director of PT Bina Karya, Boyke P Soebroto, expressed hope that this cooperation can run smoothly. “We hope that through this cooperation, all buildings in the archipelago will not only
carry the concept of green building but also green construction because they use environmentally friendly building materials,” he said.
Volvo CE in Indonesia
Volvo CE, one of the most respected construction equipment companies globally, has launched its first two electric machines in Indonesia – the ECR25 Electric compact excavator and L25 Electric compact wheeled loader – in November last year.
Such machines can support a range of underway infrastructure development and contribute to the third phase of Nusantara's development, which will focus on sustainability. Nusantara will source all energy from renewables, dedicate 10% of its land to food production, and ensure 80% of travel is by public transport, cycling, or walking. At the three-day Mining Indonesia exhibition, held in Jakarta from September 11-14 this year, the company also launched L120 Electric wheeled loader, the largest machine in Indonesia.
Tomas Kuta, Head of Region Asia, said that their Indonesian customers were now buying the broadest range of Volvo solutions, combining both loading and hauling.
“The launch of L120 Electric is a continuation of our electrification journey. I hope our customers can benefit greatly from this product to build up a sustainable Indonesia,” he added. AB
Industry
Road development boon for Kenyan quarrying sector
A big plan to develop Kenya’s road infrastructure offers attractive commercial opportunities for the East African country’s quarry operators. Shem Oirere reports
Kenya is implementing a five-year road sector development plan that will see at least 1,183 kilometres of new roadways built, including expanding and enhancing 674 kilometres of existing roads and restoring another 492 kilometres. The ambitious plan is expected to fuel a notable increase in the consumption of construction materials, including soils, aggregates, and binders such as lime, asphalt, and concrete.
One of the existing roads that are to be expanded under the plan, which is spearheaded by Kenya National Highways Authority (KeNHA) under a public-private partnership (PPP) model, is the 175-kilometre Nairobi – Nakuru – Mau Summit (A8) highway.
The motorway is to be widened into a dual two-lane motorway under a US$1.4 billion contract awarded in September 2020 to Rift Valley Highway Limited (RVHL), a company incorporated in Kenya and wholly owned by French listed concessions and construction firm VINCI Group and Meridiam Infrastructure Africa Fund each owning a 50% stake. RVHL entered into a 30-year PPP concession agreement with the Kenya government through the KeNHA to design, finance, operate and maintain the road project funded via equity by Vinci Group, debt from the African Development Bank (AfDB), and guarantees from the World Bank.
KeNHA requires all major road contractors to secure their quarries, borrowed pits, and stockpiling areas for the supply of aggregates and associated products, disposal of quarry waste, and keeping of excavated material for later use, such as in restoring the quarry area or landscaping.
“Notwithstanding any indications to the contrary in the Standard specification, the employer (in this case KeNHA) will not make available to the contractor any land for, nor
has identified any specific areas for, quarries, borrow pits, stockpiles and spoil areas, and for access thereto.”
Subsequently, Vinci Construction’s subsidiary, Sogea Satom (Sogea), acquired approval from Kenya’s National Environmental Management Authority (NEMA) to expand and develop two quarries within Nakuru County: the existing Sachangwan quarry and the greenfield Elmentaita quarry. This is in line with KeNHA’s commitment in its five-year plan to adopt construction approaches “that utilise locally sourced materials to address rampant unemployment and unfavourable foreign exchange balance.”
According to KeNHA, Sogea will “be entirely responsible for locating suitable sources of materials complying with the standard and special specifications, and for the procurement, winning, haulage to the site of these materials and all costs involved therein.” The contractor is also responsible for providing suitable areas for stockpiling materials and spoil dumps.
Despite the uncertainty surrounding the expansion of the Nairobi—Nakuru—Mau Summit toll road project, especially after the government put on hold the contract to RVHL in April 2024 due to misunderstandings on toll fees payable, the project has exposed the growth potential of Kenya’s quarry industry, which is driven by the expansion of infrastructure, particularly the road network, which is a huge consumer of construction material.
At both Sachangwan and Elementeita, Sogea proposes to install stone crushers, an asphalt plant, a precast yard, workshops, offices and other support infrastructure
Sachangwan quarry is an existing quarry located approximately 190 miles from the Rironi-Mau Summit highway and approximately 680 miles southwest of Sachangwan town. It sits on 31.12 hectares of land.
Sogea proposes to carry out stone quarrying by opencast mining. The quarrying process will involve drilling and blasting, with a target production of 58,000 tonnes per month over four years. The quarry has been producing construction materials such as aggregates, stone chippings, sand, and gravel that Sogea looks forward to scaling up. The company could not immediately confirm the sizes of the aggregates currently produced and those intended to meet the specifications of the road project.
Sachangwan quarry is surrounded by a rich agricultural area with fertile soils. Sogea
Materials processing at a Kenyan quarry Pic: Shem Oirere
A Cat 330D crawler excavator at work at County 45 Quarry in Kisii Pic: Shem Oirere
proposes extracting stone from the quarry through the opencast mining method, which entails drilling and blasting after removing the topsoil or overburden. The excavated topsoil, the company explains, will be stockpiled on site, and the excess will be disposed of appropriately in designated dump sites or for rehabilitation of some of the quarry pits.
“Some of this material can also be reserved for use in landscaping as part of the rehabilitation process once the quarry has been decommissioned,” Sogea says.
Soega explains that the depth of the blast hole will be determined by the “volume of rock to be broken in one shot, which is also related to the quantity of the explosive that has to be charged into the hole.”
The blast hole’s diameter will also depend on the type of explosive used to ensure the “most beneficial result.”
Blasting results in aggregates of diverse sizes, and Sogea says the method is “efficient, less time-consuming, and more effective and efficient for large-scale material extraction.”
“The alternative is to use wedging or heating methods for material extraction, a process that involves drilling a row of holes, either by hand or by pneumatic drill, close to each other to create a longitudinal crevice,” it says in a project brief submitted to NEMA.
However, Sogea explains that the wedging process " is time-consuming and unsuitable for large-scale mining.”
“The heating involves the application of a thermal effect to induce rock fracturing and is also less efficient in large-scale mining,” the company adds.
It continues: “Considering the large volume of aggregates required by the proponent for construction of the Mau Summit Rironi highway, this method will be less effective, too expensive and timeconsuming.”
Although Sogea could not immediately confirm details on the make and specifications of the equipment to be used, it says the quarry will “utilise a range of equipment such as a pre-screener, loading conveyor, intake hopper, magnetic separator, and a crushing unit such as jaw crushers and cone crushers.”
Sogea says it will install two crushing plants to crush the extracted hardstone material.
“Powerful hammers or metal jaws within the primary crusher break the rock down and passes through a series of screens that sift it into different sizes and may also pass through further crushing stages,” says the firm.
Sogea also plans to complete a material testing laboratory at the quarry site for the firm’s qualified personnel “to ascertain the quality of the material that will be used for the construction of the road.”
Furthermore, the company plans to install an asphalt plant with a daily production capacity of 1200 tonnes of asphalt, comprising 99% pebbles, fines, and sand.
Sogea will also install an emulsion plant at the quarry site, covering approximately 1.04 acres and having a daily capacity of 125 tonnes.
Elsewhere, a new mixing plant will be established at the site for mixing water, cement and sand to form concrete “in predetermined proportions.” A storage stock of 1000 tonnes of cement is proposed within the site.
NEMA has proposed measures to protect the environment during its day-to-day quarrying operations of drilling, blasting, and crushing, especially in terms of dust control and noise abatement, which are also triggered during the handling and transportation of the construction material.
The environmental authority says Sogea “will undertake the necessary engineering and administrative control measures to ensure noise and vibration levels due to quarrying operations are within the limits specified under the regulations.”
Some of the measures Sogea suggests include using a proper blasting pattern for effective rock fragmentation and generating
minimal fine dust in the open atmosphere through efforts such as regular sprinkling of water targeting dust-emitting sources.
Moreover, Sogea has committed to proper periodic maintenance of the company’s project and transport vehicles and equipment to check emission levels and ensure they are within permissible limits.
Other mitigation measures Sogea is expected to take to minimise the impact of air pollution include training and sensitising workers on dust suppression measures and their impact on health, implementing dust suppression measures such as sprinkling water, and carrying out annual monitoring of air quality at the quarry site and environs.
Meanwhile, Sogea looks forward to ensuring the “maximum charge weight for blasting plans vibrations is 100 kilograms or alternative technology that generates noise and vibration that is compliant to NEMA’s excessive noise and vibrations regulations requirements.”
“Rock-breaking methods adopted should be based on a balance between suitability, the required payload, cost and the impact on the environmental receptors,” NEMA advises.
During the blasting phase, NEMA says Sogea must ensure it enlists experts on explosive handling and stick to a schedule that ensures explosions are done at “pre-arranged designated times and the affected public, within approximately 1 km radius, duly informed.”
Sogea is also keen on developing the Elementaita hardstone quarry and contractors’ camp to supply aggregate materials for constructing the Rironi-NakuruMau Summit highway (A8).
The proposed Elementaita quarry is on 82 acres of land, approximately 200 miles from the Nairobi-Nakuru Highway (A8). Quarrying operations will take up 25 acres, while installations and undisturbed areas will take up 57 acres.
Similar to the planned installations at the Sachangwan quarry, Sogea has proposed several other components at the Elementaita quarry, such as a crusher plant, asphalt plant, material storage area, offices, workshop, emulsion plant, mixing plant, concrete plant and precast area, explosives store, and other support infrastructure, such as a standby generator.
An estimated 58,000 tonnes of aggregates will be produced monthly from the Elementaita quarry, and an estimated 1200 tons of asphalt, which is 99% pebbles, fines, and sands, will be generated at the quarry daily. Sogea is also investing in an emulsion plant to produce at least 125 tons of emulsified bitumen.
KeNHA, responsible for Kenya’s national trunk road network, including class S, A, and B, which totals 21,583 kilometres, plans to spend $5.4 billion on road design, construction, and maintenance by 2027. This trend will likely trigger the growth of the country's stone quarrying business and contractors' expenditures on borrowed pits and land for stockpiling. AB
A quarry worker moving material before drilling at County 45 Quarry in Kisii
Pic: Shem Oirere
A Caterpillar excavator in a Kenyan rock quarry. Pic: Shem Oirere
EFFICIENT COMPACTION
At the Steinmühle landfill site near Tirschenreuth in Bavaria, wastes containing asbestos, glass wool, and similar mineral contaminants are being efficiently compacted by a Hamm H 25i VC compactor. The crushing and compaction of the material enables
the disposal of more material at the landfill site than originally planned. This saves rare and valuable landfill capacity in the former basalt quarry and simultaneously increases the cost-effectiveness of the site by extending its active service life.
In the Heart of Istanbul
The MOBIREX MR 130i EVO2 from Kleemann is demonstrating its capabilities in Istanbul’s financial quarter. There, material for the concrete and road bed is being produced in combination with the MOBISCREEN MSS 802i EVO mobile scalper. Around a million tons of excavated material will be processed efficiently on the site over a period of about one and a half years. “We have to be especially flexible at this location,” explains Feyzullah Kahraman, managing director of construction
contractor Safir Proje, “both regarding the unusual environment and the material.”
The contractor is impressed with the high performance, low fuel consumption, and easy handling of the Kleemann machines.
Fully Electric
The NEO line is the new highperformance compact class from Kleemann. The MOBIREX MR 100(i) NEO mobile impact crusher is the first member of the new family and impresses with outstanding efficiency, performance, and versatility. Regardless of whether there is limited space on the project site or whether project sites frequently change – thanks to its compact dimensions and low transport weight, the machine can be quickly and easily moved from site to site and deployed in a wide range of situations. It is the ideal choice for uses ranging from the processing of concrete, mixed rubble, and asphalt, to the processing of soft to medium-hard natural stone. The new impact crusher is particularly sustainable in the version with E-DRIVE. This enables purely electric machine operation resulting in zero local emissions.
ON A GROWTH PATH
Commemorating 36 years in business in 2024, Portland Group remains one of the leading construction-materials suppliers in the Western Cape Province of South Africa. With a clear growth trajectory, supported by ongoing investments in infrastructure and equipment, the company is well-positioned to capitalise on the construction boom in the region. Munesu Shoko reports
Established in 1988, Portland Group has over the past 36 years enjoyed sustainable growth. Having commenced its business with one operation, the flagship 65-hectare Durbanville Quarry, the company has, through the decades, expanded operations to include another quarry and a crushing operation, as well as a footprint of readymix plants in all the infrastructure hotspots in the Western Cape, and a precast concrete facility.
In recent years, the company has enjoyed massive construction development taking place in the Western Cape, leading to high demand for aggregates and readymix concrete. Portland Group GM Martin Mostert says that the province has in the last three years witnessed massive investment in construction activity, anchored by road
upgrades as well as both commercial and residential building projects.
“We are fortunate to be located right in the thick of construction activity. One of the notable projects that we are currently supplying is the Vissershok road upgrade. Undertaken by H&I Construction, the project is on the doorstep of our Durbanville Quarry. The project – a major bypass off the N7 highway – is a significant piece of infrastructure in the Durbanville area. To provide context, apart from all the G-products, we are also supplying in excess of 800,000 tonnes of overburden for backfilling purposes,” says Mostert.
To meet the high demand for aggregates, Portland Group has embarked on significant plant upgrades at its Durbanville Quarry. The quarry is renowned for its quality aggregates from the natural Malmesbury Hornfels deposits.
“At the moment, we are busy with our second set of upgrades, entailing the installation of a new Techroq screen and automated feed bins for the two cone crushers in our plant setup. These upgrades are aimed at increasing capacity,” says Mostert.
The latest enhancements follow hard on the heels of last year’s upgrades, when the company installed a new CH430 cone crusher and a new Techroq vertical shaft impact (VSI) crusher. The cone crusher’s purpose was to increase plant capacity, while the VSI’s rockon-rock crushing is being used to improve the shape of crushed aggregate particles. In addition, the company installed a new, larger transformer to sustain the new crusher additions to the quarry.
To enhance its overall capacity, Portland Group has recently invested in two additional quarries. About two years ago, Mostert
In recent years, Portland Group has enjoyed massive construction development taking place in the Western Cape province of South Africa, leading to high demand for aggregates
explains, the company opened the Portland Worcester Quarry in Rawsonville. However, this was not a fully operational quarry; rather, it served as a crushing site that processed river material.
tonnes per month (tpm). The material was destined for Portland’s own readymix plants as well as external customers who specialise in exposed aggregate concrete.
“The Portland Worcester Quarry was a short-term project that has now concluded. In fact, at this project, we helped the community with the maintenance of the river, which, due to heavy rains, kept filling up with natural brown stone. When that happened, the river flooded nearby farms and houses. Armed with a river management plan, we removed the brown natural stone and crushed it at a nearby property to produce single-size aggregates such as 20mm and 14mm concrete stone.”
The product from this material was unique, and most of it was used to produce exposed aggregate concrete. Here, Portland Group produced between 10,000 and 15,000
In April this year, Portland Group further expanded its aggregate capacity with the acquisition of its Portland Paardeberg Quarry just outside Malmesbury, some 40km from the existing Durbanville Quarry.
“As a group, we decided to purchase this to have a variety of material to offer our clients. The granite rock here complements our Malmesbury Hornfels deposits from the Durbanville Quarry. Being able to offer different material choices to our customers makes business sense,” he says.
The acquisition of the Portland Paardeberg Quarry also expands Portland’s product range to include high-quality sand from the sand mine on the quarry. Following the acquisition, the company has also invested
in a major plant upgrade to boost capacity, entailing the installation of a new jaw crusher and a Sandvik CH430 cone crusher.
The Portland Paardeberg Quarry produces between 25,000 and 30,000tpm of single-size aggregates, while sand production is between 10,000 and 12,000tpm.
For years, Portland Readymix has provided a range of readymix concretes that is designed for the whole spectrum of the construction industry. These products are backed by the company’s expertise and tight quality control which brings a guarantee of strength and workability. The company also offers high-performance, decorative and special application concretes to cater for all the industry’s concrete needs.
“We have a rich history of product development, reliability and technical expertise and our products are specifically designed for a wide range of applications. Portland has a unique capability to pool resources and execute large and challenging pours anywhere in the Western Cape,” says Mostert.
The increased demand for concrete has in recent years led to the expansion of readymix plants in Malmesbury Swartland (2022), Saldanha (2023) and Paarl. For years, the company operated two readymix plants in Durbanville before establishing a 36m³ per hour plant in Paarl Swartland. In Paarl, the company is currently adding a second concrete batching plant, which will take the company’s capacity in the area to 90-100m³ per hour.
In March this year, Portland established a crushing plant to process waste slag for the production of readymix concrete in Saldanha. The 90m³ per hour plant is Portland Group’s largest readymix concrete batch plant to date.
In 2008, Portland expanded its operations to include the manufacture and installation of precast hollow core slabs. At the time, the company acquired state-of-the-art
A mobile crushing and screening plant deployed at Portland Group’s Durbanville Quarry
An aerial view of Portland Group’s Durbanville Quarry
technology from Elematic in Finland to make sure that it produces high-quality slabs. The company provides a complete service, from design (by its in-house design team) to manufacture (in its purpose-built factory) and finally installation (by experienced rigging teams).
Portland frequently upgrades its operations and has recently expanded its stockyard to increase storage capacity. Extra casting beds were also installed to increase capacity for production. With these new extensions, the company has created better turnaround times, higher production levels, better handling of panels (by use of the extended stockyard), and quicker loading of trucks, which in the end, has had an enormously positive outcome for all involved.
The Portland hollowcore production plant, which is situated at the Durbanville quarry premises, produces an average of 700m² of precast slabs per day. The operation has recently been boosted by the purchase of a new extruder which, according to Mostert, is a significant investment.
To further support growing operations and market demands, the company has recently invested in two 30-t Volvo articulated dump trucks (ADTs) and two excavators (Volvo and SDLG) from Babcock. The two ADTs and the Volvo excavator have been deployed at the Durbanville Quarry.
In addition, Portland has purchased new FAW readymix concrete trucks. The company runs a total fleet of 26 readymix trucks, including 6m³ and 8m³ units. “We have a stringent replacement cycle for our readymix trucks. This year alone, we have taken delivery of nine new trucks, with a few more expected before the end of the year,” says Mostert. Commenting on some of the considerations when investing in new gear, Mostert says the company always places value on the latest technology and equipment to maintain efficiency and competitiveness.
“We also consider the long-term sustainability and operational reliability of equipment. For example, the build quality of the Volvo machines fits the bill for our operational requirements. This is complemented by the excellent backup service from Babcock, particularly the service plans,” he says.
A member of surface mining industry association, ASPASA, Portland Group maintains high standards of health and safety across its operations. The company invests in regular safety training and certification to ensure that all employees are up-to-date and familiar with the necessary training procedures.
“As part of our safety protocols and procedures, we conduct routine safety
audits and inspections of our equipment and facilities. We also continuously invest in safety equipment and technology to protect workers. In addition, we develop emergency response plans and conduct regular safety drills to create familiarity with escape routes, assembly points and communication procedures, promoting a quicker and more organised response,” concludes Mostert. AB
Portland Group recently took delivery of two new 30-tonne Volvo articulated dump trucks from Babcock
A bird’s eye view of one of Portland Group’s processing plants
A Volvo articulated hauler deployed to haul material from the rock to the processing stage
Komatsu HD785-8
Built for mining and quarry applications, the HD785-8 has a powerful EU Stage V engine (849 kW / 1140 HP) and a payload capacity of 92.2 tonnes. It has a 7-gear, fully automatic transmission with two selectable reverse gears. The Komatsu Advanced Transmission (K-ATOMiCS) ensures smooth clutch engagement for a comfortable ride and reduced material spillage.
Born to rock
Tanja Gjerde has quickly made her mark in the aggregates sector, holding an important and wide-ranging role in geology and planning covering the thirteen quarry sites operated in eastern Norway by Feiring Bruk. She told Liam McLoughlin that her desire to work in the sector dates back to childhood when she became fascinated by the importance of rocks.
Some people are fortunate enough to know exactly what they want to do with their life from an early age, and that certainly applies to Tanja Gjerde who has been working as the mining engineer/ geologist at Norwegian quarrying group Feiring Bruk for three years.
She is the first person to hold this newlycreated role at the family-owned group, working across all of its thirteen sites in eastern Norway that extract and produce crushed stone, gravel, aggregates and asphalt.
Growing up in the small town of Tomrefjord on the northwest coast of Norway, her interest in all things mineral rapidly became apparent.
“We were surrounded by mountains, and my family has always been really curious when we’ve been out,” she says. “My mom is quite into the biology in nature and when I was first introduced to geology, I said to my parents that I’m going to be a geologist. They weren’t surprised and I’ve never been in doubt since. I say to my friends and family that being a geologist isn’t work, it’s a lifestyle.”
Tanja’s main duties at Feiring Bruk revolve around quarry planning, including where to drill next, where to build a new road, where to blast, and also regulatory planning regarding contact with the government.
“I am in a lot of dialogues, both internally in the company about our plans, but also with the relevant government departments which is a big part of the job,” she adds.
Another important aspect of her work at the Feiring quarries is using drones to measure the stockpiles, and making the 3D models that the company uses for operational planning.
Tanja says the data gathered from the drone operations is important both for production and controlling how much is extracted from the quarry sites, how much is being sold and investigating the production mass balance so that the amount of waste material being produced is cut down.
“When I started flying drones, we had an idea of what they could be used for and then we just realised as time passed that, wow, we can use it to a lot more than we thought initially.
“We’re trying to use all this data so that when we’re planning, we can use the 3D
models for visualisations. We can also go back in time and see if there’s some things we don’t have full control of. We have documentation on how things were, what and where we extracted at a particular time.”
Her role is quite wide-ranging and also includes health and safety issues such as the documentation for fencing round the quarries.
“I do a lot of work around quality in terms of evaluating aggregates from secondary sources. For example, if you have a tunnel in Oslo or you’re building a garage in your garden and you have too much rock material, I will go and evaluate the quality of them and then say how we can reuse them in our production at Feiring.”
Tanja joined Feiring in 2021, and took up the newly-created position of mining engineer/geologist. What was the reason for the company introducing this role?
“Our production chief had to deal with a lot of the quarry regulatory aspects and we have 13 quarries, so that’s a lot of planning. Combined with that, he had responsibilities for staff members and so it was partly to reduce his workload.”
In the period Tanja has been with Feiring the company has been putting an increasing amount of resources into its sustainability initiatives. Starting in 2020, it has been heading a four-year science project in this area, in cooperation with European research institute SINTEF, and she took over the leadership of the project in January this year. The geological survey of Norway (NGU )
and a technology company Fremby are also taking part in the project.
“We’re in the end-phase of the project this autumn, and a lot of my work was directly into the sustainability science of it.”
Among other things, the project has looked at issues including the most effective and sustainable ways to handle different types of secondary rocks and looked at the whole value-chain of recycling mass streams from construction sites. One of its findings was that only 20% of the emissions related to asphalt at Feiring sites are due to transport, with 80% occurring in the production process.
Several data scientists have worked on the project and contributed their insights on transport and emissions.
The project has involved a lot of work with different businesses including contractors and entrepreneurs, and Tanja says they are very willing to try and cut down on their CO2 emissions but do not have the resources to handle the costs and risks alone. Norway has a relatively low rate for recycled and secondary materials in total aggregates sales, and ranked 20th out of 21 countries in 2020, according to data from Aggregates Europe - UEPG and the UK Mineral Products Association. Tanja says this situation is now improving.
“At Feiring we’re taking in more and more recycled materials and that’s something that is being seen all over Norway with the amount of aggregates from secondary sources like tunnel projects and construction sites increasing.
Drone flying and stockpile measurement is an important part of Tanja’s duties at Feiring Bruk
“Our excavation from the quarries will probably be going down in the coming years, which is great because then our prime rock can go into the best quality products and we can expand the lifetime of our quarries.”
In terms of what her main objectives are in her role as mining engineer/geologist at Feiring Bruk, Tanja says she wants to combine her interests in geology and sustainability.
“I love rocks, and I also love the earth we’re living on, so I want to extract the resources in a responsible, sustainable and safe way. A lot of the choices we take today affect not only us, but the next generation. When I’m planning a quarry, the horizon I’m working in can be between 40 and 100 years, so it’s a big responsibility to do it in a sustainable and efficient way, with respect for the resources.”
Her educational background has been invaluable in her job at Feiring. Studying geology at high school where she went on field trips to Iceland, she then went on to take a bachelor degree in geology and geo-hazards at the Sogndal department of the Western Norway University of Applied Sciences in western Norway . The degree covered government regulations around rock extraction, in addition to basic geology such as the study of geohazards, glaciers, structural geology, hydrogeology and geophysics.
“There was a lot of field work, which I loved. I found I was distanced from the study of avalanches, and that I was more drawn to the in-depth study of rocks. I started my master’s thesis on bedrock and resource geology and that was when I studied mining engineering [at the Norwegian University of Science and Technology in Trondheim], because I think the whole extraction of rocks and how our society is so dependent on it is really fascinating.”
This background has provided her with a detailed understanding of the geological properties of rocks and how this is important in the planning of the quarries. She has the expertise to do a lot of structural geological measurements of the quarry cores at Feiring and work out the best way to blast rock, for example to optimise the fragmentation.
“Our site workers know how the different rock types behave, even though they don’t have the theory. I have the theory but not necessarily the practical insight, so it’s been fun having a lot of links between theory and practice.”
She is planning to become more involved in the production processes at Feiring’s quarry sites and is currently putting in the hours test-driving to get operating licences for dump trucks and wheeled loaders.
ABOVE: Collecting sediments from the fjord outside a Feiring quarry RIGHT: Attending a meeting in Brussels held by European standardisation organisation CEN BELOW: Tanja is currently studying for licences to drive Feiring’s wheeled loaders and dump trucks
ZW310 that is being re-built at Nasta’s main office in Larvik and converted to biogas.
Another area of her expertise that has been useful at Feiring is in using Esri ArcGIS mapping software. One part of the software is called SiteScan, which is the tool that Tanja and her colleagues use for drone flying and measurement of the stockpiles. It can also be used for applications to the municipalities, or landowner calculations. “I did a lot of that in my studies and it’s a great tool that I use so much here.”
In terms of what she enjoys most about her job Tanja highlights two main things, the first being that it provides the opportunity to have both office and field days.
contribute in the discussions, parallel to being surrounded by skilled people who can teach me a lot of new things.”
One of the main things she enjoys about working at Feiring Bruk is that it is a small and family-owned company, where the people all know each other and work as a team to reach their goals.
“It’s a really good environment in terms of that,” she says. “We cheer on each other and celebrate our achievements, as do our owners. They’re very innovative and let people follow their path if they’re passionate about something.”
“This will enable me to be a part of the team outside,” she says. “I plan a lot of their work guidelines so I need to understand what their challenges are.”
In furtherance of its environmental efforts Feiring is planning to introduce a biogaspowered 28-tonne wheeled loader shortly. The loader is an original diesel Hitachi
“I did not educate as a geologist to sit in an office all day, so I really love spending time outside in the quarries and the surrounding nature.”
She is generally outside more during the summer months but adds there is still plenty of tramping around in the snow in Norway’s cold winters.
She also enjoys being able to work in an interdisciplinary team where her competencies are relevant: “I have a lot to
She says that the company owners are also quite visible in the media and take their social responsibilities very seriously.
In terms of the technologies that are proving a big help to her work in quarrying, Tanja says improvements in machine data monitoring now provide greater details about their levels of efficiency and emissions.
She adds that this allows data users to be creative and have real and direct results when choosing to explore new methods in materials production.
“We can always improve and we’ve
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focused a lot on small things that we know from the machine data can reduce emissions by, for example, having good practices for maintenance on our roads.”
She says the quarry industry can do more to improve its sustainability levels and that may partly be due to it not being subject to the same levels of regulatory scrutiny that the asphalt, concrete and construction sectors are. “We are making improvements, but have not fully got there yet.”
She adds that there has been a change in the last couple of years with the increased focus on sustainability following the EU’s European Green Deal in 2020 and Critical Raw Materials Act introduced this year, which have seen politicians in Norway starting to talk more about the quarrying industry.
“We can’t just leave the responsibility with the politicians though. The quarry industry in Norway has traditionally preferred a low media profile, maybe because it’s seen as unattractive with a lot of noise and dust. Now both the industry and the politicians are starting to talk about sustainability, and this is great because it means we can show a lot of the good things we are doing.”
In general, the quarry industry remains quite male-dominated, but Tanja says she has noticed a difference in recent years, at least in her own country.
“I’m not sure how Norway is compared to the rest of Europe, but in our company the CEO is female. We have females in all positions. We have machine operators, laboratory workers, some of the heads of
departments at the different quarries are women, and I think this does something with the culture, because for us young ones coming up in the industry, we now have some role models to look up to.”
don’t have the same mechanical properties but they’re still good for some uses. We need to be able to allocate the correct quality rock to the correct purpose.”
Norway is the ninth-biggest aggregates producer in Europe according to data from European aggregates association UEPG – Aggregates Europe. It is also a major exporter, ranking second in the world for export value of pebbles, gravel, broken & crushed stone for aggregates with US$221m in 2022, behind the United Arab Emirates with US$295m (source: Observatory of Economic Complexity). The Mibau Stema Group in the west of Norway is a major exporter of aggregates to Europe.
Norway has a large number of extraction sites (1,121 in 2022, according to UEPG data), and Tanja says the quarries have historically generally served areas in the immediate vicinity within a 30km radius, with it not being cost-effective to transport them longer distances.
Tanja’s longstanding love of rocks is also reflected in her hobbies and interests outside her professional life.
“I really enjoy spending time in the mountains, so I do a lot of traditional climbing and also trail running. I’ve been running some 42km trail marathons in the mountains, and in the winters I spend as much time as possible skiing.” AB
“We have to look at the geology in the quarry and not think that everything is just the same, because it’s not and it has different qualities”
Regarding her professional ambitions in the quarrying industry going forward, Tanja says she would like to increase knowledge around the importance of the extraction sector and the best way to re-use and recycle resources.
In particular she stresses the importance of optimising rock usage for the best purpose, which she says still has plenty of room for improvement.
“We have to look at the geology in the quarry and not think that everything is just the same, because it’s not and it has different qualities. That way we can channel rocks that have great quality, rocks that are perfect to use in any kind of purpose that should go into asphalt and concrete, for example.
“Then we have many other rock types that
Tanja Gjerde has worked as the mining engineer/ geologist at quarry group Feiring Bruk since 2021
Tanja mountaineering where she grew up in northwest Norway
Crushing and screening solutions making tracks in Africa and America
Recent launches and regional rollouts in the crushing and screening sector have included a high-pressure grinding roll crusher becoming available in southern Africa, a new range of longer-life vibrating screens, and a track-mounted screening solution making its debut in North America. Liam McLoughlin reports
Having made its global debut in 2018, the Metso HRC 8 highpressure grinding roll crusher is now available in southern Africa from equipment dealer Pilot Crushtec International. While the machine is primarily targeted for the manufactured sand market, there is an opportunity to deploy it in mining, principally in pre-milling applications as a pre-grinder to help improve mill efficiency.
Pilot Crushtec says the demand for economical and efficient ways to produce crushed sand is growing, as natural sand deposits located near growth centres are being depleted and environmental regulations are becoming stricter. As a result, manufactured sand is becoming a high-demand material. The arrival of the Metso HRC 8 ushers in a new era for manufactured sand-makers.
The machine uses a method of interparticle comminution by drawing in a bed of material between two rotating rollers. The rollers, one of which is in a fixed position and another one floating, generate an extremely high pressure, extruding the feed material down to the desired smaller grain sizes.
“The HRC 8 is the ultimate solution to produce excellent quality sand that can substitute natural sand from natural deposits such as rivers. The quality of sand can be adjusted and optimised, thus reducing the amount of cement and asphalt required in concrete mixes or asphalt. The machine produces a gradation according to customer needs and delivers a perfect cubical shape for concrete and asphalt sands,” explains Oldemar Meneses, product manager, HRC Technology at Metso.
In addition, the HRC 8 can convert quarry waste into sellable product. The
machine can reprocess non-sellable waste materials to correct the gradation curve and particle shape, converting them into high-value sellable products. This not only addresses the cost factor, but also speaks to the manufactured sand market’s drive for sustainable operation.
The machine is suited for manufactured sand, and also for pre-milling applications across commodities such as chrome, lithium, gold, and copper, amongst others.
Both sand manufacturers and mines will benefit from the HRC 8’s increased throughput in a single pass, energy efficiency, reduced ultra fines and reduced operating costs as well as safety and ease of maintenance.
Southern Africa crushing and screening equipment dealer Pilot Crushtec International now offers the Metso HRC 8 high-pressure grinding roll crusher for producing manufactured sand. Pic: Pilot
The HRC 8 provides a notable increase in production efficiency. The flange design maximises the amount of material that is crushed by pulling the feed into the crushing zone. This method prevents the material passing the rollers and increases efficiency and throughput. The patented arch-frame, on the other hand, eliminates downtime caused by skewing.
“By reducing energy consumption and increasing wear life of components, the HRC 8 helps lower operational costs. Its efficient grinding mechanism also reduces the need for secondary crushing, further cutting down operational expenses,” says Francois Marais, sales and marketing director at Pilot Crushtec.
Weir has launched the all-new ENDURON Orbital range of vibrating screens, which features an all-bolted construction for longer life. Engineered for sand and aggregate, construction, and small-tonnage mining operations, the new screens are designed to meet the most demanding of applications.
The screens' all-bolted construction will significantly improve reliability by eliminating welding in high-stress areas, removing the leading mode of failure in vibrating screens. Locking bolts ensures structural integrity and durability, facilitating easy maintenance with quick replacement of individual components without extensive downtime.
“The team has worked hard for the past two years to bring our customers a product that is reliable with the lowest total cost of ownership,” says Corné Kleyn, global product manager for Vibrating Screens at Weir. “Our first screen has been successfully installed and commissioned at a large global customer, and we are gaining momentum with more units planned for both the
European and North America markets.”
The ENDURON Orbital range is available in two screen types: the E series: Elliptical Motion Horizontal Screens and the C series: Circular Motion Inclined Screens. Both screen types are designed with a commitment to innovation and quality, incorporating the latest technologies to deliver exceptional performance in a broad range of sand and aggregate and mining duties.
A wide operating window provides flexibility to adjust screen settings in line with changing applications or feed conditions without compromising the equipment’s structural integrity and minimising the risk of structural failure related to harmonic resonance.
The modular screen construction ensures that individual components can be easily replaced. Common interchangeable screen parts reduce inventory overflow and simplify maintenance. Both screens are digitally enabled, including the modular exciter technology, which senses and reports on the exciter's condition. The exciter itself features a bolt-on/bolt-off design, meaning it can be easily changed on-site and refurbished in a mechanical workshop.
EDGE Innovate’s first track scalper screen production model, the SCREENPRO S18 is making its North America debut.
The highly versatile EDGE SCREENPRO S18 signals EDGE Innovate’s emergence as a comprehensive screening-equipment solution provider for its global distributor network and individual operators in the mining, quarrying and recycling industries.
“The EDGE SCREENPRO Series represents a huge opportunity for EDGE Innovate and our partners in North America,” says Lee Williamson, EDGE Innovate’s North American distributor manager. “After years of lobbying from our distribution partners, especially in North America, for us to bring out a series of track-mounted screening solutions, we firmly believe this is now the right time.”
ABOVE: Weir has launched the all-new
track-mounted, heavy-duty scalping screen to roll off the company’s production line which will also see a range of differentsized scalping screens set to be added to the SCREENPRO range in 2024 and 2025. The new range of SCREENPRO products will allow EDGE Innovate to satisfy differing customer requirements and budgets.
The new SCREENPRO S18 features a dynamic 15.4m x 1.75m two-deck screen with interchangeable flip flow and conventional scalper screens. This flexibility allows the EDGE SCREENPRO S18 to tackle screening applications that other conventional screens cannot, such as incinerator slag or wet, damp and sticky material. Other design features include a low-level feed hopper, two- or three-way split configuration, and hydraulic folding discharge conveyors to facilitate the quick transition from operation to transport and a fully integrated power unit with large service access.
Global mobile crushing, screening, and conveying equipment manufacturer Finlay has selected Klettur as its authorised distributor in Iceland.
Headquartered in Reykjavik, with a team of skilled professionals and a well-established branch network across the island, Klettur brings extensive experience and a deep understanding of the Icelandic market. With an existing population of Finlay equipment operating under the extreme climatic conditions encountered in Iceland year-
range of
round, the strategic appointment of Klettur will strengthen Finlay's presence and provide enhanced service and support to customers in the region.
"We are thrilled to welcome Klettur as our authorised dealer in Iceland," said Adrian Millar, regional sales manager at Finlay.
"Klettur's reputation for excellence and their dedication to providing efficient and reliable service align perfectly with Finlay's values. Finlay machines thrive in the most demanding applications, including those operating in Iceland's extreme climate.”
Snorra Árnason, sales manager at Klettur, commented: "Over the years we have seen Finlay machines working effectively in quarries across Iceland during all four seasons. The Finlay range of equipment complements our existing portfolio of construction equipment, and we are committed to delivering the quality and reliability that Finlay is known for globally.”
Klettur will provide comprehensive sales, service, and support for Finlay products throughout Iceland.
Mobile crushing, screening, and conveying equipment manufacturer Powerscreen has carried out the successful installation and operation of equipment in Ladakh, Northern India - one of the world's most challenging environments.
A Powerscreen PT400X Jaw Crusher, 1000 Maxtrak Cone Crusher, and Chieftain 1700 Screen were commissioned to work on a Border Roads Organisation (BRO) project near Demchok, close to the China border, at Umling La, Leh Ladakh (UT). At an altitude of 19,024 feet, this project is at the world's highest motorable pass and aims to produce road-construction materials such as granular
ENDURON Orbital
vibrating screens. Pic: Weir BELOW: The SCREENPRO S18 from EDGE Innovate is the first of a series of scalping screens to be revealed by the company in 2024
Finlay has named Klettur as its new Iceland dealer
Top performance.
MOBIREX MR 130 PRO
Performance, precision and sustainability. The MOBIREX MR 130 PRO mobile impact crusher excels with outstanding performance in a diverse range of applications. With its double-deck post screening unit, the plant ensures top product quality with up to two graded end-products, while achieving impressive throughput rates of up to 600 t/h in natural stone and recycling. The all-electric E-DRIVE is not only efficient, it can also be operated with zero local emissions. Operation is intuitive thanks to SPECTIVE components. The MOBIREX MR 130 PRO –the sustainable powerhouse.
www.wirtgen-group.com/mr-130i-pro-kleemann
MR 130 PRO
sub base (GSB), wet mix macadam (WMM), and aggregates (5mm, 10mm, 20mm).
The site’s high altitude presented significant challenges due to low oxygen levels and temperatures, which dropped to -°3°C during the project. Additionally, the terrain was hilly with sharp bends and no feasible roads, complicating the transportation and installation of the equipment onsite.
Powerscreen says its equipment is uniquely suited and reliable in extreme climatic conditions due to its robust engineering and advanced technology, reinforced by rigorous testing and quality materials to withstand harsh environments—including high-altitude conditions. Additionally, the innovative design of Powerscreen equipment allows for dismantling and reassembly, facilitating transportation and installation in rough, inaccessible terrains. To navigate the rough terrain, the service team expertly dismantled the Powerscreen equipment for transport and reassembled it on site.
commitment to delivering high-performance solutions in the most challenging environments,” said Ranga Swamy, director –Customer and Product Support.
Despite the extreme conditions, the service team completed the installation and commissioning in 15 days.
The Powerscreen PT400X Jaw Crusher has been set up as the primary crusher and takes large and variable-sized feed material to be fed into the 1000 Maxtrak Cone Crusher, which uses Automax crusher technology to provide high volumes of excellently shaped, consistent product. This material is then screened by the Chieftain 1700 Screen to separate the product into its various sizes.
The successful deployment of Powerscreen equipment at Umling La has enabled the BRO to produce the necessary materials for their road project, ensuring the continuation of vital infrastructure development in the region. The infrastructure will improve access to remote villages, making it easier for residents to travel for medical care, education, and other essential services. The road will also facilitate the delivery of goods and services, contributing to the overall socio-economic development of the region.
At its headquarters site in Kirchheim unter Teck, Baden-Württemberg, Germany, Feess, a family business, champions the benefits of construction-material recycling in the construction sector via its trading and in-house training centre, as well as its interaction with trade associations and politicians.
A key component in Feess’ overall recycling-process chain is the Kleemann MOBIREX PRO MR 130i mobile impact crusher. The company tested the plant at the end of the development phase and was so impressed that it decided to keep it. Upgraded to serial production standard, the plant now plays an important role in Feess' climatefriendly production.
ABOVE: The Kleemann MOBIREX MR 130i mobile impact crusher operated by construction-material recycler Feess BELOW: Powerscreen equipment working against the impressive backdrop of the Ladakh region, Northern India
Company CEO Walter Feess said: "Construction and demolition wastes are a huge factor in the overall volume of waste generated – they make up over 50% of the total waste produced in Germany! At present, high-quality mineral construction resources are dumped in landfill sites every day or are, at most, utilised as materials for sub-bases or filling. This is an incredible waste of valuable resources that we are making every effort to prevent. We return large amounts of construction materials to the cycle and use them, for example, to produce R concrete aggregate.
without any disadvantages with respect to processing, appearance, haptics and strength. Unfortunately, the material is currently rarely used by architects and civil engineers –simply because it is still relatively unknown. Changing this situation is one of the points we focus on in our training centre: We want to make professional users aware of the quality of R concrete and the amazing opportunities it offers.”
Feess says his company was awarded the contract for the deconstruction of a district administration office in the region. On that project, Feess was able to return more than 90% of the materials to the construction cycle. More specifically, this meant that the aggregate for the R concrete for the new district administration office was produced from the construction materials reclaimed from the old building.
"With the MOBIREX MR 130i PRO mobile impact crusher, we process concrete demolition material and mixed rubble to produce materials such as mineral aggregates for R concrete. Around 40% of
"In other words, we turned old into new!” he adds. “The largest proportion of the mineral construction materials was crushed directly on the construction site or at our recycling depots at a rate of up to 1,800 tonnes a day.”
Feess says the overall concept of the Kleemann MOBIREX MR 130i PRO plant appealed to him and his team right away.
“The low fuel consumption, the high output and the extremely efficient double-deck post screening unit. Space is at a premium here, and with this plant we get two machines in one. We used to use a crushing plant followed by a separate screening plant - now, thanks to the high performance and the ability to discharge two classified final products, the MR 130i PRO is just what we need. It also means that we now only have to operate, service and refuel one machine in our daily routine.” AB
Searching for a more productive & efficient haul
A new driverless hauling development, an appraisal of a successful articulated haulier brand’s first three years, and new technology and the latest hauling products offer much for quarrying customers. Guy Woodford reports
September 2021 was a notable month. Cristiano Ronaldo became the all-time leading goal scorer for men’s national football teams, and SpaceX launched the first all-civilian spaceflight. But in Motherwell, Scotland, the celebrations were centred around something altogether more groundbreaking: the launch of the Rokbak brand.
Since rebranding three years ago, the Scottish articulated hauler manufacturer has carved out a unique identity based on robust and reliable products, an unwavering commitment to customers and an instantly recognisable brand.
“We had a solid product line at the time of launch, but introducing any new brand has an element of risk,” says Jacqueline Reid, Rokbak head of marketing, communications and product management. “However, we had great support from Volvo Group and a clear understanding of who we are and what we stand for, so we were able to create something that perfectly encapsulates our company, our people and our products. And since we launched our customer focus areas, we’ve been able to evolve that even further.”
Launching the Rokbak brand proved a huge success and led to five accolades at the Marketing Society Star Awards 2022. The company has gone on to become a leading name in articulated dump trucks in just three
years, with its distinctive machines delivering productive and profitable performance to customers worldwide, in demanding applications such as construction, quarrying and mining.
“We set out to create something that not only we could be proud of but that others would be proud to represent,” adds Robert Franklin, director of Sales for the Americas.
“Three years later, we have a strong brand, a strong team and a growing dealer network, all with a positive outlook on the future.”
In fact, North America has been one of Rokbak's biggest success stories. In 2021, the company’s first machines were delivered here, with a pair of RA30s sold to earthmoving, utility, and clearing company Linco Construction of Houston, Texas, via Easton Sales and Rentals.
Since then, RA30 and RA40 models have provided excellent performance in all hauling conditions to customers worldwide. From muddy terrain to slippery slopes, from scorching heat to sub-zero conditions, these trucks move earth and materials in the UK, Ireland, France, and Germany and on to Indonesia, Papua New Guinea, Australia, and New Zealand.
embraced the opportunities it presented, fostering stronger relationships and delivering a more solidified market presence.”
Rokbak's success is rooted in its commitment to customers. It emphasises close collaboration with dealers and personal partnerships with end users and owners. This strategy has been a cornerstone of Rokbak’s growth, with its dealer network expanding as the brand’s reputation grows and customer satisfaction increases.
“We’re fortunate to benefit from strong word-of-mouth referrals and have a wide range of customers and dealers who have a positive view of Rokbak,” says Franklin. “We’ve had several third-party approaches to work with us due to this. We have a different approach to others, and customers have confidence that their dealer has solid support from the OEM.”
Rokbak’s culture of openness extends to its Motherwell facility, which regularly welcomes dealers, customers, and operators to tour the factory, take training sessions, or catch up with colleagues.
Ambitious goals were set for Rokbak before its launch, which the company has not only met but exceeded, including in sustainability, as Reid explains:
“Rokbak has introduced clearer communications and built a stronger dealer network. We’ve also improved our product sustainability through reduced fuel
“We’re proud of the market image and enthusiasm generated by the Rokbak brand,” says Scott Pollock, senior product manager. “Our team members and external partners
TOP LEFT: Since its launch in September 2021, Rokbak articulated haulers have made their mark worldwide. ABOVE: Jacqueline Reid, Rokbak head of marketing, communications & product management. Pic's: Rokbak
consumption and adapting to alternative fuels such as HVO. We’re increasing the time between maintenance intervals to keep uptime high and reduce material disposal to further reduce our impact on the environment.
“It’s amazing to think how far we’ve come in three years. We have the tools and the people to prepare us for future growth, too. We’re always moving forward and already looking forward to the next three years.”
Pronto, a Silicon Valley-based autonomy pioneer, and Heidelberg Materials North America, a leading producer of construction materials, will deploy Pronto's autonomous haulage system (AHS) at Heidelberg Materials Lake Bridgeport quarry in Texas.
The announcement follows last year’s successful pilot of Pronto's technology at the same quarry, conducted in partnership with Komatsu North America. The next phase of this pilot will also be on a Komatsu platform. It will include integrating Komatsu Smart Quarry technologies, enabling enhanced data collection and analysis and improved safety and productivity.
Pronto's AHS is the industry's most cost-effective solution for recruiting skilled operatives while increasing the utilisation of haul truck assets. Pronto's AHS leverages advanced sensors, cameras, and artificial intelligence to autonomously operate haul trucks in complex and dynamic environments. Heidelberg Materials and Pronto are committed to leading the industry into a new era of efficiency, safety, and environmental responsibility by deploying this innovative technology.
UK-based Longcliffe Quarries has invested in a new Komatsu HD605-8 rigid dumper for quarrying operations.
The company says the move reinforces its commitment to continually invest in the future of its business.
With its reserves of high-purity calcium carbonate, the Derbyshire-based company produces over 100 critical mineral products,
The dumper benefits from the latest Komatsu technology and increased power. Standout features include auto engine shut-off, auto speed control, a small turning circle, and wireless performance monitoring, designed to offer maximum productivity and low operation costs. With a 778 HP engine, body capacity of 40m³, and payload of 63 tonnes, this large dumper will be well used at the quarry!
Quarry manager Jon Murgatroyd said: “The dumpers can be the unsung heroes of our operation, but they play a vital role in the primary part of our process. With its capacity to carry up to 63 tonnes of rock, this machine will help keep our process running smoothly with a continued supply of stone for crushing and milling.
“The new machine will be operated by one of our very experienced team who can move around 8,000 tonnes of rock per week, keeping customers supplied and the business operating efficiently. Over its lifetime, it will carry up to 3.5 million tonnes of limestone.”
Adam Dennett from Marubeni-Komatsu Ltd (Komatsu) added: “It’s always a pleasure working with Longcliffe, and we are extremely excited to be able to add this new machine to their fleet. We look forward to supporting this investment with a comprehensive repair and maintenance package, ensuring Longcliffe benefits from the improved efficiency and productivity.”
For the operators, this new dumper truck offers a step up in comfort and safety with a bigger cab, 360-degree vision, and a night heater. Longcliffe’s dumper trucks can provide up to 2500 hours of service a year.
Jon concludes: “This investment forms part of our plan to continually upgrade equipment and ensure we maintain our efficiency, production levels and customer service.”
Independently owned Longcliffe operates two quarries—Brassington Moor and Ryder Point— and the Ryder Point Wind Energy sustainable energy sourcing operation.
Less than a year after launching its Bell Equipment Trusted Alternative (BETA) Parts offering, Bell Equipment has expanded its footprint in South Africa and Zambia to include the major articulated dump truck markets of the European and United States
LEFT: Scott Pollock, Rokbak senior product manager. RIGHT: Robert Franklin, Rokbak director of sales for the Americas. Pic's: Rokbak
Pronto's autonomous haulage system (AHS) will be deployed at Heidelberg Materials’ Lake Bridgeport quarry in Texas. Pic: Pronto
Longcliffe quarry manager Jon Murgatroyd has welcomed the business’s investment in a new Komatsu HD605-8 rigid dumper. Pic: Longcliffe Group
dealer networks.
Meltus Badenhorst, Bell Equipment director of aftermarket and product support, said: “We introduced BETA Parts after identifying the need to give customers a convenient and competitive parts alternative, endorsed by Bell, for their more mature machines, or those looking for cost-effective solutions. We have been pleased with the interest shown by our African-based customers and their acceptance of the range and are now ready to offer BETA Parts in other regions. Our team is also constantly looking at opportunities to grow the range. It has supplemented the pilot range of alternators and starters with turbos, V-belts and ground-engaging teeth for buckets.”
According to Meltus, BETA Parts bridges the gap between Original Bell Parts, the company’s premium-quality parts designed to OEM specifications and used in production, and Bell ReMan, major components remanufactured to meet OEM specifications. Original Bell Parts and Bell ReMan have a one-year/unlimited-hour warranty, while BETA Parts carry a six-month/1000-hour warranty.
At the other end of the scale, Bell Used Parts, available in the South African dealer network, are also available but do not carry a warranty.
He says, “It’s about giving our customers choices so we can fully support their needs throughout their Bell ownership experience. Our premium Original Bell Parts is our ‘alpha’ or leading parts brand, and BETA Parts is the next best alternative. These give customers more cost-effective parts with less risk than other cheaper parts because they are endorsed by Bell and covered by a Bell warranty.
“Choosing BETA Parts also simplifies the purchasing process, offering a one-stopshop experience that eliminates the need for customers to search and compare prices from multiple suppliers in their quest for savings."
By offering BETA Parts, Bell Equipment ensures that Bell ADT, Tractor, and
Hexagon has launched the newest generation of its advanced Hexagon Collision Avoidance System (CAS) for mining and quarrying customers. Pic: Hexagon
Tri-Wheeler customers have a wider range of options to suit their needs. They also have the convenience and assurance of dealing directly with Bell Equipment’s extensive dealer network in regions where BETA Parts are available.
Hexagon, the global leader in digital reality solutions, has launched the newest generation of its advanced Hexagon Collision Avoidance System (CAS). Now supporting 4D radar technology, enhanced insights, and interoperability with the Hexagon Personal Alert tagging system, the significant upgrade positions Hexagon CAS as the most advanced collision prevention system on the market.
The upgraded CAS has already been installed in 15,000 vehicles around the globe. Its standout feature includes advanced 4D radar technology, which enables vehicleto-object detection and vehicle-to-vehicle alarming in GNSS-denied areas. GNSS (Global Navigation Satellite System) depends on the use of satellites, and there are areas of mining and quarrying operations where satellite reception is inaccessible or unreliable. The
Bell Equipment has expanded its BETA Parts footprint in South Africa and Zambia to include the major ADT markets of the European and US dealer LEFT: BETA Parts bridges the gap between Original Bell Parts, Bell Equipment’s premium-quality parts designed to OEM specifications and used in production, and Bell ReMan. Pic: Bell Equipment
4D radar enablement in Hexagon CAS means the select customers who have installed the updated system as part of its initial release can now help prevent collisions in these challenging areas.
At the same time, Hexagon is introducing CAS Insights—a robust insights platform available for use with CAS—which offers customisable, filterable reports that pinpoint the unique collision-risk issues faced at the customer's site. CAS Insights provides timely information about device health and identifies high-risk event areas, enabling operations to make targeted interventions to refine their processes and infrastructure to avoid vehicle collisions.
Lastly, the upgraded Hexagon CAS now includes interoperability with the Hexagon Personal Alert system. Personal Alert uses ultra-wideband technology for vehicle-toperson protection. Together with CAS and the award-winning Hexagon Operator Alertness System (OAS), it provides a critical additional layer of safety.
The advanced Hexagon CAS system, already recognised for its simple installation and accurate alarming, retains its EMESRT Level 7- and 8-compliant vehicle-to-vehicle alarms while offering a scalable pathway for safety upgrades to Level 9 protection.
"Our commitment to creating a zeroharm mining environment is at the heart of everything we do because the most important thing to come out of any mine is the miner," says James Dampney, vice president of Resource Optimisation and Material Movement at Hexagon."
The enhanced CAS system and its interoperability with other Hexagon safety solutions will provide our customers with the monitoring, interventions, and actionable intelligence they need to ensure the protection of people working on their sites and the efficiency and sustainability of their operations. It represents another significant stride towards safer, smarter mining." AB
A bevy of electric possibilities
An ambitious global off-highway machine manufacturer showcases its significant electric product range, and two UK building materials players make eye-catching electric equipment moves. Meanwhile, another top construction and quarrying equipment name has rigorously tested its new electric wheeled loader for UAE customers before its market launch. Guy Woodford reports
LiuGong hosted 'The BEV Experience: BEVs, Batteries, and Beyond' at its new regional hub in Stalowa Wola, Poland. Dealers and customers from 12 European countries explored the latest battery-electric equipment. They engaged in insightful conversations with BEV (Battery-Electric Vehicle) experts to see how LiuGong is going beyond expectations to give its customers a complete electric experience.
LiuGong demonstrated a range of four BEV machines along with their charging solutions, highlighting their market readiness and their aim to become a market leader in electric construction equipment. Guests participated in product demonstrations, hands-on sessions, and technical discussions to see how LiuGong is advancing its technology and market readiness infrastructure to make BEVs a fully viable option for all its customers.
"This event was a great opportunity to engage with our valued customers and dealers, discussing LiuGong's BEV machines and our expertise in electric technology," said Russell Hudson, product manager at LiuGong Europe. "Hosting the event at our new regional hub in Stalowa Wola allowed us to showcase LiuGong's cutting-edge
work and address any questions our guests had. Guests also had the opportunity to see dynamic demonstrations and participate in hands-on sessions, experiencing first-hand the capabilities of our wide range of LiuGong machines.
"We presented on a range of crucial topics, including charging solutions, machine control systems, safety and security, fleet management, ILINK, spare parts availability and advanced service and maintenance techniques. This comprehensive approach demonstrated LiuGong's commitment to providing robust support and solutions for all our customers."
Four cutting-edge BEV machines were at the forefront of LiuGong's display. The 9027FE mini excavator offers a compact and powerful solution, ideal for work in confined spaces, while the 922FE excavator combines muscle and high efficiency with the latest electric technology. In the wheeled loader category, LiuGong featured the 820TE and 856HE, each representing its dedication to sustainable solutions without sacrificing power and performance.
LiuGong also showcased its impressive line-up of ICE (Internal Combustion Engine) machines. LiuGong's versatile 375B Skid Steer Loader is robust and adaptable, suited
for various job site applications. In the mini excavator range, LiuGong presented the 9018F, 9027F, and 9057F, each designed to deliver efficiency and reliability. The excavator segment included the 915 FCR, 922F, 936F, and 952F, models that enhance productivity with advanced features. Additionally, LiuGong's wheeled loaders, such as the 856T Series, 877H, and 890H, are engineered to boost operational efficiency and performance.
The DRESSTA series includes highperformance dozers celebrated for their durability and strength. The TD-16N sets the benchmark for visibility and safety, while the TD-40, with its impressive 67 tonnes of performance, is engineered to handle the most demanding tasks with precision and power.
China leads the world in BEVs, and LiuGong is a leader in China. As a leader in China's booming BEV technology sector, LiuGong is at the forefront of driving a revolutionary wave in BEV R&D. The Liuzhou-headquartered manufacturer’s plans include launching over 40 BEV models by 2027, including new electric excavators, wheeled loaders, telehandlers and access equipment. LiuGong's pioneering efforts in electric machines are part of the company's
LiuGong hosted 'The BEV Experience: BEVs, Batteries, and Beyond' at its new regional hub in Stalowa Wola, Poland. Pic: LiuGong
CLOCKWISE FROM ABOVE: LiuGong’s 820TE wheeled loader in action at ‘The BEV Experience’ event. LiuGong demonstrated a range of four BEV machines and their charging solutions. LiuGong says its 922FE excavator combines muscle and high efficiency with the latest electric technology. Pics: LiuGong
strategy to become Europe's No. 1 leader in BEV technology by 2027.
European product director Harry Mellor said: "At LiuGong's 'BEV Experience', guests saw first-hand our impressive range of BEV machines and the comprehensive strategies and solutions we offer. This event highlighted our commitment to sustainable technology, reinforcing our leadership in Europe's transition to electric construction equipment. As a company, we are on a mission to create a more sustainable future in the construction equipment industry. Our continued investments in R&D, customer insights, and new facilities like the one in Stalowa Wola exemplify that commitment."
Attendees had the opportunity to interact with LiuGong's dedicated BEV team, comprising of experts from product management, service, parts, and sales departments. These professionals are committed to supporting LiuGong's BEV products and ensuring their optimal performance in the market.
Guests were given an exclusive tour of LiuGong's new regional hub in Stalowa Wola, demonstrating its commitment to market readiness and investment in Europe. This integrated facility includes an impressive dealer training centre where professionals gain hands-on experience with the latest machinery and technology.
Additionally, the hub features a sophisticated parts distribution centre equipped with advanced smart logistics and ordering systems, ensuring efficient and timely component delivery. The productproving grounds offer a practical environment for testing and showcasing the capabilities of LiuGong's equipment range. Furthermore, the service repair centre underscores LiuGong's dedication to exceptional maintenance and support services.
This comprehensive tour highlighted LiuGong's capabilities and strategic focus on enhancing customer satisfaction and operational excellence.
According to LiuGong Europe chairman Howard Dale: "We wanted to give our customers and dealers an unforgettable
and informative journey through LiuGong's electric capabilities, and we did just that with the 'BEV Experience'. Our guests left with a deeper understanding of our impressive line-up of BEV machines and an appreciation of the hard work that the LiuGong team put in behind the scenes at facilities like this new regional hub in Stalowa Wola. Through the 'BEV Experience', we have once again showcased our substantial market readiness and significant investments in our facilities and the European market. As a result, LiuGong continues to establish itself as a highly credible alternative to the old mainstream brands."
Signifying another step towards a net-zero future, Volvo Construction Equipment (Volvo CE) has successfully staged its first-ever electric construction equipment trials in the United Arab Emirates (UAE) by testing an L120H Electric wheeled loader in collaboration with dealer Al-Futtaim Auto & Machinery Company (FAMCO) and various customers including leading Abu Dhabi-based
concrete supplier ALAS Emirates Ready Mix.
The L120H Electric is a 20-tonne wheeled loader that uses the market-recognised conventional machine as its base. It promises the same performance as the conventional machine but alongside the environmental advantage of being emission-free, with near-silent operation and a much more comfortable work environment. It is powered by 282kWh batteries for a runtime of eight hours in light and medium-duty applications, with the ability to work indoors and in noisesensitive areas.
Equipped with cutting-edge electric propulsion technology, the Volvo CE L120H Electric wheeled loader represents a leap forward in reducing carbon emissions and noise pollution associated with traditional diesel-powered construction machinery. By leveraging the power of electricity, the loader offers a cleaner, quieter, and more efficient solution for construction projects.
Plant and machinery specialist FAMCO conducted the trial of the Volvo L120H Electric
wheeled loader at the ALAS Emirates Ready Mix worksite in Abu Dhabi. The machine was tasked with loading from stockpiles to a feeder hopper for the ready mix.
"We've been privileged to experience firsthand the high-performance capabilities of the Volvo L120 Electric," says ALAS Emirates Ready Mix production manager Elie Touma. "The wheeled loader is extremely impressive, reliable, and efficient, with quick response time. The low noise and vibration reduction has created a comfortable work environment for our operators, which has been reflected in a measured uptick in productivity."
Volvo CE developed a solution to convert the tried and trusted L120 wheeled loader to electric as part of an industry-leading ambition to advance its electromobility offering without detriment to speed and reliability. Volvo CE is continuing its longtime focus on environmental care and driving industry transformation and decarbonisation to combat climate change. The target of net-zero value chain greenhouse gas emissions by 2040 is a united commitment for Volvo Group across all business areas. It is set for ten years earlier than the Science Based Targets initiative as the industry advances the discovery of best practices for constructive environmental change.
"Zero carbon emissions is a big plus for us in helping us achieve our business goals," Touma adds. "Corporate and environmental responsibility significantly influence how we work and try to lead the industry, and we can see the Volvo Electric wheeled loaders as part of that path in our future projects."
The decision to test the L120H Electric wheeled loader in the UAE reflects Volvo CE's dedication to meeting the evolving needs of the construction industry in the region. With the UAE's growing focus on sustainability and green initiatives, introducing the electric loader underscores Volvo CE's commitment to supporting the nation's sustainability
ABOVE: Volvo CE has successfully staged its first-ever electric construction equipment trials in the UAE by testing an L120H Electric wheeled loader in collaboration with dealer FAMCO and various customers. Pic: Volvo CE BELOW: Following a successful trial during the summer months, Aggregate Industries is set to deploy the first electric cement truck in Britain, with more to come. Pic: Aggregate Industries
goals and contributing to a greener future as the nation continues to prosper. The UAE construction market was valued at $98.3 billion in 2023.
During the testing phase, Volvo CE evaluated the performance, efficiency, and suitability of the L120H Electric wheeled loader for various applications in the UAE's unique climate and operating conditions. The insights gained from this testing process ensure that the electric loader meets the rigorous standards expected by customers in the region.
"Bringing our L120H Electric wheeled
loader to the UAE for testing means seeing the machine working in one of the most dynamic and ambitious markets in the world," says Ilkay Fidan, commercial manager for Volvo CE in the Middle East. "This reflects our ongoing efforts to drive sustainability and innovation in the construction industry. By working closely with our partners and customers in the UAE, we aim to deliver solutions that meet their operational needs and contribute to a cleaner and more sustainable future.
"The UAE emerged as the ideal location to pilot electric machines as a mature construction equipment market with strong potential for e-mobility. The L120H Electric has been tested extensively in applications including ready-mix concrete production and the results have been very encouraging, demonstrating strong performance while significantly reducing emissions. This success strengthens our confidence in a wider launch of these electric models in the UAE and around target areas of the Middle East. We believe this is a significant step forward for sustainable construction in the region, and we're excited to be at the forefront of this change."
Volvo CE remains committed to advancing the development and adoption of electrified construction equipment, paving the way for a more sustainable and environmentally conscious construction industry. As testing the L120H Electric wheeled loader concludes in the UAE, Volvo CE looks forward to its commercial launch in the key market.
Aggregate Industries has announced a groundbreaking step in its commitment to sustainability with the introduction of Volvo electric trucks to its cement fleet.
Following a successful trial during the summer months, the UK building materials major is set to deploy the first electric cement truck in Britain, with more to follow.
The new trucks will be based out of the company's Cauldon cement plant near Stoke, alongside its existing 60-strong fleet and several electric charging points. These represent a significant leap towards environmental responsibility that will
complement further low-emission vehicles within the fleet, including biofuel.
"Introducing electric trucks in our operations marks a pivotal shift towards efficiency and sustainability and is all part of our ongoing effort to decarbonise the business and contribute to our own Net Zero Strategy," says Steve Curley, managing director of Aggregate Industries' cement division.
"The clean and powerful performance of electric vehicles reduces our carbon footprint and enhances operational efficiency, ensuring a reliable and eco-friendly solution for transporting material. "By harnessing cuttingedge technology, we are not just modernising; we are optimising our processes to build a greener and more efficient future for our industry."
Electric cement trucks offer versatile performance due to their ability to deliver bulk and bagged cement. The new Breedon trucks also come with a powerful 600KW motor, offering a sustainable alternative for transporting cement.
Furthermore, as part of the move to electric, Aggregate Industries is partnering with Lomas Distribution, its strategic distribution ally and contracted haulier for the UK domestic market.
"We are excited to work together with Aggregate Industries in adopting sustainable practices," says Gareth Durnall, general manager at Lomas Distribution.
"This exciting step forward perfectly aligns with our joint commitment to environmental responsibility, reflecting a shared dedication to fostering a better and cleaner future."
Breedon Group, a leading vertically integrated construction materials group in Great Britain, Ireland and the United States, recently completed a three-month trial of a fully electric ready-mix concrete vehicle at the Raisby quarry in County Durham, northeast England.
The trial, launched in June 2024 in partnership with Putzmeister and Zenobê,
was a significant step for Breedon in Britain as it executes its ambitious net-zero strategy.
With approximately eight hours of running time in urban areas without a recharge, the iONTRON eMixer can support a full day's operations. Its electric motor significantly reduces noise emissions, further aiding its suitability for operations in densely populated urban environments. The 9m3 drum is comparable to conventional mixers, resulting in operational performance comparable to Breedon’s existing internal combustion engine-powered fleet.
The custom-built vehicle is 100% electrically powered and equipped with a substantial 350kWh battery provided by SANY, the parent company of Putzmeister. Zenobê will monitor the vehicle's operational performance and provide the charging infrastructure: a 120kWh free-standing DS Series charging unit located at Breedon’s Raisby quarry.
By working collaboratively with Putzmeister and Zenobê, leading operators in the battery-electric vehicle and charging infrastructure ecosystem, Breedon is enhancing its understanding of BEVs and how introducing them can help the industry cut emissions.
Breedon is committed to achieving its ambitious carbon reduction targets, and the findings of this trial could pave the way for the widespread adoption of electric vehicles across the quarrying and construction sectors.
Mike Pearce, managing director of Breedon GB Materials, said: “We are very pleased to be part of this exciting development, which shows our commitment to helping our sector reduce carbon emissions. Our trial of the battery electric ready-mix vehicle is a major step forward in our decarbonisation journey and demonstrates our responsibility and ambition to embrace innovative solutions.
“Breedon is always looking for ways to evolve and utilise new technologies to reduce the impact of our products and services on the environment, communities and colleagues. Over the next three months, we look forward to working closely with our partners on this trial and exploring how our findings can support greater change across the entire industry.”
completed
Kevin Eichele, head of business development at SANY eTrucks, stated: “At SANY and Putzmeister, we’re not just building machines that reduce emissions; we’re building a cleaner future for people. Used in urban areas, our eMixer will outperform diesel mixers on noise levels and TCO, and we are very excited to bring this into action together with Breedon.”
Steven Meersman, co-founder and director of Zenobê, said: “We know that data and analysis are crucial for successful electrification – from planning through delivery and operation. This trial with Breedon Group, SANY and Putzmeister is another fantastic demonstration of the viability of heavy fleet electrification in the construction sector. Through collaboration, we will gain shared insights that will further the electrification of the sector at speed and scale.” AB
Breedon Group recently
a three-month trial of a fully electric ready-mix concrete vehicle at the Raisby quarry in County Durham.
Pic: Breedon Group
By working collaboratively with Putzmeister and Zenobē, Breedon is improving its understanding of BEVs and their role in industry decarbonisation. Pic: Breedon Group
Admirable water saving & other pressing matters
A big UK wash plant installation, a filter-press first, and a five-year filter-press manufacturing anniversary. Guy Woodford reports
Sustainability has become a key focus in the aggregate processing industry worldwide. Many producers strive to create as little waste as possible.
Preventing potentially usable products from entering landfills, settling ponds, or spoil tips not only cuts down on the amount of waste materials being produced but also allows for more profit for a producer by generating an additional saleable product. Reclaiming process water for reuse can also increase production sustainability by reducing freshwater requirements.
Water is a limited resource that quarry operations must manage carefully and strategically. A tailings and water management programme can significantly enhance a site's ability to retain, recycle and reuse water. A well-developed tailings and water management plan can also create a potentially saleable product, minimise pond cleaning and maintenance, and generate clean, recyclable process water.
A secondary aggregate producer in the UK has partnered with McLanahan to implement a wash plant with water recycling capabilities to further add to its sustainability goals. Goonvean Aggregates, based in Saint Austell, Cornwall, southwest England, specialises in processing granite-based
secondary aggregates, which are byproducts from china clay processing. These secondary aggregates are used as alternatives to primary aggregates, promoting sustainable construction, supporting the circular economy and enhancing overall environmental sustainability.
Currently, Goonvean Aggregates sources its secondary aggregates from a supplier. After processing, some of this material was being returned to the supplier and ultimately sent to a tip. Given Goonvean Aggregates' commitment to sustainability, the company was looking for a solution to utilise all its material completely, eliminating the need to return any to the supplier or send any to tip.
To accomplish this goal, Goonvean Aggregates installed a McLanahan UltraWASH modular wash plant, UltraSAND plant and 10m EcoCycle high-rate thickener.
The feed material is introduced into the UltraWASH modular wash plant directly from the crushing process or through the feed hopper. The UltraWASH washes and sorts the material into three distinct aggregate sizes and a double-washed sand product. Meanwhile, the UltraSAND plant processes the residual product, integrating it into one of the sand products.
The EcoCycle Thickener handles the waste streams from both the UltraWASH and UltraSAND plants. It concentrates the solids in
the slurry and allows Goonvean Aggregates to recover process water that can be reused in the washing process, enhancing the site's overall sustainability.
The McLanahan UltraWASH modular wash plant, UltraSAND plant and EcoCycle high-rate thickener are helping Goonvean Aggregates meet its sustainability goals.
“Our goals as a business are to be more sustainable in every facet of how we operate as a business,” Matthew Penny, general manager of Goonvean Aggregates, shared. “It’s an ongoing process, and we’re looking to reduce our carbon footprint. With the McLanahan plant on site, that’s allowing us to do so.”
Processing waste through tailings management equipment can also increase sustainability while yielding clean, reusable water. This is another benefit of managing the waste stream effectively. Historically, quarries have not fully considered the advantages of recovering extra material and water from the waste stream. However, with increasing water scarcity and stricter regulations, many quarries now recognise the need to adopt mechanical methods for better water and tailings management.
Goonvean Aggregates chose a high-rate thickener to reclaim water. These thickeners
recover approximately 85% of water for reuse. This efficient water recovery system ensures that water consumption remains sustainable and significantly reduces the volume of slurry sent to waste ponds.
The system is designed to recover immediately reusable process water, significantly reduce the demand for make-up water and help to maintain sustainable water consumption levels. It also leads to a drastic reduction in the slurry volume that must be sent to waste ponds. Thickeners can be supplied with flat-bottom, on-ground tanks or elevated tanks, which feature short suction lines that reduce the risk of plugging. The tanks can be supplied as welded-together or bolt-together units, with options for concrete or steel bottoms. A minimum-drag rake arm design reduces the torque needed to move the rakes through the settled solids while minimising disturbance to the already settled material. The system features a hydraulic drive to power the rakes and operate the rake lift, along with accurate rake torque monitoring. It allows the rakes to operate in both forward and reverse directions.
mining sectors and integrates the latest technological advancements to deliver exceptional operational efficiency and maximum water recovery.
Collier Quarrying and Recycling is the first CDE customer to integrate the new ProPress into its wash plant setup. Commissioned in April this year at the company’s Goathill Quarry in Fife, its ProPress X4-200, the largest model in CDE’s new range of filter presses, benefits from 200 plates and can process 20m3 per mechanical cycle.
A longstanding customer, Collier Quarrying and Recycling operates two existing CDE wash plants.
“They’re very efficient, so when I found out CDE was designing its new filter press, I knew it wouldn’t let me down," said owner Duncan Collier. "We’re very familiar with the technology under the hood and fully trusted CDE to deliver – and they really have.”
Using the McLanahan UltraWASH modular wash plant, UltraSAND plant, and EcoCycle high-rate thickener, Goonvean Aggregates has successfully met its sustainability goals. The McLanahan equipment also allows the granite-based secondary aggregate supplier to utilise all its feed material and produce zero waste, eliminating the step of taking material to the tip.
“Since we’ve had the McLanahan plant on site, our productivity and efficiencies have increased. We’re able to provide additional products to the local and national market,” said Penny. “As part of this, it means as a company, we’re ‘zero to tip’. Every part of the product which comes into us, we’re able to process and resell as a finished product.”
Penny said that being “zero to tip” has huge environmental impacts for business. Specifically, for Goonvean Aggregates, it means the company can process all its feed material to be more efficient and
more productive. It has allowed Goonvean Aggregates to reduce its carbon emissions as well as given the company an additional product offering, increasing profitability.
“It’s enhanced our product offering, our productivity, our efficiencies and our profitability,” Penny said about processing all the material with the McLanahan wash plants and thickener.
Overall, Penny is pleased with the McLanahan equipment and the support Goonvean Aggregates has received from McLanahan throughout the process.
“The support from McLanahan has been excellent and allowed us to proceed and to push on with our strategic goals as a business,” Penny said.
The first ProPress high-performance filter press commissioned by wet processing experts CDE has exceeded processing targets and significantly reduced reliance on costly settling ponds, says the owner of one of Scotland’s leading aggregate specialists.
The ProPress was developed to meet the evolving needs of the construction and demolition waste recycling, quarrying, and
By the end of the year, the ProPress will be found on eight plants across three regions, processing around 1000tph of material.
With the CDE ProPress, owners and operators can recycle up to 95% of process water for immediate reuse in their wash plant, eliminating the need for settling ponds, which typically require extensive maintenance, consume labour resources, and incur significant costs.
CDE business development manager Fergal Campbell said: “Settling ponds are known to be a source of considerable revenue losses. They occupy a very large site footprint, maintenance costs are high, and they adversely impact the production of saleable material due to the amount of management needed. With the CDE ProPress, we can
LEFT: Fergal Campbell, CDE business development manager. BELOW: Collier Quarrying and Recycling is the first CDE customer to integrate the new ProPress into its wash plant setup. Pic's: CDE
Looking towards the McLanahan UltraSAND plant. Pic: McLanahan
A Terex Washing Systems’ 165-plate filter press is part of a wash recycling solution for Albin Borer in Switzerland. Pic: Terex Washing Systems
address many of these pain points with a single solution.”
When Collier Quarrying and Recycling acquired Goathill Quarry, it began recycling demolition waste into reusable aggregates and sub-base materials. This process requires significant water resources along with virgin material processing.
“We’ve been managing settling ponds for over a decade now. More and more, our business is focused on recycling demolition waste, and as that side of the business continues to grow, our water needs increase substantially,” said Collier.
“The time we spend creating and managing the ponds to ensure we have clean water readily available really impacts our productivity, so the integration of a new filter press to dispose of waste and contaminants while quickly returning clean water to our two wash plants has been a really positive development.”
Jordan McCooe, CDE programme manager in the UK & Ireland, said: “For Collier, the challenge with pond management was doubled because it required clean water to supply two active wash plants. Initially, it was thought that two filter presses would be needed, one for each plant. When we reviewed current and projected throughput, we found that a single, large filter press had the capacity to process materials from both plants.”
The CDE ProPress is available in eight different sizes to suit all markets and applications, ranging from the ProPress X1-60, which has 60 plates and can process 6m3 per mechanical cycle, to the ProPress X4-200, which has 200 plates and can process 20m3 per mechanical cycle.
A centrally located 600m3 buffer tank is receiving sludge from both wash plants simultaneously.
McCooe continued: “The ProPress features plates that are 25% larger. The combination of greater chamber volume, fewer plates overall, and the buffer tank means that just one ProPress unit had the capacity to receive and
process sludge from both of Collier’s wash plants.”
Collier said it has allowed Collier Quarrying and Recycling to reduce its reliance on settling ponds.
He added: “This is hugely positive, not only from a production standpoint but also in terms of health and safety. There’s less maintenance involved, and open water areas have been scaled back greatly.”
With the CDE ProPress, safe and efficient maintenance is made possible by integrated plate-shaking technology, which addresses filter cake build-up within chambers to help reduce the need for manual intervention. An access walkway provides clear and unobstructed means to carry out maintenance safely and efficiently, and flush-mounted drip trays reduce material entrapment and lock in place to provide a secure maintenance platform for operators.
Operational now for three months, the new ProPress is processing at a higher volume than anticipated,” Collier said.
“It’s capable of doing what CDE said it would do, and more besides. It’s absolutely first class and helping to really accelerate our return on investment.”
Commenting on the functionality of the CDE ProPress, Duncan Collier said it’s “very user-friendly.”
An innovative, multifunctional robot supports the smart design of the CDE ProPress. This robot serves as the main workhorse for the ProPress, controlling plate opening, plate shaking, cloth washing, plate winch, and the maintenance platform.
Once the ProPress is commissioned, every customer is also introduced to the CDE CustomCare team, which provides aftersales support to help customers achieve maximum performance from their equipment. On any given day, the UK and Ireland team has eight service vans and six pick-ups on the road, supporting customers in meeting their production targets.
The CDE ProPress’s range of sizes make is suitable for all markets and applications.
Available globally, it is also largely pre-assembled to minimise construction time on site and expedite commissioning, allowing operators to get up and running quickly to help achieve a fast return on investment.
Terex Washing Systems (TWS), a global leader with over 60 years of expertise in the design and manufacture of washing equipment, is proudly celebrating five years of manufacturing filter presses.
This milestone underscores the team’s commitment to environmental responsibility in quarry operations worldwide. TWS filter presses process around 100 million tonnes annually.
"Our journey in the design and development of our own filter presses began in 2019 and today, we stand as a global leader in delivering complete ‘Feeder to Filterpress’ solutions," says Mark Fisher, business line director of TWS. "The evolution of our filter press technology underscores our commitment to driving efficiency and sustainability in the quarrying industry."
One of the key advantages of the TWS filter presses is their efficiency in water recycling. They reclaim over 95% of the water used in the washing process, minimising water consumption and reducing the need for freshwater input. Filter presses also aid in waste reduction by producing a dry filter cake waste product.
This dry cake is easily transportable and can be reintegrated into the quarry or used for other applications. By maximising water recycling and minimising waste generation, these systems help quarry owners meet environmental regulations and demonstrate a strong commitment to responsible quarrying practices. Another benefit of filter presses is improved overall efficiency of the wash plant by streamlining the water treatment process. By effectively separating solids from liquids, they produce cleaner water for reuse and optimise the performance of downstream equipment. Quality assurance is another significant advantage as filter presses provide clean, recycled water to re-enter the washing process, improving the quality of washed sand and aggregates.
Since the inception of in-house filter press manufacturing in 2019 at TWS headquarters in Dungannon, Northern Ireland, the team has refined its filter press technology and integrated it into their comprehensive ‘Feeder to Filterpress’ washing solutions. These systems divert waste from landfills while recycling the water used during the process, significantly reducing environmental impact and improving aggregate production for quarry customers.
Beyond innovation, TWS offers comprehensive global support and service. With 40 distributors worldwide and regional offices in the US, Europe, Asia-Pacific, and Australia, Terex Washing Systems provides localised expertise and service. Supported by a dedicated technical team and advanced laboratory facilities, TWS ensures optimal equipment performance and sustainability throughout its customers' operations. AB
Electrifying the hammers and breakers sector
Lekatech’s electric hammering technologies are used in mining, quarrying and construction
Two Finnish companies have combined to provide a major new force in the hammers and breakers market, while an advanced surface automation solutions business has rebranded in the US. Liam McLoughlin reports
In a major move in the hammers and breakers sector Normet has taken full ownership of fellow Finnish company Lekatech, a start-up founded in 2018 with the ambition to revolutionise hammering technologies by introducing linear electric technology for hammering applications.
Prior to the full takeover announced in August 2024, Normet had initially made a minority investment in 2023 in Lekatech, whose electric hammering technologies are used in the mining, quarrying and construction industries. Lekatech has its premises in Iitti, Finland.
Founded in 1962, Normet’s main products are solutions for charging and blasting, drilling processes, and ground support in tunnel construction and underground mining. It employs over 1,800 dedicated professionals in more than 50 locations in 30 countries around the world
Normet says the ownership aligns with its overall strategy for expanding its electric offering portfolio and demonstrates its search for related, mutually beneficial technologies. It adds that Lekatech’s fully-electric hammer combined with Normet SmartDrive batteryelectric architecture and Normet XRock boom and breaker systems will define the future of underground scaling and breaking.
“Lekatech’s revolutionary linear electric
hammering technology further strengthens our resolve to lead the electric transformation in the industry. We are proud of what has been achieved at Lekatech and we now look forward to the next steps in the joint journey. We are excited to welcome Lekatech’s experts to Normet,” comments Kari Hämäläinen, executive vice president, Strategic business development at Normet.
Lekatech CEO Antti Anttila adds: “Normet enables us to expand and speed up the adoption of the electric hammering technology across industries on a global scale. Having collaborated with Normet for several years we have realised that there is a strong cultural fit and that we share the same values.”
Following the transaction Lekatech will continue to operate as an independent company as part of the Normet Group.
Lekatech unveiled its latest development at Hillhead 2024, the new Electric Hammer LEKA Toras 35.
The patented Lekatech linear electric motor technology is the result of many years of dedicated research and innovation. Its development is now disrupting the traditional hydraulic impact hammer market as its electric technology produces high levels of performance, delivering huge benefits on urban construction projects and in quarry or mine environments, above or below ground.
Lekatech says its electric hammer
technology is a major advance in hammer design and construction. Of light weight and high power, but producing low vibrations, Lekatech hammers are built for operator comfort, economic use and high productivity. Electrically powered, Lekatech’s linear electric motor produces low emissions and operating costs, and as such, is transforming breaking globally.
Designed to seamlessly integrate with electric carrier machines, Lekatech electric hammers have been designed to be the perfect match for electrically powered machinery. The original Lekatech Electric Hammer delivers up to 70% energy savings when factoring in overall energy consumption of the equipment. In addition to energy efficiency, the Lekatech Electric Hammer has been able to significantly outperform comparable traditional technology, providing twice the blow impact energy of a hydraulic hammer of the same size.
Lekatech CEO Anttila commented on the newly-launched LEKA Toras 35: “The Lekatech Electric Hammer is highly efficient and has a power-to-weight ratio superior to similar traditionally powered hammers. Furthermore, it was introduced to the market at the same time as electric excavators and is thus a natural partner for electric-powered equipment and the ideal choice when working in zero or low-emission areas. Through listening to our customers and distributors,
we have now improved the Lekatech Electric Hammer.
As with its existing electric hammers, the LEKA Toras 35 has been developed using the latest technology in conjunction and working with breaking experts in the field. The LEKA Toras 35 is based on tubular linear (permanent magnet) electric motor technology which is designed to withstand the harsh conditions of breaker hammer use. Despite weighing only 540kg, the structure is robustly constructed with a minimum number of wear parts.
“For an operator, the effectiveness of the hammer is often the most important feature of a working machine. With LEKA Toras 35, significantly higher performance values are reached than with conventional technologies. It is also highly flexible, with adjustability being integral to its development. Every blow and every gap between the blows can be adjusted individually and dynamically, enabling unprecedented possibilities for hammering applications,” explains Anttila.
“In designing the LEKA Toras 35, we built on the success of our original Lekatech Electric Hammer. This was developed so that users could benefit from using a breaker where each hit of the hammer is optimised with the machine adapting to changing conditions. In effect, using a high precision force that learns. Lekatech technology is an embodiment of digitalisation in hammering and is a catalyst for the electric transformation in the ecosystem.
“Through the latest development, the LEKA Toras 35, we have developed an electric hammer which further revolutionises the breaking and hammering industry. It has been tried and tested in demolition, hard rock quarrying and many other applications, and we are now proud to introduce it to professionals and companies who will truly benefit from its unique and marketchanging features. We feel that given the historical importance of Hillhead to the global hammering and breaking industry, that the show will be the perfect environment to introduce our latest development to the world.”
As with the original Lekatech Electric Hammer, the LEKA Toras 35 is based on Lekatech’s patented linear electric motor technology and uses electric impact hammer technology. This technological breakthrough not only enables more energy-efficient earthmoving, quarrying and mining operations but also strengthens the realisation of a green transition in these fields.
“Environmental friendliness and performance go hand in hand with the LEKA Toras 35, with its programmable features providing flexibility that enables continuous digital development. Furthermore, the innovative hammer eliminates the need for oil and the oil-associated environmental impact of hammering, with oil consumption being reduced by 98% when compared to hydraulic hammers,” concludes Anttila.
The LEKA Toras 35 is now available in a limited number of European countries and its strategically located partners worldwide.
Epiroc, the Swedenheadquartered, global market manufacturer of drill rigs and hydraulic breakers for the quarrying, mining, and construction industries, has unveiled its new generation PowerROC T35 surface drill
rig, offering increased fuel efficiency and faster operations. This updated edition to the well-known and trusted PowerROC family of surface drill rigs is good news for quarries and construction companies worldwide.
“We are very excited to launch an updated version of this highly regarded surface drill rig. This new generation PowerROC T35 is our most fuel-efficient PowerROC rig ever, says Masanori Kogushi, senior product manager, Epiroc Surface division.
The new generation PowerROC T35 is loaded with benefits that will add value and bring efficiency to quarry and construction operations around the globe. Fuel consumption is up to 40% lower than the previous PowerROC T35 rig. This is due to the Auto engine speed control, which optimises automatic engine speed for all operations.
The PowerROC T35 will also boost production. It is 45% faster at changing rods than the previous version, which decreases the total time to finish the hole. The updated PoweROC T35 data is presented to the operator via a 12-inch touch screen. The intuitive display makes the rig easier to run and will speed up the training of new operators. Operators can drill only with a few actions, reducing the lever operations required by the operator to approximately 80 % compared to the current version.
A troubleshooting function is also built into the touch-screen display. A new hydraulic return filter has been included with the compact design, which reduces the amount of hydraulic oil required by 50%. Service points are also easily accessible, which makes maintenance easier. In addition, the longer service intervals will help to lower the Total Cost of Ownership (TCO)
The operator will also be happy to discover several improvements in the cabin. The cabin is now equipped with updated ergonomic joysticks, which make operation more comfortable. The upgraded air conditioner, with higher cooling performance, will also positively affect the cabin environment.
The new PowerROC T35 is equipped with a COPSC19 rock drill. The drill features a frequency of 50 Hz, which gives it higher performance in hard rock conditions. The SC19 rock drill is also fitted with a dual damper, which helps to improve energy efficiency during drilling.
The new generation PowerROC T35 offers two engine alternatives: a Tier 4 Final/Stage V or Tier 3 engine.
Italian attachments specialist Indeco, whose products include hydraulic hammers, has announced the opening of a new branch in Canada, which it says marks an important step in the process of strengthening its foothold and impact in the North American market.
Indeco comments: “This important new development demonstrates our commitment to offering superior-quality products and services, maintaining a high standard of excellence and providing top-tier customer support.”
The new subsidiary will be headed up by a team of highly qualified professionals with in-depth knowledge of the industry and consolidated expertise: Mike Pietroniro, a heavy equipment industry veteran with 40 years of experience, in the role of chairman and general manager; Pierre Cloutier, with over 25 years of experience in the heavy
equipment industry, will lead the Canadian sales team; Denis Forget, who has been at Indeco North America for three years and Jason Pietroniro, with 20 years of experience in the sales and manufacture of boom systems, will be the sales managers; Andrew Caruana will be in charge of parts and services.
Indeco adds: “This new chapter not only strengthens our global network, it also represents a unique opportunity to consolidate the direct collaboration with our clients, listening to their needs and responding with targeted solutions.” AB
Big acquisition amid strong tyre sustainability focus
A major sector acquisition has further enlivened an off-highway equipment tyre market focused on sustainability. Guy Woodford reports
The Goodyear Tire & Rubber Company (Goodyear) has signed a definitive agreement to sell its off-the-road (OTR) tyre business, which provides tyres for applications including quarrying and construction, to The Yokohama Rubber Company for US$905 million.
The cash transaction follows a previously announced strategic review of the OTR tyre business, part of the Goodyear Forward transformation plan.
The Goodyear OTR tyre business provides OTR tyres worldwide for surface and underground mining, construction and quarry, and port and industrial end markets. Goodyear OTR offers a suite of products, services, and tyre management solutions to help customers optimise their operations and improve productivity and efficiency.
"The sale of the OTR business marks an important milestone as we continue to execute against our Goodyear Forward transformation plan," said Mark Stewart, Goodyear CEO and president. "We are grateful to our OTR colleagues who have driven the success of the business and are committed to working closely with Yokohama to ensure a smooth transition for customers and associates."
Goodyear will retain its business supplying OTR tyres for US military and defence applications. Adhering to a product supply agreement to be entered into with Yokohama
in connection with the closing of the transaction, Goodyear will also manufacture certain OTR tyres for Yokohama at some of its manufacturing locations for an initial period of up to five years after the closing of the transaction.
The deal is subject to regulatory approvals, other customary closing conditions and consultations. It is expected to close by early 2025. Goodyear says it intends to use transaction proceeds to reduce leverage and fund initiatives related to the Goodyear Forward transformation plan.
Evercore is Goodyear's exclusive financial advisor, and Sullivan & Cromwell is its legal advisor.
Off-highway tyre manufacturer BKT is making a major move towards greater sustainability by adopting greener principles. The firm has joined the Global Platform for Sustainable Natural Rubber (GPSNR). According to BKT, this will help promote longterm sustainable practices, culminating in environmentally conscious production in line with the principles defined by GPSNR.
Natural rubber production offers environmental and social opportunities for improvement. Expanding rubber plantations will likely influence tropical forests, but sustainable practices can help protect biodiversity and reduce greenhouse gas emissions. Similarly, ensuring dignified working conditions and respecting workers' rights on rubber plantations can help promote
an ethical and sustainable industry.
To address these challenges and promote sustainable solutions, the GPSNR unites natural rubber producers, traders, tyre manufacturers, non-governmental organisations, academic institutions and other industry partners.
Through its membership of GPSNR, BKT is strengthening its commitment to aligning the natural rubber supply chain with the organisation's guidelines. As a member of GPSNR, the company has access to a platform that aims to standardise manufacturers’ sustainability reporting and digital platforms for compliance with the European Deforestation Regulation (EUDR) requirements, which will come into effect in December 2024.
"The principles on which GPSNR bases its roots align with our ESG policy. This path will allow us to develop and align our digital tracking initiative for the sustainable sourcing of natural rubber under internationally accepted principles. At the same time, the GPSNR membership allows us to sustain and expand our sustainability initiatives to accelerate structural and quality changes in our natural rubber supply chain over the next five years," said Rajiv Poddar, joint managing director of BKT.
To support its mission, BKT is cooperating closely with several Indian government agencies, including the Rubber Board and Automotive Tyre Manufacturers Association of India, as well as some of the world's leading players in the natural rubber industry.
"Being a member of GPSNR also means that we have direct contact with suppliers of premium natural rubber across the world, which is crucial for a company like ours that has always focused on high-quality standards," said Poddar. "This is a strategic and conscious choice that supports our growth ambitions and allows us to pursue ever higher levels in sustainable production."
By joining GPSNR, BKT further confirms its compliance with core principles in sustainable forestry, water resource management, protection of rights and territories, human and labour rights, equality, traceability, transparency and anti-corruption, and training and education.
Goodyear has signed a definitive agreement to sell its OTR tyre business to The Yokohama Rubber Company for US$905mn. Pic: Goodyear
A LONG WAY TOGETHER
EARTHMAX SR 49
Experience unparalleled tyre performance with BKT’S EARTHMAX SR 49. Designed to equip your fleet of loaders, dozers, low profile dump trucks (LPDT), and load haul dumps (LHD), this tyre is engineered for excellence. With its All Steel radial construction and block pattern structure, EARTHMAX SR 49 delivers unmatched reliability and efficiency, whether on construction sites or in severe mining operations. Say goodbye to downtime—the tyre’s cut and chip-resistant design ensures durability even in the toughest conditions. Trust BKT to fuel your business growth and choose EARTHMAX SR 49 for unbeatable performance and reliability.
Anteneh Gebremeskel, GPE Product Manager at Volvo Construction Equipment (Volvo CE), has explained the importance of proper tyre management and how the OEM’s Tyre Pressure Monitoring System makes it easier and more convenient to keep tyres in optimum condition.
As construction companies and quarry operators strive for better efficiency, costeffectiveness, and safety in their operations, one crucial factor that could be overlooked is the tyre pressure on their articulated haulers and wheeled loaders. When these machines move, their tyres encounter rolling resistance, a force that opposes their movement, and the right tyre pressure plays a vital role in how well they perform on the job.
If tyres are underinflated, they have a larger contact area with the road, generating more friction and increasing the rolling resistance. This means the engine needs to work harder to overcome the resistance and consumes more fuel. In addition, the tyre carcass will be exposed to unnecessary loads, which causes premature failure. On the other hand, overinflated tyres wear prematurely in the centre of the tread pattern, leading to decreased tyre service life, operator comfort, and increased fuel consumption.
Furthermore, incorrect tyre pressure can pose a serious safety risk as underinflated, or overinflated tyres make it more difficult to handle an articulated haulier or wheeled loader. Traction and stability decrease, braking distances are longer, and blowouts are more likely. This is when a tyre rapidly deflates during operation and can lead to a sudden loss of control.
Regular tyre pressure checks and maintenance following the operator's manual are essential to maximise fuel efficiency and safety. This straightforward step can save money on fuel costs and reduce the risk of accidents for everyone on site.
To make it easier and more convenient for operators to maintain optimum tyre
pressure, Volvo CE has included a Tyre Pressure Monitoring System as an app on Volvo Co-Pilot with Haul Assist for articulated haulers and Load Assist for wheeled loaders. The system, consisting of a transceiver and six tyre valve sensors, can also be fitted retroactively.
Tyre pressure and temperature are displayed in real time on the cab screen. Each tyre is monitored independently, and pressure limits are set per axle. If any tyre deviates from the set parameters, the operator is alerted—alarm limits are displayed as nominal values and percentages.
Correct tyre pressure significantly impacts machine performance and site safety.
A blue message lets the operator know there are inconsistencies in pressure or temperature and that the situation should be monitored. In contrast, an amber message indicates that these inconsistencies have worsened, and the operator must take action. All Tyre Pressure Monitoring System data is fed to the cloud and displayed in real time. Deviations in pressure or temperature are displayed as error codes in the CareTrack telematics portal. Users can make informed decisions on tyre parameters based on similar site conditions by reviewing and analysing trends.
Tyre pressure management is not just a maintenance chore; it's an essential aspect of construction equipment management that directly impacts operations. With the cuttingedge Tyre Pressure Monitoring System, customers can conveniently benefit from increased safety, lower fuel consumption and emissions, enhanced operator comfort, greater uptime, and lower maintenance costs. Triangle Tyre has always been committed to the ongoing development of its earthmover tyre range with continuous product testing and go-to-market of new products for quarries, underground and surface mining, construction and port-industrial applications. The range includes radial tyres up to a 63-inch rim, the largest size currently existing in the world in this segment: it is fitted in mines on rigid dump trucks with a load capacity of up to 300 tons and confirms
A BKT EARTHMAX SR 468 tyre for rigid haulers Pic: BKT
BKT joint MD Rajiv Poddar has welcomed the company joining the Global Platform for Sustainable Natural Rubber (GPSNR). Pic: BKT
Pic: Volvo CE
Triangle as one of the world's leading manufacturers in the Earthmoving tyre sector.
Triangle’s road ahead has marked an important step during the current year, thanks to the introduction of new patterns using cutting-edge technology.
The TL578S E4/L4 tyre in size 35/65R33 has been the perfect example of a new product introduction: a dual-marking tyre for wheeled loaders, characterised by maximum load capacity for use on Block Handler loaders, suitable for handling extremely heavy loads on abrasive and aggressive surfaces and in underground transport.
The TL578 range has been extended by introducing new sizes, such as 29.5R25 and 29.5R29, to make the product compatible with wheeled loaders and underground mine operators seeking higher speed capabilities.
The year 2024 also saw the launch of the new TB577A SUPER in size 24.00R35 for the rigid dump truck segment: the tyre is available in 5 different compounds aimed at improving performance and preventing overheating during long hauls, with customised performance able to meet customer needs.
Triangle has further reinforced its leadership in this segment by enlarging its existing TB526S E4 range with the introduction of the new “3 stars” sizes 18.00R33, 21.00R33, and 24.00R35, which offer increased load capacity and productivity.
All products with alternative tread compounds are available to meet all end users' demands regarding tons per kilometre per hour productivity.
The Forklift and Reach Stakers segment commonly used in materials handling operations has also been involved in the
process of new product introduction with the launch of TL 619 IND-4, a new line currently available in sizes 14.00-24.
The TL619 IND-4 is ideal for meeting customer needs in Port-Industrial applications, thanks to the reinforced casing, which assures higher load capacity with a reinforced bead area and cut and chip resistance.
LEFT: Anteneh Gebremeskel, GPE product manager, Volvo Construction Equipment. BELOW: The pressure and temperature of each tyre are shown on a screen in the cab. Pic's: Volvo CE
to the Triangle OTR portfolio, the Chinese tyre manufacturer range for wheeled loaders and articulated dump trucks will be completed by the end of the year with the introduction of the TSMS PRO L5S pattern in sizes 20.5R25, 23.5R25, 29.5R29, and 35/65R33 for loaders operating in glass and waste recycling work and underground mining. The new reinforced 3-star casing design and a new tread compound will be used.
Another launch by the end of 2024 will be the new dual-marked TL538 PRO E4/L4 for articulated dump trucks and loaders, initially available in 26.5R25 and 29.5R25 sizes.
Introducing new 3- and 4-star-rated patterns confirms Triangle’s pursuit of meeting the highest load-carrying capacity requirements, providing the end users with the best cost per hour, and representing the number one alternative to premium brands.
These developments were presented at prominent industry exhibitions in 2024, such as Intermat in Paris and Hillhead in the UK.
In April 2025, Triangle will attend bauma in Munich, Germany, displaying its TPMS system and sharing best practices and knowledge with professional operators.
Triangle maintains a close relationship with the market and end users thanks to its solid collaboration network with leading specialist dealers in the OTR sector. This allows the company to fully understand customers' needs and develop a product range to meet their requirements, including the highest safety standards.
Triangle provides tyres and services for many of the world's top machinery manufacturers, including Caterpillar to Sany, Hyundai, Komatsu, Liebherr, Hitachi, Zoomlion, Terex, Develon, and CNH.
Caterpillar, the world's biggest manufacturer of off-highway equipment, has awarded Triangle with the ‘Supplier Excellence Recognition’ for nine consecutive years. AB
LEFT: A front-on view of Triangle’s TL578S tyre. The tyre suits wheeled loaders and underground mine operators seeking higher speed capabilities. RIGHT: Triangle’s new TB577A SUPER tyre in size 24.00R35 for rigid dump trucks. Pic's: Triangle Tyre
Increasingly sophisticated blasting analysis
A vibrant blasting technology sector offers cutting-edge productivity and efficiency gains to the global aggregates industry. Guy Woodford reports
Drilling and blasting specialists EPC-UK and EPC Metrics have released their ‘next generation’ drilling and blasting service, ROG+ (Rock on Ground Plus), to customers. This development streamlines operations from a cost management perspective and enables greener credentials through more optimised processes.
Sister companies EPC-UK and EPC Metrics have delivered proven results using ROG tools for many years. However, the recent groundbreaking development of ROG+ coherently brings together the concepts and technologies to create bespoke packages for customers.
ROG+ is a highly sophisticated and accurate blasting service. It involves EPC-UK customers choosing only the specific drill and blast elements needed to support equipment and tools already on site or adding new telematic measurements. This enables entire value chains to be improved, from faceto-gate or mine-to-mill. It also streamlines operations from a cost management perspective and supports greener credentials.
ROG+ involves measuring blast impact through many advanced tools on a continual
feedback loop basis, using a combination of accessible site data and engineer expertise.
“By creating a ‘continuous feedback loop’, we’re able to see how our blasting activities are impacting the overall downstream of a customer’s quarrying operation,” EPC-UK and EPC Metrics’ commercial manager Ryan Ward explains. “As well as the performance and value gained from the materials that are being extracted. We feed that information into the next blast decision-making process and, by making slight adjustments each time, can progressively enable customers’ blasts and operations to become even more optimised.
“Using ROG+’s data suite and our engineering team’s expert knowledge, we’re making better, tailored decisions about how customers blast in the ‘ever-changing’ quarrying environment,” he continues.
“The advantage of choosing only the tech elements from the service offers that apply to each site means customers can significantly improve activity and expenditure within their quarry—whether linked to loading, hauling, fuel usage or crushing to get all the value possible. Equally, it’s helping us to improve choices regarding emulsion types and blends, detonators, timings, top and bottom priming
and blasting parameters. Furthermore, by putting holes in the ground as accurately as possible, the maximum performance is realised from the explosive products used.”
EPC-UK’s general manager, Blasting and Explosives, Ben Coppock, adds: “As the need to operate more sustainably becomes increasingly important, customers can rely on the ROG+ service to optimise their blast performance to improve carbon reductions. This is because more optimised fragmentation requires less fuel for loading and hauling, and the power consumption for crusher systems is reduced. In addition, the ROG+ service works alongside customers who are introducing a ‘green multi blend’ into their operations to improve environmental performance through sustainable products and blasting efficiency.
“Furthermore, as we use technology to assess performance, measure optimisation and digitally report data from the entire value chain through advanced, real-time KPI dashboard visuals, efficiencies made aren’t just environmental, but also financial.”
EPC-UK and EPC Metrics’ ROG+ service is integrated with EPC-UK’s state-of-the-art software solution, VERTEX.
Vertex combines the highly advanced platforms of EXPERTIR, EXPERTAB, and EXPLORE to upload, analyse, and store information used to optimise relevant blast performance. By centrally storing current and historical information and making it easy to access and straightforward to understand, engineers and operators can review past blast performance more effectively and improve future blast designs.
EXPERTIR is a blast design software programme that uses site-collected data to produce the best blasting specifications and outcomes for each blast. It incorporates data from drone surveys, GPS, and hole probes to facilitate design from initial drilling to initiation.
ROG+ involves measuring blast impact through many advanced tools on a continual feedback loop basis. Pic: EPC-UK
EXPERTAB is a notebook version of the EXPERTIR software designed to support MEMU truck and drill rig operators in the field. Using EXPERTAB, operators can capture digital drilling information while on-site and transfer it back to the drill and blast engineers. The data enables the required blast to be designed and sent to the MEMU for hole loading. All the results are recorded, and information and relevant data are stored and then sent back into EXPERTIR.
EXPLORE allows all drill and blast KPI data to be submitted, stored, and analysed together within an online cloud-based database. The digital solution enables engineers to make effective decisions regarding future blast designs and blast parameter changes to improve fragmentation and efficiencies and deliver a true ‘mine-to-mill’ understanding.
Coppock adds: “Our tailored ROG+ service is just one element within a suite of capabilities that EPC-UK will use to shape the future of the drilling and blasting industry for the better. Using knowledge and expertise, we’re succeeding in improving customer efficiencies across the sector with passion and purpose.”
Maptek will soon release BlastMCF, targeting automated blast design. This move will lighten the engineering load while allowing drill and blast engineers to control parameters and outcomes.
Fixed factors like geology, bench height, drill setup, and variable inputs like geometry, explosives, and timing all influence blast outcomes. Balancing these interrelated factors can be time-consuming. Maptek BlastMCF revolutionises blast design for surface operations, quickly generating scenarios that consider competing objectives.
The Maptek Compute Framework (MCF) leverages cloud computational power for rapid results.
BlastMCF automates optimised and detailed blast designs encompassing drill patterns, per-hole charging, and timing, reserving more time for engineers to concentrate on scenario analysis and fine adjustment before exporting to downstream applications.
A large iron ore mine tried a pre-release of
BlastMCF for ease of use, speed to generate scenarios, and value of results, assessing it against day-to-day design and mediumterm planning horizons. BlastMCF was significantly more intuitive and easier to use than traditional CAD-based drill pattern tools. Optimal designs were achieved with fine-tuning to remove, add, or move holes in post-processing.
According to Mark Roberts, Maptek's global strategy manager, BlastMCF is the first important step in orchestrating and automating blast design routines incorporating measured outcomes like vibration, dig rates, and crusher throughput.
Mines can optimise designs to achieve their desired outcomes based on what
vibration—are integrated with BlastMCF to measure the quality or fitness of each design generated. Competing objectives are optimised only after honouring the constraints. Where constraint thresholds are very tight, the design with the least violation is returned for review and parameter adjustment.
BlastMCF requires only a polygon, surfaces, and user-defined design bounds like min/max spacing. Hundreds to thousands of possible designs are generated to target good fragmentation and low-vibration objectives before converging on the most optimal.
Engineers are presented with an array of 15 results for evaluation. Graphical and 3D view displays allow them to easily understand the trade-off in design parameters for every blast as they choose the optimum.
Blast designs are readily applied downstream through native integration with Maptek BlastLogic; charge plans and
LEFT: EXPLORE allows all drill and blast KPI data to be submitted, stored, and analysed together within an online cloud-based database RIGHT: The EPC-UK ROG+ Blast Dashboard. Pic: EPC-UK
A Maptek BlastMCF 3D window pattern. Pic: Maptek
‘Mines are investing heavily to measure key outputs across the mining value chain. Automating scripts and workflows to handle repetitive tasks and integrating these with processes and cloud computing allows them to orchestrate blast design routines that optimise based on measured performance,' Roberts said.
This approach is crucial for managing complex orebody knowledge or mine planning processes and will deliver valuable insights that enable miners to make better decisions.
The Maptek BlastMCF web-based solution will be available soon. It will be natively integrated with BlastLogic Enterprise System (on-premise) and BlastLogic Single Site Cloud Access.
In Mongolia, drill and blast specialists Blast LLC employ Maptek Vulcan and BlastLogic to optimise resources and improve customer productivity. Applying Maptek decision-support systems is helping them achieve a data-driven approach that incorporates production metrics, vibration modelling, and fly rock data.
Vulcan is used for the precise design and execution of drill and blast plans, where customisation aligned with geological conditions improves fragmentation and overall efficiency. Advanced data management and realtime analytics in BlastLogic support better decision-making and enhanced safety protocols. Together, these technologies streamline processes, establishing cost-effective pathways and highquality outcomes for every project.
According to Blast LLC, one of the standout benefits of working with Maptek was the significant improvement in drill and blast accuracy and efficiency. This is particularly important for complying with new regulatory standards. Boosting data analytics around performance metrics, vibration, and fly rock data will deliver further value to local clients in managing resources.
In other Maptek drill and blast developments, a new BlastLogic API will integrate third-party systems, custom software, scripts, and tools with the BlastLogic ecosystem. The primary focus is to make adding new data easier.
material. Before Orica’s FRAGTrack was deployed, the New Windsor site team had to stop the belt and take a belt cut to sample the belt contents and monitor the particle size distribution using traditional manual sieving techniques. This was performed as often as once a week all year round.
Over-crushing could also occur due to the lack of real-time monitoring, which increases costs associated with crusher power draw and equipment wear. FRAGTrack technology was shared with Heidelberg Materials as a potential solution to these operational constraints.
Kwaku Boakye, regional mining manager at Heidelberg Materials North America, says: “Since installation at New Windsor quarry, I've had a great experience with FRAGTrack, with several operational impacts.
“FRAGTrack eliminates crusher standby time for a belt cut needed for the lab's PSD
This would be the ideal location to monitor the resulting crushed sizes produced by the primary crusher and help improve quality control over the first processing stage.
As part of the FRAGTrack deployment, Orica’s regional technical services team would assist the quarry operators in targeting an ideal powder factor using the measured results from FRAGTrack. Automated reporting dashboards were created using Microsoft PowerBI and the FRAGTrack external API as part of FRAGTrack’s data services in collaboration with New Windsor. This work ensures that important metrics are quickly viewable and summarised in an automated daily email without additional work. This custom dashboard is used to quickly review the fragmentation performance of the past day.
Due to the improved data visibility from FRAGTrack, several key changes were implemented in the quarry operation. The fast data collection and presentation of the FRAGTrack results allowed a quicker response to size control, helping to better target needed product sizes. Results only updated once a month before, are now available within minutes without operational downtime.
With the introduction of automated fragmentation measurement, New Windsor was able to end the need to perform the belt cuts required to sample the size distribution. In addition to the safety benefits of avoiding working around the belt, this led to an estimated savings of US$10,000 per monthly stoppage. Ending the sampling of belt stoppages avoids restart costs and added strain on equipment, which can cost $8,000 per event. On an annualised basis, this would contribute over $216,000 in operation efficiencies gained through added production, reduced power charges, and reduced equipment wear.
BlastMCF and the BlastLogic API are earmarked for release before the end of 2024.
Heidelberg Materials North America’s New Windsor (New Windsor) quarry is located near Frederick, Maryland, USA. The quarry processes approximately 3.4 million tons of material annually and supplies limestone to the Baltimore and Washington, D.C. region.
New Windsor is a large operation with multiple beltlines, and its management must carefully consider any downtime and the operational effects that will have on its production.
Control of product sizing is important to maximise returns and minimise waste
[particle-size distribution] analysis. "This was required as part of our BPM [business process management] once a month. It also eliminates labour to perform belt cuts for PSD lab analysis, saving on tangible and intangible costs and possible injuries. It also gives real-time analysis of PSD data, so an impact crusher spacing adjustment can be made to reduce over-crushing," said Kwaku Boakye, regional mining manager at Heidelberg Materials North America.
Boakye says FRAGTrack allows producers to reduce crusher power usage and wear rate while adjusting drilling and blasting designs to reduce fines and improve fragmentation. “This helps the overall optimisation of the operation,” he concluded.
Orica’s FRAGTrack conveyor solution was launched in November 2022 as a complete solution for automated capture and aggregation of particle size for the conveyor system at New Windsor. A post-primary location was decided upon for the installation.
New Windsor utilises the FRAGTrack system in day-to-day operations, which allows for a quick check that crushed rock is in the expected size range of 4.5-5 inches (P80). This allows for rapid response and adjustment if the rock exceeds the expected product size. Using the automated dashboard, the quarry can now reset the closed-side setting on the crusher to help meet the PSD target for the raw mill. Helping avoid over-crushing (creation of fines) minimises undesirable byproducts and reduces power use. The formerly used belt-cut method did not allow for this fast adjustment.
Collaborating with Orica technical services, a typical blast pattern size was increased from 15x15 to 16x16 ft, reducing blasting costs. Using the measurements from the FRAGTrack system, blasting performance and effects on the processing circuit were closely monitored for optimum throughput. Data from FRAGTrack helped achieve a target powder factor of 0.6 lbs per ton, which improved floor control. AB
