Weighing more than 47 tonnes, this all-new mining motor grader comes with a high-power Komatsu engine, a choice of 5.5 or 6.1 meter (18 or 20 ft) moldboard, and new cabin ergonomics that deliver an effortless intuitive driving experience. All main components are heavy duty, Komatsu designed and manufactured, so you can be sure of maximum uptime in even the most extreme applications.
WASHING – 1
“The ability to process material closer to the point of use is a major attraction of mobile plants” p37
Regulars
05 COMMENT
A victory for the quarry everyman
06 NEWS
Record-breaking Breedon acquires BMC Enterprises for $300mn; Titan achieves record annual profitability hat-trick; Metso reveals big rise in Planet Positive sales in 2023 annual report
09 ASSOCIATION NEWS
Introducing the Aggregates Europe-UEPG RocksTalk podcast
50 EVENTS
All the key events in the quarrying & aggregates world
Features
30 LOADING
Fully electric wheeled loaders are rising in popularity among building material companies focused on sustainability and lower fuel costs
32 HAULING
A big advance in driverless hauling and a leading articulated hauler manufacturer’s useful advice on choosing the right machines for your working needs
37 WASHING – 1
Premium haulers are key fleet assets at major quarrying sites in the UK and Italy
A new premium breaker range and a new technology-enhanced drill rig that combines high penetration rates with superior hole quality
45 SCREENING MEDIA
42 DRILL RIGS, HAMMERS & BREAKERS – 1
Looking beyond cost per tonne to gauge operational productivity
48 DUST SUPPRESSION
Innovation in dust suppression is evident in the latest manufacturer solutions
Specials
10 INTERVIEW 1
COVER STORY: Cemex’s Swinderby Quarry is increasing its sustainable sand and gravel supply after a major investment in a premium CDE wash plant. Pic: Guy Woodford
Beau Lintereur explains how Cummins’ future will be built on multiple power plays
14 INTERVIEW 2
Mark Gillespie discusses Recycl8’s ambitious net-zero and circular economy goals
20 MARKET REPORT
Decarbonisation and machine performance gains are among the priorities of growthseeking French aggregates producers
24 QUARRY PROFILE
Cemex’s Swinderby Quarry is set to significantly increase its high-quality sand and gravel output after investing in a state-of-the-art CDE plant
27 FEATURE
Two Holcim subsidiary sales have enhanced business opportunities in an increasingly lively East African infrastructure market
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IGUY WOODFORD
was delighted to read that Moreton Cullimore has won his planning appeal to create a 160-acre quarry at Bow Farm in Gloucestershire, western England.
The victory over Gloucestershire County Council means Moreton, managing director of The Cullimore Group, can now access up to 1.5 million tonnes of sand and gravel over the next nine years, helping to future-proof his highly successful aggregates and haulage supply business.
I fondly remember my 2019 visit to the group’s Netherhills HQ site, nine miles southwest of Gloucester. I had a long and highly interesting conversation with Moreton and toured Netherhills, taking in its impressive crushing, screening, load, and haul operations. The trip resulted in a great Quarry Pro le feature for this magazine, and I’ve kept in touch with Moreton, who became the youngest-ever chairman of the Road Haulage Association in 2021, ever since.
I am highlighting Moreton’s successful planning appeal as a good example of the new and extended quarry planning approvals desperately needed across Europe so that the mineral products industry can maintain its essential aggregates supply.
On the same topic, I was up at Longcliffe Quarries in Derbyshire, central England, last month speaking to Paul Boustead, Longcliffe’s managing director, and some of his management team about, among other topics, the business’s plans to extend its Brassington Moor Quarry into a new Aldwark South extraction area. After a lengthy public consultation, the company recently submitted its formal planning application to Derbyshire County Council. If successful, Longcliffe Quarries can extract another 27 years of high-purity industrial minerals, safeguarding many jobs and the business’s future.
The likes of the Mineral Products Association (MPA) in the UK and Aggregates Europe-UEPG (European Aggregates Association) have long highlighted the essentiality of raw materials to sustain our quality of life and all of society’s built environment. The latter association notes, and I fully agree, that failure to satisfy Europe’s threebillion-tonne aggregates demand would cause
EDITOR
A victory for the quarry everyman
“I think rather than not enough people coming into ‘the trades’, too many people are being pushed out of them”
our known world to “fall apart”. The association undertakes campaigns to raise the attention of EU and national policymakers to prevent supply from being taken for granted. Aggregates Europe-UEPG, MPA, and all other national and regional aggregates associations’ relentless industry-championing work is vital.
Further vital work involves effectively communicating with and educating the general public about the importance of the aggregates industry and the wider quarrying and construction equipment world. During a fascinating recent conversation with John Somers, the Association of Equipment Manufacturers (AEM) vice president for the construction & utility sector, we discussed how longstanding labour and skills shortages affect the US construction equipment market. This is also a wider global industry problem, and Somers highlighted how changing public perception is one way to help solve it.
“I think rather than not enough people coming into ‘the trades’, too many people are being pushed out of them,” said Somers. “I think my generation was a prime example of this. When you talked to anyone in high school, the rst question was, ‘Which college are you going to?’. If you said you’re not going to college, they would say, ‘Cool, have fun working at McDonalds the rest of your life’. Nothing in the middle was considered.
“Since then, I think we’ve overcome much of that but are still some way behind where we want to be. The perception of the construction industry is not accurate.”
I urge every reader of this magazine to do their bit and continue spreading a positive message about our great industry, helping to future-proof it and the prosperity of wider society. GW
Record-breaking Breedon acquires BMC Enterprises for $300mn
Breedon Group is acquiring US-based BMC Enterprises (BMC) for $300 million (£238.1mn) and celebrating record annual trading gures.
BMC supplies readymixed concrete, aggregates, and building products. It is headquartered in St. Louis, Missouri, and has a strong track record of organic and transactional growth.
The move marks the taking of what Breedon, a leading vertically integrated construction materials group in Great Britain and Ireland, describes as a “compelling opportunity” to launch a scalable third platform for the Group in the fragmented and growing US construction materials market.
Breedon says the deal sees them gain a “highly attractive, established business with excellent margins,” run by a “well-regarded and experienced
management team with a long track record who will remain with the business.”
The acquisition is expected to deliver attractive nancial returns for Breedon while maintaining a strong balance sheet.
In the 12 months ending 31
October 2023, BMC recorded unaudited revenue of US$ 178.9 million. Since 2013, BMC has delivered CAGR revenue and adjusted EBITDA growth of c.12% and c.22%, respectively, through organic growth and bolt-on acquisitions.
The purchase of BMC, which
has over 400 million tonnes of reserves and resources, is due to be completed by 7 March 2024, subject to customary closing conditions.
Breedon’s chief executive of cer, Rob Wood, said: “The acquisition of BMC represents a compelling opportunity for Breedon to launch our third platform in the USA. BMC has an excellent performance track record over a sustained period and is positioned in an attractive market for future growth.”
Breedon has revealed that its full-year 2023 revenues rose 7% to a record £1.487.5bn, with an underlying EBIT of £156.2mn, also an annual record. Breedon says its underlying EBIT achievement was due to a disciplined focus on cost recovery and self-help measures. The Group’s 2023 pre-tax pro t was down 1% to £134.4mn.
Titan achieves record annual profitability hat-trick
Titan Cement International (Titan) achieved record annual profitability for the third consecutive year in 2023, fuelled by strong sales growth.
The Greece-headquartered Group’s worldwide sales of €2,547 million were up 11.6%. The US and Europe contributed over 90% of Titan’s sales and profitability.
Titan’s record EBITDA 2023 performance of €540.3 million was a 63.1% year-on-year rise, achieving margin expansion. All regions posted double-digit profitability growth, thanks to increased sales across all main products, firm pricing, operational e ciencies and improved performance of energy costs.
Titan reduced specific net CO2 emissions by 11kg year-over-year to 608 kg/ton of cementitious product due to improved alternative fuel usage and a lower clinker-to-cement ratio. The Group’s greenproduct sales share within overall sales reached 23.4%.
2023 was another consecutive year of Titan’s inclusion in the CDP’s ‘A’ list. The Group also achieved an ‘AA’ score in its MSCI ESG ratings, recognising its leadership in corporate transparency and climate change performance.
Last year, Titan signed a €234 million grant agreement with the EU Innovation Fund for its pioneering IFESTOS carbon-capture project in Greece.
Titan’s Strategy 2026 execution was accelerated in 2023, with five acquisitions and partnerships adding access to reserves of more than 100 million tonnes of supplementary cementitious materials and more than 90 million tonnes of aggregates in attractive markets. The Group completed four investments through its Venture Capital initiative. Titan also accelerated its digital transformation in 2023 with productivity improvements and reductions in energy consumption. As of the end of 2023, real-time optimisers and failure-prediction systems were deployed in most plants.
Titan reports a positive trading outlook thanks to improved volumes and pricing in its attractive US and European markets. The Group says the completion of growth-oriented projects will result in further margin performance.
Marcel Cobuz, chairman of the Group Executive Committee, said: “This year’s remarkable performance showcases our relentless focus on executing our strategy, delivering above-market results while positioning for further growth. In 2023, we have strengthened our presence in our core growth markets, delivered e ciency improvements and broadened our solutions, serving our customers’ increased and evolving needs. The results come from our experienced teams, whose hard work and growth mindset have enabled this record performance.”
Breedon is expanding into the US with its acquisition of BMC Enterprises, and is celebrating a record trading year in 2023. Pictured is the CDE plant installation at Breedon’s North Cave Quarry. Pic: Breedon
LEFT: Marcel Cobuz, chairman of Titan Cement International’s Group Executive Committee. Pic: TCI BELOW: Titan’s Kamari cement plant in Viotia, Greece. Pic: Yannis Kontos.com
Metso reveals big rise in Planet Positive sales in 2023 annual report
Metso’s 2023 annual report has revealed a big rise in Planet Positive-linked sales.
The Finnish quarrying and mining equipment major’s Planet Positive-related sales were worth €1.447 billion in 2023, up from €1.225 billion in 2022. Metso’s Planet Positive initiative helps customers cut their CO2 emissions and achieve their other sustainability priorities, such as reducing pollution.
The Planet Positive portfolio already includes over 100 Metso products, and the company aims to have a Planet Positive product for every part of a customer’s value chain. To achieve this, all Metso’s R&D projects must have sustainability bene ts, with a target of 80% of R&D spending on Planet Positive product and service-offering development by 2030.
Metso has revealed strong Planet Positive sustainability-focused sales in its 2023 annual report. Pic: Metso
In Metso’s 2023 annual report, company president and CEO Pekka Vauramo stresses that sustainability is vital for Metso and the company’s industries. “By far, the biggest impact of our sustainability
actions materialises in our customers’ operations. Metso is committed to the 1.5-degree climate target, and our goal is Planet Positive sales— an offering that has proven sustainability bene ts—grow faster than our overall sales. In Planet Positive sales
“We measure the CO2 emissions of our operations, and our target is to become net-zero by 2030. Last year, we reached a 73% reduction level in our emissions compared to the baseline of 2019. Similarly, we aim to reduce our logistics CO2 emissions by 20% by 2025, and at the end of 2023, the result was -7%. We have also set a target for our spending from direct suppliers that have set science-based emissions targets to reach 30% by 2025, and at the end of 2023, the share was just over 26%.”
Built to Last: Powerscreen unveils new global HQ
Powerscreen has unveiled its new global headquarters in Dungannon, Co. Tyrone, Northern Ireland.
Under the theme Built to Last, the revitalised facility was revealed to local stakeholders, including First Minister of Northern Ireland Michelle O’Neill, at an of cial ribbon-cutting ceremony and celebration.
Following a tour of the new facility, O’Neill said: “Your new headquarters are really impressive. It’s a physical demonstration of your success and a welcome statement of your future ambition. Your growth on this site since the original Powerscreen days is a testament to entrepreneurial spirit and resilience. You have been instrumental in growing an engineering cluster here. You have set the standard in terms of quality and product development, and you have been pioneers in research, development and innovation.”
Dr Dominik von Achten, chairman of Heidelberg Materials’ management board. Pic: Heidelberg Materials
THREE MORE YEARS Heidelberg Materials’ supervisory board has extended the mandate of managing board chairman Dr Dominik von Achten, which expires at the end of January 2025, by three years until 31 January 2028.
Having been chairman of the managing board since February 2020, von Achten has led Heidelberg Materials successfully in challenging times. He has played a decisive role in expanding the company’s global pioneering role in the decarbonisation and digitalisation of the building materials industry in combination with Heidelberg Materials’ convincing financial performance.
Sean Loughran, Powerscreen business line director & general manager of Terex Dungannon, with First Minister Michelle O’Neill MLA at the o cial ribbon-cutting ceremony of Powerscreen’s new headquarters. Pic: Powerscreen
“With Dr von Achten, we have an experienced manager at the helm of the company who has excellently positioned Heidelberg Materials on a global scale and set the course for the future with great commitment,” says Dr Bernd Scheifele, chairman of Heidelberg Materials’ supervisory board.
Sean Loughran, Powerscreen business line director & general manager, said: “As pioneers in mobile crushing and screening, we’ve always believed in building not just equipment but legacies. As Powerscreen approaches 60 years of operating, we understand the value of durability and innovation. Our new headquarters isn’t just bricks
and mortar; it’s a testament to our commitment to lasting excellence. Built to Last isn’t just a strapline for us; it’s a promise to our team members, customers, and community—a promise of enduring quality, reliability, and progress.”
The new headquarters on Coalisland Road includes a new 8,500 sq ft state-of-the-art of ce space, a modern wellness centre to promote teammember wellbeing, and several energy-saving enhancements to reduce carbon emissions.
“We look forward to continuing the trustful work with him. We are convinced that he will keep driving the transformation into a sustainable and digital future with verve and continue to successfully lead the company in the coming years.”
A longstanding Heidelberg Materials executive, von Achten has been a managing board member since 2007. He served as deputy chairman of the company’s managing board before taking on his present chairman role.
Aggregates Business editor Guy Woodford in conversation with Aggregates Europe-UEPG secretary-general Dirk Fincke on the first-ever RocksTalk podcast. Pic: Aggregates Europe-UEPG
Rocking the airwaves:
In a world where podcasts have become the new rock concerts, one series is setting out to literally discuss... well, rocks. Aggregates Europe - UEPG has just launched RocksTalk, a podcast that promises to be the Rolling Stones of the aggregates industry. Now available on Spotify, this series isn’t just a bunch of people talking about stones and sand. It’s an electrifying journey from the rugged quarries to the forefront of sustainable practices, all packed into dynamic and engaging episodes. Imagine sitting in on a conversation where experts, policymakers, and industry insiders come together not just to talk shop but to dig deep into the challenges and innovations shaping the landscapes and infrastructures of our world. Whether you’re a professional in the eld, a student of geology, or someone who’s ever wondered about the materials that build our world, RocksTalk has got you covered.
Why RocksTalk Rocks
In a time when most people zone out at the mention of “aggregates”, RocksTalk steps in as the much-needed bridge between the industry, policymakers and society, linking raw materials and societal needs. Each episode features a lineup of guests who are experts in their area to share their views on topical policies. Aggregates Europe – UEPG invites its stakeholders to its purpose-built, in-house podcast studio to ask simple questions on complex topics such as nature restoration, biodiversity in quarries, the potential of the circular economy, energy transition, the attractiveness of the industry
for young people, and anything which members of Aggregates Europe – UEPG always wanted to address with a wider public.
First Episode with Aggregates Business editor Guy Woodford
Do journalists do all interviews? Not with RocksTalk. We turned things upside down and asked Guy Woodford, a real-life journalist, how we do as an industry in communicating success stories to a wider audience. No spoiler alert is offered here, so listen in to the rst episode.
Stay tuned for more!
RocksTalk will be produced monthly and is insightful whether you’re a professional in the eld, a student of geology, or simply curious about the materials that build our world. Tune in to discover the bedrock of Europe’s aggregates industry!
Listen to the first episode here
Aggregates Europe - UEPG unveils RocksTalk podcast on Spotify
Pics: Aggregates Europe-UEPG
BEAU LINTEREUR
Succeeding with multiple power plays
Cummins is continuing its commitment to helping customers navigate their energy transitions under the leadership of Beau Lintereur, its recently appointed o -highway engine business executive director. He spoke with Guy Woodford about Cummins’ progress towards Destination Zero: its strategy to reduce its products’ greenhouse gas and air quality impacts further and faster. He also highlighted what quarrying and heavy-construction customers can expect to see from the US-headquartered o -highway power solutions giant in 2024 and beyond
Pic: Cummins
Beau Lintereur predicts quarries will feature hydrogen fuelcell- and hydrogen internal combustion engine-powered machines before 2030. “I don’t think quarries will be the lead market on this, but that timescale is very realistic. It will happen rst in the larger markets, like the US, Japan, and Korea, with larger companies that will attract investment to make the technology costeffective, with the infrastructure to support it.”
Lintereur manages Cummins’ construction, agriculture, and industrial segments as well as global OEM (original equipment manufacturer) customers. He succeeded Eric Neal as off-highway engine business executive director in August 2023, after Neal took on a new role leading Cummins’ new-product introduction programmes, developing the next-generation combustion engine
Possessing extensive experience with the global power and technology leader he joined in 1998, Lintereur took on his new senior executive role after heading up Cummins’ Mining and Aftermarket businesses for Power Systems. He has also held roles in the Power Electronics, global transfer switch, Power Generation, and Filtration businesses, including overseas assignments in China and India.
Lintereur explains that Cummins is focused on advancing its internal combustion engine technology while reducing carbon emissions without impacting operations, weight, or uptime as part of its Destination Zero strategy. Simultaneously, Accelera, Cummins’ zero-emission technology brand, is focused on developing battery-electric and fuel-cell powertrain solutions and electrolysers for green hydrogen production.
“We’re trying to create a bridge from where we are today to lower emissions globally. We’re taking our existing knowledge, technology and history with the internal combustion engine and double downing on that,” explains Lintereur. “We are doing that as we know there are not only more traditional emissions [regulations] coming, but it also gives us a bridge to alternative fuels like natural gas and hydrogen internal combustion. We feel we need, essentially, a clean-sheet engine design to do all those things. We are making the biggest investment I’ve seen in my career in new engine designs that cover the range we’re talking about.”
Lintereur says Cummins’ variety of ‘bridge’ power-solution options emphasises how the company intends to be with customers “every step of the way”, helping them navigate the energy transition. “In mining, we are the independent power guys in every market. We saw many things and talked to everybody, and it was not certain that one magical technology would emerge to replace diesel. Diesel is this power solution that works above ground, below ground, at altitude, in this and that application, in big and small trucks, and on- and off-highway.
“I think [power solution] technology will fork and be based on application, fuel availability, infrastructure availability, and government policy and incentives. There won’t be a one-size- ts-all technology. Cummins is not saying, ‘This is the answer; it has to be this’.”
Cummins’ European Technical Centre in Darlington, northeast England, is leading the way in developing a hydrogen-fuelled internal combustion engine (H2-ICE).
The UK government-backed Brunel Project, named after another pioneer of the modern industrial age, Isambard Kingdom Brunel, has received £14.6 million through the UK’s Advanced Propulsion Centre’s Collaborative R&D competition, which supports businesses developing innovative automotive technology.
Tests are underway on a medium-duty Cummins 6.7-litre and a heavy-duty 15-litre engine to help decarbonise commercial vehicles and construction equipment.
The Brunel Project dovetails perfectly with plans to turn the Tees Valley into a Transport Hydrogen Hub, the rst of its kind in the UK.
Lintereur notes that Cummins has been an integral part of Darlington and the northeast of England for almost 60 years, with its large
“It’s about looking at the engine, transmission, controls and integration system rather than just the engine”
facility in the town home to around 1,800 employees. Cummins Darlington services over 200 customers across more than 40 countries. “The site’s international reach is set to continue in 2024, with the launch of a new Powertrain Test Facility, which will help accelerate the move towards cleaner power energies focused on reducing greenhouse gas emissions and improving air quality.
“The facility is already leading in advancements in hydrogen internal combustion engine (ICE) technology, with the development of Cummins engines as part of the fuel-agnostic engine range. Cummins is evolving its capabilities and expanding hydrogen technology innovation with signi cant research and development.
As part of this, Cummins’ European Technical Centre in Darlington continues to oversee a consortium of leading sub-system manufacturers in the UK to achieve commercial viability for hydrogen internal combustion engines.”
Lintereur stresses the need to commit resources to further developing technologies like hydrogen combustion in Darlington. These can support industries’ essential decarbonisation while creating valuable employment in engineering.
At CONEXPO/CON-AGG 2023 in Las Vegas [14-18 March], Cummins showcased its new fuel-agnostic 15-litre engine platform with hydrogen, natural gas, and advanced diesel engines. This platform offers OEMs the opportunity to accelerate the decarbonisation of heavy-duty off-highway applications.
Beau Lintereur talks to Cummins’ stand visitors at an o -highway equipment industry event. Pic: Cummins
The 15-litre next-generation engine’s fuel-agnostic architecture utilises a common base engine with cylinder heads and fuel systems speci cally tailored for hydrogen, natural gas, diesel, and biofuels, including HVO [hydrotreated vegetable oil].
Cummins claims this new platform, designed for the next level of emissions, will signi cantly increase power density with a more compact installation envelope, enabling OEMs to increase machine capability and productivity without impacting running costs.
Timed to coincide with the event, Cummins announced that in addition to recent investments in Fridley, the company is investing more than $1 billion across its US engine manufacturing network in Indiana, North Carolina and New York.
In October 2022, just two months after President Biden signed the In ation Reduction Act, Cummins announced it would begin manufacturing electrolysers in the US for the rst time at its Fridley location. An 89,000 sq. ft. area will be dedicated to Accelera electrolyser manufacturing.
The 15-litre hydrogen engine will be available with ratings from 400 to 530hp and a 2600Nm peak torque. This engine will offer ratings from 400 to 510hp for applications powered by renewable biogas with a 2500Nm peak torque. The advanced diesel version features a broad power range of 450 to 650hp with an impressive 3200Nm peak torque.
“The platform appeals to OEMs who want to work with a technology provider that can allow them to engineer a solution for customers wanting different power solutions for their applications, be it diesel, natural gas, or hydrogen. It exempli es how Cummins has adopted the right strategy,” says Lintereur.
The big Las Vegas off-highway industry showpiece event also saw Accelera showcase its next-generation fuel-cell engine, which suits heavy-duty off-highway applications’ duty cycle, performance, and packaging requirements. Available in 150kW and 300kW fuel-cell engine con gurations, it incorporates variable-pressure technology, which provides improved power density, ef ciency, and durability, all while delivering a lower total cost of ownership.
Less than three weeks after CONEXPO/ CON-AGG 2023, Cummins welcomed US President Joe Biden, Minnesota Governor Tim
Walz, Democratic Members of Congress from Minnesota, and local Twin Cities community leaders to its Fridley, Minnesota plant.
The Biden Administration scheduled the visit to showcase how investments in the Bipartisan Infrastructure Law (BIL) and In ation Reduction Act (IRA) bene t American manufacturing jobs. Cummins supported the bills through the legislative process and worked closely with the White House and Congress to champion them. President Biden’s and other special guests’ visit included a plant tour and interactions with many Cummins Fridley employees.
Electrolysers help produce clean hydrogen, essential for reducing emissions and creating good-paying jobs in the manufacturing and industrial sectors. At the same time, they play a critical role in cleanenergy supply chains that have historically largely been produced overseas.
“It was great that our work on alternative power solutions was recognised at the highest level of the US government, with President Biden visiting our Fridley plant. We are actively harnessing [US government, green energy] incentives,” says Lintereur.
“Our pipeline of projects on the electrolyser side is the biggest and most exciting piece on Accelera’s current work, as you need green hydrogen to power anything like a fuel-cell power solution or hydrogen internal combustion engine.”
Lintereur says that from an off-highway perspective, its mining, quarrying, and construction machine customers, especially larger company or group customers, have ambitious ESG [Environmental, Social and Corporate Governance] agendas that are increasingly keen on adopting alternative power solutions themselves, rather than being led by new government legislation and incentives.
Cummins’ 15-litre fuel-agnostic engine platform was showcased at CONEXPO/CON-AGG 2023. Pic: Cummins
Cummins’ X15H hydrogen engine. Pic: Cummins
“In mining, for example, achieving the lowest cost of production is the goal. Now, though, it is achieving the sustainable lowest cost of production. However, no one wants to go backwards, saying, ‘I want to increase my cost of production to lower my carbon emissions’. That’s where it gets tricky for them, and that is why they are pushing us and others and saying, ‘Give me a sustainable [alternative power] solution that makes economic sense’. That solution will vary between customers, so Cummins’ approach is right.”
Is Lintereur applying key takeaways from his extensive experience in the mining equipment industry to his work as Cummins’ off-highway engine business executive director? “One would be an obsession with nding a solution to the problem the end customer is trying to solve. With mining, you get a great appreciation of what it takes to successfully run a site. Part of this is the criticality of customer support. It’s not just about having a solution that mathematically supplies good economics. Mining machines are complex and run in dif cult environments for long duty cycles. The cost of downtime for these customers is huge. It’s not so much about being issue-free. It’s about what you can do to insulate the customer from pain by making their equipment run as best as it can.”
In September 2023, Accelera revealed it was partnering with Daimler Trucks & Buses US and PACCAR to start battery-cell production and a battery supply chain in the US. Accelera, Daimler Truck, and PACCAR will each own and control 30% of the joint venture.
iron-phosphate (LFP) battery technology family for commercial battery-electric trucks.
“This is a massive investment by Cummins and its partners, around $1 billion each,” stresses Lintereur. “The rst applications involving the US-manufactured battery cells will be in the on-highway space. Creating the infrastructure to support battery cell-powered vehicles, like battery-charging stations, will be huge.
“With hydrogen fuel-cell- and hydrogen internal combustion engines, we have to get the manufacturing and supply chain scale right for the on-highway industry before replicating it in the off-highway industry.”
University and an M.Sc. in the same eld from MIT, Lintereur also has an M.Sc. in Management and a certi cate in Public Management Policy from Stanford University.
I ask if his aeronautical and astronautical engineering expertise can be useful in his senior role with Cummins. “I was at the Agritechnica show [12-18 November 2023} in Hanover, Germany, talking about my engineering background with some agriculture guys. I had my team with me, and I turned to them and said, ‘Hey, if you want a farm on Mars, I’m your guy!’.
Chinese battery maker EVE Energy, established in 2021, will have 10% ownership and contribute its battery-cell design and manufacturing know-how. EVE Energy is a major manufacturer of LFP battery cells for the vehicle industry and is publicly traded on the Shenzhen stock exchange in China.
The transaction is subject to customary closing conditions and receipt of applicable merger control and regulatory approvals, including submitting a voluntary notice to the Committee on Foreign Investment in the US.
The planned joint venture will manufacture battery cells for electric commercial vehicles and industrial applications, creating attractive US manufacturing jobs in the growing cleantechnology sector. The plant’s total investment is expected to be between US$2-3 billion, with an annual production capacity of 21 GWh. It will focus initially on the lithium-
Turning to electric-powered off-highway machines, including diesel-electric hybrid and fully-electric crushing, screening, loading and hauling models found in quarries, Lintereur says: “You will see more Cummins’ investments in the untethered, electricmobility side of things for both on- and off-highway, including electric drivetrains, alternative power, battery storage, and battery-management systems.
“From a quarrying perspective, you may have one excavator at the quarry face feeding multiple haul trucks. You can’t put an electric cable on all those trucks, so they’re untethered. However, given the power requirement and the long duty cycle of those trucks, there are no batteries that wouldn’t increase your payload to such an extent that it made economic sense to use them.”
In addition to a B.Sc. in Aeronautical and Astronautical Engineering from Purdue
“Jokes aside, there are a couple of things. When you think about aeronautical and astronautical engineering, it’s fundamentally a multi-disciplinary engineering eld that applies that knowledge to air and space. You need to know about structures, propulsion systems, controls and dynamics. It’s not like electrical and chemical engineering, for example, which are very speci c. Being trained in a multi-disciplinary engineering eld helps me examine problems in my Cummins work. It’s about looking at the engine, transmission, controls and integration system rather than just the engine.
“The second way my background helps me is that with aeronautical and astronautical engineering, particularly on the space side, you often deal with things you cannot see. I worked on billion-dollarplus military-base systems and had to solve associated engineering problems. Thinking through and solving problems you can’t see is a great challenge. I think there’s a connection with Cummins’ approach to Destination Zero. We must imagine the work site infrastructure, how [off-highway] applications will be done, and how we can best help customers with our power-solution options.” AB
Cummins’ European Technical Centre in Darlington, northeast England, is spearheading the development of a hydrogen-fuelled internal combustion engine (H2-ICE)
Accelera, Cummins’ zero-emission technology brand, is partnering with Daimler Trucks & Buses US and PACCAR to start US battery-cell production and a US battery supply chain. Pic: Cummins
MARK GILLESPIE
A higher state of clean, green consciousness
Mark Gillespie is CEO of Aberdeenshire, Scotland-based Recycl8, a company that collaborates with the waste-to-energy and global construction industries to transform incinerator bottom ash aggregate (IBAA), often destined for landfill, into a sustainable component for concrete. He spoke to Guy Woodford about Recycl8’s current trading and future growth plans as a socially and environmentally conscious company committed to the circular economy and net-zero goals
Recycl8 CEO Mark Gillespie with some R8 Mix solution-inclusive concrete blocks. Pic: Recycl8
Anotable leader across the energy and renewables sectors, having held senior executive roles with several multinational blue-chip companies, Mark Gillespie has an enviable track record in heading teams and repositioning businesses to become market leaders on a trajectory for sustained future growth.
Initially, one of several high-pro le investors in Recycl8, founded in 2019 by Ian Skene, a man with over 30 years of experience in the waste management industry and a highly regarded authority on waste strategies, Gillespie became the company’s CEO in 2022. Since then, he has leveraged his vast leadership and commercial and operational experience to accelerate the use of Recycl8’s groundbreaking solution, the R8 Mix, in multiple industries, including construction and renewable energy.
“In my previous management roles, I worked for oil and gas organisations transitioning to renewable energy. I was involved in a business with Mike Wilson (now a fellow Recycl8 investor) focused on underwater cable-laying and trenching for offshore wind farms. After successfully selling that business, we had a real appetite to work with a business focused on circular economy and lower-carbon solutions. Mike identi ed the Recycl8 opportunity in 2021, becoming the lead investor, and I quickly saw it as a good investment and a great way of becoming involved in a sustainable business.
“The rst 12-18 months of Recycl8 were about environmental testing [of the R8 Mix]. After that, it was about business positioning and commercialisation, and that’s when I decided to come on board as CEO.”
According to Statista, a major business data and market intelligence consultancy, global emissions from cement manufacture stood at 1.6 billion tonnes of CO2 in 2022 –around 8% of annual planet-warming carbon dioxide emissions.
Gillespie says that while successive COP [Conference of the Parties] summits have seen delegates stressing the need to reduce CO2 signi cantly and agreeing on cement’s high-emitter status, the world’s rising population and the need for new infrastructure to support it means that huge amounts of money will be spent on building works, utilising the planet’s limited resources, creating even greater cementbased CO2 emissions unless cleaner and greener solutions, such as Recycl8’s, are used in construction works.
“We’ve had senior-level conversations with companies saying, “I wish you were here four years ago”. They say that, but no one was buying into this agenda like they are now. The change has been dramatic,” emphasises Gillespie.
Recycl8’s breakthrough R8 Mix solution repurposes incinerator bottom ash aggregate (IBAA) as a sustainable constituent part of
“Our R8 Mix gives life to materials that would otherwise be discarded”
the concrete mix as a high-performance admixture and binder, offering a lowercarbon concrete utilising the circular economy.
“Our R8 Mix gives life to materials that would otherwise be discarded, reducing the reliance on virgin quarried materials and has signi cantly lower embodied carbon than traditional mixes. We believe this is the future of construction,” says Gillespie.
The Scottish company offers a win-win process: waste-to-energy facilities can avoid sending their ash to land lls, and concrete manufacturers can source a sustainable raw material that limits the use of virgin quarried materials and has a signi cantly lower embodied carbon than traditional mixes.
“We have aligned ourselves with various IBAA providers in Scotland and England. With the R8 quality assurance process, we ensure that the resulting IBAA meets our environmental criteria and is suitable for an R8 Mix industry application,” Gillespie explains. “We are not a disruptor to a client’s manufacturing process. They don’t have to do something different. They introduce the R8
Mix [to their concrete pour]. We have the UK patent for the R8 Mix and have others applied for Europe and beyond.”
In September 2023, Recycl8 completed the rst industry pour of its R8 Mix concrete made with recycled materials in partnership with Breedon Group.
Comprising Recycl8’s pioneering R8 Mix and blended cement and aggregate, the concrete was supplied to civil engineering and construction rm W M Donald for installation on a housing foundation on Barratt and David Wilson Homes’ new Huntingtower development in Perth, Scotland.
“We are really pleased to be involved in this innovative project using Recycl8’s sustainable R8 Mix concrete technology,” said Craig Godsman, commercial manager at Breedon. “It aligns perfectly with our commitment to decarbonisation, with the provision of lower-carbon solutions through our Breedon Balance range of products.”
David Palmer, Barratt and David Wilson Homes managing director, added: “We are committed to sustainable construction
The Recycl8 executive team. Pictured left to right: Raymond Cowan, finance director; Mark Gillespie, Recycl8 CEO; Ian Skene, chief technical o cer; Yvonne Walker, business operations manager, and Jim Young, technical industry consultant Pic: Recycl8
Pic: Recycl8
“Others have tried to do what we’re doing and are still trying to do it.”
and reducing our environmental impact. We are excited to see Recycl8’s innovative low-carbon R8 Mix concrete used by Breedon on our new Huntingtower project in Perthshire as part of that commitment.”
Earlier this year, Recycl8 and Breedon Group partnered again for Recycl8’s rst large-scale commercial project. Breedon supplied the pioneering R8 Mix concrete to civil engineering contractor Nicol of Skene for the installation of an industrial oor slab for international energy transition rm Aurora Energy Services’ new Operations and Training HQ in Inverness.
So, does Gillespie see a much bigger potential market for Recycl8’s R8 Mix? “There are 2.5 to 3 million tonnes of IBAA available annually in the UK, and the accessible amount is growing constantly. So far, we’ve worked with only tens of tonnes of IBAA.
“With more incinerator plants coming in the years ahead, we can access more IBAA and take it [the R8 Mix] far wider in the UK, Europe, and globally.”
Gillespie believes his rm’s innovative R8 Mix is a truly unique solution. “Others
have tried to do what we’re doing and are still trying to do it. We’ve got our IBAA technology and our binder, which is patented. There is no silver bullet [on cement and concrete carbon reduction]. We offer part of a combined solution, like how Breedon uses R8 Mix with its Balance product range.”
Recycl8’s seven-strong team works with highly respected specialists from various industrial sectors and academia, including the University of Aberdeen and Aberdeenbased Robert Gordon University. The company also has good working relationships with SEPA (Scottish Environment Protection Agency), EA (Environmental Agency), and the Building Research Establishment (BRE). It has bene tted from Scottish Enterprise and Innovate UK investment.
A six- gure Low Carbon Manufacturing Challenge Fund (LCMCF) grant, awarded last year by Scottish Enterprise, enabled Recycl8 to recruit its rst graduate engineer, Daniel Wisely.
“We’ve been working with Scottish Enterprise’s High Growth Ventures Team for three years. They’ve been of great support
to Recycl8. We’ve received different funding awards, including for crucial independent market research,” says Gillespie. “Further funds from our investors have also backed up the LCMCF money. It’s one thing for investors to spend their money; when you introduce other organisations who spend money on your business, it’s market validation.”
Gillespie says Recycl8 is preparing to work with building rms involved with marine and harbour defence projects. “Being linked up with the likes of Breedon, who have outlets across the UK, others take notice and ask questions about what you offer.
“It’s also the case that the more largescale applications you can do, the more data you generate and the greater understanding you gain of what your technology can do on a bigger scale. The media coverage we’re getting is also helping generate wider interest. Companies in the Middle East and Asia are contacting us, saying they’ve got applications we could help with. They’ve also got their own circular economy goals.”
Gillespie believes Recycl8’s R8 Mix would be ideal for building contractors needing large volumes of low-carbon concrete for offshore wind farm projects. “We’ve been in some of the conversations linked to these large projects due to start in ve, six, seven years. The scale of the concrete required means you have to be talking to sustainability-minded suppliers now.
“I’ve never seen the offshore industry so connected back into the construction industry as it is right now. When I joined the oil and gas industry in the early 1990s, the industry had stopped making large gravity-based concrete jacket structures in the 1970s.
“Offshore wind farm developers are already committing to build oating wind turbines, some of which will be with oating concrete structures weighing thousands of tonnes. The developers focus on delivering renewable energy with green products where possible.
“If we can get to the state where none of the produced IBAA has to go to land ll, what a great position that will put us in.”
Most major UK building materials suppliers have published net zero and carbon reduction plans in the last year or two, with their efforts to build an even more sustainability-minded product and services portfolio, sometimes enhanced by acquisition. One example was Aggregate Industries’ Q3 2023 acquisition of Kent, southeast England-headquartered OCL Regeneration, a leading provider of highway waste-recycling solutions.
Would Recycl8 be open to being acquired by a UK industry major? “You have to be careful not to think too far ahead. Ian [Skene] saw an opportunity, and we, as investors, joined the journey. We are still focused on working with our strategic partners and developing our technology. We want to ensure that different sectors can embrace our solution as much as possible. We are here to do the right thing for the environment and want to be good ancestors.”
AB
Recycl8’s Mark Gillespie and David Duguid of Aurora Energy Services. Pic: Recycl8
Recycl8’s Jim Young (left) and Mark Gillespie with Breedon’s Craig Godsman at the Huntingtower development in Perth, Scotland. Pic: Recycl8
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Sustainable projects rise to challenge of French aggregates downturn
The current real-estate crisis in France has been instrumental in a downturn in French aggregates production in early 2024. However, a number of new sustainability initiatives in the industry and ongoing major infrastructure projects are presenting opportunities for quarrying OEMs. Liam McLoughlin reports
French aggregates and quarrying association UNICEM says that it has been a “bleak start to the year” for the industry in the country.
In its March 2024 monthly economic newsletter, the association stated: “The real estate crisis has contaminated the entire sector: construction, materials, developers, agencies, notaries, etc. leading to a rebound in business insolvencies and downsizing.
“The level of interest rates is still high compared to the past, but their expected evolution is more downward than upwards, while, on the price side, their deceleration is well underway.
“In terms of materials, the start of the year is looking bad…[ready-mixed concrete] production is declining, and the evolution of building permits does not augur well for a recovery in the short term.
“Supported by the electoral cycle and construction sites in major cities, public works activity is doing better, even if the beginning of the year seems to mark a pause... However, this improvement has not bene ted the aggregates sector.”
“But the deleterious effects of in ation and tighter monetary policy on households' purchasing power and solvency continue to spread across sectors of the economy.”
French construction industry network GIE de CERC said in its March 2024 update that the dif culties in new construction remain particularly marked for housing –with construction starts falling by 23.3% year-on-year over the three months to the end of January 2024. Over the same period, new premises started fell by 11.2% and authorisations by 14.7%.
UNICEM continues: “The main triggers of the real estate crisis, namely the in ationary surge and the sharp rise in interest rates, are now behind us.
After a rather dynamic year for the public works activity (up by 4% in volume in 2023), UNICEM says the month of January 2024 marked a halt with a decline in the volume of work carried out by 3.4% compared to December and down by 1.9% year-on-year (CVS-JO data). According to the French professional organisation FNTP (National Federation of Public Works), bad weather, with the number of non-working hours 1.5 times higher than a normal January, can in certain regions explain this dip in activity.
In terms of public works, GIE de CERC says that activity remains on an upward trend, mainly due to the number of major contracts that have been concluded in the process of awarding several major projects. Public works completed during the three months to the end of January 2024 were up by 1.3% on the preceding three-month period, and by 4.3% year-on-year.
UNICEM states: “Maintaining a good level of order books and the optimism of professionals for their future activity suggest that this pause could be temporary. However, announcements of budgetary savings (€1bn potential cancellation of state credits to nance the ecological transition), coupled with the risk of the fallout from the real estate crisis on private investments, could, in the long term, weigh on the dynamic of activity in the sector.”
Paul Culliford, regional sales manager EMEA at articulated hauler manufacturer Rokbak, says that French customers in quarries and aggregates prioritise performance, seeking haulers adaptable to various conditions, inclines, and rigorous
Volvo CE says that limiting vehicle emissions and fuel consumption is front of mind for French quarry operators
off-road tasks, all while ensuring costeffectiveness and ef cient maintenance. He adds that Rokbak’s RA30 and RA40 haulers, equipped with EU Stage V engines, offer up to a 7% fuel consumption reduction compared to previous EU Stage IV engines.
“In addition to performance, machine owners in France prioritise operator satisfaction, including ride control and spacious cabins,” says Culliford.
Since its rebranding in 2021, Rokbak has been busy raising brand awareness in the French articulated hauler market. In the year prior to the Rokbak launch, approximately 200 units were sold annually across all brands in the French articulated hauler market. Subsequently, yearly sales gures rose and have remained at around 280 units.
Culliford says that French customers predominantly use articulated haulers in construction, infrastructure and quarry applications. Machines need to be capable of functioning in diverse conditions, manoeuvring through challenging spaces and excelling at hauling material over rough terrain.
“France is witnessing extensive infrastructure development projects, presenting ideal opportunities for durable and dependable equipment like Rokbak ADTs that deliver high productivity at a low total cost of ownership,” he adds.
“Rokbak’s RA30 and RA40 units, with payloads of 28 and 38 metric tonnes respectively, thrive in demanding environments. In particular, the 30-tonne trucks are integral to the French ADT market due to their ease of transportation to quarrying and aggregates job sites.”
Rokbak currently works with three dealers in France. Manu Lorraine Group covers the north-east of France, Framateq,
the south-east of the country, and Griset Matériel, which covers the Rhône-Alpes area. Rokbak plans to continue expanding its dealer presence nationwide to capitalise on the country's historically strong ADT market. Culliford says the company’s plans to enhance the dealer network will support customers and reinforce Rokbak’s position in this pivotal hauler market.
“Rokbak's commitment in France, as is the same elsewhere, centres around customer and dealer satisfaction, geographical expansion and product awareness growth,” he states. “Seeking reputable dealerships with diverse product portfolios, Rokbak aims to see even more of its trucks contributing to the quarry and aggregates industries in France and beyond.
“Through active participation with the trucks and team members at French events throughout 2024, Rokbak aims to elevate its brand visibility, engage with current and prospective customers and dealers and further
solidify itself as a trusted manufacturer offering robust, reliable articulated haulers that elevate construction projects and set new standards in performance and cost ef ciency.”
David Forget, product manager for wheeled loaders and articulated haulers within region Europe at Volvo CE, says that the quarrying and construction equipment manufacturer’s longstanding commitment to environmental care is bene tting its business in France.
“Over the years, we've made strong progress in reducing the carbon footprint of our operations and developing hybrid and electric machines to minimise emissions on site in quarries and on construction projects,” Forget states. “We're now delighted to see many other companies joining us on this decarbonisation journey, particularly in the French quarrying and aggregates sector.”
The French materials production sector is seeing a number of innovative current decarbonisation projects. One of
Rokbak says French operators want haulers that are adaptable to varying conditions and rigorous o -road tasks
these is a collaboration between industrial engineering specialist Fives Group and cement manufacturer Holcim to optimise hydrogen combustion and increase the rate of biogenic fuels in the rotary kiln at Holcim’s La Malle site. Fives provided an injection nozzle and a gas gantry which enabled a hydrogen substitution rate of more than 50%.
In another sustainability project launched in March this year Heidelberg Materials has started a carbon capture, utilisation and storage (CCUS) initiative at its Airvault cement plant in the French New Aquitaine region.
The AirvaultGOCO2 project, with a planned capture capacity of around 1 million tonnes annually, is part of the GOCO2 initiative to decarbonise the West of France.
Dominik von Achten, chairman of the managing board of Heidelberg Materials, said: "We started an ambitious modernisation programme for our French sites several years ago, with a planned investment of more than €400 million. With the integration of AirvaultGOCO2, we are now adding a cuttingedge project in the eld of carbon capture to our previous efforts, which will enable a further, massive reduction of Heidelberg Materials' carbon footprint in France."
The Airvault modernisation project is currently under construction. This includes replacing the two current semi-dry ring lines with a new dry line, including a pre-calciner with a capacity of 4,000 tonnes per day. In future, almost 90% of the plant's energy demand will be covered by alternative fuels. The project will also reduce the electricity consumption per tonne of cement by 10%. In addition, the proportion of clinker in the cement will be lowered. Together, these measures will reduce the carbon footprint of the cement produced at the Airvault plant by
A rendering of the Heidelberg Materials Airvault cement plant after completion of its CCUS project. Pic: Heidelberg Materials
almost 30% compared to current production.
In January this year Hoffmann Green Cement Technologies signed a strategic partnership with Viavilla, a high-end real estate company specialising in the construction of villas on the French Atlantic coast.
Hoffmann says the partnership between the two France-based companies, which runs until the end of 2027, will make it possible to combine high-end and sustainable construction by offering low-carbon villas based on 0% clinker cements.
As a creator of luxury villas in the heart
“30-tonne trucks are integral to the French ADT market due to their ease of transportation to quarrying and aggregates job sites,”
of the most sought-after seaside resorts on the Atlantic coast, Viavilla joins forces with its investor partners to develop high-end real estate for seasonal rental. Based in Les Sables-d'Olonne in western France, Viavilla says it endeavours to combine strategic location, comfort and eco-responsible architecture in all its projects.
Paul Culliford, regional sales manager EMEA at articulated hauler manufacturer Rokbak
Julien Blanchard and David Hoffmann, co-founders of Hoffmann Green Cement Technologies, commented: "The distribution of our innovative clinker-free cements continues, and we look forward to seeing the development of Viavilla's low-carbon real estate programmes on our territory."
Also in January this year, Heidelberg Materials announced it had successfully completed the sale of its capital-intensive French cement transportation business Tratel to five regional transport specialists: Groupe Garnier in the North-West and Île-de-France region, e-b-trans in the SouthEast and South-West, Groupe DESERT in the West, and T2GL in the East of France.
Heidelberg Materials France will keep managing order intake, chartering, and dispatch activities, which it says will guarantee a seamless customer experience and interface. The financial terms of the transaction, which includes more than 450 trucks and around 770 trailers, have not been disclosed.
The building materials provider says the divestment of the French transport business enables it to place greater focus on key activities in its operations in France, and is part of Heidelberg Materials’ ongoing portfolio optimisation strategy of focusing on its core businesses in promising market positions.
Heidelberg Materials France is active in cement, aggregates, and concrete businesses with around 300 production sites. The company is currently implementing an ambitious modernisation programme across its main operations located in Airvault (Deux-Sèvres), Bussac-Forêt (Charente-Maritime), Beaucaire (Gard), and Couvrot (Marne) with the aim of substantially reducing their carbon footprint. An additional investment of €65m in the company’s Bussac-Forêt plant announced last year aims to accelerate innovative technologies with a focus on substituting cement clinker with calcined clay, thereby expanding Heidelberg Materials’ portfolio of low-carbon products.
Volvo CE’s Forget says companies in the French quarrying sector are increasingly recognising decarbonisation as not just the right thing to do but also as crucial for their success. They have implemented detailed environmental policies and set ambitious targets to mitigate the impact of quarrying on the environment.
“Our electromobility solutions can play a significant role in this endeavour. However, even with our conventional diesel-powered machines, customers in France are consistently comparing fuel consumption between manufacturers, especially for wheeled loaders, as a way to limit emissions,” he adds.
Beyond fuel efficiency, Forget says Volvo CE sees an opportunity to support customers in the French quarrying and aggregates sector to decarbonise through tailored combinations of services. “Every link in the value chain must work together to reduce
the environmental impact of the quarrying and aggregates industry, and we're eager to collaborate.”
He adds that digitalisation plays a central role in this effort.
“There is a clear need to decarbonise and despite the immense potential of electric machines to make significant cuts to emissions, it’s not an overnight switch, rather a gradual transition,” says Forget. “So it’s important we collaborate with customers now to increase the efficiency of operations with conventional technology as much as we can, while paving the way for the future.
“Digitalisation is central to decarbonisation, and can also help with the challenge of attracting and retaining skilled workers by making quarries a more appealing workplace. Automated processes, reduced administrative burdens, and the implementation of innovative technologies create a more modern and engaging work environment that can attract a wider talent pool.”
Forget says, however, there are some obstacles to the widespread adoption of digital solutions, such as the mindset shift required. Digitalisation requires adopting new ways of working and success hinges on clear communication of the business case and buy-in from everyone involved. It’s important for quarries to ensure that the entire team is on board, committed, and kept informed of tangible improvements and their impact on the bottom line.
“There’s also a misconception that implementing digital solutions in quarries requires a hefty budget or one-time
overhaul,” says Forget. “At Volvo, we're reshaping the perception that digitalisation is only feasible for those with substantial financial resources. Our subscription-based solutions empower customers to start their digitalisation journey regardless of budget constraints, enabling them to initiate smallscale implementations and refine their approach along the way, rather than waiting for the perfect plan.
“French quarry operators are looking for the machinery that offers the best fuel efficiency while meeting productivity targets. For working on the quarry face our 50-tonne class L350H wheeled loader with its new transmission is the ideal production machine.”
Three new mobile impact crushers and a screening plant from Wirtgen were commissioned by France-based Sylvestre Group at its quarry site in Robion, southeastern France. Taking on very different tasks and producing very different end products, the three new MOBIREX MR 110i EVO2 impact crushers with double-deck post-screening units have excelled with outstanding flexibility.
Sylvestre is a family-run business with a workforce of around 80 employees at different sites. The company’s fields of activity are diverse – ranging from quarrying to various recycling applications. When it came to expanding its fleet, Sylvestre made a big move: Three MOBIREX MR 110i EVO2 mobile impact crushers with double-deck postscreening units and a MOBISCREEN MSC 953i EVO classifying screening plant were purchased for use at different locations. AB
Julien Blanchard, chairman of Hoffmann Green's management board (left), with Viavilla CEO David Talon. Image: Hoffmann Green Cement Technologies
INCREASING SUSTAINABLE SAND AND GRAVEL SUPPLY
After investing in a new premium plant, Cemex’s Swinderby Quarry is poised to significantly increase its high-quality sand and gravel production. Guy Woodford reports
The new multi-million-pound state-of-the-art CDE plant looks impressive as you turn off the highway into Cemex UK’s Swinderby Quarry near Lincoln in England’s East Midlands.
I am visiting the around 450,000-tonnes-a-year site, Cemex UK’s biggest land-based sand and gravel operation, in mid-January 2024 as its giant new production plant is undergoing nal testing.
Quarry manager Vanessa Smithson, Kevin Cage, Cemex UK head of aggregates operations, and Mark Brown, Cemex Midlands aggregates operations manager, are talking to me in the quarry’s administration of ces before my Monday morning plant tour in the ice-cold winter weather.
The advanced CDE plant installation is Cemex UK’s largest sand and gravel-based site investment in the last decade. Increasing Swinderby Quarry’s prized Trent Valley sand and gravel output to up to 700,000 tonnes a year, the new plant features a CDE wash plant, CDE In nity screens, a Metso Nordberg GP100 cone crusher, two grading screens with Tema Isenmann screen media, a Wileman barrel washer, and circulating conveyors.
At the quarry face, sand and gravel are extracted by a Komatsu PC490LC-11 hydraulic excavator and fed into a 20-tonne hopper feeder by a Komatsu WA480 loading shovel. A 1.2-mile long, up-to-400-tonnesper-hour Canning Conveyor modular stringer eld conveyor system transfers the sand and gravel to the production plant. The conveyor system comprises a radial stockpiler and ve separate conveyors fed from the skidmounted hopper feeder.
The hopper infeed features a grizzly screen with a 150mm aperture to separate and collect the oversized product. Hydraulic cylinders actuate it to pivot up and eject collected material when necessary. The screen can also be unhooked and separated from the hydraulics for transportation.
At its maximum length, the Canning Conveyor will save an estimated 250,000 litres of fuel per year, the equivalent of taking 143 cars off the road. In addition to reducing the site’s dust and noise, Swinderby Quarry’s new production setup cuts CO2 emissions by around 50% per tonne of gravel and sand, in line with Cemex’s Future in Action programme.
Highlighting other reasons why Cemex UK opted for a CDE plant at its agship sand and gravel quarry, Cage says: “Part of
it was the size of the project and needing a manufacturer that could deliver what we wanted to our timescale. The price was right, and the software and AI [arti cial intelligence] element linked to plant operation and condition monitoring and maintenance was good. Of all the companies that tendered, CDE was the best supplier to meet our needs.”
When asked about choosing a Metso Nordberg cone crusher within the plant setup, he says: “Metso crushers are always well-engineered and good quality. You cannot fault them.”
Smithson notes that she and her team have been working closely with a CDE project engineering manager during the plant installation and testing. “Bad weather conditions did not help with installation. They had to dig down where the plant was going and build it back up. It delayed the project by four to ve months. Now, you look out there at the plant, and things are really good.”
Asked about what will happen to the current Swinderby Quarry plant, Cage says it will be stripped down and used in various locations across the UK as individual pieces of equipment.
Located on the old RAF Swinderby air eld, south of Swinderby village, adjacent
to the A46, Swinderby Quarry has a 0-40mm product range, with a 50-50 split between sand and gravel sales. Customers in Nottinghamshire, Lincolnshire, and Leicestershire purchase the products for largely concrete and asphalt production, with some of the products also used in Cemex’s ready-mix concrete and asphalt businesses. Smithson says the most popular products are 0-4mm sand and 4-20mm gravel. Ful lment is split between Swinderby Quarry’s customers, who collect their product orders, and the remainder delivered by the site’s 12-strong truck eet.
There is also planning permission for a third party to install a bagging facility within Swinderby Quarry to take a strong portion of the additional CDE plant-generated sand and gravel. Ten Cemex employees run Swinderby Quarry from 7am to 5pm Monday to Friday and 7am to 12pm on Saturdays. Smithson says an additional employee may be required due to the new CDE plant’s higher production volume.
CDE’s SmartTech suite of digital technologies, including SmartTech Prevention, which uses CheckProof as the platform, will help production run smoothly, partly by allowing swift and easy communication between Cemex
and CDE personnel. “Any defect alerts and maintenance scheduling will go through CheckProof,” says Cage.
Smithson explains that dewatering at Swinderby Quarry occurs “24/7” to keep pond sizes low and maximise work and stockpile material space. “If we have to top up the quarry’s freshwater lagoons, we can pump back water into them. We can do that with a two-valve system.”
A planning application has been made to start extracting material from another part of Swinderby Quarry within the next three years. The site has up to eight million tonnes of reserves.
A three-stage solar-panel installation is part of wider plans to decarbonise Swinderby Quarry’s production. The quarry is designated a Cemex Regenera site, a business specialising in providing circularity solutions to extend the lifecycle of products and materials by reusing them as value-added products.
“We have a very good relationship with neighbouring residents,” notes Smithson, formerly based at Cemex’s now-closed commercial sand and gravel extraction site adjacent to Attenborough Nature Reserve near Nottingham.
After seven years as Swinderby Quarry
The high-spec CDE plant at Cemex’s Swinderby Quarry. Pic: Andrew Higson
The old Cemex Swinderby Quarry plant (in the foreground) will be stripped down and used in various locations across the UK as individual pieces of equipment. Pic: Andrew Higson
manager, I ask her how her role has evolved. “Your hats are always changing, from working with staff and handling health and safety, well-being and development matters to carrying out machine checks. More checks need to be done now, as we have a massive asset out there that we need to maintain. We need to look at how much electricity we use. Every penny spent counts. We are busier than ever.”
Speaking about the high-spec plant installation at Cemex’s Swinderby Quarry, Colum Bryson, CDE head of operations – UK & Ireland, said: “While CDE is well versed in delivering large turnkey projects there were a few unique aspects in this project. We can accommodate two feed sources, whether from CDE’s L45 hopper or directly from Cemex’s existing network of land conveyors culminating in a radial stockpiler with motorised trouser leg chute. The CDE plant is designed to process 450-tonne feed as dug sand and gravel ballast which contains lignite. CDE will employ the use of two CFCU 200 upward- ow classi cation units to ef ciently remove lignite and accurately achieve the desired sharp sand spec.
“The CDE plant will produce two sands, one ne and one coarse. We have the unique ability to blend 0 to 100% of nes sand into the coarse sand via a motorised blending chute, which the plant’s main HMI controls can electronically operate. The CDE plant also incorporates a crushing loop for the +20mm product with a bypass option.
“As with most projects of this scale, CDE spent signi cant resources in the design and technical stage making sure the client speci cations were met. We worked with their project management team and also very closely with Vanessa and her operations team to ultimately get input from people who will run the plant to ensure they had their say. This process involved several site visits and remote workshops to ensure all parties were content with the plant.”
Bryson said CDE made a particular effort to ensure that Cemex Swinderby’s high H&S standards were met, many of which exceed the British Standard. “We paid particular attention to wear-liner access, removable lightweight guards, and extensive walkway access for maintenance. Extensive site lighting has also been provided so the plant can operate safely in the darker winter months.
“When site works kicked off, CDE worked closely with their CDM co-ordinator on-site during the build, ensuring that every personnel was kept safe during a complex build program involving cranes and assembly at height. We are now in the commissioning phase and producing materials with some ne-tuning and optimisation to deliver precisely to Cemex requirements. Our world-leading Proman project management methodology executed the entire project to help ensure we seamlessly coordinated and delivered each project phase alongside working with Cemex. We are now looking forward to full production.” AB
“Your hats are always changing, from working with staff and handling health and safety”
Feeding the 20-tonne hopper feeder with sand and gravel. The Canning Conveyor modular stringer field conveyor system takes the material to the production plant. Pic: Andrew Higson
Vanessa Smithson, foreground, Mike Brown and Kevin Cage on the new CDE production plant. Pic: Guy Woodford
Close-up of 4-20mm gravel stockpiled at Cemex Swinderby Quarry. Pic: Guy Woodford
Holcim subsidiary sales enliven East African cement market
Holcim has continued its African subsidiary divestments by selling two East African subsidiaries. The deals have alerted established regional cement producers and new sector entrants to commercial opportunities in an increasingly lively infrastructure market. Shem Oirere reports
Swiss cement giant Holcim Group’s decision to sell two East African subsidiaries is part of its transformation agenda focused on expanding its share of mature cement markets, especially North America.
Holcim said in November 2023 that it had signed agreements to divest its businesses in Uganda and Tanzania, two East African countries with high economic growth prospects and increasing competition among local cement makers and importers.
The largest cement producer in the world with a presence in 90 markets, Holcim has agreed to sell its Uganda subsidiary, Hima Cement, to Rwimi Holdings, a wholly owned subsidiary of Sarrai Group, a privately owned conglomerate in East Africa and Southern Africa, at approximately $120 million in a transaction to be completed in the first quarter of 2024.
Hima is 70% owned by Himcem, a subsidiary of Bamburi Cement and a member of Holcim Group. Hima has a total cement production capacity of 2.1 million tonnes annually with an integrated Hima Plant in Kasese, a blending station at Namanve Blending Station in Kampala and a grinding
station in Tororo, all in Uganda.
“The sale of these Sale Shares is in addition to the sale of the remaining 30% of the shares in Hima, which will simultaneously be sold by Cementia, a part of the Holcim Group, to the Purchasers,” said John Simba, chairman Bamburi Cement.
In Tanzania, Holcim, which targets achieving a 10% return on invested capital in 2025, has approved the sale of its majority stake in Mbeya Cement Company Ltd, popular for its Tembo cement brand, to Amsons Group, a group of family-owned businesses operating across various sectors in the East African country. Holcim’s 65% interest in Mbeya Cement is held through its subsidiaries, Pan African Cement of Mauritius (51%) and Lafarge Cement Zambia (14%). The government of Tanzania holds 20%, while the country’s National Social Security Fund (NSSF) holds the remaining 15%. Holcim has
not disclosed the value of the transaction.
“These divestments advance our strategy to consolidate our leadership in core markets as the global leader in innovative and sustainable building solutions. With the Sarrai Group and Amsons Group, we are pleased to have found strategic and trusted partners best positioned to develop these businesses long-term,” said Martin Kriegner, regional head of Asia, Middle East & Africa.
Both transactions are subject to regulatory approval.
Holcim’s divestiture coincides with emerging optimism about the region’s economic growth for 2023 and 2024. New tax policies are being introduced to rejuvenate local cement production and reduce the import bill, especially for Tanzania, Uganda, and Kenya.
Economic analysts predict strong economic growth for East Africa, reaching at least 5.1% in 2023 and potentially 5.8% in 2024, largely driven by a rebound in economic performance by Kenya, Uganda, and Tanzania.
For instance, the African Development Bank (AfDB) said Uganda’s growth in 2024 could expand to 6.5%, while Ethiopia, Kenya,
Workers at a Kenyan cement plant
Holcim is continuing its African divestments by selling two East African subsidiaries. Pic: Holcim
Djibouti, and Tanzania's expected growth is 5.8%, 5.6%, 5.4% and 5.3%, respectively.
The Bank said: “The rebound in the selected EA [East Africa] countries will be driven by the pandemic recovery in the services sector and the performance of exports.”
This anticipated strong economic growth could drive upwards the consumption level of cement triggered by increased public and private investments in cement-consuming sectors such as road construction and affordable housing programmes.
For instance, as of April 2023, Tanzania confirmed that more than 1,484km of new roads were under construction to bitumen standard. In Kenya, the government has unveiled an affordable housing project targeting 500,000 new houses by 2030. Such projects will likely catalyse high cement consumption in the short to medium term.
However, AfDB said, in the short term, several external and domestic downside risks could rattle this projected positive economic growth for East Africa, such as a global economic slowdown, further commodity price volatility, continuation of the conflict in Ukraine, a slowdown in international trade, tighter global financial conditions, rising debtservice costs, and the possible resurgence of COVID-19.
The AfDB said risks such as large gaps in infrastructure, expanded domestic conflicts and political instability, adverse climate change impacts, and a high level of macroeconomic uncertainty could impede economic growth and, hence, have a
direct correlation to the manufacture and consumption of building materials closer to home.
“Medium-term projections show that East Africa will continue to post the highest inflation rates in Africa although the inflation pressure is slowly easing,” the Bank said.
Although the AfDB predicts a decline in inflation to 21.8% in 2023, down from 28.9% in 2022, with a further fall to 17.7% in 2024, some countries, such as Tanzania, Kenya, and Uganda, are intensifying their tax policy reforms that could have a direct impact on the region’s building materials market, especially cement.
For instance, Tanzania has introduced a new excise duty on cement in the Finance Act 2023, both imported and domestically manufactured, at TZS 20 (US$0.008) for every kilo of cement. This translates to an excise duty of TZS 1,000 (US$0.39) for each 50kg cement bag.
An analysis by Ernest & Young stated: “The amendment may have adverse impacts on construction activities due to the increase
A budget analysis report by KPMG, a multinational professional services provider, also noted: “In essence, the price increment that consumers will feel is expected to be higher than TZS 1,000 (US$0.39) on each 50kg cement bag because cement is a standard-rated supply, which means that 18% VAT will apply on top of the introduced excise
“There is also a likelihood that the market price will deviate much from the ex-factory price since transport costs are likely to increase due to the increased road and fuel tolls by TZS 100 ($0.39) per litre of petrol and diesel,” it added.
KPMG stated that the taxation is likely to affect both real estate developers and other
builders, and “whilst the introduced excise duty is an income for the Government on one end, it may also increase Government expenditure on the other hand, especially in light of the ongoing strategic construction projects.”
Tanzania’s finance minister, Dr Lameck Mwigulu, said introducing excise duty on imported and manufactured cement would enhance policy stability and improve Tanzania’s investment climate. He announced TZS 20 ($0.0078) for every kilogram of imported cement.
“This measure is intended to increase government revenue to finance public spending, including cushioning environmental effects caused by the emission of carbon dioxide and other greenhouse gases,” he said.
Tanzania is expected to generate at least TZS 148 billion ($58 million) by June 2024.
Uganda has also imposed excise duty on cement at UGX 500 ($0.13) per 50kg bag.
Although cement manufactured within the East African region and imported into Uganda attracts no import levy, the importers have to declare the product and pay 18% VAT, a 6% withholding tax, and a 1.5% infrastructure levy, according to the Uganda Revenue Authority (URA).
For instance, URA says it collected over UGX I billion ($260,000) in taxes from cement imports from Kenya since July 2023.
Analysts see the exit of Holcim from East Africa as a response to the region’s increasing competition from competitors such as Nigeria’s Dangote Group, whose entry into the region led to increased production levels that surpassed demand, especially in Tanzania, where Dangote installed a three-million plant in Mtwara, about 400km from Dar es Salaam. The plant was commissioned in December 2015,
Martin Kriegner, Holcim regional head of Asia, Middle East & Africa. Pic: Holcim
A Bamburi Cement worker in front of a company truck. Bamburi Cement is a member of the Holcim Group. Pic: Bamburi Cement
becoming Tanzania's largest cement factory. The company estimates the limestone feeding the new plant has an estimated 500 million tonnes of limestone reserves, “enough for 149 years.”
Dangote’s new plant increased Tanzania's cement output to an estimated 6.5 million tonnes, up from the 2.8 million tonnes reported in 2014.
The Bank of Tanzania report stated: “The level of production is slightly above the estimated demand of 6 million tonnes, exposing the industry to price changes in the event of supply and demand shocks.”
Before Dangote entered the Tanzanian market, imported cement was equivalent to 7% of the country’s consumption but has since fallen to less than 3%.
The Bank added: “Large import volumes were observed between 2009 and 2015 when the government allowed cement imports to cover deficits, which caused soaring cement prices during that period.”
Tanzania restricted imports in 2016 by increasing the excise duty on imports to 35% from 10% at the instigation of the Tanzania Arm of East Africa Cement Producers Association.
Former finance minister Philip Mpango, the country’s vice president, said Tanzania opted to increase the import duty rate on cement to 35% to encourage and protect “local production of cement in the country against stiff competition from imported cement.”
Holcim’s divestiture from Tanzania and Uganda followed the June 2023 acquisition of Lafarge South Africa Holdings by South African mining and materials major Afrimat at an estimated purchase price of $6 million.
Afrimat said the acquisition forms part of its ongoing diversification strategy and will increase its offering in the construction industry “by expanding our quarry and ready-mix operations nationally and allowing Afrimat to enter the cement value chain competitively.”
Afrimat will pay an additional ZAR900 million ($48 million) as “repayment by or on behalf of LSA of an amount owing by LSA to the Holcim Group.”
Holcim’s divestments from Uganda and Tanzania were the first in 2023, following the company’s January and May 2022 divestments in Northern Ireland, where it sold its cement business to Cookstown Cement Ltd and invested in a joint venture in Cuba.
The sale of its 76.45% stake in Lafarge Cement Zimbabwe to Fossil Mines was completed in December 2022.
Previously, Holcim sold its stakes in
Lafarge Zambia and Lafarge Cement Malawi to Chinese cement producer Huaxin Cement for $150 million and $10 million, respectively. Huaxin acquired a 75% stake in Lafarge Zambia and 100% of Pan African Cement from Lafarge Cement Malawi.
With the divestments in Africa so far, Holcim’s footprint in the continent’s cement business continues to shrink as the company appears focused on expanding elsewhere and growing its new roofing business.
Holcim’s recent divestments in East Africa create new investment opportunities for new entrants in the market with a likelihood of intensified competition as existing industry players are expected to put up a tough fight to protect their share of the market.
key concern for many of East Africa’s cement
The AfDB believes several external and domestic downside risks could rattle short-term projected positive economic growth in East Africa. Pic: Timon Schneider, Dreamstime.com
A Hima Cement factory in Uganda. Pic: Hima Cement
ABOVE: Analysts see the exit of Holcim from East Africa as a response to the region’s increasing competitiveness from competitors such as Nigeria’s Dangote Group. Pic: Piotr Swat, Dreamstime.com
Advance of the electric loaders
All-electric wheeled loader rollouts are gathering pace with the latest at a concrete company in Sweden. Advances in diesel -engine technology are also providing benefits in fuel and operational e ciency to quarry operators. Liam McLoughlin reports
Thomas Concrete Group has introduced series-produced, fullyelectric wheeled loaders to two of its subsidiaries in Sweden.
The two new machines will be utilised at Thomas Betong's plant in Västerås and Thomas Cement's port, Stockholm Bulkhamn, in Stora Vika. These heavywheeled loaders are expected to reduce operational costs and the group's carbon footprint.
This strategic development initiative marks the company as the rst concrete supplier in Sweden to adopt fully electric wheeled loaders. The aim is to build expertise in electri cation and further strengthen Thomas Concrete Group's sustainability efforts and industry innovation.
"In 2021, we were the rst in Sweden to begin using series-produced 100 per cent electric-powered concrete trucks. We're taking the next step by introducing fully electric wheeled loaders in our commitment to lead in sustainability, innovation, and industry development. This is another milestone, and we are proud to be the rst concrete supplier in Sweden to take this step," says Hans Karlander, CEO of Thomas Concrete Group.
The two 21-tonne electric wheeled loaders, LiuGong 865E, operate entirely on electricity. Each is equipped with a 423-kWh battery, which can run for 12 hours for lighter applications and nine hours for heavier ones.
The wheeled loaders feature fast-charging capability and are equipped with a CATL battery pack and control system, meeting the highest European standards. Additionally, the electric wheeled loaders are expected to reduce operational costs compared to dieselfuelled machines of the same type. Rental Group supplies the wheeled loaders, which will be leased for 12 months for evaluation purposes.
"This is truly inspiring as it gives us the opportunity to build knowledge and learn more about how fossil-free, heavyconstruction equipment operates in everyday scenarios, both in a bulk port and at a concrete plant. These lessons will bene t our other subsidiaries in Europe and notably in the USA. By utilising electric wheeled loaders, we continue to reduce our carbon footprint and lead the way towards a more sustainable construction sector," concludes Karlander.
Max Wild, based in Berkheim in BadenWürttemberg, Germany, has added a new Develon DL420CVT-7 wheeled loader to its eet. The company tested the machine, and the drivers' feedback was very positive. The local authorised Develon dealer, Süddeutsche Baumaschinen Handels, supplied the DL420CVT-7.
When Roland Wild, managing director of Max Wild, and Thomas Macho, regional sales manager for Süddeutsche Baumaschinen Handels, talked about purchasing a new wheeled loader in the class with a 4m³ bucket
volume, Macho suggested the DL420CVT-7 from Develon. Since Max Wild had already had a machine from Develon (formerly Doosan Construction Equipment) in the company for several years, which had left a good impression, Max Wild decided to take a new DL420CVT-7 for testing for two weeks.
After the drivers' positive assessment, the machine was taken on long-term rental at the end of the rst test period. When the performance was convincing in the second rental period, the in-house paint shop purchased and repainted the wheeled loader in Max Wild's green company colours.
Roland Wild says: “Our drivers have a right to have a say in the selection of our machines. When they expressed their satisfaction with the wheeled loader after the initial test period, we continued testing the DL420CVT-7 on a long-term rental. When the wheeled loader was also convincing in this period, we nally decided to buy it.”
One of the operators adds: “The performance of the machine was top. For me as a driver, the machine is also very comfortable to use, and together with the low fuel consumption, that absolutely convinced me.”
The new wheeled loader is used in the company's gravel pit. Here, the machine usually performs continuously for eight hours a day. The main tasks range from truck loading to direct quarrying to feeding the screening plant. Wild says: “In the 3 months since purchasing the machine, we have achieved an average fuel consumption of 12.4 l/h. That is a very good value. We haven’t had any interruptions as the wheeled loader has proven to be very reliable.”
One of the main reasons for the
Thomas Concrete Group has introduced LiuGong fully-electric wheeled loaders to two of its subsidiaries in Sweden. Pic: Thomas Concrete Group
machine's excellent fuel ef ciency is its CVT transmission. Marc Glesius, sales manager GSA at Develon, says: “The advantages of a mechanical and hydrostatic transmission are combined, eliminating the disadvantages of both systems. The variable transmission changes continuously from the hydrostatic to the mechanical drive as the speed increases depending on the operational requirements.
“The system's advantages include, in particular, the excellent traction offered by a hydrostatic transmission and the ability to drive over longer distances with a purely mechanical transmission. The fuel savings of up to 30% are thanks to the lower engine speed than conventional transmissions, which is necessary to achieve maximum speed and traction.”
Roland Wild adds: “The combination of the two drive types makes the wheeled loader optimal for the work that needs to be done in its area.”
Max Wild offers its customers a wide range of services under the motto ‘Professionals without Borders’. Based in Berkheim, the company has been ensuring the professional and sustainable implementation of numerous services in construction, demolition, the environment, recycling and logistics since 1955. The company is now being run by the founder's children and grandchildren and with the support of 650 employees and more than 60 trainees. The company's own machinery now includes around 200 construction machines from small to large and around 100 trucks. This does not include the construction equipment in the recently founded rental eet. The company has its own workshop, ‘The Workshop’, which employs around 50 people. ‘The Workshop’ works on its own machines and offers other customers workshop services, including the paint shop.
Founded in 1991, Develon dealer BAU Süddeutsche Baumaschinen Handels has been a dependable partner of Max Wild for many years. More than 120 employees support the dealer’s customers at seven locations in Germany and Austria. The company relies on many years of experience
and expertise in rental, sales and service. The distinctive service concept begins with expert advice on technology and nancing and ends with fast and reliable construction machinery maintenance. As a successful partner, the company offers tailor-made solutions for every application and need that meet the high demands of their customers.
The recycling specialists at Hans Dömkes process more than 160,000 tonnes of mineral waste each year.
Three Liebherr wheeled loaders feed the delivered construction waste to the screening and crushing plants and heap the sorted material at the numerous storage areas on the site. The recycled building materials are then loaded onto trucks by an L 576 XPower with High Lift arms. The High Lift variant, available on customer request, offers increased reach and ef cient loading at height. The recycled building materials are then reused in road construction and concrete mixing, as well as in gardening and landscaping.
More than a decade ago, Udo Dömkes, managing director of Dömkes, opted for a Liebherr wheeled loader, leading to a partnership that continues today. "Back then, as now, we were impressed by the much lower fuel consumption yet higher performance compared to other wheeled loaders in the same class size. Our XPower wheeled loaders currently consume an
average of eleven and a half to twelve litres of fuel per hour when heaping, reloading, and when feeding the screening and crushing plants," says the entrepreneur.
The fuel ef ciency of the XPower generation of wheeled loaders is due to the power-split XPower travel drive, which combines hydrostatic and mechanical propulsion. Hydrostatic power dominates when starting up and during short-loading operations. When travelling at higher speeds and uphill, mechanical power comes more into play. Together, both components always transmit 100% of the diesel-engine power, while only the ratio between them changes. This means the wheeled loader always operates at maximum performance and ef ciency, whatever it is being used for. The result is up to 30% of fuel savings compared to conventionally driven wheeled loaders.
Markus Schepers, the Liebherr wheeled loader operator at Dömkes, adds: "The XPower drive system not only ensures low fuel consumption but also a very comfortable ride. When heaping material, the wheeled loader automatically and smoothly shifts between travel ranges, depending on how much force is required. This makes the work easier for the operator. In addition, numerous systems provide day-to-day assistance and ensure a safe working environment.
An example of this is the active personnel detection with brake assistant, which reacts as soon as anyone comes close to the rear of the wheeled loader. An alarm sounds, and the brake-assist system automatically reduces the speed of the wheeled loader."
The intelligent installation of the components and cleverly designed access to the engine compartment are designed to ensure ef cient maintenance work on the Liebherr wheeled loaders. All installed parts that need to be serviced can be reached safely and quickly. This saves time and money. Udo Dömkes is also convinced of this: "The quality of the Liebherr machines speaks for itself. Very rarely do we need a Liebherr service technician on-site, and when we do, help is guaranteed within 24 hours. This means that downtimes can be minimised. We feel excellently looked after." AB
The new Develon DL420CVT-7 wheeled loader at the Max Wild gravel pit in Germany
Dömkes has deployed three new Liebherr wheeled loaders
Autonomous hauling for today and tomorrow
A big advance in driverless hauling and useful advice on choosing the right articulated dump truck for your working needs. Guy Woodford reports
AUK-
rst project centred on an autonomous ADT designed to help future-proof the effectiveness and competitiveness of quarrying operations within the minerals and aggregates sector was recently showcased to a large crowd of industry representatives.
The development of autonomous driving capability opens the door to a range of operational ef ciency, safety, environmental, and employee bene ts that will underpin the sector in the future.
Chepstow Plant Plant International (CPI) and Bell Equipment initially conceptualised the project following long-term trials between Bell Equipment and technology-platform specialist xtonomy.
CPI identi ed Sibelco, a long-term, valued, strategic customer, as the ideal partner to bring the project to reality in a live-working quarry environment. Collectively, the four key stakeholders have collaborated to develop and launch an innovative quarry transportation proposition that has its eyes on the future.
The venture's launch event on 14 March 2024 was held at Sibelco’s china-clay Cornwood quarry in Devon, southwest England. Key industry guests were invited to witness a full demonstration of the new autonomous solution in a working quarry setting.
Interactive presentations highlighted innovative onboard hardware and software technologies, including robust radar sensors, high-precision GPS, multi-channel
communication systems and onboard processing hardware. Economy has incorporated them into a standard B40E dump truck to create an autonomous-ready, drive-by-wire B40E solution.
As a result, the combination offers true and safe autonomy with a resilient navigation system that dynamically plans ADT paths and predictively controls the vehicle around the entire quarry site.
Among the key objectives of this pilot scheme will be to demonstrate the potential to reduce vehicular incidents and subsequent accidents and upskill the existing workforce to further support the future of quarry operations.
Operational ef ciencies will be enhanced as the autonomous ADTs can operate longer during the working day, deliver highly accurate tipping results, and ensure that the existing quarry shift patterns can be tailored to improve productivity. Further bene ts will be available thanks to improved component life and reduced wear and tear on the Bell B40E dump truck, leading to improved asset availability for the quarry.
Environmental advantages will also be leveraged through the AI-enabled transformation. With enhanced driving accuracy and ef ciency across the quarry, less fuel will be consumed, helping to reduce carbon emissions caused by a
quarry’s daily activities.
To further enhance the autonomous ADT's impact on the environment, the Bell B40E uses HVO instead of diesel. This pushes the machine to be as near ‘carbon-neutral’ as possible within the quarry and mining sector.
John Corcoran, managing director at Chepstow Plant International, said: “CPI is delighted to be involved in this exciting and UK- rst collaboration, one focused on a next-generation adventure to ensure UK quarries continue to maximise operational ef ciencies and remain competitive. It is important that stakeholders come together in this way to drive advancements and support the industry’s prospects whilst continually remaining committed to our safety standards and net-zero commitments.
“We are sure that this Pilot project will deliver progress and further challenges, both of which will provide the pathway towards the ultimate goal.”
The Bell B40E dump truck features an autonomous-ready, drive-by-wire solution. Pic: Bell Equipment/Sibelco/Chepstow Plant International/xtonomy
Ben Uphill, director of operationsKingsteignton Cluster at quarry-owner Sibelco, said: “We envisage many bene ts from having access to this sector- rst autonomous ADT solution. The minerals & aggregates sector must embrace technology to continually deliver improvements across our daily operations and cost base. At Sibelco, we strive for continuous improvement, focusing on safety and the environment through energy ef ciency and CO2 reduction. Automation is used in many parts of our operations and business to maximise ef ciency and manage skills shortages. This has been a fantastic example of collaborative ethos from all partners and has resulted in a safe and productive autonomous driving setup for a key part of our operations.”
the quarrying sector, and we are pleased that our evolutionary E-series and the B40E dump truck sit at the heart of this innovative project. The ability to transform our marketleading vehicle through added technology functionality into a safe, robust, effective, and autonomous quarrying asset is welcome. It sets the standard for future developments across our vehicle range.”
Nic Grout, managing director at Bell Equipment, said: “Bell Equipment is a leading supplier in the ADT market and, as such, is proud to be part of this exciting project. Its success can help transform the future of
Dr Christian Riedel, CEO at xtonomy, said: “Supporting the quarrying sector through the appliance of result-orientated automationplatform solutions is a key commitment for the business. Expectations and needs are changing as the industry looks to transition to a future where improved ef ciency, better safety, and targeted environmental considerations are key priorities. Our AI technology incorporated onto the already successful Bell B40E dump truck evolves it to a next-generation payload transportation blueprint.”
Articulated haulers are crucial in various applications, from commercial construction projects to quarries, mines and infrastructure developments. The best ADTs offer ef cient transportation of heavy loads across challenging terrain and easy manoeuvrability on tight, tricky sites. Before investing in an articulated dump truck, it's essential to consider several factors to ensure that the machine aligns with your speci c needs and operational requirements. With its trucks designed and built for the toughest jobs and roughest sites, Scottish articulated hauler manufacturer Rokbak outlines ve key considerations that should be integral to your purchasing decision.
Capacity and load handling
One of the primary factors to consider is the truck’s hauling capacity. You need to assess typical load capacity and weight to ensure that the chosen equipment can handle the
Rokbak has outlined five key considerations that should be integral to an ADT purchasing decision. Pic: Rokbak
speci c application's demands. Rokbak offers two hauler models: the RA40 is the largest, with a gross power of 331kW, a maximum torque of 2,225 Nm and a 38-tonne payload. It is a popular choice for major infrastructure projects, with its effective power-to-weight ratio enabling the fast movement of heavyduty materials. Like the RA40, the 28-tonne RA30, with a gross power of 276kW and a maximum torque of 1880 Nm, also bene ts from a transmission retardation system, a fully adaptable drivetrain and easy maintenance to suit a variety of different job sites.
Consideration of the type and size of material being handled allows the truck's load-carrying body to be speci ed correctly to ensure optimum payload, load retention and longevity. Body options such as side extensions for lighter materials, tailgates for free- owing material retention and additional liner plates for highly abrasive or large blasted rocks are all popular. Matching the hauler to existing complementary equipment ensures onsite ef ciencies and safety.
Terrain and site conditions
Articulated haulers are designed to navigate challenging terrain, but the extent of their capabilities can vary. Both the RA30 and RA40 provide excellent performance in all hauling conditions, from muddy terrain to slippery slopes and the scorching heat to sub-zero temperatures. It’s important to evaluate the application and climate the truck will be used in, as well as consider the materials that will be transported and the site's topography, including slope gradients, ground conditions and potential obstacles. Rokbak trucks offer top-level off-road performance. Choosing a hauler that can handle the site's speci c conditions is crucial for optimal ef ciency and safety.
German contractor Stefan Jodlbauer has invested in its first HD Hyundai HA30 articulated dump truck. Pic: HD Hyundai
Fuel ef ciency and operating costs
Operating costs, including fuel consumption and maintenance, are signi cant considerations for any heavy-equipment investment. Ef ciency in the use of power is as important as having a high-performance truck. Rokbak articulated haulers are built to perform while also setting new standards for total cost of ownership and a commitment to sustainability as part of the Volvo Group’s journey to net zero. A lean-burning, high-performing engine and responsive transmission shift control are good for low fuel consumption and environmental impact – as well as increased uptime and extended service intervals. An adaptable, perfectly
balanced drivetrain provides performance and productivity in all hauling conditions, while meeting worldwide emission standards with low cost of operation.
High-level, user-friendly retardation systems, as found in Rokbak trucks, facilitate control of the machine and allow the operator to manage the safety and speed of the hauler – increasing ef ciency and reducing wear-and-tear with shorter cycle times on the haul route.
Machine owners should also look for strong after-sales support and assess the availability of spare parts and maintenance services. A well-supported machine will lead to increased uptime and lower operating costs throughout the equipment’s lifecycle.
Operator comfort and safety
The well-being of operators is paramount in any heavy equipment operation. Features such as ergonomic design, operator visibility and the quality of the cabin environment provide a
Articulated haulers are designed to navigate challenging terrain, but Rokbak notes that the extent of their capabilities can vary. Pic: Rokbak
comfortable and safe workspace that not only enhances productivity but also contributes to employee satisfaction and retention. A planetary gear transmission – as found in the RA40 to deliver smooth, ef cient gear shifting – also increases operator comfort. Haulers equipped with safety features such as stability systems with traction control, body tip inhibits and advanced braking mechanisms help to ensure a secure working environment.
Connectivity
Modern articulated haulers often come equipped with advanced technology and telematics solutions. These features can provide valuable insights into machine performance, fuel ef ciency, and maintenance needs, helping machine owners manage their operating costs. The RA30 and RA40 are linked to the Rokbak Haul Track telematics system, providing customers with complete visibility and control of the hauler. This enables you to monitor and manage eets effectively.
German contractor Stefan Jodlbauer, from Engertsham near Passau, has put its rst HD Hyundai HA30 articulated dump truck (ADT) to work in the toughest conditions, hauling six days a week through 500mm deep ruts.
In its rst two weeks of operation, the machine contributed to the movement of 10,000 tonnes of ne loess soil on a site in Ehol ng. This soil, covered with topsoil, has been distributed over around 15,000m².
The 30-tonne capacity HA30 was launched at bauma 2022, and Jodlbauer was one of the rst in Germany to add the machine to its eet. The contractor is primarily involved in demolition, earthworks and civil engineering.
“Tractors with trailers or four-axle trucks cannot do this work,” said the experienced muckshifter.
The ADT is loaded in eight cycles by an 18-tonne HD Hyundai excavator, and the two machines are maintained and supported by local HD Hyundai dealer Mörtlbauer Baumaschinen.
Operator Philip Müller has been particularly happy with the new machine, saying: “It is quiet, the transmission shifts smoothly, and the machine can get through everywhere. In dif cult terrain and constantly fully laden, it consumes around 16-18 litres of diesel per hour, which is a good value.”
Jodlbauer was impressed by the performance, too, along with the ergonomic cabin and the tailgate, which allows full loading of the dump body. With optional integral body heating, the chance of material sticking to the bottom of the dump body has also been minimised.
The HA30’s compact chassis results in a very small turning radius and outstanding stability. The front axle's self-levelling hydropneumatic suspension supports comfortable driving and facilitates steering in dif cult ground conditions. The two rear axles work
with a tandem bogie design, a single-centre differential, and a double internal gear drive on each side of the dumper. Thanks to the extreme articulation angles that can be achieved, the four rear wheels maintain good contact with the ground even on dif cult terrain.
The HA30 has near-perfect weight distribution, with a slanted rear frame providing stability through better load distribution for a low centre of gravity. The tandem bogie delivers high ground clearance and rst-class traction, and the machine has an innovative transmission design for a shorter front end. This allows the articulation joint to be mounted close to the front axle for even weight distribution from front to back and across the front axle when steering.
The HA30A has a body capacity of 16.8m³, which increases to 17.8m³ with the tailgate. Body heating is optional. Wear plates are also available to transport more abrasive material.
An eight-speed ZF automatic transmission with an integrated retarder delivers power to the wheels, and the torque converter, with lock-up in all gears, reduces fuel consumption. For greater constructionsite safety and fuel, AdBlue and a standard automatic lubrication system are accessible from the ground. The engine cover also tilts forward for access to lters and lling points, while the entire cab structure can tilt toward the rear of the dumper to allow access for repairs and maintenance. AB
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Aggregates washing goes mobile
Mobile aggregates and sand-washing equipment is increasingly in demand from customers who want to process closer to the point of use and those with multiple processing sites. Liam McLoughlin and Guy Woodford report
Customers looking for washing plant equipment often have two requests for manufacturers – some want the ability to process closer to the point of use, while others seek equipment that can be used at multiple sites with low volumes or multiple sites that have restrictions on further planning or permitting.
Eunan Kelly, head of business development for Europe at Northern Ireland-based wet processing equipment experts CDE, observes that customers are increasingly seeking mobile capability in their washing plants. He adds that mobile plants also enable operators to access urban or mountain areas or the need to quickly recover material, resulting in the possibility of generating a faster return on investment, especially for waste-type material.
The ability to process material closer to the point of use is a major attraction of mobile plants, as it reduces the carbon footprint and need to move material longer distances, which in turn cuts transport costs and makes the project more pro table for the user.
“The demand for mobile plants can come from those who are nding it dif cult to achieve the static wash permits and planning,” Kelly states. “It’s also aimed at the eet operators who can go in and do a short-term contract that’s either standalone or complements their crushing and screening.”
FreeFlow is a fully-mobile washing solution for aggregate and sand classi cation. Designed and built on a trailer for optimal mobility, the mobile plant helps achieve maximum in-situ material recovery. With integrated water storage and recycling, FreeFlow bene ts from a closed-loop water system to maximise water recovery and recirculation.
To meet the growing desire for mobility, Cookstown, County Tyrone-headquartered CDE has recently brought in a number of new and improved features to the FreeFlow mobile plant, that offer materials producers even greater exibility and processing capacity. Its all-on-one chassis is designed and built onto the bed of a semi-trailer. With a removable three-axle bogie approved for road use in Europe, FreeFlow is designed to provide unrivalled mobility so operators can, with greater ease than ever before, relocate their mobile plant across multiple sites or to remote locations. On-board system control and integrated 55kW power generator mean an external connection isn’t required, allowing for highly ef cient plant set-up between sites.
exibility to process more material and is particularly ideal for crushed feed material which was before limited to 20t. Separation ef ciency and yield better for high percentage of silt.
CDE says that, with a capacity of up to 70 tonnes per hour (tph), FreeFlow supports superior recovery and retention across a wide range of feed materials, including sand, gravel, crushed rock, scalpings, manufactured sand, and overburden.
In addition to its ability to produce an extensive suite of high-quality washed construction materials, the FreeFlow has now been upgraded to include dual sliding conveyors to offer even greater exibility and improve capacity for a wider range of end products.
CDE says its FreeFlow mobile washing plant has proven particularly suitable for multi-site quarries companies, equipment rental or hire businesses, and road works and temporary site works.
The upgraded FreeFlow now also has an option to have a cyclone with a bigger diameter (400ml instead of 325ml). This increases the capacity and provides the
Removing the need to manually blend materials with a loader, the integration of dual sliding conveyors enables materials producers to expand their product portfolio with new mixed ne sand and coarse products – up to 4mm for sand fractions and up to 32mm for aggregate fractions –while also delivering improved operational ef ciency by eliminating the double handling of materials. In addition to its new dual sliding conveyors, the latest generation of FreeFlow also bene ts from improved cyclone capacity. Materials producers can now opt
for a cyclone that is almost 25% larger in diameter, helping to further improve the flexibility and profitability of an operation by significantly increasing processing capacity. The new cyclone design is ideal for crushed feed material and enhances separation efficiency for maximum yield.
FreeFlow houses all five processes on its single trailer, from screening and washing to dewatering, desliming and water treatment.
The FreeFlow mobile plant has been mostly marketed in Europe including the UK so far.
Drawing on over 30 years’ expertise in wet processing solutions, CDE says the FreeFlow is the pinnacle of mobile washing technology in its equipment range and reflects the company’s commitment to researching and developing solutions that respond directly to the needs of the market. Its main innovation resides in that it is entirely mobile, with a compact chassis to minimise site footprint and offer ultimate portability. It is also pre-tested and pre-wired before dispatch so it’s ready to go straight away.
“The FreeFlow plant was initially almost like a solution to a problem that one particular customer had,” he adds. “They wanted to travel around the UK with their contracting division and wash road chippings. We encompassed all of the proven technology – the dewatering screens, the cyclones and water treatment – and built that onto a trailer for mobility and low footprint impact, but still with the same output efficiency and effective washing.
“That was developed into a product and we discovered a growing interest and demand for mobility.”
Kelly adds that mobility has been a core feature of CDE’s design ethos to date and its portfolio offers different degrees of flexibility to suit various applications, from 5 to 1200tph: fully mobile plant (FreeFlow, D:Max,
MSU10G) and semi-mobile (M-Series), all being modular and scalable solutions.
“We've delivered FreeFlow plants to the UK, France, Austria, Germany. And now we realise the potential demand and the interest that we're receiving for the revised plant,” he says.
“From the first FreeFlow to the one that we have now, we've made a number of process improvements and efficiency improvements. We have moved the legs of the sliding conveyor to the front, which allows you to either make two separate products or blend one of the products and to make a different spec.”
The upgraded FreeFlow plant is available globally and its 3-axle semi-trailer is already suitable for transportation on both UK and EU roads.
The aggregates washing division of Molson Group has recently added an upgraded FreeFlow plant to its fleet in the south of England, with the mobile capability being a major factor in the decision.
Kelly says major customers for FreeFlow include fleet operators who use it to complement their crushing and screening plant on projects including road planings and utility works. Customers also include quarry site managers, quarry owners, project managers, operations managers, purchasing managers and operators, contractors, construction managers, construction contracts managers, and construction plant hire advisers.
Kelly says that there is demand for both static and mobile plants from customers to respond to different needs - feed materials/ location/production needs and capabilities.
“Most new projects are done on a longterm feasibility study, and generally only entered into when there is a significant resource available, so that will be a very permanent static build,” he says.
In terms of current developments in the washing plant sector, CDE business development executive for the South of England Thomas Doyle says there is an increasing move in the UK and Europe towards data-driven processes to fully monitor a plant’s production process.
“Our SmartTech plant management app enables customers to be very invested in what's gone into the plant, alerting them in real time about what resources the plant is using, what products are being produced out of the plant and what is being consumed to do that,” Doyle says.
He explains that enhanced water recovery and re-use is a major issue in parts of the world where water is a scarce resource. “Reusing as much of that water in the washing plant as possible with minimal additional water being required is a very important issue, but without sacrificing any of the product quality,” Doyle adds.
Kelly says that CDE’s nearly two decades of experience in waste recycling means that it has successfully been able to develop its technology to adapt to current complexities and challenges that are making the recycling of waste material more difficult. This includes a poorer quality of material available in the market with higher contamination levels, higher clay levels, and that is more variable in terms of the physical and chemical characteristics.
He cites the reduction of PFAS (per-and poly fluoroalkyl substances) chemical contamination in water as one of the most high-profile issues: “We have a project at the moment live at Antwerp in Belgium with one of the biggest construction companies in Europe where there is a massive PFAS issue that has come from a chemical factory. That environmental disaster has been processed through a CDE tertiary watertreatment plant reducing the PFAS in the soil, and we are putting the soil back in situ again. That has been a challenging project
Eunan Kelly, CDE head of business development for Europe. Pic: CDE
The FM 120BW bucket wheel’s automated processes help make Hoddam Quarry & Concrete Products' washing operations more efficient. Pic: Hoddam Quarry & Concrete ProductsTerex Washing Systems
Kelly says that a number of major construction and infrastructure projects in Europe and globally are proving major opportunities for CDE’s washing plant business, including the upcoming 2024
He also cites the massive Fehmarnbelt project building an 18km immersed tunnel located 40m beneath the Baltic Sea that connects the Danish island of Lolland with the German island Fehmarn. On completion it will be the world's largest immersed tunnel, featuring a two-track railroad and a four-track
“A number of our customers are supplying sand products to the infrastructure and road network around the tunnel,” Kelly says.
Kelly and Doyle state that the main interests in the washing industry currently lie in: increasing the processing capacity; the quality of output produced (e.g. smart sand treatment); processing dif cult material/a wider range of material (for instance: solidliquid waste, trommel nes, contaminated waste, road sweepings); data-driven solutions to drive ef ciency and reduce operational costs (digitalisation/smart tech); and enhanced water recovery and effective use of plant footprint.
Hoddam Quarry & Concrete Products, a long-standing, family-run business headquartered in Dumfriesshire, Scotland, has been a key player in the building materials and concrete-supply industry since its inception in 1958. The company boasts a diverse portfolio of quarry materials and quality-assured ready-mixed concrete.
With a commitment to serving a wide range of clients, from large construction rms to individual homeowners, Hoddam Quarry & Concrete Products operates two sand and gravel quarries at Kilblane and Broom, along with a recently inaugurated hard-rock quarry at Hazelbank, St. Ann’s.
In 2022, Hoddam Quarry & Concrete Products faced the challenge of upgrading their existing wash plant at the Hoddam site. The goal was to enhance ef ciency, increase
Hoddam Quarry & Concrete Products-Terex Washing Systems
product variety, and streamline operations while maintaining the highest quality standards in their offerings. The previous wash plant was becoming outdated, leading to inef ciencies in production and limited product options.
In partnership with Terex Washing Systems and their local dealer, Blue Machinery (Scotland), Hoddam Contracting opted for a wash-plant setup featuring the Terex Washing Systems M2100 and FM 120BW. This new installation revolutionised their washing processes, producing ve distinct products: 2mm sand, 4mm sand, 4-10mm aggregate, 10-20mm aggregate, and 20-40mm aggregate, including a specialised type 1 product.
The Terex M2100 is a high-capacity mobile washing unit that offers exceptional exibility and ef ciency. It is designed to work independently or as part of an entire washplant system.
With its robust construction and easy setup, the M2100 allows for quick deployment and relocation as needed, making it ideal for Hoddam Quarry & Concrete Products' dynamic operations.
The machine features a triple-deck screenbox with a choice of modular top and middle decks, allowing for the simultaneous production of various products.
Terex Washing Systems FM 120 Bucket Wheel is a compact, versatile bucket-wheel system for ef cient material classi cation and washing.
Operating as a single or twin sand plant, the FM 120BW effectively removes silts, slimes, and clays from the nal product, ensuring superior quality.
Its modular design and adjustable weirs allow Hoddam Quarry & Concrete Products to easily adjust product speci cations.
The M2100, in conjunction with the FM 120BW bucket wheel, allows Hoddam Quarry & Concrete Products to produce a diverse range of products. The M2100's
triple-deck screenbox and modular design, combined with the FM 120BW's ef cient material washing, allow for the simultaneous production of multiple products.
The M2100's easy setup and operation and the FM 120BW's automated processes streamline Hoddam Quarry & Concrete Products' washing operations. This simplicity of operation reduces operator training time and minimises downtime.
The M2100 and FM 120BW are known for their robust construction and reliable performance. Hoddam Quarry & Concrete Products can depend on these machines to deliver consistent results, ensuring customer satisfaction with the quality of their products.
Partnering with Blue Machinery (Scotland) Ltd brought numerous advantages to the project:
Being local meant Blue Machinery (Scotland) could provide swift assistance with routine maintenance or unforeseen technical issues.
The Blue Machinery (Scotland) team understood the unique requirements of Hoddam Quarry & Concrete Products operations and offered tailored solutions and expert advice.
Direct communication channels facilitated quick responses to queries and ensured minimal downtime for the wash plant.
Graeme Farish, manager of Hoddam Quarry & Concrete Products, said: "Terex Washing Systems and Blue Machinery (Scotland) have exceeded our expectations with installing the M2100 and FM 120BW wash plant at our Broom Quarry. The plant's ability to produce ve distinct products has been a game-changer for our operations. We are particularly impressed with the simplicity of the setup and the plant's reliability.
“The Terex M2100 and FM 120BW work seamlessly together, providing us with the
The Terex Washing Systems’ plant setup for Hoddam Quarry & Concrete Products. Pic:
versatility to meet the demands of our diverse clientele. Having the local support of Blue Machinery (Scotland) Ltd gives us peace of mind, although we haven't needed it yet, thanks to the plant's robust performance. We are so satis ed with the results that we have installed another FM 120BW at one of our additional sites.
“Hoddam Quarry & Concrete Products looks forward to a continued partnership with Terex and Blue Machinery (Scotland) Ltd as we focus on delivering top-quality products to our diverse clientele."
The collaboration between Hoddam Quarry & Concrete Products, Terex Washing Systems, and Blue Machinery (Scotland) is a testament to the success achieved through innovative solutions and local support. The installation of the M2100 and FM 120BW wash plant not only met but exceeded the customer's expectations, enabling increased product variety, streamlined operations, and enhanced ef ciency.
As Hoddam Quarry & Concrete Products continues its commitment to quality and sustainability, it can rely on the expertise of Terex Washing Systems and the dedicated support of Blue Machinery (Scotland) Ltd to drive its success into the future.
Goonvean aggregates. is a privately owned, family-run aggregate supplier based in Cornwall, southwest England. Founded in 1931, Goonvean Aggregates serves a wide range of markets, including construction, sports, agriculture and more, with a variety of products, such as sub-bases and lls, drainage media, graded construction aggregates, mortar and plastering sands and walling stone. The company is committed to providing quality products to the marketplace while helping other businesses make a positive contribution to improving environmental sustainability.
At its Melbur Quarry, Goonvean Aggregates processes granite-based
Pic: Hoddam Quarry & Concrete Products-Terex Washing Systems
secondary aggregates. Secondary aggregates are the byproducts of other industrial processes. They are used as fully compliant alternatives to primary aggregates, contributing to sustainable construction practices, the circular economy and overall environmental sustainability.
Goonvean Aggregates receives its feed material—the secondary aggregates—from a supplier. After processing the aggregate, a portion is sent back to the supplier and taken to the land ll or tip. Since sustainability is extremely important to Goonvean Aggregates, the company wanted a way to utilise all its materials without having to send any back to the supplier and without having to take any to the tip.
Goonvean Aggregates partnered with McLanahan to design a wash plant with water-recycling capabilities to integrate with its existing crushing plant or to be fed independently. McLanahan supplied an UltraWASH Modular Wash Plant, UltraSAND Plant and 10m EcoCycle High-Rate Thickener.
from
or directly through a
The UltraWASH washes the material and separates it into three aggregate sizes and one double-washed sand product. The UltraSAND Plant washes the residue product, which is then incorporated into one of the other sand products.
The EcoCycle Thickener accepts the waste streams generated from the UltraWASH and UltraSAND Plants and separates the solids from the liquid in the slurry to recover immediately reusable process water. This process water is then reused back in the wash plants for cleaning the aggregate material, further adding to the site’s sustainability.
“Since we chose McLanahan as a partner, we’ve been quite productive in the way we’ve been able to reutilise and adapt the plant to
Graeme Farish, Hoddam Quarry & Concrete Products manager (left), and Martin Loughran, Terex Washing Systems’ regional sales manager UK & Ireland.
The feed material enters the UltraWASH Modular Wash Plant either directly
the crushing process
feed hopper.
McLanahan’s EcoCycle High-Rate Thickener and conveyors for Goonvean Aggregates. Pic: McLanahan
our bespoke nature for the product we’re looking to produce,” said Matthew Penny, general manager of Goonvean Aggregates. “The dialogue and feedback have been very strong and allowed us to end up with a plant that meets our requirements and needs.”
The McLanahan UltraWASH Modular Wash Plant, UltraSAND Plant and EcoCycle High-Rate Thickener are helping Goonvean Aggregates to meet its sustainability goals.
“Our goals as a business are to be more sustainable in every facet of how we operate as a business,” said Penny. “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.”
In addition to helping Goonvean Aggregates meet its sustainability goals, the McLanahan equipment is also allowing the granite-based secondary aggregate supplier to utilise all its feed material and produce zero waste in the process, eliminating the step of taking material to tip.
“Since we’ve had the McLanahan plant on site, our productivity and ef ciencies have increased. We’re able to provide additional products to the local and national market,” explained Penny. As part of this, it means that as a company, we’re ‘zero to tip’. Every part of the product that comes into us, we’re able to process and resell as a nished product.”
Penny said that being “zero to tip” has huge environmental impacts for businesses. Speci cally, for Goonvean Aggregates, it means the company can process all its feed material more ef ciently and productively. This has allowed Goonvean Aggregates to reduce its carbon emissions and given the company an additional product offering, increasing pro tability.
“It’s enhanced our product offering, productivity, ef ciencies, and pro tability,” Penny said about being able to process all the material with the McLanahan wash plants and Thickener.
Overall, Penny is pleased not only with the McLanahan equipment but also with 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.”
Grudzen Las is a silica mine owned by Group Atlas, the biggest Polish manufacturer of materials for glassworks, metallurgy, and civil construction. The mine has operated since the 1970s and produces high-quality glass sand.
Glass sand must meet high standards and have narrow parameters to ensure optimised quality. This is dif cult to achieve with standard sand-washing technology. Grudzen Las sought a complex solution to optimise its glass sand plant using hydrosizers and a new dewatering system.
Weir Minerals’ team in Poland has developed a strong relationship with Grudzen Las. Regular discussions indicated that the company required a solution to optimise their product quality and capacity to meet growing market demands.
The existing glass sand plant was built in the 1970s and utilised old technologies.
This installation had an output of 40-50tph of silica with the quality required for the glass industry.
Grudzen Las aimed to maximise the output of this silica grade to increase its exposure to the most pro table silica applications in super-white and extra-transparent glass.
The challenge was to develop a complex solution to integrate an alternative classi cation system into an existing process constrained by old infrastructure.
Focusing on capacity and product quality, Weir Minerals developed and introduced a multistage sand-washing plant.
Using state-of-the-art software, Weir Minerals engineers' simulation of the washing
pattern helped identify areas for improvement and guided change by proposing three different sizes of hydrocyclones to get a better product. The solution included seven Cavex CVX hydrocyclones and three Linatex-lined, at-bottom classi ers. When integrated into the plant, this increased the capacity to 160t/h of prime sand at 70% concentration.
The classi cation capabilities of the Cavex CVX hydrocyclones and the precise separation of material by the Linatex-lined, at-bottom classi ers have set a new benchmark for glass sand production in Poland.
The low headroom design resulted in low installation and maintenance costs and easier inspections. No moving parts in hydrocyclones and classi ers are exposed to process slurry, meaning little maintenance is required for a long operating life. The minimised bypass in the at-bottom classi er under ow ensures that sand is clean and of premium quality to meet advanced speci cations.
Combining Weir Minerals technologies and engineering expertise, the plant optimisation took only 13 months, from the initial conceptual stage to commissioning.
The new sand-washing solution by Weir Minerals increased Grudzen Las’ output of high-quality glass sand by 300%, delivering both an increased plant output and product quality. It met the new production requirements and generated additional pro t from operational exibility by allowing the product properties to be tailored for a particular order or speci cation, adjusting to market demand. AB
CDE is holding an English-language webinar on May 2nd at 10am GMT to showcase its FreeFlow plant. The webinar will cover the following topics: Technical features; Detailed explanation of the different stages of the washing process; How CDE can ensure compliance with speci cations and a higher quality of sand and aggregates; The output products and their applications for the end customer. Registrations will be done at https://www.cdegroup.com/ free ow-webinar
Weir Minerals’ solution for Grudzen Las includes seven Cavex CVX hydrocyclones and three Linatex-lined, flat-bottom classifiers. Pic: Weir Minerals
Robust growth for global hydraulic hammer market
The worldwide hydraulic hammer market is predicted to experience a decade of growth over the next decade, driven by factors including advances in technology and eco-friendly options. Top-hammer manufacturers operating in Europe have faced challenges over the last year, including the loss of the Russian market. Liam McLoughlin reports
The hydraulic hammer market is experiencing notable growth. The sector was valued at US$ 1.2bn in 2022, and worldwide sales of hydraulic hammers are forecast to increase at a CAGR of 5.6% and reach a value of US$ 2.1bn by the end of 2033.
The growth is being driven by the construction and mining industries' demand for ef cient and powerful equipment, according to Persistence Market Research which has compiled the gures.
The company states: “With ongoing infrastructure development and urbanisation projects worldwide, the demand for hydraulic hammers is expected to continue rising. Advancements in technology, improved durability, and eco-friendly options are further propelling market growth. Moreover, expanding construction activities in emerging economies are contributing to the global expansion of the hydraulic hammer market.”
Persistence adds that modernisation and development of infrastructure in the construction industry have boosted the demand for hydraulic hammers on a global scale.
Persistence comments: “In recent years, there has been a noticeable increase in safety concerns among end-use industries when using heavy equipment such as hydraulic hammers. Despite the challenges faced by businesses, including labour and time, the advantages of using hydraulic hammers have made work much easier. The higher operational ef ciency of hydraulic hammers is a key factor that is driving their demand across industries and regions.”
Finnish company Robit says that the year of 2023 presented challenges for those operating in the top-hammer sector.
Robit manufactures top hammer, down -the-hole and geotechnical drilling products. The top-hammer drilling method is primarily used in quarrying, mining, earthworks, underground quarrying, and the quarrying of rock material.
Jorge Leal, VP top hammer at Robit, said the company’s construction segment in Europe faced adversity, particularly due to the loss of the Russian market
He added: “Despite these hurdles, the mining market sustained its strength, but de-stocking at customer and distributor side reduced the demand also in the mining segment.”
The Mendiger basalt quarry in Germany is modernising its hydraulic breakers fleet with an Epiroc HB 7000 equipped with the HATCON fleet management system. Image: Epiroc
Leal said that Robit won new customers in Australia as well as in some EMEA (Europe, Middle East and Africa) countries: “The growth experienced in Australia is a result of dedicated efforts, combining Robit’s superior products with the expertise of the company’s pro cient local team.”
He added that net sales in the EMEA region were close to 2022 level. The slowdown in European construction contributed to the lack of substantial expansion.
Robit took part in a recent drilling and blasting industry event held in Costa Rica in November 2023. The event drew 115 attendants from Central America to the Radisson San Jose hotel.
The event host was Explotec, a supplier
of explosives and mining tools throughout Central America. Headquartered in Costa Rica, the company has created a solid network distributing its products to Nicaragua, Honduras, El Salvador, Guatemala, and beyond. It also organises training events.
For expert insight, Explotec invited Robit’s drillmaster Juan Padilla to showcase examples and discuss best practices in the choice of drilling steels and proper equipment commissioning. The event also hosted Emilio López-Jimeno, a renowned lecturer and blasting expert, who discussed the importance of choosing the right parameters for effective blasting.
“Robit’s role in these types of events is fundamental for developing our clients’ knowhow and thus their ability to gain more market share in drilling steels,” said Carlos Alarcón Álvarez, technical manager at Explotec.
Other speakers at the event included Luis Carlos, who spoke about blasting grid optimisation, load factors, and improving fragmentation; Pedro Chaves discussed pre-cutting in blasting for mines and hydroelectric projects; Álvaro Rodríguez presented successful cases in blasting grid optimization and cost-cutting; and Carlos Alarcón examined the Royex rock-breaking system as an alternative in fragmentation.
Lekatech, a Finnish company aiming to revolutionise hammer and other attachment technology through its direct electric-drive products, has appointed Jyrki Nissinen as its product development engineer.
Before joining the Kausala-based manufacturer on 1 February 2023, Nissinen worked for several years in the research and development side of the construction equipment industry.
Seppo Jurvanen, Lekatech's senior engineering director, said Nissinen's expertise in mechanical engineering, electronics and measurements will strengthen the Lekatech product development team.
"Jyrki is responsible for the development, design and maintenance of Lekatech's products, and he will participate in product development projects as a product development team member. We welcome Jyrki to Lekatech and wish him all success in his new job!"
Being trialled at ve open-pit and underground mines and one quarry, Lekatech
says its groundbreaking fully electric hammer is up to 70% more efficient than a conventional hydraulic hammer attachment, providing significant energy savings for mining and quarrying customers while doubling impact force.
Italy-based Indeco provides the HP series of hydraulic demolition hammers which it states represents the maximum expression of high technology and construction quality applied to demolition.
Indeco says that their outstanding features include the efficiency of the intelligent hydraulic system which automatically varies the energy and frequency of the blows, depending on the material to be demolished.
It adds that the convenience of the fuelsaving system enables savings of up to 20% compared to competing breakers of the same class .
The HD Series also has exceptional construction strength due to the use of special steels produced exclusively for Indeco.
The company continues: “With its numerous models, available in different versions, Indeco boasts the most extensive range of demolition hammers ever. This allows users to make the ideal hammer/ machine pairing and make the best choice for the type of work to be carried out. Let’s see what the most common applications of Indeco demolition hammers of the three small, medium and large classes are.”
The company says its small hydraulic demolition hammers offer silence and high performance. Despite their small size, they are perfect demolition hammers for road construction sites thanks to their efficiency in excavation work. A wide choice of hammers for excavators from 0.5 to 14 tonnes, ideal for those looking for hammers for the demolition and renovation of buildings, demolitions and
a slender structure. Indeco says these hammers for 6.5 to 32 tonne excavators are ideal both as hammers for building demolition, excavation in urban areas and secondary demolition in quarries, and for more specific uses. They are in fact used as demolition hammers for underwater work (using a special kit), demolition hammers for road construction sites to be used for excavating narrow and deep trenches as well as hammers for removing slag in foundries.
Indeco’s large hydraulic demolition hammers are capable of combining
for use in quarries for primary excavation. They can swiftly carry out most demanding tasks such as massive demolition works, excavation of foundations, excavation of large road tunnels and railway tunnels.
In the breakers sector, HD Hyundai is adding to the versatility and productivity of its extensive line of wheeled and crawler excavators, with the introduction of a range of silenced hydraulic breakers. The equipment manufacturer says the HRB Series hammers have a range of innovative features to provide efficient performance and high -impact energy.
There are six models of the hammers for excavators from 1.2 to 26 tonnes operating weight, with varying specifications available on larger models.
Box housings reduce noise levels, making the breakers ideal for urban job sites. Ultra-high-grade working-tool materials deliver maximum durability. A urethane damper prevents carrier machine damage and wear, and there is a standard two-year manufacturer’s warranty .
All feature a silenced box housing, to
Representatives from Robit took part in a drilling and blasting event held in Costa Rica by Explotec
Jyrki Nissinen, Lekatech's new senior engineering director. Pic: Lekatech
HD Hyundai has introduced a range of silenced hydraulic breakers
reduce external noise levels, making them suitable for use on urban projects. They have a urethane damper to prevent vibration being transmitted to the carrier machine, reducing wear and improving operator comfort. The front-head assembly also incorporates a bushing to reduce shocks from the working tool.
High-quality steels are used in the main cylinder and in the piston of the HRB Series hammers, with an advanced heat-treatment process delivering best-in-class service life for the main through-bolts. A choice of high-grade tools includes a conical moil point for demolition, concrete and hard ground. A pyramidal moil point can be used for trenching, general excavation, asphalt, quarrying and reinforced concrete. The flat wedge chisel is also ideal for trenching and general excavation work, along with mass excavation in quarries and for reinforced concrete demolition. Lastly, a blunt flat end is designed for block splitting, compacting abrasive materials and concrete-slab demolition work.
Several options are available on the two larger breakers. All HRB140 and HRB250 models come with auto greasing through a front-head grease hole and a cylinder-head grease hole. HRB140 and HRB250 models can also be ordered with anti-blank firing technology. The HRB250 is available with a nitrogen gas accumulator in the back-head section, increasing the impact energy of the piston.
The HRB030 is designed for mini excavators with operating weights of 1.2-3.0 tonnes. The breaker features an impact rate of 700-1,200bpm. The HRB040 is for 2.5-4.0 tonne mini excavators and boasts an impact rate of 600-1,200bpm. Machines weighing 4.0-7.0 tonnes are suited to the HRB050, which has an impact rate of 500-900bpm and the HRB060 works with 6.0-9.0 tonne machines, offering 400-800bpm impact rate.
For larger excavators, in the 10-15 tonne class, the HRB140 delivers 350-700bpm. The HRB140 is offered in three specifications, with auto-greasing, with anti-blank firing or with both options. The largest model in the line-up, the HRB250, is designed to work with 18-26 tonne machines. It has the accumulator and auto-greasing as standard, plus it can be had with anti-blank firing if desired.
All HD Hyundai HRB Series breakers are delivered with a choice of two chisels
and they come with a standard two-year manufacturer’s warranty, guaranteeing peace of mind for customers. Though designed to deliver ultimate performance with the A-Series range of HD Hyundai excavators, the HRB breakers can be used with other manufacturers’ carrier machines, to suit customers with mixed fleets.
In the drill rigs market, Epiroc has just released the new long-feed version of its SmartROC C50.
The SmartROC C50 drill rig will now be available with a choice of two feeds, the standard feed or a long feed. This rig combines high penetration rates with superior hole quality – even in the most challenging conditions.
The long feed enables this COPROD rig to deliver even more metres per shift by increasing drilling time and reducing the time changing rods. Additionally, less rod -changing reduces wear on consumables and helps lower fuel costs. This makes this machine even more cost-effective.
Epiroc says the SmartROC C50 is one of the fastest, safest, and most efficient drill rigs available on the market. The wellknown surface drill rig is a favoured choice for contractors and mining customers who require both raw power and precision. This is due to the COPROD technology, which offers the unique combination of precision and speed. Together with the new long feed this rig will be beneficial to mining and quarrying operations all around the globe.
The SmartROC C50 with a long feed can carry a 7.3m starter rod and 6m rods in the carousel, which increases the maximum hole depth to 37m. There is also a significant increase in its single-pass capacity.
“We have taken this top-class surface drill rig and made it even more appealing with this new long-feed option. With its smart Rig Control System (RCS) and easy-to-use touch screen, we are proud to call the SmartROC C50 a class-leading rig,” says Ulf Gyllander, global product manager at Epiroc.
Since 2012, Mendiger Basalt Schmitz
The new long-feed version of the
Naturstein has been using Epiroc hydraulic breakers in its Basalt quarry in the Eifel region of Germany for primary breaking. Now, the company is modernising its fleet with an Epiroc HB 7000 equipped with the HATCON fleet management system. Mendiger Basalt is opting for a full-service rental agreement for the first time, covering the equipment's maintenance, wear parts and consumables such as chisels and lubricants.
The breaker was handed over by Epiroc Business Partner A.B.T. Abbruchtechnik, which, through years of collaboration with Epiroc, possesses in-depth expertise in handling Epiroc attachments, especially in heavy-duty applications.
The rental cost is calculated based on the actual operating hours recorded by the HATCO system from Epiroc. "This combination provides optimal planning security for both companies and enables extremely reliable scheduling of maintenance, leading to very high availability of the attachment and a reduction in downtime costs," said Marvin Venker, MD of A.B.T. Abbruchtechnik, during the handover of the hydraulic breaker.
For some time, Mendiger Basalt has been using excavator attachments instead of the usual drilling and blasting method, bringing several advantages to the operation. The blast-free extraction results in significantly lower noise and environmental impact compared to traditional methods, greatly enhances workplace safety, and allows for quarrying despite nearby residential areas. Extensive closures and associated work interruptions are eliminated, enabling simultaneous work in multiple areas of the quarry. Additionally, the use of hydraulic tools supports the extraction of high-quality material directly and precisely, even in heterogeneous rock.
"Due to the interplay of all these factors, the cost of using hydraulic breakers is not significantly higher than conventional blasting operations," said Rainer Krings, MD of Mendiger Basalt Schmitz Naturstein. AB
Epiroc SmartROC C50
Proponents
Mastering stratification to increase aggregates productivity
Stratification is an essential element of e ective screening, so how can materials producers optimise and capitalise on this process? Liam McLoughlin reports
The concept of strati cation is a familiar one to aggregates producers - a natural phenomenon vital to their material screening productivity. Strati cation is the process by which vibration in a bed of material — or material passing over screen media — causes coarse material to rise to the top and ne material to fall to the bottom.
Matthew Armstrong, business development analyst at screening media company MAJOR, says that strati cation is essential for effective screening. Increased strati cation leads to a greater quantity of ne material passing through the open area of the screen media, increasing the effective capacity of the machine. It also helps prevent common screening challenges, like blinding, pegging, limited throughput and increased downtime for frequent replacement needs.
“Wise producers know that strati cation is one of their best weapons against screening challenges, offering a cleaner retained product, greater ef ciency and higher pro ts,” Armstrong states.
“Some manufacturers design screen
media to maximise strati cation with highvibration wires that operate independently along the full length of the screen. Also important is that custom-designed, highvibration screen media can ensure a perfect t and more precise screening. Each custom- t panel is designed to strike the right balance of wear resistance, throughput, and blinding and pegging resistance to meet processing demands. One of the goals behind these designs is to increase vibration frequency, which accelerates strati cation.”
The vibration of screen media is primarily induced by the media bed. Traditional woven wire screen media relies on the screen box to do the majority of the heavy lifting when it comes to vibration. Armstrong says this means these screens run at between 600 and 1,200 strokes per minute, sometimes as high as 4,200 for high-frequency equipment. However, with wire screens that vibrate independently of the screen, the vibrating effect is magni ed — reaching frequencies of 6,000 to 10,000 cycles per minute. That’s up to 13 times greater than the vibration of a standard screen box. This enhanced vibration
gives producers reliable productivity from their screens, among other bene ts.
“One quarry in California saw immediate results when switching from rectangular woven wire screen media to round wire screen media with square openings that featured high-vibration wires,” says Armstrong. “Their previous screen media didn’t vibrate easily and was hard to tension. The rectangular wire led to signi cant blinding and pegging issues on up to 70% of the screen media’s surface, which caused both product contamination and an increase in equipment downtime to clean away debris.”
He adds that switching to high-vibration screen media was ideal for precise sizing. The round wires created a funnel effect for strati cation, and the narrow points of contact ultimately decreased the risk of blinding and pegging.
Achieving higher vibration frequency and accelerated strati cation sounds impressive, but what do aggregate producers really get out of it? Armstrong says there are a few bene ts an operation can see from the use of highvibration screen media:
• Signi cantly improved production. Producers have shown a documented increase in production with highvibration wire screens — as much as 40% greater in many different materials, including various rock types, salt and coal. The added vibration moves nes through the screen faster, allowing more tonnes per hour on the machine. The product manager at the quarry in California said they substantially reduced operating costs and improved operating margins by producing more end product that then became available to customers.
• Cleaner retained product. The high-vibration screen-media design achieves maximum throughput thanks to better material-to-screen contact. High strati cation and a wider material spread result in a high-quality retained product with no carryover. This means producers can, in some cases, screen their material dry, thus lowering their total water consumption and eliminating the need for water treatment.
“Wise producers know that stratification is one of their best weapons against screening challenges, o ering a cleaner retained product, greater e ciency and higher profits,” says Matthew Armstrong of
contact a local dealer or screen media manufacturer about the options available to take your operation to the next level.”
Finnish quarrying and mining solutions company Metso has issued analysis of screening media challenges and how to solve them.
• Longer wear life. Woven wire and some self-cleaning screen-media designs have shorter lifespans due to cross wires that inevitably see more wear over time. High-vibration screens eliminate this issue, enjoying up to ve times longer wear life than woven wire screens. This extends service intervals and allows producers to reduce the number of pro t-reducing shutdowns needed to keep their operations running at peak ef ciency.
Armstrong concludes: “Mastering strati cation is key to ensuring screening productivity. With the right high-performance screen media, operations can see a production increase of up to 40%. To learn more about high-vibration screen media,
The company states that when inspecting a screening process, the suggested improvements are always dependent on the customer-speci c processing conditions and exact application. It adds that there is no universal solution to solve all screening media-related challenges, and a good start is to look at pegging, blinding, and maintenance – three areas which greatly impact the screening process.
Pegging occurs when rocks get trapped in the openings of the screen surface. It can vary from minor pegging to the most challenging situation in which the entire cloth is clogged with rocks.
"Pegging limits screening capacity, and it can be dif cult to know exactly what the best solution for the problem is," Metso states. "Initially, you should look at the size of the apertures to investigate why pegging occurs in your production. In the case of smaller openings, factors such as screen settings and conditions, level of exibility and cloth design
should be taken into consideration. With larger openings, crossbeams, ledge angles and other mechanical parts are factors to consider to prevent pegging."
Metso adds that blinding is another performance-limiting factor that highly in uences your screening process. Blinding is a buildup of nes and dirt materials that stick to the screen surface due to humidity. It gradually covers the openings, and it can eventually cover your entire screen area. The level of blinding depends on how sticky the material is. To reduce blinding, there are a few actions which can be undertaken:
1. Minimise the blank area on the screen
2. Reduce thickness of media - if possible
3. Try softer synthetic materials.
Metso says that maintenance and simple measures are often overlooked as factors that affect the performance of the screening media. In some cases, it is not the screening media that is causing the problem, but is actually related to other underlying issues. There are three key areas that need to be considered:
1. Tension level
2. Feed chute distribution
3. Condition of the screen cloth supporting pro les
"Whether your issues come down to pegging, blinding or a service-related issue, the key is to take a step back and look for the root cause to the issue before deciding on a quick x," Metso states. "Bringing in a screening expert can also help you choose a solution that works for your speci c site or screening operation.
For the European market, Metso's new Trellex GS screening media is now available in both rubber and polyurethane, depending on the application.
Metso has inaugurated its new screening -media factory in the Mexican city of Irapuato.
Metso says its screening installed base in the Americas has grown signi cantly and it delivered 250 new screening machines to aggregates and mining customers in 2023.
The company says the new factory will
MAJOR
Metso says pegging, blinding, and maintenance are three areas which greatly impact the screening process
significantly increase its supply and delivery capabilities for aggregates and mining customers in North and Central America.
The screening-media centre employs 46 people and is located on a 9,000+ m2 lot. The new screening-media factory uses advanced and sustainable manufacturing practices, and the installed solar panels will cover approximately 50% of the needed electricity.
“We are very pleased to officially inaugurate our new screening-media factory in Irapuato. This milestone is yet another indication of our deep commitment to customer success. The Irapuato region is an important centre of excellence for high-quality products for our mining and aggregates customers. All our factories are modern and focused on safety, employee wellbeing, and continuous development,” says Alfredo Monreal, vice president, sales and service, Mexico and Central America at Metso.
“Our target is to continuously develop our operations close to customers to further improve our service capability. The investment of a new factory in Mexico aligns with our strategy and improves our lead times, and it offers scalability in production volumes in a very important region,” says Jouni Mähönen, vice president, Screening business line, Metso.
Metso now has around 730 employees working in production, sales, and field service in Mexico.
In the same industrial area in Irapuato, Metso also has a new rubber and Poly-Met media factory. Construction of a new polymer filter plate factory will be finalised during 2024, and the factory will be operational in early 2025.
Metso’s fellow screening-media provider MAJOR has also provided some analysis for aggregates producers on looking beyond cost per tonne to gauge operational productivity.
MAJOR says productivity is essential in any plant’s operation, which understandably makes a low cost of production per tonne a desired goal. Many variables contribute to a plant’s cost of production per tonne, including the cost of mining, transportation, processing and labour. Screen media plays a vital role in increasing the efficiency and productivity of processing, which makes choosing the best screen media for operations essential.
“Cost is often a motivating factor when choosing between screen-media options, but the full story of productivity can’t be summed up by just looking at either screen-mediapanel cost or number of replacements,” MAJOR comments. “Much like a scale, the amount of output needs to be weighed against end-product quality. By producing more to-spec material through its superior screening, high-vibration screen media offers added value to processing operations.
Because of its durability and longer wear life, MAJOR adds that synthetic media, such as polyurethane, is often selected as a lower-cost option since it requires fewer replacements than high-vibration screens.
Its durability is also effective when used to handle high-impact materials screening such as dewatering or when processing large amounts of minerals with little risk of pegging or blinding.
However, polyurethane panels trade durability for less open area and it’s often very rigid and relies on the vibrating screen to do most of the work. The static movement of the screens limits vibration to 800-900 cycles per minute, which can decrease throughput and invite blinding and pegging with finer minerals.
In comparison, MAJOR says its FLEX-MAT has as much as 50% more open area than polyurethane, which allows more material to be sized accurately in less time. This result is achieved through the high frequency of its wires — 8,000 to 10,000 cycles per minute — that adds to the vibration of the screen box to speed up material separation and passing.
MAJOR says: “This performance requires more changeouts of screens because unprotected woven wire breaks more easily than polyurethane. The trade-off to more frequent replacements is that the
increased screening action improves material throughput, virtually eliminates pegging and clogging across the top and bottom decks and yields a better-quality product. With FLEX-MAT, a higher investment upfront can lead to greater production gains down the road.”
MAJOR continues: “It should also be noted that while polyurethane screens currently outlast a wire product, this gap has been closing. The inclusion of polyurethane strips within FLEX-MAT Modular Plus panels boosts its durability without sacrificing open area. This addition means that these high-vibration panels can withstand harsher screening conditions with the most abrasive materials, such as granite and basalt.”
In some applications, MAJOR says that the strengths of polyurethane and high-vibration screens can complement one another. In cases where the top deck receives heavy material with a high impact and requires a longer wear life, using a synthetic screen would be best. Once the polyurethane has taken the impact and the material is spread out more easily on the lower deck, a highvibration screen can be used to overcome the limitations of the open area of the synthetic screen and produce more throughput. One industry case study reveals the benefits of such a pairing.
A granite aggregate operation running polyurethane panels on the top deck and woven wire screens on the bottom decks experienced diminished throughput due to low open area as well as poor material stratification and pegging and blinding issues. Replacing the middle deck with a highvibration panel tripled its operational life, eliminated pegging and blinding, and resulted in a 200% increase in production volume.
When it comes to making the best purchasing decision for your operations, MAJOR says that added value should take the place of cost per tonne. At the outset, polyurethane may seem like a cheaper alternative to many premium high-vibration wire products. In the longer term, FLEXMAT’s customised high-vibration screens offer a more cost-saving and high-yield solution. AB
Metso has inaugurated a new screening-media factory in Irapuato, Mexico
MAJOR’s FLEX-MAT Modular Plus product. Image : MAJOR
Biting the dust
Innovation in dust suppression is evident in the latest manufacturer solutions, which is good news for sustainability-minded quarry operators. Guy Woodford reports
The DustBoss DB-45 Surge is the next iteration of BossTek’s popular Surge series. It features an innovative pressurised centre nozzle paired with the industryproven fan and misting ring system to suppress surface dust and airborne particulates. With three remote-controlled stages and precision oscillation for optimum command over water volume and coverage area, the DB-45 Surge is said to deliver the dependability of atomised mist along with J2P (jet-to-plume) nozzle technology that surges for over 60 metres, even in troublesome windy conditions. The result is an easily manoeuvrable, autonomous, and versatile dust-control solution for outdoor operations in all weather conditions.
“Our rst iteration of this technology was larger for operations with high-reach cranes and enormous coverage areas,” explains BossTek dust-control specialist Mike Lewis. “Managers of medium and smaller operations were impressed with the existing technology but wanted a lighter, more compact option that offered the same excellent eld-tested versatility and results. With a 200-foot (60m) throw range, I’d say that most of our customers will be well-served by the new model.”
Demolition contractors with high-reach cranes, port operators that host tall cargo ships, and bulk handlers with tall raw material stockpiles commonly experience windy conditions high above the ground.
In turbulent situations, dust is lifted into the atmosphere and carried beyond the site line over long distances, which can lead to permit violations. Operators often mitigate particulate emissions using sprinklers or hoses to saturate a material’s surface. The stronger the wind, the more water pressure is required to break through the wind shear, resulting in more water lling the surrounding work area -- often 300 GPM (1135lpm) or more.
The DB-45 Surge combines the power of a 25-horsepower industrial fan, misting ring and heavy-duty barrel with the reach of a central high-pressure spray nozzle. The misting ring introduces millions of tiny dust-capturing droplets into an area for proven dust suppression. The pressurised spray resists wind shear and uses the force of the wind to further fragment droplets, enhancing its dust-suppression capabilities. This is achieved with a maximum of 72 GPM (372lpm) and as little as 17 GPM (77lpm) when using only the misting ring and fan. The cannon also features a VFD (variable frequency drive), which allows the unit to operate more ef ciently at lower water pressure.
The three stages are easily input by the touch-screen system, protected by a sealed NEMA 4 cabinet or controlled by a heavy-duty hand-held remote control with a 305-metre range. Stage one is highly effective on moderate days and uses the powerful 30,000m³ per minute fan and misting ring for wide-area coverage. For windy days, stage two features a pressurised stream delivered by the J2P nozzle to pinpoint the source of the dust. On highwind days, operators can choose stage three, which utilises the fan, misting ring and centre nozzle for maximum coverage.
This allows the DB-45 Surge to be “set it and forget it” autonomous equipment, unlike hoses and industrial sprinklers, which typically require constant manual labour to monitor and operate. Manual operation keeps workers in active zones near moving equipment, increasing the chance of injury and raising the operation costs for sprinklers and hoses due to extra labour and possible liability.
The DB-45 Surge addresses wind, labour and water-usage issues. While striving to stay compliant with dust regulations, operators can now better match the water requirements to the speci c application. Fed by a standard 1-½ in. (38 mm) hose with a cam-and-groove quick disconnect coupling, the powerful booster pump delivers as much as 500 PSI (27.5 BAR) of water pressure to the centre nozzle.
The coverage area is extended with the customisable 260º horizontal oscillation range and 0º-50º vertical throw angle. Mounted on a heavy-duty roadworthy trailer for towing at highway speeds with a standard ball hitch, it can be placed by a pickup truck, skid steer or lift truck wherever dust suppression is needed. As supplied, the DB-45 Surge can run potable or non-potable
BossTek’s DustBoss DB-45 Surge includes an innovative pressurised centre nozzle paired with the fan and misting ring system to combat surface dust and airborne particulates. Pic: BossTek
Fine-particle specialist RST Solutions says the best way to achieve optimal DEM (dustextinction moisture level) is to signi cantly reduce the volume of water needed to attain the material's DEM sweet spot.
Applying DEM HydroBoost Pro to any material type is a simple process that requires a dosage rate of between 0.1 to 0.5 litres per m³. The dilution rate is calculated based on the water needed to ensure even product distribution throughout the material mass to achieve the desired, reduced DEM content.
RST Solutions claims that DEM Hydroboost Pro offers a typical reduction of 2.5% to 3.5% in a material's DEM, which is signi cant considering that a typical DEM reduction can be between 7% and 12%.
A gentle spray of water is all that is needed to reactivate the chemistry. It requires very little effort to generate the right amount of moisture, improving and continuing dust management throughout the entire material supply chain and adding more value to the product for clients downstream.
water, as it is equipped with two in-line 30 mesh, 595-micron lters to avoid clogging. One lter is located at the water entry point to the booster pump, and another is before the pipe feeding the central nozzle.
Other options are already available, including tower mounting for permanent locations. The cannon is also available as part of the company’s popular Fusion lineup, pairing the DB-45 Surge with a trailermounted generator to alleviate the need for a nearby power source. With a 15HP booster pump, the unit only requires a 45kW generator, which most demo contractors already have in their equipment arsenal
DEM Hydroboost Pro is RST Solutions’ new advanced product, designed to control on-site dust using less water. Designed for use in industries including quarrying, mining and construction, the DEM Hydroboost Pro also preserves product quality, reaching the end user in the same condition it left the supplier.
Complementing RST Solutions’ full range of dust-suppression products for foaming and spray systems, DEM Hydroboost Pro is added once by watercart or other spray methods at the starting point of the material supply chain. It is evenly distributed throughout the bulk of the material to improve material handling and dust control during transferring and transportation.
Only a small amount of water is required at different points along the material supply chain, removing the risk of overwatering and potential issues such as excess weight and stickiness.
Following successful trials to address the issue of overwatering raw minerals that can reduce the quality of materials for the end user, DEM Hydroboost Pro has now been released to the market as an advanced multipurpose dust-control solution, requiring 42% less water than regular dust-control methods.
Water constraints and increasing costs make common dust control methods unsustainable in many parts of the world. Alternative solutions are being sourced to meet dust control regulations and cost savings. RST Solutions customises the application methods for DEM Hydroboost Pro with speci c dosage levels and application methods for compatibility with all bulk materials.
This achieves far better moisture control to manage dust than just using water or other solutions that may be broad-spectrum and not targeted speci cally for the type of material being extracted.
An Australian business operating internationally, with presence and projects in Australia, North and South America, Africa, the Middle East, Asia and the Paci c, RST Solutions specialises in supplying alternative methods tailored speci cally to a project and the on-site materials, a site’s application equipment and systems, local weather patterns and budget parameters. AB
Containers full of DEM Hydroboost Pro destined for RST Solutions’ customer sites
ABOVE: The DustBoss DB-45 Surge is the new model in BossTek’s popular Surge series. Pic: BossTek BELOW: RST Solutions’ DEM HydroBoost Pro in action on a quarry site. Pic: RST Solutions
