Quarry February 2024

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FEBRUARY 2024

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

FEBRUARY 2024

The Australian Bulk Handling Expo will return after a successful event in 2022.

LEAVING A LEGACY Finds out why Sheridan’s Hard Rock Quarries decided to install a modular fixed plant.

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www.quarrymagazine.com

BULK2024 TO RETURN

FINDING RESILIENCE Jason Egan tells Quarry about his mental health journey in hopes of helping others.


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IN THIS ISSUE

FEBRUARY 2024

VOLUME 33, ISSUE 2

FEATURES 18 TURNING DATA INTO ACTIONABLE INFORMATION 22 AN ENDURING ALLIANCE 26 SUPER STEEL 28 ORICA DIGITAL SOLUTIONS DIVES INTO DIGITAL

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BULK2024 TO RETURN QUARRY LEARNS HOW THE SHOW PLANS TO GROW THE INDUSTRY.

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ULTRA MOBILITY THE LATEST DYNAROX RANGE PRESENTS ITS LATEST INNOVATION.

QUARRYING 30 PILING UP: SUPERIOR’S STOCKPILES SHINE 32 AN EXCELLENT EXCAVATOR 40 SAWN OFF THE OLD BLOCK 42 WINDS OF CHANGE IN DUBAI 44 DIRE WARNING FOR

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LEAVING A LEGACY FIND OUT WHY THIS QUARRY INSTALLED A MODULAR FIXED PLANT.

FEBRUARY 2024

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

FEBRUARY 2024

LEAVING A LEGACY Finds out why Sheridan’s Hard Rock Quarries decided to install a modular fixed plant.

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38

QUARRY

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www.quarrymagazine.com

BULK2024 TO RETURN

The Australian Bulk Handling Expo will return after a successful event in 2022.

FINDING RESILIENCE Jason Egan tells Quarry about his mental health journey in hopes of helping others.

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QUARRY SUPPLY FINDING RESILIENCE JASON EGAN SHARES HIS JOURNEY WITHIN THE INDUSTRY.

TURNING DATA INTO ACTIONABLE INFORMATION There is more data at our fingertips now than at any point in human history. The internet, mobile devices, machines, and AI provide a tremendous amount of data. Steve Franklin, founder of Eltirus, asks the question: how much does this flood of data help us?

EVERY MONTH 04 FROM THE EDITOR

16 PRODUCT FOCUS

06 FROM THE PRESIDENT

48 IQA NEWS

08 INDUSTRY NEWS

50 GEOLOGY TALK

Quarry February 2024 3


EDITORIAL

CROSS COLLABORATION

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uarrying requires a diverse range of equipment, from crushers, screeners, excavators, and conveyors. While much of the machinery is designed and built for quarrying specifically, other industries have incorporated it into their day-today operations. The construction and earthworks industry use excavators, recycling companies use screening equipment, and mining companies use plenty of similar gear. Each industry has different ways of optimising equipment use to best fit their needs, and have learned to get the most out of the technology for their specific application. There is a lot of potential value from sharing these strategies, learning what works elsewhere, and finding ways to incorporate it into quarrying. That’s partially the goal of the upcoming Australian Bulk Handling Expo (BULK2024). The show plans to bring industries that use bulk material handling equipment together to showcase the latest technologies, innovations, and provide an opportunity to network with likeminded peers.

Published by:

It’s the only dedicated Australian expo for of bulk commodities such as concrete, sand, stone, grains, coal, iron ore, animal feed, or woodchips. Equipment like conveyors, silos, motors, dust control systems, weigh scales, level measuring products and more will be on display at the show. In particular, the show will highlight the latest advances in the Internet of Things, automation, and artificial intelligence. Attendees will also be able to attend several networking events, offering the opportunity to meet with new potential clients and learn about new markets. It will also host the 2024 Australian Bulk Handling Awards, which celebrates the achievements of companies and individuals that have demonstrated innovative practices and superior performances across the year. BULK2024 will take place at the Melbourne Convention and Exhibition Centre from 18–19 September, 2024. William Arnott Editor

EACH INDUSTRY HAS DIFFERENT WAYS OF OPTIMISING EQUIPMENT USE TO BEST FIT THEIR NEEDS, AND HAVE LEARNED TO GET THE MOST OUT OF THE TECHNOLOGY FOR THEIR SPECIFIC APPLICATION.

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SAVE THE DATE

15-17 OCT 2024

The IQA is proud to announce Innovate And Create, our National Conference for 2024. Adelaide will play host to the 64th National Conference from Tuesday 15 to Thursday 17 October 2024, to be held at the Adelaide Convention Centre.

Innovation is a key strategy for our industry which will create growth opportunities to move forward. The theme, Innovate And Create, will provide fantastic opportunities for members, suppliers and stakeholders to understand the changing environment, network with key decision makers, industry professionals and so much more. Watch this space for more exciting details to come. PLATINUM SPONSORS


PRESIDENT’S REPORT

YEAR OF EDUCATION The Institute of Quarrying Australia

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t’s remarkable how quickly the year has gotten underway as we look at the second issue of Quarry for 2024. Much like our industry, the Institute of Quarrying Australia has been busy behind the scenes to make the year ahead one of our best yet. We remain highly committed to providing our members with the best education opportunities and this year we aim to create workshops that cater to different roles and levels of experience to ensure we have something for everyone across our diverse workforce. The start of a new year can often bring a new wave of employees to any industry – and the Australian quarrying industry is no different. That can also be incredibly exciting. At the IQA, we encourage anyone who is new to the industry – as well as more people who might be looking to upskill or for a refresher – to consider our suite of educational opportunities held throughout the year. Those who attended any of our workshops in 2023 would know

that these are rich educational opportunities. Courses like Plant and Equipment can often be completed in individually modules or packaged into a variety of short courses. We’re all very fortunate to work in a sector with experienced operators and talented managers, and these courses help these seasoned professionals share their wisdom across the industry. While educational programs can sometimes be seen as a chore, I agree with the sentiment that a rising tide lifts all boats. If we all collectively invest in our education and personal development by taking advantage of the IQA’s workshops, we will become a better, safer and more efficient sector. Let’s make 2024 the year of quarrying education and make the industry one of the best workplaces across Australia. Duncan Harris President Institute of Quarrying Australia

Educating and connecting our extractive industry

www.quarry.com.au

AT THE IQA, WE ENCOURAGE ANYONE WHO IS NEW TO THE INDUSTRY – AS WELL AS MORE PEOPLE WHO MIGHT BE LOOKING TO UPSKILL OR FOR A REFRESHER – TO CONSIDER OUR SUITE OF EDUCATIONAL OPPORTUNITIES HELD THROUGHOUT THE YEAR.

The IQA’s Strategic Plan 2023 to 2026 embodies the following vision, values and strategic priorities: Vision: Thriving communities supported by a sustainable industry Operational Priorities: • Deepen industry participation • Sustainable revenue streams • Highly capable team

• Technological innovation • Effective engagement • Great governance

Strategic Priorities: • Support industry participants with compliance and regulation

• Build a diverse and skilled industry workforce

• Foster strong industry connectivity

IQA Contacts:

Phone: 02 9484 0577 Email: admin@quarry.com.au Deputy President Sarah Bellman

Company Secretary Rod Lester

For all education, member and branch enquires please email: admin@quarry.com.au.

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NEWS

Image credit: CHR

CHR REVEALS DEAL TO ACQUIRE ADBRI “THIS ACQUISITION WOULD STRONGLY COMPLEMENT OUR EXISTING AUSTRALIAN BUSINESS, CREATING ADDITIONAL OPPORTUNITIES FOR GROWTH AND DEVELOPMENT.” ALBERT MANIFOLD CHR has a major presence in North America and Europe, including Poland’s Drahle sand quarry.

CRH has revealed it could potentially acquire Adbri Australia in a move that would shake up the country’s cement industry. The company, which already has a major presence in Europe and North America, has partnered with Barro Group to take the next steps to acquire Adbri. Adbri, formerly Adelaide Brighton, is a major construction materials supplier after establishing itself in 1882. CRH chief executive Albert Manifold said the potential deal would benefit its existing Australian plans. “We have held a long-term interest in the Australian construction materials market, which has attractive attributes including stable market dynamics and positive growth prospects, similar in

nature to the Southern United States and Central and Eastern Europe where we have a significant presence,” he said in a statement. “Adbri is an attractive business with quality assets that complement our core competencies in cement, concrete, and aggregates. With its leading market positions in Australia, we are delighted that this opportunity has presented itself to us. “It is the next logical step for CRH to expand our existing presence in Australia, where we have been operating for 15 years.” The agreed cash consideration of $3.20 per share values Adbri at an equity valuation of $2.1 billion (US$1.4 billion) on a 100 per cent basis and values the approximately 53 per cent

of issued share capital that the Partners do not currently have an interest in and which CRH has agreed to acquire at A$1.1 billion (US$0.75 billion). Barro is an Australian family-owned business and approximately 43 per cent shareholder of Adbri. Under the partnership, CRH would acquire approximately 57 per cent of Adbri’s shares not owned by Barro with the intention to delist Adbri from the ASX. “This acquisition would strongly complement our existing Australian business, creating additional opportunities for growth and development,” Manifold said. “We look forward to working with the Barro family over the coming years to enhance the long-term performance of the business, leveraging our scale, industry knowledge and technical expertise to improve long-term growth and operating performance and drive value to achieve the true potential of the business.” CRH and Adbri, in separate releases, confirmed the deal was subject to CRH completing due diligence, Foreign Investment Review Board (FIRB) approval and Adbri independent directors unanimously recommending and committing to vote in favour of the proposal. Adbri’s independent board committee has recommended entering into a process and exclusivity deed with CRH and the Barro Group to progress a potential transaction. •

SRM Concrete and Vulcan Materials have confirmed details of a significant acquisition that will shape the American ready-mix concrete sector. SRM, one of America’s largest ready-mix concrete producers, has acquired Vulcan’s ready-mix concrete assets in Texas. Under the agreement, SRM will take over 82 ready-mix plants and 11 locations across the state. “We’re excited about welcoming more than 1,100 new team members to our SRM family,” SRM Concrete chief executive Jeff Hollingshead said.

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“We will be gaining nearly 100 new locations and a significant amount of equipment, but what really matters to us is the people. “It’s their skills and experience that are our true assets. We can’t wait to start working and growing together in Texas, side-by-side with our new team.” The agreement will see SRM enter new markets and strengthen its presence in Houston and Dallas-Fort Worth. These additions make SRM one of the largest ready-mix suppliers in Texas after being founded in 1999 by Mike and Melissa Hollingshead. •

Image credit: Adobe Stock/Maurice Norbet

SRM CONCRETE CONFIRMS MAJOR TEXAS ACQUISITION

SRM has acquired several of Vulcan Materials’ assets in Texas.



NEWS

Image credit: Adobe Stock

FIRE ANT WARNING RE-ISSUED FOR NSW QUARRIES

Businesses are being asked to remain vigilant as fire ants appear across NSW.

Australia’s eastern coast quarries are being asked to remain vigilant after red imported fire ant nests were destroyed in South Murwillumbah. Authorities had to eradicate five red imported fire ant nests recently with further checks, including detection dogs continuing on-site and around South Murwillumbah in the days following the discovery. They are inspecting local high-risk premises linked to materials that red imported fire ants like to nest

and travel in, such as soil, mulch, quarry products, potted plants and baled materials. The on-ground teams from the NSW Department of Primary Industries (DPI) have also communicated with businesses within the 5km biosecurity control zone, advising them of their biosecurity obligations under the emergency order. “I urge everyone in the local area to check their premises, yards and paddocks for the red imported

“I URGE EVERYONE IN THE LOCAL AREA TO CHECK THEIR PREMISES, YARDS AND PADDOCKS FOR THE RED IMPORTED FIRE ANTS.” TARA MORIARTY

fire ants and then report any suspected sighting immediately,” NSW Agriculture Minister Tara Moriarty said. The NSW Government has announced its intention to continue its surveillance operation, including tracing, surveillance and educating local businesses and the community. Residents and businesses can report any suspicious ant activity to 1800 680 244launch or by visiting the Department of Primary Industries. •

Position Partners has announced a new name for the new year as it charts its continued rise within the industry. The intelligent positioning and automation solutions provider has revealed it will take on the name Aptella. The rebranding has been carried out to reflect the breadth of automation and positioning solutions and services the company offers, it explains. “The Position Partners name and brand has served us well,” chief executive Martin Nix said. “Sentiment from our employees and customers was that the time was right for a fresh new identity to better represent the

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experiences people can expect from us as their vital technology provider.” The company has been transitioning the brand with new signage, apparel and other marketing collateral to be rolled out across early 2024. The business continued trading as Position Partners until late January, and is now trading as Aptella. The company said as there is no change to legal entities, all existing contracts and agreements do not need to change. “Our team is energised and ready to engage with customers and partners in the New Year as Aptella,” marketing communications manager Gina Velde said.

Image credit: Position Partners

POSITION PARTNERS REVEALS APTELLA NAME

Position Partners will roll out the new Aptella branding in the early part of 2024.

“Whilst the name and branding are changing, the core aspects of our business and what people love about us remain as strong as ever.” •

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NEWS

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HEIDELBERG MATERIALS SECURES EU FUNDING “GEZERO SHOWS HOW CLIMATE PROTECTION THROUGH NEW TECHNOLOGIES AND PROCESSES CAN ALSO BE ACHIEVED IN ENERGYINTENSIVE INDUSTRIES.” MONA NEUBAUR Heidelberg Materials has confirmed details about its German project.

Heidelberg Materials has revealed the EU Innovation Fund will turbocharge its plans for a fully decarbonised cement plant in Germany. The fund, which is one of the world’s largest for low-carbon technology, will invest €191 million to develop the project at Heidelberg Material’s German Geseke cement plant. The plant will produce carbon captured net-zero cement and clinker with the help of the funding which became active on January 1 following the successful grant agreement. Chief sustainability officer and member of the managing board of Heidelberg Materials Dr Nicola Kimm said the successful agreement was a major milestone.

“(It) demonstrates the relevance of GeZero for the decarbonisation of our sector, and the trust that European authorities place in our approach,” she said. “We just recently introduced our evoZero brand, the world’s first carbon captured net-zero cement on the market. The product will initially be offered through our Brevik CCS project in Norway. Once other capture projects such as GeZero start operations, these plants will also be able to deliver net-zero cement and clinker to customers, significantly speeding up the decarbonisation of our industry.” Deputy Prime Minister of the State of North Rhine-Westphalia Mona

Neubaur said the project was a boost for the German region. “About one third of the German cement production is located in North Rhine-Westphalia. We are therefore delighted that the first carbon-free cement plant in Geseke in the district of Soest is a flagship project for a sustainable and climate-neutral future in the cement industry,” she said. “GeZero shows how climate protection through new technologies and processes can also be achieved in energy-intensive industries. The project represents a decisive step towards a future-proof cement production and the transition to a net-zero industry in North Rhine-Westphalia, Germany and beyond.” The EU Innovation Fund focuses on flagship projects with European value added that can bring significant emission reductions. In response to its third call for large-scale projects, the European Commission had received 239 applications while 37 were selected for funding. Last year, Heidelberg Materials’ Bulgaria site was chosen by the fund. “Together with our partners, we walk the talk and pave the way for CCUS in Germany,” Christian Knell, general manager for Germany of Heidelberg Materials, said. •

CRH Ventures has unveiled its latest move in the artificial intelligence space, which will further digital support for quarries. CRH Ventures has partnered with SafeAI for the program which will take place at one of the former’s quarrying subsidiaries in North America. The test truck will be equipped with SafeAI’s technology and operated under the supervision of the test driver. It will evaluate the feasibility and capabilities of SafeAI’s innovative technology for autonomous operations in quarrying. “This pilot program with SafeAI aligns with our commitment to explore innovative solutions for more efficient and sustainable quarrying operations,” Head of CRH Ventures Eduardo Gomez said. “We are excited to assess the potential of autonomous hauling technology

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in a controlled environment and the possibilities for future scaling. “While this marks an important step in our exploration of autonomous hauling solutions, it’s crucial to clarify that, at this stage, CRH Ventures is focusing on piloting the technology before finalising any strategic investments.” The pilot program is designed to simulate quarry operations and will run for approximately one year. The success of the initiative will be evaluated based on predetermined Key Performance Indicators (KPIs) over various test scenarios, comparing autonomous performance against traditionally staffed operations. “We’re excited to partner with CRH to advance its vision for sustainable, efficient quarry operations. Together, we can showcase the capacity for new technologies to create a safer, more

Image: Gorodenkoff / Adobe Stock

CRH VENTURES REVEAL NEW PARTNERSHIP WITH SAFEAI

CRH Ventures and SafeAI have launched a new partnership.

productive future for the quarrying and construction industry,” SafeAI chief executive and founder Bibhrajit Halder said. “Autonomous solutions have the potential to transform heavy industry; we work with forward-thinking companies to bring this potential to life.” •


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NEWS

Image credit: ipopba/Adobe Stock

CEMEX INCREASES INVESTMENT IN UK HYDROGEN STARTUP

Cemex has increased its investment in HiiROC.

Cemex has bolstered its investment in an English zero-emission hydrogen startup as part of its decarbonisation plans. The company, through its venture capital and innovation arm Cemex Ventures, increased its stake in HiiROC, which produces hydrogen through a low-cost and low-emission proprietary method. According to its statement, Cemex believes hydrogen is a “high potential” fuel alternative as the company looks to shift away from fossil fuels.

“This news comes at a critical moment when COP28 has brought the world together to address and refocus the climate agenda and buckle down on the responsibility of governments and private corporations to deliver on their decarbonization objectives ahead of 2030,” said Gonzalo Galindo, Head of Cemex Ventures. “With our increased investment in HiiROC, we are especially proud to be number one in the use of hydrogen in the cement sector and are committed to keep scouting new ways to deploy

“WITH OUR INCREASED INVESTMENT IN HIIROC, WE ARE ESPECIALLY PROUD TO BE NUMBER ONE IN THE USE OF HYDROGEN IN THE CEMENT SECTOR AND ARE COMMITTED TO KEEP SCOUTING NEW WAYS TO DEPLOY HYDROGEN AT A GRAND SCALE AT CEMEX’S 60 CEMENT AND GRINDING PLANTS.” GONZALO GALINDO

hydrogen at a grand scale at Cemex’s 60 cement and grinding plants.” HiiROC’s technology produces highgrade hydrogen that requires a fraction of the energy consumed by water electrolysis and avoids the need for intensive Carbon Capture, Utilisation, and Storage (CCUS) methods required for traditional steam methane reforming. HiiROC’s production units are modular and scalable, use no water, and carbon black, a coproduct of the hydrogen production process, becomes an additional area of opportunity to further decarbonize heavy industries. The English-based startup, with sites in Hull and South England, has raised £30m ($56m AUD) from investors including Melrose, Wintershall Dea, Centrica, HydrogenOne, Hyundai, Cemex and Kia. HiiROC began in 2019, but Cemex’s first investment came in 2022. Cemex confirmed it plans to increase hydrogen reliance at its Rugby site in the United Kingdom before gradually deploying it further. It comes after the company significantly increased its use of Ventura concrete, a low-carbon option, in projects across the globe last year. •

Nationwide research has uncovered the barriers that are prohibiting Australian women from pursuing careers in construction, including sexual harassment. The research, from Australian Catholic University’s Dr Marzena Baker, found 31.9 per cent of women were discouraged by the stigma of sexual harassment in the sector. Career opportunity was a great attraction, with 70 per cent of the 655 respondents considering that to be either slightly or highly influential as a lure to the sector. “Attracting women to the workforce is a complex process,” Dr Baker said. “There is no one-size-fits-all approach, and there needs to be nuanced strategies to attract and retain women.” Dr Baker’s study, which was published in the International Journal of Construction

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Management, highlighted male-dominated culture, lack of work/family balance, gender stereotypes, unequal allocation of posts and activities, and unequal promotions as major barriers. The project also sought a deeper understanding of how those factors differed by age and role level. Other barriers cited by respondents also included sexist work cultures, harassment and lack of respect, and unrecognised work performance. “With construction employment rising, recruiting and retaining women must be a priority,” Dr Baker said. “If organisations are genuine about attracting women, they would benefit from tailoring their recruitment policies and practices.” •

Image credit: amorn/Adobe Stock

NEW CONSTRUCTION DATA SHOWS ‘COMPLEX’ BARRIERS FOR WOMEN

New research highlights the barriers facing women in construction.



PRODUCT FOCUS

To submit new product and equipment releases, email: les.ilyefalvy@primecreative.com.au

CLEARING UP THE RIPRAP The MDS M515 Heavy Duty Trommel is the flagship model in the MDS range. It excels at crafting riprap and reclaiming rocks entangled with clay and other adhesive materials. The updated design incorporates new elements that enhance transportation, accessibility, and stockpile capacities. Maintenance is a breeze with the engine’s swing-out feature and a convenient access platform. Both the fines and mid-product conveyors have been extended to elevate stockpile heights. The engine’s side placement allows for easy fitting on smaller bed trailers, reducing transportation expenses. The MDS M515 rock trommel screens boast a drum with a 4m fines section and a 1.5m mid-product section. There is a range of drum configurations available, including frames with interchangeable screens or fully welded drums. The precise setup is tailored to meet the specific demands and applications.

For more information, call 1300 859 885 or visit triconequipment.com.au

A LONG HERITAGE OF EXPERTISE – KLEEMANN’S NEW MSS802 EVO SCALPING SCREEN Kleemann has been developing and manufacturing machines and plants for the past 100 years. As a powerful mobile screen for coarse elements, the Mobiscreen MSS 802 EVO has been designed for evolving challenges in different applications. With its ingenious machine design and flexible conversion option, an ideal throughput can be guaranteed for natural stone and recycling applications. Changing work locations and new applications often create challenges for screening plants. The MSS 802(i) EVO mobile scalping screen is ideally equipped to take them on successfully. Electric operation via an external power supply is possible with the optional electric-hydraulic dual power drive. The temperature-controlled fan ensures a significant reduction of noise emissions, saves diesel and reduces the amount of dust entering the engine compartment. this means that environment friendly work with zero emissions can be realised with even lower operating costs.

For more information, visit wirtgen-group.com/ocs/en-us/ kleemann/kleemann-products-97-c/

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Hardox® 500 Tuf is a new wear-resistant steel from SSAB. It combines the hardness of Hardox® 500 with the toughness of Hardox® 450. The high wear resistance of Hardox® 500 Tuf makes it possible to increase the load capacity by using a thinner plate and still have the same outstanding service life. Or stay with the same thickness and increase service life by 30% or more, depending on the abrasive material.

Hardox® 500 Tuf is also tough enough to perform as a structural steel, allowing for a stronger and lighter mining body with less supporting structures. Hardox® 500 Tuf takes the load instead. Get the full story of Hardox® 500 Tuf at www.hardox.com

Contact SSAB Brisbane. Melbourne. Perth G1, 28 Balacalva Street Woolloongabba, QLD 4102 Email: australia@ssab.com www.hardox.com

Explore the world of Hardox® wear plate


COVER STORY

TURNING DATA

INTO ACTIONABLE INFORMATION There is more data at our fingertips now than at any point in human history. Steve Franklin, founder of Eltirus, asks the question: how much does this flood of data help us?

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expected oil pressure) to provide me with what I am going to term “actionable information”. You will note that I am not calling it understanding as without some training or experience, the actionable information might be ignored, and the engine will fail as a consequence. Let’s now look at this in a little more detail.

DATA Data and information are often used interchangeably, but they are not the same thing. Data are raw facts or figures that can be collected, measured, or observed. As an example, a modern car will continually analyse the engine oil pressure (among some fifty to one hundred other variables) on a continual basis. Can you imagine if these were

continuously streamed across the instrument panel as you drove the car. It would at best be meaningless and at worst, a distraction. That said, the raw data must be collected. If the oil pressure sensor stopped recording (and the system didn’t flag it), eventually a situation could occur where this lack of data could result in a seized engine. Data collection is important.

INFORMATION Information is the result of processing, interpreting, or organizing data in a meaningful way. For example, a list of numbers is data, but a chart that shows the trend of those numbers is information. Continuing the oil pressure analogy, the data coming in needs to be turned into Images courtesy of: Eltirus

hether in business, or in life broadly, our ability to act is primarily determined by our understanding of the situation around us. You could further say that that understanding is built up of data, turned into knowledge which then helps us to understand that which is happening around us and facilitate action. Let’s try and break that down to a simple example. If I am driving my car down the road and the oil pressure light comes on, I know that I have at best thirty seconds to bring the car to a safe halt and turn off the engine or it will seize up (no engine oil pressure = no lubrication), resulting in a very expensive repair. In this example, data (oil pressure) has been turned into information (current oil pressure vs.

Eltirus provides its clients with actionable information in the areas of survey, geological, geotechnical or quarry engineering.

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information by validating it. For example, engine oil pressure can vary by around 50 per cent depending on oil temperature and how hard the engine is working (amongst other factors). If by way of example the normal, operating oil pressure should be in the range of 350kpa (50 psi), readings of 2,000kPa should be disregarded by the system as outliers, but should be logged as a potential issue with the sensor for maintenance to investigate. Contextualisation of data helps to turn it into information. As noted above, you must be able to make sense of the information presented to you. Many older machines that had mechanical/electric gauges often helped contextualise the data by providing a green and red shaded area behind the needle - a simple and effective approach. Do you need to know the exact oil pressure, or do you need to know if it isn’t in an acceptable range?

ACTIONABLE INFORMATION Given how much information the average quarry operation generates, some real thought needs to go into what is actionable information and what is not. Perhaps an appropriate way to consider it is, if you can do something with that piece of information to change, improve or prevent something happening (to the betterment of the operation), then it is valuable as it is a ‘lever’ of some kind to help steer and guide and could be considered actionable information. But what if you don’t understand either the significance of the oil pressure light coming on or how long you have to act even if you did? The result is the same – a seized engine. I suspect that what we are discussing here is really that elusive quality – “common sense”, which we could define ‘as having actionable information, knowing its importance and what to do with it (and acting of course!). By way of example. Many of you will be aware that modern machines often have (for want of a better term) a ‘black box recorder’ that the dealer (or maintenance team) can access in the event of a catastrophic failure or accident to better understand what happened. One of my favourite examples of this type of analysis was a Cat 789 haul truck that seized the engine. You could play back the data and see the point the oil pressure light came on, at which point the throttle position returned to zero (the operator saw the warning light), then see it go back to full throttle and the oil pressure continue to drop as the engine temperature went up, until the engine failed catastrophically.

Data Inputs

Integration

Analysis

Results

Actionable Information

Better decision making

Sales

Stocks

Targets

Drill & Blast

Load & Haul Data Collection & Validation Crush & Screen

Quality

Environment

Budgets

Energy

Eltirus Enable is a secure, easy to use system that can pull data out of other systems using an API.

Why? Because the operator decided that as it was a hot day, he would rather take the truck back to the crib room than pull over straight away (and save the engine). You can guess that the supervisory and management teams thoughts on the operators reasoning were likely unprintable. But whether through wilfulness or ignorance, the failure occurred despite the information being available to prevent the disaster. One could say that the moral of the story is that ensuring that staff have either the training or experience needed to turn information into action is vital to getting the right result.

TURNING ACTIONABLE INFORMATION INTO ACTION Since starting the quarry digital transformation initiative in 2017, we have worked to ensure that we provide our clients with actionable information, whether that be in the areas of survey, geological, geotechnical or quarry engineering. Some two years ago we noticed that many of our clients had an increasing amount of data available to them but were not using it. It prompted us to start looking for systems that could pull data together from multiple sources and surprisingly, we didn’t really find what we were looking for. As a result, we started development of a system that could do just that – pull in data from disparate systems and turn it into actionable information.

Available broadly from February 2024, we call this system Eltirus Enable. It has now been in day-to-day use with one of the largest quarries in the region for some twelve months and has continually proved its worth in helping site and senior management to make more predictive and less reactive decisions. So, what is it? Simply put, a secure, easy to use system that can pull data out of other systems using an API, that can replace paper-based forms with electronic forms on ruggedised tablets, bring in data from spreadsheets as needed and then validate and contextualise the data for you. Modules include sales, stocks, drill and blast, load and haul, crush and screen, quality, environment and energy. As you can imagine, what is actionable to a supervisor is different to a general manager and so the system has different views of the information depending on what is relevant to the specific role. Likewise, from a commercial perspective, data relevant to a senior manager would not be made available to a supervisor. Does it replace other systems? Not really, if you wanted to drill down into the raw data, the best place to do so is in the respective vendor system – you can instead think of Eltirus Enable as your operational Executive Summary. • f you have any questions, please contact me at steve.franklin@eltirus.com

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LEAVE NO STONE UNTURNED T: 1300 859 885 E: sales@triconequipment.com.au www.triconequipment.com.au

Michael Tripolone 0417 281 795 | Paul Knauer 0488 012 384 | Chris Mulally 0488 288 374


KING OF THE STOCKPILE T: 1300 859 885 E: sales@triconequipment.com.au www.triconequipment.com.au

Michael Tripolone 0417 281 795 | Paul Knauer 0488 012 384 | Chris Mulally 0488 288 374


DIGITAL

b AN ENDURING ALLIANCE After collaborating with iVolve on the globally successful Smart Quarry Site, Komatsu has officially acquired its partner as it looks to digitalise the quarrying industry.

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Muir said Komatsu used iVolve technology at its mining operations, so making the leap into quarrying was a logical evolution. “The opportunity for this partnership came up while we were looking for a technology that

“With Smart Quarry Site, operators and site managers can pull all of that information from the machines in real time.” Since its launch, Smart Quarry Site has been a global hit. Muir said that the company is in the process of rolling it out across North America and Europe. In the wake of Smart Quarry Site’s success, Komatsu and iVolve ratified their relationship, with iVolve officially becoming part of Komatsu in December 2023. “Our customers will benefit from this new alignment, as we leverage the expertise, commitment and reach of Komatsu to improve our offering,” iVolve chief executive officer and co-founder Kim Parascos said. It’s an acquisition, Muir said, that will help deliver high-calibre technology to Komatsu’s customers. “While it is great to be able to give real-time information to these quarries with Smart Quarry Site, now we want to take that further and be able to provide historical data so they can make informed choices on pit design, truck routes and anything that will help make their jobs easier,” he said. Aside from iVolve’s technological expertise, another main draw was the fact that its solutions are entirely brand-agnostic. This means Komatsu’s customers, who typically run mixed fleets, can access technologies like Smart Quarry Site on machines from other manufacturers. “We’re going to be looking to continually improve our products and technology for our customers, really keeping them front of mind during the design phase,” Muir said. “Going forward, we know that technology will play a big role in Komatsu machines. We really want to educate our customers on these platforms and how they can use them to help achieve their business goals, whether that’s productivity, sustainability or achieving a more accurate payload. “With the acquisition of iVolve, we are really jumping headlong into the digital era.” •

Image credit: Komatsu

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he shift towards digitalisation in the resources industry is making operations more predictable, efficient and sustainable than ever before. Realtime data for site operators is helping to manage the health of assets, streamline efficiency and empower informed decision-making. “Data is king in the quarrying sector,” Komatsu general manager smart construction James Muir told Quarry. “It has become so incredibly important and being able to access this data from your machine is critical for almost all modern quarries.” Though common in other industries like mining and construction, technology such as fleet management solutions have been largely unrealised in the quarry industry. That is until Komatsu and iVolve introduced Smart Quarry Site. Smart Quarry Site is an agnostic fleet management solution, which allows site and project management personnel to see real-time animated overview of their machines, including trucks, loaders, excavators, graders, dozers, and more. “With Smart Quarry Site, machines are able to receive, transit and act on information,” Muir said. “Site managers can see every movement of their machines in real-time, by monitoring the location and status of their fleets through the platform. “It also provides critical information about volumes and tonnes being hauled and loaded, and is brand agnostic, meaning the platform is compatible across mixed fleets of machinery regardless of manufacturer.” The technology has auto-reporting capabilities for machine faults, automatic service metre readings, automatic machine utilisation measuring, and access through myKomatsu online customer parts portal for parts and service kits. More than a typical fleet management solution, Smart Quarry Site is specialised for the quarry industry, striking a balance between iVolve’s back-end technological skill and Komatsu’s focus on the end-user experience.

Smart Quarry Site is Komatsu and iVolve’s agnostic fleet management solution.

gives real-time information and data on quarry operations, including productivity information, speeding events and real-time positioning of the machines on the site,” he said. “We were impressed with iVolve’s capabilities and the great synergy between our companies, but we also know exactly what our customers want. “So, with the voice of our customers like Hanson and Holcim ringing in our ears, we set out to fine-tune the program for our quarry end-users.” Komatsu and iVolve have partnered up to deliver Smart Quarry Site. Komatsu pays special attention to the machine dashboards to help streamline essential fleet management information for its customers. “We created five dashboards covering productivity, machine health, operator efficiency and everything a quarry operator needs to know, including idling and sustainability measures,” Muir said.

For more information, visit komatsu.com.au


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CONTACT YOUR LOCAL BRANCH FOR MORE INFORMATION CJD.COM.AU | 1300 139 804 | ENQUIRIES@CJD.COM.AU Bonus upgrade to 3-year/6000 hour component warranty and free 3-year Volvo Active Care subscription is valid for every new 14-35 tonne Volvo excavator purchased between 1st January 2024 and 30th June 2024. Offer available on new Volvo excavator models EC140D, EC140E, ECR145E, EC220D, EC220E, ECR235E, EC250D, EC250E, EC300D, EC300E, EC350D, EC350E, ECR355E, including Dig Assist and hybrid models (excludes Volvo wheeled excavators). Machine must be delivered by 31st of August 2024. Warranty is valid on component only. The warranty is limited to three years or 6000 operating hours, whichever occurs first, commencing from the date of delivery. Normal manufacturer’s warranty terms and conditions apply. Images are for illustration purposes only. CJD Equipment reserves the right to withdraw this offer at any time without notice.


BULK2024

BULK2024 TO RETURN The Australian Bulk Handling Expo will return after a successful event in 2022. Quarry learns more about the show and how it plans to grow the industry.

Industry decision makers will be invited to the expo.

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Images courtesy of: James Thomas

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he bulk handling industry is a diverse sector – made up of businesses that transport and handle bulk solids. At first glance it might seem that a major iron ore mine, a cement plant, or a grain shipping terminal don’t have much in common. However, they each use similar equipment like conveyors, silos, hoppers, and more to move their materials from one point to another. They are also grappling with a labour shortage. Skilled labour has also become harder to find, and much harder to retain. The skills priority list released by Jobs and Skills Australia in October found that 36 per cent of occupations were in a shortage. Technicians and trade workers had some of the highest shortages, particularly in regional and remote areas. Jobs and Skills Australia found that the shortage is being driven by the continues tightness in labour market conditions, reflecting either a lack of people who have the essential technical skills, or those with the right skills and qualities who aren’t willing to apply for vacancies under current pay and working conditions. Occupations with a strong gender imbalance were also more likely be in shortage.

The latest equipment will be on display at BULK2024

A range of strategies are being implemented across the country to help address the issue, but there is no silver bullet. It has led many organisations to begin looking at innovations like autonomous machinery to help increase their efficiencies

as much as possible, whether it’s a port, mine, or manufacturer. The Australian Bulk Handling Expo (BULK2024) plans to bring this diverse industry together, under the one roof. Located at the Melbourne Exhibition and Convention Centre, the event aims to help spread industrial knowledge, showcase the latest technologies and innovations, and provide an opportunity to network with likeminded peers. Lauren Chartres, BULK2024 Show Director, said the event is the only dedicated Australian expo for producers of bulk commodities such as grains, coal, iron ore, cement, animal feed and woodchips. “The bulk handling industry is a vital part of Australia’s economy, with a wealth of knowledge and expertise to share,” Chartres said. “To have all these exhibitors under one roof is not only a great place for business opportunities, but a fantastic occasion to network within this essential industry.” BULK2024 is aimed at bulk commodity producers who are looking to run their businesses more efficiently and keep one step ahead of the competition.


Images courtesy of: James Thomas

To ensure they can do that, the latest in equipment will be on display, including conveyors, silos, motors and drives, belt scrapers, container tipplers, dust control systems, and weighing or level measuring products. “Industries around the world are revolutionising as technology becomes more connected. Industry 4.0, automation, and AI have the potential to radically change the way businesses operate,” Chartres said.

“Stakeholders from a broad range of sectors will share their insight and expertise on how to stay at the cutting edge of technology and avoid being left behind.” Attendees will have the chance to connect with industry leaders and innovators on the show floor and at various networking opportunities at the show. It will also offer the opportunity to meet with new clients and connect with customers you might never have met elsewhere.

The expo will be held in conjunction with one of Australia’s biggest transport, logistics and supply chain events, MEGATRANS2020. The two events will be hosted over 30,000 square metres at the Melbourne Convention and Exhibition Centre, with one ticket entry for access to both exhibitions. It will also host the 2024 Australian Bulk Handling Awards, the only awards program specifically for the bulk handling industry. Chartres said the awards are an opportunity to acknowledge and celebrate the outstanding achievements and successes of companies and individuals that have demonstrated innovative practices and superior performances across the year. Nominations are currently open for the awards night and can be submitted online at the Bulk Handling Awards website. Winners will be announced at a gala dinner held on 18 September. “We’re inviting everyone to be a part of this game-changing expo – from handson decision makers in the bulk handling industry to CEOs, COOs, regulatory bodies, and government at all levels,” Chartres said. “We’ve seen how impactful bringing the industry together was at BULK2022 and are excited to see the industry continue to grow.” • BULK2024 will take place at the Melbourne Convention

Networking opportunities will be available at the event.

FOR EVERYTHING BELOW THE BELT

and Exhibition Centre from 18–19 September 2024.


WEAR PLATES

SSAB has invested heavily in its customer service team to help provide technical support to resolve incidents.

SUPER STEEL SSAB is offering high-quality and environmentally friendly steel and wear plates for the Australian quarry industry.

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owntime is one of the Australian quarrying industries’ long-standing pain points. Often striking at the most unexpected time, it can decimate finances and lead to lengthy delays, necessitating the need for quality parts and wear plates. Having been in Australia for nearly two decades, SSAB has prioritised understanding the country’s quarry industry needs. “We are always looking to produce new products and improve the ones we already have. One of the ways we do this is with Hardox 500 Tuf,” SSAB area sales manager – Australia and New Zealand Matthew Spiteri told Quarry. “Hardox 500 Tuf allows for the optimised design of all kinds of truck and trailer bodies with its unique combination of hardness and toughness.” SSAB has designed Hardox 500 Tuf to allow quarry sites to haul more, allowing for better site efficiency and more material being shifted to customers. Spiteri said even a small change, like using a 1mm thinner wear plate, could significantly benefit quarries. “The examples of savings by upgrading to Hardox 500 Tuf are based on a truck travelling 100,000km per year for six years. “The increased load capacity and other benefits in operation and production result

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from changing from 6mm-thick Hardox 450 to 5mm-thick Hardox 500 Tuf,” he said. According to Spiteri, the weight benefits of reducing plate thickness are easy to calculate. “Not only does it make the body of the machine 17 per cent lighter, but you need to purchase, store and handle 17 per cent less steel,” he said. “A 17 per cent reduction in plate thickness reduces welding time and the need for welding consumables.” Hardox 500 Tuf has a hardness interval of 475–505 HBW (Brinell hardness calculation) for high wear resistance in the most challenging abrasive applications. The 500 Tuf iteration combines the best features of the Hardox 450 and Hardox 500. SSAB’s clients have used Hardox 500 Tuf in truck and tipper bodies, containers, mining dumpers, buckets, liners, and wear parts in extreme heat or freezing conditions. The toughness makes Hardox 500 Tuf perform as a structural wear steel, keeping dump bodies in good shape and standing up to impacts from large, heavy objects striking the plate. “Hardox 450 has been the workhorse for wear applications for a long time,” Spiteri said. “Now it’s time for the next step with the arrival of Hardox 500 Tuf.

Hardox 500 Tuf allows for the optimised design of all kinds of truck and trailer bodies.

“The hardness of this steel has jumped more than 10 per cent compared to Hardox 450. And since wear resistance isn’t a linear phenomenon, the increase in hardness can increase wear life as high as 50 per cent – depending on the abrasive material and operating conditions, of course. “So if you’re looking for a longer-lasting body, Hardox 500 Tuf is the way to go.” Whether Hardox 500 Tuf is welded, bent, or machined, customers can expect the steel to deliver predictable performance. Hardox 500 Tuf comes with guarantees for narrow flatness and thickness tolerances and bending performance, ensuring cost efficiency and product quality in the workshop. Using thinner dimensions means less bending force is required. “The Hardox 500 Tuf has been on the market since 2017,” Spiteri said. “Our end-


Images courtesy of: SSAB

their operations in line with international goals to achieve net zero by 2050. Manufacturers and producers will be required to work in partnership to achieve this aim, as highlighted by the Cement Industry Federation in its Decarbonisation Pathways for the Australian Cement and Concrete Sector report. SSAB is also trying to minimise its carbon footprint and reduce global emissions. “We know that steel production is one of the highest producers of CO2,” Spiteri said. “Our first step toward minimising CO2 within our steel production is the introduction of SSAB Zero.” SSAB Zero steel is made of recycled steel and produced with fossil-free electricity and

biogas. The result is steel with virtually no carbon emissions. Spiteri said it’s essential for SSAB to continue providing solutions for the global energy transition to ensure the quarrying industry stays competitive and able to produce the high-quality ore for which it is known. “I think being net-zero or fossil-fuel-free is a big thing to aspire to, but it’s also a big thing to look forward to,” Spiteri said. “We’re not just looking at Australia; we’re looking at the entire world. That’s a lot of CO2 we can reduce and a lot of help we give the environment for future generations.”• For more information, visit ssab.com

users and quarries love the material because of its impact toughness. “We’ve made sure that our teams are on hand to support our customers who might be upgrading from Hardox 450 to 500 Tuf.”

REDUCING DOWNTIME While downtime costs vary depending on the business, incident and repair time, the result is a significant cost to the company. Data from a 2022 report on predictive maintenance stated downtime had increased by nearly 50 per cent in all industries surveyed in recent years. SSAB understands quarries cannot afford to see their downtime increase while no material is being shifted. This is why the company has invested heavily in its customer service team to help provide technical support to resolve incidents on-site. Spiteri said this type of support has changed the game for SSAB’s customers regardless of whether they are in metro or remote areas. “It sounds simple, but local technical support can really go a long way,” Spiteri said. “Technical support comes in all different facets, but whenever the customer needs us, we’ll be there.” ENVIRONMENTAL CARE In recent years, environmental considerations like decarbonisation and increased sustainability have been among the most significant shifts within Australian quarrying. Many multinational and local companies within the Australian quarrying sector have started on their pathway to decarbonising

SSAB is also trying to minimise its carbon footprint and reduce global emissions.

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DIGITAL

ORICA DIGITAL SOLUTIONS

DIVES INTO DIGITAL QUARRYING

Images courtesy of: Orica Digital Solutions

Orica Digital Solutions connects the physical and digital worlds, giving customers the right intelligence at the right time across their operations for better decisions and more predictable outcomes.

The BlastIQ Quarry’s smart and integrated solutions are designed to achieve streamlined and improved blasting.

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igital solutions are becoming increasingly vital to a quarry’s daily operations across Australia. Orica, the Australian-based technology solutions provider, has revealed how customer feedback shaped its BlastIQ program designed for the quarrying sector. Orica’s senior manager for technology, blast design and execution, Matthew Craft, details the key benefits of the blast control solution to Quarry. “Overall, BlastIQ Quarry is a powerful and comprehensive solution that can help quarries improve the efficiency of their drill and blast operations, reduce overall cost, ensure data accuracy, drive productivity, and maintain regulatory compliance,” he said. “Its integrated and connected components provide a complete solution that delivers real results and drives continuous improvement for the industry.” BlastIQ Quarry uses digital technologies to help quarry operators improve their drill and blast activities in near real-time. It allows quarry operators to design blasts according to performance objectives and presents

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Quarry workers can collect data on the bench with BlastIQ Mobile Lite.

drill and blast insights for continuous blast optimisation. The company revealed the platform was developed by leveraging customer feedback and Orica’s deep blasting experience in quarry operations. Craft said the smart digital blast optimisation platform provides a single source of truth and delivers instant pre- and post-blast insights. Operators can collate their data digitally instead of manually handling paper-based information and derive insights to inform their drill and blast performance. Complementary applications to enable a “synergistic workflow” include the SHOTPlus blast design and modelling software; BlastIQ Mobile Lite, which places blast designs and hole conditions in the palm of operators and engineers; and BlastIQ Insights, which enables the tracking of key performance indicators and comprehensive document storage. “These technologies work together to offer customers improved productivity. The blast loading instructions and rules are instantly


digitally communicated to field operations to ensure the right explosive product and quantity is used at the right place and initiated at the right time,” Craft said. Operators can achieve improved in-field blast quality control and assurance by using the BlastIQ Mobile Lite application, which captures auditable data directly. Operations and engineering personnel can share the blasthole condition, which is captured in near real-time, allowing data to empower rapid decision-making and improved operational efficiencies. With these features, the BlastIQ Quarry solution can integrate easily into existing operational systems and processes. “This allows quarries to significantly improve blast quality control, eliminate rework, and reduce excess drilling and explosives consumption,” Craft said. “It allows quarry operators to confidently optimise their drill and blast activities, reduce costs, improve productivity,

and manage regulatory compliance, ensuring the long-term success of their quarry operations.”

KEY FEATURES The BlastIQ Quarry platform is compatible with the public application programming interface and allows custom reporting and software integration in a single workflow. The electronic capture and transfer of field data to BlastIQ Insights eliminates manual entry and enables rapid reporting, intelligence, and audits with minimal transcription errors. Orica designed the platform to eliminate excess expenses and reduce the risk of poor environmental outcomes while enabling efficient documentation management. “Smart and automated capabilities ensure the right explosive product with the right energy is loaded every time. Blast documentation and job pack functionality

ensure relevant documentation is uploaded throughout the drill and blast execution process,” Craft said. Craft said other key features include remote auditing, centralised collaboration, and market-leading blast design tools. “With information securely and centrally stored, drill and blast information can be audited remotely. In addition, information can be shared collaboratively via cloudhosted web portals,” he said. “Exception reports can be generated to provide better visibility to manage blast quality control. Market-leading blast design tools are available for survey, profiling, loading and timing rules. “BlastIQ Quarry undergoes continuous development and works with users to improve its value, and is supported 24/7 by Orica’s global network of support engineers and technology specialists.” • For more information, visit orica.com/blastiqquarry

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SPECIAL REPORT

PILING UP:

SUPERIOR’S STOCKPILES SHINE As quarry operators deal with intense demand levels, stockpilers can offer quarries the flexibility and customisation required to handle different aggregates around the work site.

Superior Industries’ TeleStacker Conveyor is the company’s largest radial stacking conveyor.

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“This nearly unlimited flexibility can add efficiency to an overall operation, as well as provide a higher quality product,” Superior Industries business development manager Marcis Pavars said.

STATE OF PLAY Some of the most popular aggregate production within Australia focuses on asphalt, concrete, and road bases. Still, there is a growing demand for sand and clay as deposits and demand differ. In recent years, regulations have tightened and changed on many aggregates. This has meant operators need to ensure the quality of their product batch and find equipment to help them achieve this level of consistency.

Pavars said Superior Industries has listened to feedback from customers about this. “Each year, contractors spend millions of dollars to produce aggregate products,” he said. “Creating the products for these applications is very complex and costly. “Tighter specifications and tolerances mean that the importance of product quality is becoming increasingly significant.” While many operators have considered their machinery and processes to achieve better quality aggregate, stockpiling can often be overlooked. Poor stockpiling techniques can see otherwise good quality products being wasted due to not being “in spec” or falling foul of the quality regulations. Images courtesy of: Superior Industries

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ustralian quarries are facing high demand for all types of excavated products, from hard rock to sand and clay, as big build projects continue to propel the construction industry and regional infrastructure efforts. As Australian quarry operators manage their demand, stockpiling segregation can be one of the unspoken headaches on site. Operators often want to blend products to even grading levels before the product enters the market, especially in sand and clay production. Superior Industries’ Telestacker Conveyor, their largest radial stacking conveyor, can enable operators to create different sizes, shapes, and aggregate configurations.


By using stockpilers and the correct stockpiling technique, operators can gain several key business advantages: • A storage method that achieves material availability • Mitigating the impact of the three main stockpiling issues: improper segregation, degradation and contamination. • Improved product quality. Superior Industries’ TeleStaker Conveyor has had an enduring reputation within the aggregates industry, which Pavars said had called it the “king of the stockpile”. The TeleStacker Conveyor has been on the market for close to three decades. Still, Superior’s team of designers and engineers have consistently fine-tuned the design and features to ensure it meets the demands of the modern quarrying industry. The stockpiler features variable height, length, and axle positions. It may seem insignificant, but this trifecta is vital to the Telestacker Conveyor to create a layered stockpile construction critical to achieving partially and fully desegregated piles across several aggregate types. Superior’s automated TeleStaker Conveyor has a specially designed control system that makes it easy for all operators to use, according to Superior Industries chief conveying engineer Travis Thooft. It allows operators to select from four pile types: radial windrow for fully and partially desegrated piles, inline windrow, and radial and inline conical. The Inline windrow setting is helpful for small areas using constant stinger motion, enabling more volume. In contrast, the radial conical pile can make small piles with less movement of the stacker but does not make a desegregated pile. The inline option does a similar aspect, just with inline rather than radial positioning. “One major advantage of the automation system is the ability to save stockpiles. The operator can save where they’re at and shut down the machine, and the next day start right where they left off without reintroducing the parameters,” he said. “It’s a user-friendly control system that improves performance in the field.” The automated technology on the TeleStacker Conveyor uses technology exclusive to Superior Industries to stockpile higher in the back and lower in the front. “It enables our stacker to produce 30 per cent more capacity than a regular radial stacker’s method,” Thooft said.

The TeleStacker Conveyor has been on the market for close to 30 years but remains a staple of the quarrying sector.

Superior Industries has implemented several features to ensure it is easy to use for operators.

Pavars said that the automated features on the TeleStacker Conveyor would benefit most Australian quarry operators. “It can offer a means of achieving higher productivity and higher quality products in many different types of operations,” he said. Superior also employs winch technology in its TeleStacker’s stinger to ensure reliability and safety. The winch at the back end of the stinger ensures material is building up on top of the stinger, requiring less maintenance to maintain the cable tension. “The way we’ve engineered our winch for stinger extensions allows for the safest and most reliable operation on the market,” Thooft said.

AUSTRALIAN CAPACITY While some may see Superior Industries as a United States brand, the company has recently invested heavily in the Australian market. Superior has two dealers in the Australian

market. Tricon Mining Equipment offers a complete line of Superior products ranging from all product segments, including portable, modular, and stationary crushing, screening, washing and stockpiling equipment like the TeleStacker Conveyor. Tricon manages the Australian Capital Territory, New South Wales, Queensland, Tasmania, and Victoria for Superior Industries. The conveyor is designed in-house, enabling faster support for operators when required. Superior’s Australian dealers are fully equipped and trained to service all quarry operators and their needs for the Telestacker Conveyor. “Our Australian dealers are known for not only their expertise in the industry but also their dedication to customer service,” Pavars said. “Our customers can have confidence in enjoying the benefits of our high-quality products and their next-level service.” • For more information, visit superior-ind.com

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Images courtesy of: CJD

EXCAVATORS

EC480E UNLEASHING

THE POWER OF PRODUCTIVITY Quarry looks at Volvo Construction’s EC480EL and the suite of technology packages that complement the needs of the modern quarry.

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uarries face the challenge of optimising machinery amidst escalating fuel costs and growing sustainability considerations. Balancing the pursuit of increased productivity without excessive fuel consumption presents a significant dilemma in the quarrying sector in Australia. Addressing this challenge, Volvo Construction Equipment presents the EC480E as a solution. Exploring the diverse capabilities of the EC480E excavator, Quarry chats to Hayden Grant, the national product manager at CJD Equipment, regarding this versatile excavator and the optional technologies that can be integrated into this machinery positioning the EC480E as a leading choice in the market.

ECONOMIC FOR THE ENVIRONMENT Being the latest generation, the Volvo EC480E, equipped with a D13 Stage V engine and delivering 374 hp, is designed to meet the latest emission standards

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and improve fuel efficiency without any performance loss in most operating conditions. Its operating weight of around 48 tonnes and bucket capacity of up to 3.5m3 facilitate substantial work in various terrains. “The D13 Stage V engine boasts more power while allowing operators to reduce fuel consumption and emissions and achieve superior quality, reliability and durability,” he said. “The engine was designed off proven, advanced technology and built on decades of experience.” At the heart of the Volvo EC480E is an electro-hydraulic system that can control flow and reduce internal losses in the machine’s hydraulic circuit. This system increases the operator’s controllability and shortens cycle times, which helps improve fuel efficiency and productivity. The EC480E has two automatic modes. The automatic idling system reduces the engine speed after inactive periods, while the

automatic engine shutdown turns the engine off after a long period of inaction. As part of the machine’s ECO mode, the two features help reduce the excavator’s fuel consumption around the job site. This mode is activated as default, but operators can turn it off at the keypad. Grant said eco mode and the D13 engine improved fuel efficiency without any performance loss in most operating conditions. Operators can monitor fuel consumption levels with the improved fuel display, showing real-time and average fuel consumption. This real-time data lets operators make informed decisions about tasks and fleet management.

PRODUCTIVITY PROMISE To get the maximum productivity from the EC480E excavator, Volvo designed it with the operator in mind. Its spacious cab provides a welcoming environment, equipped with adjustable seats and controls tailored to ergonomic ease. “With ideally placed controls and switches and a user-friendly LCD monitor and keypad, the task at hand becomes easier,


and operators will work more efficiently – resulting in more productivity,” Grant said. The Volvo EC480E LCD monitor serves as the centre for efficiency, not just displaying information but also streamlining operations though customisable shortcuts, features can be hot-keyed to suit the operator’s access to them while working. Features like the windscreen wipers, camera and audio mute can be placed on the EC480E’s shortcut panel for easy access. This innovative interface allows operators to tailor the monitor to their preferences, creating quick-access shortcuts to frequently used functions and settings. The LCD monitor also provides the operator with machine information, including fuel consumption and service alerts, to enable them and quarry managers to make informed decisions on-site. The productivity focus extends beyond the operator cabin with several critical features adapted into the EC480E’s build. An optional diesel-driven coolant heater can help start the engine in low temperatures while heating the cab, with the ability to be set to turn on for a future date and time. The hydraulically driven, electronically controlled cooling fan regulates the temperature of the vital components. It automatically activates only when needed to ensure it cuts down on fuel consumption. The optional reversible functionality – which blows air in the opposite direction – enables self-cleaning of the cooling units to provide less maintenance and more productivity.

Volvo’s EC480E is designed to be a fuel-efficient excavator.

The Volvo Co-Pilot is an optional system to help operators get the most from their machine.

TECHNOLOGY-BASED SAFETY Volvo Construction Equipment has embraced the latest technology to provide owners and operators of the EC480E excavator with critical features to optimise their operations. Volvo Co-Pilot, a 10-inch touch screen display, is an optional extra for the Volvo EC480E, available through Volvo’s Australian dealer CJD Equipment, which opens a world of options for operators. With Volvo Co-Pilot installed, customers can purchase a dig assist quarry package that combines Dig Assist strategy and OnBoard Weighing (OBW). Through this package, operators can access the basic level of Dig Assist, which provides real-time data feedback for operators. Operators can quickly gauge when they have reached target depths and slopes, eliminating the need for manual grade and level checks. This technology optimises safety and ensures high precision, faster project completion and reduced over/under excavation. The Dig Assist quarry package also enables the full use of the OBW with minimum digging functionality, with OBW being the system that links up to external productivity services. It is also possible to upgrade to Dig Assist In-Field Design and Topcon and Trimble 3D after installing the Volvo Co-Pilot and Dig Assist package on the EC480E excavator. “The Volvo Co-Pilot is a state-of-the-art technology designed to work seamlessly and simultaneously with Volvo Assist, comprising of Dig Assist, Haul Assist and Load Assist, providing real-time operational data for a responsive, harmonious and efficient operating experience,” Grant said.

“The beauty of Dig Assist is that you can load applications similarly to how you would download an app on a mobile phone. For example, it is possible to have both Trimble and Topcon in Dig Assist; you can switch between them once they have been set up.” Volvo Co-Pilot serves as the central command hub for all Volvo Assist platforms. It leverages the potential of onboard machine data and high-precision sensors to streamline tasks, which Volvo CE has engaged to reduce completion times substantially. Co-Pilot’s user-friendly interface ensures operators can quickly initiate projects with a few simple taps, selecting the required job parameters. The strategically placed display minimises operator engagement with fewer on-screen menus, thereby maintaining concentration on the immediate tasks. Volvo Co-Pilot alerts the operator with auditory and visual signs by establishing predetermined operational boundaries. This reduces the need for additional personnel on-site by eliminating physical movement around the machinery. Grant said CJD Equipment’s team of experts can guide customers through the best options and setup for their needs. “Volvo is one of the world’s best manufacturers of safe, high-quality, and technologically advanced machinery. Telematics is just one step forward in the transformation towards strategic customer partnerships - with additional productivity services available,” he said. “CJD Equipment has an extensive national support network to ensure you are well supported, no matter where or when.” • For more information, visit cjd.com.au

Quarry February 2024 33


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Images courtesy of: Hazemag

CRUSHING Hazemag’s Dynarox mobile crusher is the latest innovation to their crushing range.

ULTRA MOBILITY Hazemag has always focused on building a crushing and screening range for modern times. The latest Dynarox range presents its latest forward-thinking innovation.

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azemag has a unique history within the quarrying and aggregate recycling sector, which started in the embers of wartime Germany. The German company, registered by Dr Ehrhardt Andreas and Richard Rendemann in 1946, began in the crushing sector following World War II. Hazemag’s original impact crusher, the Andreas-type impact crusher, was used to help process a large amount of building rubble left in the wake of German cities destroyed by the war. The crusher proved successful as Germany rebuilt itself in the following months and years, and Hazemag’s enduring success has lived on close to eight decades later. The German original equipment manufacturer, a European household name, has consistently built mobile crushing equipment to suit modern needs. Hazemag and allmineral managing director of Australia Teddy Craies and project and service engineer Jaco Botha spoke to Quarry about how this concept has helped redefine their new Dynarox range of mobile crushers.

STRONG FOUNDATIONS Hazemag’s designers and engineers went into the industry to better understand their customer’s pain points regarding crushing and screening equipment. There were three resounding responses: It needed to help

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their sustainability goals, be mobile, and help improve aggregate quality. Craies and Botha believe Hazemag’s new Dynarox range will impress Australian customers on all three fronts. “We’re excited to see how it will perform and how our customers will receive it,” Botha said. “And especially to see it in Australia, we think it offers some real advantages to quarry operators here.” Hazemag understood many of its customers and potential customers in Australia and abroad were operating across multiple sites. As operations expanded to cover different sites and sometimes various aggregates, they wanted a machine to go with them wherever needed. In the past, this has been a drawn-out process. The crushing and screening unit needed to be dismantled and moved onto a truck via crane, which soaked up valuable time from the operator’s standpoint. Hazemag completely redesigned its Dynarox crushing and screening unit to be highly transportable from site to site. The Dynarox I-120 mobile crushers’ feeding unit, which features a 5m³ hopper, has its hydraulics foldable into a compact, travelready design. The outfeed conveyor and the vibrating screen can fold down and towards the machine, as can the front conveyor. The hydraulics can be controlled by an operator with the ease of a flick of a switch.

The movability of these features enables the machine to be easily moved for transport around a site or to a site further away. Botha said if the right conditions were in play, the machine could take around 30 minutes to fold down and be ready for transportation. “It used to take a lot longer because you had to dismantle and set up in a very intensive way and sometimes required a crane,” Craies said. “It was hard to get away from that because the mobile crusher, traditionally, has been a bulky piece of equipment, but we’ve redefined that with this compact, lightweight model. “This machine is much more efficient; it improves the movability in the pit and on-site, and it also improves the movability on the road due to the compact design.” The light and compact machine can also improve fuel burn. The lessened weight compared to other units on the market allows for reduced towing load when transporting, which helps reduce quarries’ impact on the environment. The mobile crusher also features a diesel-electric direct drive, which extends fuel efficacy and allows lower emission levels. Yet, Hazemag’s new range of mobile crushers is far from just lightweight crushers in a portable package. Hazemag has packed it with customisable options to ensure clients can alter the equipment to suit the needs of their operation and aggregate. The pre-screen conveyor and postscreening unit, available as a single or


The Dynarox mobile crusher can be easily transported from site to site.

double deck, are optional to suit the needs of the quarry. The double deck pre-screen allows for efficient fines screening. It contains an integrated bypass flap to transfer the fines to the pre-screen or the final product. “This came about from our experience on the market, which we saw needed a compact and customisable solution that is easy to move around,” Craies said. “Many operators we spoke to are also moving towards the green economy, and we needed to build a machine that is more in tune with how customers are changing their footprint. “While there is a standard model, we can work with the customer to customise it to suit their needs and how they operate best.” Hazemag has added a wind sifter and an optional magnetic separator to the Dynarox I-120 model. The optional separator efficiently extracts steel from the aggregate mix while the wind

sifter shifts lightweight materials such as wood, plastic, and paper from the mix. This results in quarries being able to produce aggregate with assurance about the quality of its gradings being up to specification and regulations. “The combination of these features will reduce the amount of contamination in your product and improve the quality,” Craies said.

SPECIALISED SUPPORT Few original equipment manufacturers can match Hazemag’s history within the industry. Customers who invest in Hazemag’s Dynarox mobile crushers can the benefit of the company’s Australian-based staff, like Botha and Craies, as well as its renowned engineers in Germany. Hazemag’s German engineers also get flown to Australia to train new customers to get the best out of their new equipment. The company has extensive stock for all its machines in the

Canning Vale warehouse, located in Western Australia. Craies said Hazemag has invested heavily in upskilling its staff on the new Dynarox equipment and remote access capabilities. “We’ve invested heavily in this area to help customers manage their equipment, do predictive maintenance and HazConnect, which customers can track how their machine performs via their mobile phone,” he said. While its first-ever crusher was built to suit the era’s needs, in the new Dynarox range, Hazemag has delivered a mobile crusher to suit the needs of modern quarrying. “There are many years of experience and development that has gone into developing what we have today,” Craies said. “We’ve designed this technology to help get quarries to be able to move, and we’re excited to bring this to the market.” • For more information, visit hazemag.com


CRUSHING

LEAVING A LEGACY Quarry finds out why Sheridan’s Hard Rock Quarries decided to install a modular fixed plant instead of replacing its mobile machinery.

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“The quarry also produces road base used for pavement construction for highways, gravel roads, road maintenance, and filling potholes. We can also provide finely crushed aggregate which can be used for driveways, pathways, and gardens.” The quarry provides direct employment to more than 20 people from the local region, and over 40 local contractors may be engaged by the company at any time. Graham and Sonia’s children, Toby and Abbey, are also involved in the family business, applying their production, maintenance, and engineering skills to the team. The Sheridan’s hope to keep the business in the family for many years to come.

After more than a decade of operation, the quarry’s mobile gear was beginning to wear out. Sheridan decided that instead of replacing it with a mobile plant, he wanted something fixed. A key factor for the decision the ability to move the plant, and the ease of assembly. Sheridan told Quarry that in another 10 years’ time, the team at Sheridan’s Hard Rock Quarries would likely have to move the plant to another location on site as the quarry grows. “We looked around at several plants, but they seemed complex,” he said. “We liked the simplicity of the Terex range. It’s a full-on modular system that stood out to us.” Images courtesy of: Terex

raham Sheridan likes to think long term. In 2011, he started Sheridan’s Hard Rock Quarries with his wife Sonia, located on farmland that has been in the Sheridan family for decades. The main quarrying operation at Hernani, NSW, was developed on land rich with volcanic soil, which fostered a history of potato and cattle farming, and still operates as the latter to this day. Sheridan takes pride in being a specialist in basalt products, providing his customers with quality, high grade, silica free aggregates and quarry supplies. “We produce silica free 5mm, 7mm, 10mm, 14mm, 20mm aggregate products to suit a wide range of applications,” he said.

Terex Jaques has designed its modular plant range to meet a wide range of static crushing and screening applications.

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Sheridan’s Hard Rock Quarries provides his customers with quality, high grade, silica free aggregates and quarry supplies.

Terex Jaques has designed its modular plant range to meet a wide range of static crushing and screening applications. All modules are pre-engineered, pre-built, pre-wired and pre-tested to operate on a small footprint with low civil engineering and operating costs. The modules and components can be easily transported in standard shipping containers or by road, allowing quarries to move the machinery on site to a different location, if required. The company worked closely with Sheridan Quarry, considering product and capacity requirements, to design a modular plant that delivered the desired outcome while fitting within the available footprint. The collaborative approach between Sheridan Quarry and Terex ensured that the solution was right before proceeding to final design and installation.

Sheridan said he wanted to be able to look back in around 30 to 40 years and still have a reliable plant. The machines selected were a TG320 Cedarapids cone crusher with surge bin and pan feeder module, three Terex Cedarapids horizontal screen modules, Terex Canica Model 100 VSI module and a radial stockpile conveyor with some other fixed conveyors to link the modules together. When the plant was ready to be commissioned, Terex Jaques’ service technicians worked in conjunction with Sheridan Quarry staff to get the plant operational and producing quality, in-spec aggregates at the required plant throughput. Terex Jaques has a global service network with in-depth industrial knowledge to assist quarries. It also offers a set of field services to help meet maintenance, repair, and refurbishment needs.

As an original equipment manufacturer, Terex Jaques can also provide spare and wear parts when required. They are manufactured to strict standards, using high-quality materials, tools, and techniques. The company can repair damaged equipment to like-new condition and restore worn or irreplaceable equipment. The communication and strong working relationship between Terex and Sheridan Quarry has been critical to the success of this project. Sheridan said Terex were good at liaising with the quarry team and had no complaints with how the plant was operating. “The modular construction made assembly easy,” he said. “If we had any issues, or if something wasn’t quite right, Terex were good at making sure everything was fixed. • For more information, visit terexmps.com

Quarry February 2024 39


Images courtesy of: Kobelco

EXCAVATORS

SAWN OFF

THE OLD BLOCK

A new Kobelco digger is helping a Sydney quarry flourish. Quarry speaks to Dan Jones, the third generation family business founder, to learn more.

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wo years ago, Dan Jones was working full time at his grandparents’ quarry while finishing a business degree at university. He saw there was an opportunity to grow the business, but with his grandparents being in their 70s, didn’t want to burden them with extra work to sustain it. He decided instead to start his own business working alongside them, and from there the Jones Quarries Group was born. The quarry operation is primarily focused on extracting, processing, and supplying sandstone products – usually in the form of logs or cut into specific sizes for use in walls, finishes, stairs and more. Jones told Quarry that he strives to provide the highest-level service to his customers. “We’re a small, family-business,” he said. “They’re dealing directly with the company, and we make sure there won’t be any issues. “It doesn’t matter if our clients have an issue at 5am on a Monday, or 9pm on a Saturday, I’m always available to help out,” he said.

Daniel Jones, founder of the Jones Quarries Group.

Efficiency and precision are key to this service, which is why Jones uses a custom saw attachment. Jones said they have become a popular tool among sandstone quarries – almost a standard for the industry. The saws are at 500mm and one metre intervals, which allows an excavator to saw a dimensional grid without having to mark every individual cut using a single blade. This significantly speeds up the process, but the equipment weighs around four tonnes. Jones needed an excavator that could extend and hold its arm fully, without tipping or affecting the overall end product. “We explored the market and Kobelco came out on top,” he said. “Pricewise they were competitive, and we got a good feeling from our local Kobelco dealer STM Trucks & Machinery (STM) when I went to their yard. “STM is a family business as well and share our values. In the end, we decided it was the right fit.”

Peter Moore from STM Trucks & Machinery (Left) and Daniel Jones (Right). Image: Kobelco

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The Kobelco SK380XDLC was one of the first machines Jones purchased when setting up his business. It had the right amount of power to do the job, and most importantly, it weighed almost 40t, making it perfect for the sawing application. Kobelco’s XD series of excavators are designed specifically for quarry-like environments, featuring a rugged machine body with additional reinforcement across the boom arm and undercarriage. It is built to exacting Japanese standards for quality and reliability and is one of the company’s heaviest excavators it produces. Safety is paramount for the operation, which is why Jones had additional features installed onto the SK380XDLC. Because sandstone is high in silica, Jones installed a HEPA filter and made sure the air inside the cab is pressurised. This ensures that any dust created by the sawing cannot enter the cab. The digger also features an additional camera on the right-hand side, along with another LCD screen to provide 360° vision at all times. Jones said the comfort in the cab has been a standout. “When you’re sitting in the cab all day, you want the environment to be comfy,” he said. “The design of the cab makes it appealing to work in – the vision is fantastic. It sets it apart from other diggers.” The SK380XDLC features a large air conditioner that blows from behind and to the right and left of the operator’s seat. These can be adjusted to put out a direct flow of cool or warm air for long summer days. Coil springs help to absorb small vibrations and high suspension mounts filled with silicone oil reduce heavy vibration. Jones adds that he was lucky to see all of the different diggers in person before deciding which one to buy. “Having hands-on, up-close experience with all the brands we were thinking of was so


important. If you’re exploring the market, make sure you test the waters, do your research, and find out if it’s the right gear for you.” While the digger was primarily bought to handle the sawing, it’s become a jack of all trades. The team have attached buckets, hammers, and rippers to it to handle odd jobs around the quarry. This flexibility is very important for the small business. Jones said that knowing he has a machine that can cover all bases helps when there is downtime for other equipment. “Having the right gear for the job is one of the most important lessons we’ve learned,” he said. “Previously we’ve done jobs using older equipment and made do with what we had. In hindsight, we could have done it quicker. “Whether it’s a bigger digger for the job, or a different tool or attachment – it’s super important we’re using the right gear. It saves on both downtime and labour.” • For more information, visit kobelco.com.au

A custom saw attachment allows the excavator to create a dimensional grid. A saw attachment significantly speeds up the process but weighs around four tonnes.

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Image credit: Xajandali

CEMENT

WINDS OF

CHANGE IN DUBAI It is one of the world’s largest cement associations, and the last few months of 2023 have set up the WCA for a bright year.

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n the heart of Dubai, a path forward was charted for the World Cement Association. Partners from across the global cement industry gathered in the most populous city in the United Arab Emirates for the association’s annual conference last year. The association, founded in 2016, used the conference as a platform to deliver a suit of major changes for 2024 and its members. Quarry has examined the major changes and what they mean for the global cement industry.

NEW LEADERSHIP The association has brought a new leader into the fold in an announcement that will end one of the organisation’s founding legacies. Wei Rushan was unveiled as the new president of the global organisation in October. Wei’s elevation to the top role sees him replace Song Zhiping, the founding president of the WCA.

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Song has over 40 years of business and management experience in China’s building material industry and has served as WCA president since its establishment in 2016. WCA chief executive Ian Riley paid tribute to Song’s contribution to the organisation. “On behalf of the board and employees at WCA, I would like to express our gratitude to Song Zhiping for his invaluable contribution in founding and nurturing WCA,” Riley said. “Wei Rushan brings a new range of skills and ideas that will mark a new chapter in WCA’s growth. I am excited to work with him for the good of the whole cement industry.” The association was founded to represent cement producers across the globe in a unified approach incorporating large cement producers to single-plant companies. Producers from China, Ireland, Korea, the USA, Germany, Cyprus, Bulgaria, Denmark, Bangladesh, and France joined the association.

Wei used the association’s annual conference in Dubai in October to signal his intention for the organisation’s new direction. “WCA shall follow the principles of openness, inclusiveness, connectivity and win-win cooperation, and continue to provide value-added services to its members through annual conferences, member forums, professional committee activities, etc,” he said. “There is an African proverb, ‘one person can go faster, but a group of people can go further.’ Let’s work together, build a consensus and create a healthier and more sustainable future for the industry.”

NEW DIRECTION While Dubai marked the emergence of Wei’s leadership, it also delivered a rallying cry to the broader industry. WCA founder and director Ali Emir Adiguzel used his conference address to confront the current state of cement industry and the challenges it faces. “We have enough cement for the next 25 years,” he told the conference. “Despite our achievements, there is more work to be done in the years to come. To reach our Net Zero goal by 2050, we must significantly reduce carbon emissions. “The technologies and mechanisms for this endeavour appear available, though currently miniscule, and not economically fully feasible.


Image credit: World Cement Association

“Regulatory frameworks must evolve to minimise costs for end customers. Collaboration between the private and public sectors is imperative to facilitate carbon reduction.” The current trends across the industry are seeing more investment to turn waste into fuel, expanding recycling construction and demolition waste, and utilising clinker substitutes. Other initiatives include promoting renewable energy, and market-driven carbon pricing mechanisms should drive investments in decarbonisation technologies. The WCA believes the goal is to achieve a Net Zero CO2 industry by 2050 if coupled with increased funding for new technologies. “The time to act is now. We possess the tools, knowledge, and commitment to transform this vision into reality,” Adigzuel said. “Together, we can make substantial strides towards shaping a sustainable

Former WCA president Song Zhiping received a lifetime achievement award in 2023

future for the cement industry and, by extension, our planet.”

INCREASED COLLABORATION To help achieve these aims, the WCA also announced a networking platform for its members to boost collaboration. The Cement Network has been designed in collaboration with World Cement Association and the World Cement Network. In a statement, the WCA said the initiative will combine industry experts, cement

modular solutions Simple, robust design. ▪ Pre-Engineered ▪ Proven Design ▪ Easy to install ▪ Maximum Productivity

E: jaques@terex.com www.terexjaques.com © 2024 Terex Corporation. All rights reserved. Terex and Jaques are trademarks of Terex Corporation or its subsidiaries.

producers, suppliers, and service providers on a single platform. “The Cement Network serves as a unifying platform for industry professional, encouraging innovation and sustainable practices while addressing the ever-evolving challenges faced by the cement sector,” Adiguzel said. “By facilitating an open exchange of ideas and fostering collaboration, the WCA aims to steer the industry toward a more efficient, and prosperous future.” •


INVESTIGATION

DIRE WARNING

FOR QUARRY SUPPLY

Australia’s infrastructure regulator has sounded an alarm for the future of quarry supply. Quarry breaks down the concerns and suggestions from its latest report.

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nfrastructure Australia has sounded an alarm over the future of the country’s quarry supply in the years to come. The regulator has detailed its latest concerns for the sector within its 2023 Infrastructure Market Capacity report. The third iteration of the report highlighted “acute quarry shortages”, especially in Melbourne, NSW’s Mid North Coast and South East Queensland, as critical issues for Australia’s infrastructure market. Infrastructure Australia chief executive Adam Copp said these concerns were amplified by a historic increase in demand for building materials and construction activity in Australia. “With so much construction activity underway, the industry is finding it increasingly difficult to source key building materials and workers – particularly engineers, skilled trades and labourers,” he said. “A clear message in this year’s report is that limited access to local steel and cement, as well as localised shortages of quarry products, is contributing to price uncertainty in the supply chain, leading to delays and cost overruns. “The infrastructure sector is delivering a major public infrastructure pipeline valued at $230 billion over five years. This is occurring alongside a plan to build 1.2 million new homes and a major investment in the energy sector, which is quadrupling over that same period.” Infrastructure Australia released 14 recommendations for the federal government in partnership with state and territory

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governments to solve concerns about quarry supply and additional infrastructure issues. Quarry examines the report’s concerns and solutions for the future of Australian quarrying.

QUARRY SUPPLY The latest report from the infrastructure regulator suggests the country’s local materials supply, particularly for quarries and especially within regional areas experiencing construction growth. “Acute quarry shortages loom in several regions nationally, with long lead times from quarry approval to extraction making it difficult to source alternative supplies when and where they are needed, increasing project schedules, costs, and carbon emissions,” the report stated. The differing levels of raw quarry data available per state impact the data within the report. Overall, the regulator highlights concern about the long lead times for quarry approvals. On one hand, this impedes the construction industry’s ability to supply materials for residential and larger infrastructure construction. It also impacts the ability to plan to replace extinguished quarry supply or quarries with expiring licences and approvals. The regulator suggests several issues contribute to the delay of quarry approvals, including external regulation and policies around environmental standards, cultural heritage, and net-zero targets. The report highlighted three locations of concern, including Melbourne, South

East Queensland, and Mid North Coast New South Wales. According to its research, Melbourne’s chief concern is that several quarry consents are due to expire before new quarries are established. While it highlighted the Victorian government’s Quarry Approvals Coordination Unit as a positive for the state’s quarrying sector, it was concerned about how significantly construction costs would increase without more quarries being approved. Quarry operators, who were kept anonymous within the regulator’s report, shared concerns about the length of the approval process. “Developing quarries is. five-10-year process, and a lot of people are just giving up, saying it’s just too hard and too costly. And there’s no guarantee of a return,” one said. The regulator believes the lack of quarries in regional areas will impact South East Queensland and the NSW Mid North Coast. The two regions have significant investments tied up in the Brisbane Olympics in 2032 and the Coffs Harbour Bypass, which could suffer due to the lack of quarries, serviceability, and quarry capacity to serve those infrastructure projects. Two suppliers echoed the sentiment within the report about serviceability with concerns about the road network. “Generally, across the company, road access networks for our trucks are fairly prohibitive, and assets and reserves are moving further and further away from metropolitan areas,


which means they’re getting more expensive,” one supplier told the report. Another supplier added: “Clearly, we use more truck drivers than anything else. So, that’s where we’re feeling the labour shortage the most. “But (even) quarry operators are very hard to find now. Even admin staff in offices are very difficult to come by.” The report finds that Australia’s overall infrastructure workforce must grow by 127 per cent to meet demand. It is the third time in three reports that the regulator has highlighted workforce shortages.

SOLUTIONS Many of the concerns Infrastructure Australia shared within its reports would be familiar to those in the industry and those within state and federal governments. The Victorian Government’s joint ministerial statement from 2018, signed by state treasurer Tim Pallas and then Planning Minister Richard Wynne, highlighted streamlining the approval process, protecting resources of extractive resources of strategic importance, and preventing the incursion of new development into quarry buffer zones. “We need a ready supply of raw materials as Victoria grows. That’s why we are supporting the industry by putting in place the right protections for our quarries,” Pallas said. “The challenge facing Victoria is a significant one. This statement is part of our proactive plan to drive affordability of extractive resources.”

Image credit: Adobe Stock

Image credit: Adobe Stock/Alice Nerr Some suppliers noted the lack of truck drivers as an issue for the industry.

Infrastructure Australia has noted a lack of building material supply in areas across the country.

The State of Victoria Department of Energy, Environment and Climate Action released its Extractive Resources Supply and Demand Study 2022-30. The report estimated demand for the extractive resources would continue to grow by 2.5 per cent until 2030. According to its data, the level of demand would service an extra 32 quarries in 2030 based on 500,000 tonnes per year. However, that report notes the current quarry replenishment rate is “deteriorating” with community attitudes and competing land uses, creating “uncertainty” and longer timeframes. “While market forces may stimulate new quarry developments as material prices rise, barriers to entry for new quarries are increasing and may be reducing competition,” the Victorian report reads. “Without a response, it is likely that Victoria will face significant transport distance and material cost increases up to 2030. Determining the response is complex. The state must balance competing land use policies and priorities, particularly in periurban areas. “It must also consider regulatory reform, better enable the approval of new quarries and quarry expansions and maintain carbon emission reduction targets.” The Victorian report suggested the state government should consider “multiple smaller work authorities” located in regional areas, which would work on the limited existing greenfield areas for “explicit use” of extractive resources. But what does Infrastructure Australia want to do about it?

The regulator has made two critical recommendations as part of a targeted solution to boost quarry output to match the “historic” local demand level. The first recommendation would see Victoria’s quarry approvals coordinator model replicated across the states and territories. According to Infrastructure Australia, this model would support applications to increase quarry supplies for priority infrastructure projects. The regulator has also asked the federal government to consider exploring options to improve data collection and transparency of national quarry supplies to support longer-term planning. The regulator suggests the recommendations need to be commenced within six months. “Australia’s lack of domestic capacity to supply building materials exposes investments to cost-overruns, delays and future global supply chain risks,” Copp said. “Currently, there is no method for collecting or analysing data on local manufacturing and production outputs at the national level, hindering the ability to predict supply and mitigate shortfalls, as we can do with labour. “We urge governments to work together and with industry to address this structural workforce shortage. While broad skills and workforce reforms are underway nationally, we need to urgently boost the pipeline of workers into the sector and develop a national infrastructure workforce strategy.” •

Quarry February 2024 45


MENTAL HEALTH

FINDING RESILIENCE Jason Egan has spent more than three decades working across the quarrying sector. He tells Quarry about his mental health journey within the industry in hopes of helping others.

W

hen Jason Egan first stepped foot in Readymix Dubbo in 1991, he’d never been inside a quarry, let alone knew much about what they entailed. However, those first steps in Dubbo started a career within Australia’s quarrying sector, taking him from Dubbo to Darwin to Hervey Bay and across Queensland. Egan carved out a successful career in concrete and quarrying operations as he worked for “great companies in some great locations” before working in quarry equipment sales. In his own words, behind the scenes of his extensive career, he was battling the “black dog.”

medicate the pain he was feeling and the dark thoughts that clouded his mind. Egan sunk to a dark place in Darwin, and as he acknowledged, he started to plan to take his own life, but each time he stopped. “I wanted to take my own life without hurting my family,” he said. “But thankfully, I was able to get some help.” Egan’s manager in Darwin noticed his employee was not his usual self and took steps to reach out and offer help via the Employee Assistance Program (EAP). “To this day he remains one of my close friends and set up the help through the EAP, which I think every company should have,” Egan said. “I felt weak, and like a loser for going and seeing a counsellor and doctor, but through the program and the medication, I was able to feel better.” After leaving Darwin, Egan went across the country, working in several quarry, area and operations manager roles including in the ready-mixed concrete sector. While on the outside, it appeared Egan was paving a successful career in the Images courtesy of Jason Egan

QUARRYING After a year-long stint as an exchange student in Thailand, Egan was at a loss for what to do in 1990. The South Australian travelled to Dubbo to spend time with his father, where he worked in the shearing industry and played footy on weekends. The club’s captain-coach needed a new employee at the local quarry, and Egan fitted the bill perfectly, except for a tiny matter. “I had no idea what a quarry was,” he said.

“But I took them up on it anyway, started on a shovel and in a few months, they’d trained me up on the dump trucks and loaders.” Egan made an impression because he was the quarry supervisor at Readymix Albion Park five years later, which started his career in operations and quarry management. “It was a bit different as the boy from the bush, and it was a fairly unionised area. It was a tough challenge but a pretty good experience for me.” Two years later, Egan was on the road again, headed for Darwin to be the quarry manager for Readymix. But, in the Northern Territory’s capital, he found his first experience with the “black dog”. The then 26-year-old was far from home and found himself regularly upset, and almost everything had lost its joy. “I felt useless; I felt at work that I wasn’t performing, and when you’re 26 years old, you should be bullet-proof; you think you’re tough and rough,” he said. “But this really strange thing was happening to me, and I didn’t understand it.” Away from work, he was using alcohol to self-

Exp Inn Res

Crus Jason Egan was invited to share his mental health journey through Beyond Blue.

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Egan is part of the Unbreakable Man group on the Gold Coast.

HA

2/6 info

For

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construction materials space across some of Australia’s biggest companies, internally, he was struggling. By 2018, Egan had been in an on-and-off battle with the “black dog” for two decades. He admits he was continuing to use alcohol to cope as the suicide of his cousin and friend within a few months of each other left him feeling “angry, frustrated and depressed”. As he prepared to leave the industry to accommodate the 50 per cent care of his daughters, an unexpected opportunity with Screenmasters Australia left Jason “forever grateful”. The long-time operations manager took on a sales role, and the left-field change gave him the balance on the worksite and at home he had been looking for. Recently, Egan joined Astec Australia to head up sales on the Australia’s east coast for its material solutions business. “I’d had a crack at a lot of things within the industry, and sometimes the black dog almost got me, but I had tools and strategies to manage it,” he said. This journey gave Egan an insight into the struggles many working men face, and he wanted to help.

BEYOND BLUE Egan remembers the first time he worked with Beyond Blue, selling charity raffle tickets in Suncorp Stadium. Afterwards, Egan was invited to share his mental health journey

in the hope of helping others like him. Over the past seven years Jason has presented to community groups, workplaces, conferences and correctional facilities. Last year, he spoke at the IQA’s Victorian branch meeting. It was a series of firsts for Egan as he told his story in front of industry peers and his wife, who was also listening for the first time. “Presenting in front of people who know you personally requires a huge level of vulnerability, and you must be honest; you have to be vulnerable; otherwise, the message doesn’t get across.” “With my sales work I’ve been to close to 200 sites, and unfortunately, I continue to see the effects of people making choices that aren’t the best for their physical or mental health.I tend to see people looking after the interests of businesses and other people rather than themselves which sounds selfish, but it is actually the best possible choice an individual can make. “It’d be great to see more of our quarrying people make their own health and wellbeing a priority in their lives.” Egan has been working with quarry professionals to help them understand that their health away from the workplace can make them better operators within it. “One of the best tools I recommend to people when they reach out is to undertake a Beyond Blue K10 self-assessment and from there, they start their journey,” he said.

In his own experience, Egan has found that focusing on physical and mental fitness has enabled him to cope better with life’s pressures. Egan works out regularly with a group called Unbreakable Man on the Gold Coast. “It’s changed me for the better, and it has identified some of the root causes of why I struggled for so many years,” Egan said. “Not only did I lose a lot of weight and become fitter, but they’re a tremendous bunch of guys; because of this group, I’ve introduced gratitude into my life. “It’s shifted my focus to what I have and am grateful for. It has been incredibly empowering and helped develop resilience.” Beyond Blue’s research shows one in eight men will experience depression, and one in five men will experience anxiety on average. Egan said it was important that men give themselves outlets and support. “You need those things when life goes pearshaped, which is a guarantee: no one’s life will work out perfectly. I always thought it would be, but when I couldn’t handle it, the black dog would appear,” he said. “Poor mental health does not discriminate. It impacts high achievers and CEO’s, managers and workers alike. Together though, we can make a difference. As with my presentations, if this story can help just one person then its well worth the effort.” • If you or anyone you know needs help, contact Lifeline on 13 11 14, or Beyond Blue on 1300 224 636.

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IQA NEWS

The Institute of Quarrying Australia

Images courtesy of: IQA

OUT AND ABOUT WITH THE IQA BRANCHES

Almost 100 people attended the Victorian sub-branch networking dinner and presentation.

VICTORIAN SUB-BRANCH NETWORKING DINNER AND PRESENTATION This fantastic event was held at the All Seasons Hotel in Bendigo on Thursday 30 November 2023. The evening commenced with a technical presentation by Byron Albrecht from Komatsu, who showcased MyFleet – a simplified Komatsu experience that

L–R: Victorian sub-branch chair Adrian Bourke and special guest speaker Billy Brownless.

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streamlines customers’ heavy equipment fleet management with a single log-in to access all system information. The special guest presenter was Billy Brownless, who first came to prominence playing AFL as a high-flying forward for the Geelong Football Club before moving into media, hosting a popular television segment on the AFL Footy Show. He has spent the

Komatsu’s Byron Albrecht showcased MyFleet.

last decade on radio, co-hosting Triple M’s The Rush Hour with his good friend, James Brayshaw. Billy had everybody captivated with his quirky storytelling, later answering a range of questions from attendees. The event was a wonderful night, with 95 registered attendees who all enjoyed a great meal and the opportunity to network with their peers.


IQA NEWS

The Institute of Quarrying Australia

UPCOMING COURSES AND EVENTS Event

Date

Plant and equipment safety: Guarding and isolation

Thu 15 Feb

Slope stability

Wed 21 Feb

Plant and equipment safety: Mobile plant

Plant and equipment workshop and Komatsu tour

Thu 22 Feb

Wed 28 Feb

Plant and equipment safety: Conveyors

Thu 29 Feb

Introduction to quarrying

Wed 6 Mar

VICTORIAN BRANCH END-OF-YEAR EVENT The IQA Victorian branch hosted its end-ofyear event at the Terminus Hotel in Clifton Hill, an inner-city suburb of Melbourne, on Thursday 7 December 2023. Set in the venue’s beer garden, this gathering provided the chance for attendees to network with members, nonmembers and associates in an informal setting while enjoying delicious finger food and refreshments. It also provided an opportunity for the branch to officially thank retiring committee member Chris Prowse FIQ for his service, and to acknowledge his 30 years of membership with the IQA. This event was a great way to wrap up 2023 and had everyone looking forward to a big year in 2024.

Time 1–2pm (NSW, ACT, Vic, Tas) 12–1pm (Qld) 12.30–1.30pm (SA) 10–11am 9WA) 11.30am–12.30pm (NT) 9am–4.30pm (AEDT) 9–10am (NSW, ACT, Vic, Tas) 8–9.am (Qld) 8.30–9.30am (SA) 6–7am (WA) 7.30–8.30am (NT)

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9–10am (NSW, ACT, Vic, Tas) 8–9am (Qld) 8.30–9.30am (SA) 6–7am (WA) 7.30–8.30am (NT)

10am–2pm (AEDT)

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Retiring committee member Chris Prowse (left) was honoured following his 30 years of membership with the IQA.

03 7046 0848 www.tothink.com.au


GEOLOGY TALK

Image credit: Adobe Stock/ Leonid Andronov

Image credit: Adobe Stock/Marco

TRADITION IN STONE CARVING

The town of Escolásticas is close to three hours away from Mexico City.

The town of Escolásticas is close to three hours away from Mexico City.

An older generation is helping maintain the tradition of stone carving and have an impact on their towns in the surrounds of Mexico City.

city’s far east side, much of its stone carvings can be seen in cemeteries and churches throughout the wider Mexico City. They work free of charge to maintain the stonework at the local church, the Santa María de Guadalupe, which is 250 years old. Like Escolásticas, many carvers in Chimalhuacan use hammers and chisels despite some moving towards electric grinders and cutters. Mexico State Office director Carolina Montesinos Mendoza told Associated Press there are only around 300 registered carvers now which is half what there was a decade ago. The local quarry was subsumed by the urban sprawl like much of Mexico City. The former quarry site is home to families and houses with the carvers’ stone imported from across the country. While they fight to keep the tradition of stone carving alive in their towns, it is a reminder of how quarrying is about more than just infrastructure projects and roads. It is also about people, jobs which provide for families and helping maintain cultures and communities from as far away as Mexico City. •

D

eep in the heart of Central Mexico, stone carvers use quarried rock to make intricate sculptures which decorate, in a practice some reports estimate goes back to the reign of the Aztecs. The town of Escolásticas is close to three hours away from Mexico City, but its supply of volcanic rock, which is found on the outskirts of the town, acts as a lifeblood to its residents. Often quarries can be referenced as providing the backbone of infrastructure and houses in the Western world but in this town of 3000 people, it provides an economy and reliable jobs. The town has 200 open air workshops with an estimated 300 people carving stone which will be shipped across Mexico and the United States. They carve volcanic rocks with hammers and chisels, but some have adapted electric grinders into artifacts for tourists and exports. From angel statues to rock slabs used in Mexico’s own construction industry, Escolásticas’ stone works have as much

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impact on the region’s art culture as it does infrastructure projects. Angelo Camargo picked up the sculpting profession from his father and now in his thirties, runs his own open-air workshop designing and sculpting the volcanic rock he grew up around. “(These jobs) give us the ability to pay for food, transportation and many other things,” he told CGTN America. “We have our own source of employment, so people don’t have to leave and seek work in factories, and they don’t have to migrate to the United States.” The stone carving practice remains in villages around Mexico. A three-hour journey from Escolásticas will take you to the ancient village of Xochiaca which houses the borough known as Chimalhuacan. The area is now envelope by Mexico City which has grown and expanded over many decades and taken over these ancient villages to cater for a growing population and the need for houses and buildings. While the borough is tucked away on the


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