Quarry July 2023

KEEPING SUSTAINABILITY SIMPLE

The best ideas are often the simplest. Volvo CE has taken this idea to heart with its hybrid excavator range.

SAFETY ON THE MIND AND IN THE WORKPLACE Coverage of the Quarrying and Mining Safety and Health Conference.

SHAPING TOMORROW, TODAY Delta Group is diverting construction and demolition waste from landfills to help build a better tomorrow.

32 EXTRA CLEARANCE SCREENING

One of the world’s largest producers of modular, portable, and static mineral screening equipment has engineering a new horizontal screen with innovative features that sets it apart.

34 THE LITTLE DETAILS MATTER A LOT FOR KLEEMANN

Kleemann is matching technology with staff know-how to get the customer’s job done.

36 THE SECRET TO LOW EMISSIONS CONCRETE

Kayasand helps the construction industry be more sustainable with its manufactured sand plants.

38 MEET THE BOAPOD: MONEY AND TIME SAVER

A new, mobile, all-terrain hydraulic hose repair unit is proving to be the silver bullet for quarries facing downtime costs due to hydraulic hose failures.

40 SHELL LUBRIANTS KEEP CONSTRUCTION POWERED UP The right oils and greases can help machines handle a booming construction industry.

42 MINIMISING DUST FOR A BETTER WORK SITE

McLanahan is helping clients build an environmentally friendly future.

48 LEAPING FORWARD ON SUSTAINABILITY

John Deere makes significant strides in reducing emissions and engine sustainability.

52 KINDER CLEANS QUARRY CLEATS

Peter Laskey, a field applications specialist at Kinder Australia, told Quarry about a solution to cleated belt carryback.

2022 LIPPMANN L300C CONE CRUSHER

The Lippmann 300c is a heavy duty cone crusher with an innovative material flow that maximizes capacity and throughput while delivering a consistently high quality product. POA

Heavy duty 20x6 screen box, Cat C7.1 engine, hopper extensions, apron feeder, full radio remote control function

TEREX M515 HEAVY DUTY ROCK TROMMEL

New & Used units available throughout Australia, Tricon is Australia’s only authorised Terex MDS distributor.

LIPPMANN

&

MOBILE SCREENS

Lippmann LS range, 22x6 and 20x5 triple deck finishing screens now available, POA

LIPPMANN L620R 20x6 SCALPER

LS520

LS622

SUPERIOR TSSA 150' TELESTACKER

New Superior Telestackers in stock, 1000TPH, 46m, AS3000 electrics, AS4324 structure, auto stockpile, radio remote control. POA

SUPERIOR ALLIANCE LOW WATER WASHER

Wash your natural, manufactured or recycled sands with a greatly reduced water demand. POA

SUPERIOR TSSA 130' TELESTACKER

TSSA 130’ telestackers back in stock, 1000TPH, AS3000 electrics, AS4324 structure, auto stockpile, radio remote control. POA

SUPERIOR

SUPERIOR GUARDIAN 6203

Superior Guardian 6203 20x6 horizontal screen boxes now available Australia wide (ex QLD & NSW) POA

RAZERTAIL TRUCK UNLOADER

THE ROBOTS ARE COMING –IN FACT, THEY’RE ALREADY HERE

Automated machines are no longer the realm of science fiction authors; they’re vital tools that are being deployed in almost every industry, quarrying chief among them.

Machine learning, artificial intelligence and advanced robotics are already beginning to transform Australia’s economy, and it couldn’t have come at a more important time.

The COVID-19 pandemic highlighted several issues within the industry, particularly when it comes to staffing and labour. It’s becoming a lot more difficult to find (and, indeed, to keep) new employees to perform jobs that could be considered dirty, dangerous and dull. Add a virus that brought much of the world to a standstill into the mix and a factory supporting an essential industry could face temporary shutdowns and a serious restriction of productivity.

The technology is aiding organisations of all sizes. Major mining companies are designing robots to haul iron ore to ports, improve on-site safety, and optimise the maintenance of equipment.

The big car manufacturers are also getting on board, developing the vehicles of the future. So-called ‘selfdriving cars’ are still in their infancy, but they have the potential to revolutionise the transport industry.

McKinsey’s Australia’s automation opportunity report highlighted the benefits of embracing the technology. It found there was an opportunity for increases of up to 150 per cent in annual productivity, $4000–15,000 in additional income per Australian by 2030, and an addition $170 to $600 billion annual gross domestic product (GDP) by 2030.

However, the authors of the McKinsey report were clear

in saying that capturing the potential upsides of automation will not magically happen on its own. To overcome the risks of disruption, and to make the most of the opportunities, Australia needs the combine national efforts of accelerating automation with ensuring social inclusion, with national mechanisms for policy and coordination.

“Automation holds great promise for Australia and could help to rekindle the kind of economic growth that delivers higher living standards and more choices for everyone,” the report stated.

“Of course, automation will inevitably create challenges, but Australia has in the past confronted similar challenges head on and found ways to maximise opportunities to build sustainable and inclusive growth for all.”

The quarrying industry is no exception. There is massive potential in the new technology, as many jobs on a site could be more suited for a machine. Why put a person in a potentially unsafe environment when a robot can do it instead?

It’s vital to note that these workers will not be displaced and left behind. They can then be redeployed and add value to the operation elsewhere, using the skills, creativity and human nuance that a machine simply cannot provide.

The quarries and associated service-providers who are best positioned to innovate and adapt have exceptional opportunities ahead of them.

The question we should all be asking ourselves is, what are we doing to prepare?

Paul Hayes Managing Editor

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“MACHINE LEARNING, ARTIFICIAL INTELLIGENCE AND ADVANCED ROBOTICS ARE ALREADY BEGINNING TO TRANSFORM AUSTRALIA’S ECONOMY”

ALL ABOUT EDUCATION

It’s shaping up as an exciting year across our industry, and at the forefront of that is the IQA’s new and improved education offering which will be unveiled later in 2023.

Education is at the heart of everything we do and plays a major part in terms of what we hope to achieve going into the future.

Ahead of the formal launch of the IQA competency framework and personal learning cloud system later in the year, I wanted to take a moment to explain why these offerings are so important for our members.

The quarrying industry is rapidly changing, and our members are having to adapt to that changing work environment. It is for this reason that we want to be ready and accessible to help improve the skills of our members while also improving the health and safety standards through improved and innovative practices.

We have aligned our courses with an updated competency framework that integrates with the IQA’s existing Quarry Manager Certification Scheme and the requirements across each state. The courses will also be aligned to the levels in the Australian Qualifications Framework.

The framework will be divided up into areas that are all crucial to the extractive industry: safety and risk management, leadership, emergency management, operations, and personal effectiveness.

We understand that the framework needs to offer a tailored approach that can be suited to members’ needs. This is why our education programs will be delivered to different levels depending on a person’s role.

We also understand that the program needs to be flexible, deliverable and accessible for all our members in all states to ensure that safety is provided across all worksites.

Importantly, this framework will allow us to connect the extractive and associated industries by further

evolving our education offering to ensure its quality and relevancy.

With this new adaption, workers should be able to demonstrate their skills and competencies regardless of where they work, or differing state regulations and past and present regulations.

The training will be offered on a rolling 12-month calendar of courses to ensure sites and workers can plan effectively.

To further support our members to be the best they can be on the worksite, we have arranged for the workshops to be delivered either face-to-face or online with facilitators who are experienced industry professionals.

In addition, we have partnered with registered training organisations to help provide education for formal qualifications to make sure they are up to national and state standards, and to provide a holistic approach that includes technical and soft skills.

This will be further complimented by our online learning platform, the personal learning cloud. We are excited to launch the online platform later this year to enable workers and quarry operations access to ondemand online education.

We hope these additions will help companies and workers become the best versions of themselves to maximise the opportunities that are in front of them.

With education at the centre of what we’re planning to do, we hope to place the industry in the best possible position as it faces several challenges, including workforce shortages and trying to grow diversity and awareness.

Let’s work together to make our industry shine.

Duncan Harris President Institute of Quarrying Australia

www.quarry.com.au

The IQA’s Strategic Plan 2020 to 2025 embodies the following vision, values and strategic priorities:

Vision:

Educating and connecting the extractive and associated industries.

Values:

• A safe and sustainable environment.

• Diversity and inclusion.

• Working development skills, careers and life-long learning.

• Networking, connection, trust and communication.

Strategic Priorities:

• Maximise outcomes for industry through education and sustainable practise.

• Increase our relevance.

• A high performing and sustainable organisation.

IQA Contacts:

Phone: 02 9484 0577

Email: admin@quarry.com.au

Chief Executive Officer

Kylie Fahey

Deputy President

Sarah Bellman

Company Secretary

Rod Lester

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

The Institute of Quarrying Australia

Educating and connecting our extractive industry

“EDUCATION IS AT THE HEART OF EVERYTHING WE DO AND PLAYS A MAJOR PART IN TERMS OF WHAT WE HOPE TO ACHIEVE GOING INTO THE FUTURE.”

Resource optimisation.

DOOKIE QUARRY SET FOR ROCKING CHANGE

A name change is on the cards for a famous Goulburn Valley quarry which transforms into rocking amphitheater for the night.

The quarry produced granite during its main operations and was a key part of Dookie.

Operations ceased in the 1970s and the site was used as the local tip for a couple of years before being remediated.

While part of the quarry has been deemed a mineralogical reserve by the Mineralogical Society

of Victoria and the Shepparton Council, another part is home to the sounds of music.

The change of Dookie Quarry into an entertainment space after work to remodel it was completed in 2014 and transformed into an open-air arts arena.

The quarry has played a big part in the Secret Garden Gigs tour as the Dookie Quarry Festival with patrons flocking to the unique venue despite it being more than two hours from Melbourne.

WHILE PART OF THE QUARRY HAS BEEN DEEMED A MINERALOGICAL RESERVE BY THE MINERALOGICAL SOCIETY OF VICTORIA AND THE SHEPPARTON COUNCIL, ANOTHER PART IS HOME TO THE SOUNDS OF MUSIC

FOSSIL FOUND IN ENGLISH QUARRY ON SHOW

A prehistoric fossil that was discovered in an English quarry in Harbury will be shown to the public in an interesting insight into the old-time quarrying.

The fossil was originally found in Harbury’s cement quarry, in Coventry, England in 1933 before becoming part of the museum’s exhibit a few decades later in the 1960s.

The quarry was a popular spot for fossils which included the remains of marine reptiles (the ichthyosaurs and plesiosaurs) which were found in 1927 and 1928 and other things from the Jurassic Era in England.

The quarry was in operation for around 150 years and excavated for a distinctive blue-grey limestone and building stone and supplied nearby cement works.

It comes after a new search was started closer to Australian shores in Lark Quarry in Queensland.

Museum curator Amy Wells said it was an exciting opportunity to examine the specimen which arrived more than 60 years ago.

“I am delighted at the opportunity to discover more about one of our specimens. Parts of the creature’s teeth,

Residents will get to decide what name the new concert appears under as it gets set to return in December.

The lucky punter is set to be rewarded for their solution with a lifetime pass to the event.

The event’s creative director Jamie Lea said it was time for the famous Dookie music event to become its own standalone experience away from the Secret Garden Gigs name.

eye ring and skull are visible but the conservation work has brought it to life even more,” Wells told Coventry Live.

“And on top of that there’s the opportunity to have the fossil scanned by Warwick Manufacturing Group to reveal what’s inside, something that was not possible when the specimen first arrived at the museum in 1961.”

Operations were shut down in 1994 before being acquired by a property group in 2001 to be rehabilitated as a leisure and recreation with three parts of it designated as sites of special scientific interest.

The quarry produced granite during its main operations.

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ECKLIN SOUTH QUARRY UPGRADE SET TO REDUCE LANDFILL

A long-time Ecklin South quarry is set to be upgraded with a new facility which will help reduce landfill in the local area.

The proposed site has been a gravel quarry since 1990 and according to the Corangamite Shire Council’s report, it is nearing its productive life cycle.

Councillors debated a proposal for the quarry to be transformed and rehabilitated with space for hard waste recycling.

The Ecklin site would mainly be used for recycling bricks and concrete which would be crushed, screened and blended to be used in road base.

“The resource recovery is something that is very important to

us as we move through making our roads stronger, our footpaths, all the hard services that we need,” Cr Laurie Hickey said.

“It is very important that we can have somewhere where this is recycled and developed.

“I think this is the best outcome for the quarry.”

Crushing material would be stored on site until it is commercially “worthwhile” to crush but no fixed infrastructure or buildings to be established on site.

Located on Lilleys Lane, the operations are expected to be intermittent.

North of the Ecklin South site is another quarry that has been

QUARRY RESERVE GIVEN A FACELIFT FOR LOCALS

One of Melbourne’s most popular quarries has been revitalised with a makeover to transform it into a tourist hot spot.

Quarry Reserve in Ferntree Gully, Melbourne was once a thriving bluestone quarry and contributed considerably to Victoria’s infrastructure. The quarry was in operation for close to a century as its milled product helped build Victorian roads and

railways before it was closed and decommissioned in 1996.

A masterplan for a $2.05 million upgrade was implemented in 2015 before the quarry was officially opened by Federal Infrastructure Minister Catherine King recently.

THE RESOURCE RECOVERY IS SOMETHING THAT IS VERY IMPORTANT TO US AS WE MOVE THROUGH MAKING OUR ROADS STRONGER, OUR FOOTPATHS, ALL THE HARD SERVICES THAT WE NEED

CR LAURIE HICKEY

operating since 1974 with a focus on stone extraction.

Councillor Jo Beard said she hoped the two properties would be able to help each other and benefit the local area.

“I assume there has been a good neighbour approach and I hope that continues between the two properties,” Beard said.

“Both are resources that are really well needed by our community and regionally to service our agriculture sector particularly but also our local roads and tracks.”

The plan could help boost the circular economy and produce materials for the end user to create value like roads and tracks which will help reduce landfill.

The final part of the upgrade will see a lookout installed over the quarry which is expected to be completed later this year.

The plan could help boost the circular economy.

Bluestone helped build roads and railways.

ROCK STAR! NEVER IDLE

In this business, the show must always go on. And that’s why you can count on Deere’s 1050K Crawler Dozer, with its suspended doublebogie undercarriage, to put in a rock star performance. When you’re cranking out over 40 hours a week in the cab, a comfortable operating environment isn’t just an option – it’s a necessity. And with the right features at hand in the right places, it makes it easier for you and your crew to enjoy getting the job done, however long it takes. Add a rock star to your line-up, today.

NEW IDEAS WANTED FOR SUNSHINE COAST QUARRIES

The futures of two Sunshine Coast quarries are set to be decided later this year as part of a local council’s tender process.

Image Flat Quarry has operated in the Sunshine Coast since the 1960s while Dulong Quarry opened up a decade later in the 1970s but last year, the Sunshine Coast Council decided to lease both quarries to a commercial business.

Black Cat Civil has received an $8.5 million contract for work at the two quarries in 2021 for mobile crushing and screening work.

Image Flat Quarry was originally commissioned to produce suitable

rock for the concrete wall at Wappa Dam while Dulong Quarry was focused on producing rock for spray sealing and asphalt production.

“The council is currently operating the two quarries. Products from Image Flat Quarry and Dulong Quarry sites have historically been used within council projects and sold to external suppliers and contractors,” a council report said earlier this year.

“An asphalt plant operated at Image Flat Quarry until the temporary closure of the plant in 2020.

“The quarry business has been impacted by the closure of the asphalt plant and is competing with

THE QUARRY BUSINESS HAS BEEN IMPACTED BY THE CLOSURE OF THE ASPHALT PLANT AND IS COMPETING WITH OTHER PRIVATELY OWNED FACILITIES WITH THE CAPABILITY OF LARGERSCALE VERTICAL INTEGRATION AND CAPACITY FOR CAPITAL INVESTMENT

other privately owned facilities with the capability of largerscale vertical integration and capacity for capital investment.”

Despite the EOI process, operations are still ongoing at the two quarries with truck hauling scheduled for later this month according to the council’s website.

Blasted rock is set to be collected from Dulong quarry and transported to Image Flat Quarry for crushing, sorting and sales.

The truck haul is set to go from May 29 until mid-July.

MITCHELL SHIRE COUNCIL BACKS QUARRY CONTRACT

New contracts have been handed out in the quarrying industry with a big boost to those businesses in Romsey, Shepparton and Kilmore.

Newnham Earthmoving, M and M Ryan Earthmovers, and Norville Quarries were named as successful contractors.

The three businesses will share in the contract which is worth $900,000 for a three-year period from July 1 2023 until June 30 2026.

The contract also contains an option to extend the deal beyond the initial time period subject to the

requirements of the council and the contractors’ performance.

The three companies, who were the only three to apply during the tender process, hail from Romsey, Kilmore and Shepparton respectively.

“This contract gives us a degree of flexibility, the maintenance of roads is a visible and important part of what we do,” Cr Rob Eldridge said in the meeting.

“The flexibility this gives for us to provide timely maintenance is imperative.”

The contract was awarded after a unanimous vote.

Operations are still ongoing at the two quarries.

The three businesses will share in the contract.

BORAL’S WAURN PONDS

Boral’s former cement manufacturing plant in Waurn Ponds is getting revitalised with a seismic change set for the facility after more than five decades as a production powerhouse.

The long-time manufacturing plant is part of a proposed plan to be part of a new precinct that will feature adventure tourism as well as an iconic convention and events centre. Plans would also include a mixed-use commercial precinct, warehouses as well as a business park and community infrastructure replacing the old cement site.

The initiative comes after Boral moved its operations and committed to regenerating the old site.

Geelong is expected to become

FACTORY GETS NEW LEASE ON LIFE

one of Australia’s biggest regional cities in the coming years with one of the fastest growth rates in the country according to census data.

Census data has predicted the city will grow to around 282,000 people by 2026 and surpass 300,000 people by 2036.

The plans for the precinct would help provide access to more housing in Geelong according to Boral.

The Geelong City Council has identified the Waurn Ponds area as a potential solution to easing market demand for housing in its draft southwest Geelong employment land review.

The plans come after Boral handed a portion of land at the

THE VALUE OF THIS GESTURE BY BORAL IN RETURNING THIS SITE, WHICH HOLDS GREAT SIGNIFICANCE TO THE WADAWURRUNG PEOPLE, CANNOT BE UNDERSTATED

PAUL DAVIS

LINCOM APPOINTED AS MDS DISTRIBUTOR

The Lincom Group has appointed as the exclusive distributor for MDS, a Terex brand, in WA, NT, SA, Papua New Guinea, and New Caledonia.

MDS is headquartered in Ireland where it designs and manufactures heavy duty rock trommels. Its equipment is designed to deliver maximum efficiency, reliability, and versatility.

The MDS heavy-duty rock trommels can screen rocks as large as 800mm and include features such as hydraulic jacking legs, remote control, modular drums, drum cleaners and electronic systems to monitor and control aspects of the trommel.

The range includes mobile, semi-mobile

or static, and the MDS trommels are built to last in harsh conditions.

The Lincom Group has supplied equipment and services to the mining, quarrying, recycling and waste industries for more than 27 years. Its portfolio includes mobile crushers, screeners, conveyors, and other specialised equipment.

The partnership between the two companies marks a significant milestone for both businesses and is set to bring new opportunities to the local market.

Lincom Group CEO Stephen Watterson said the partnership with MDS is a testament to company’s core value of supplying only the best-in- class equipment.

Waurn Ponds area back to the Wadawurrung Traditional Owners Aboriginal Corporation.

WTOAC chief executive Paul Davis welcomed the gesture from Boral as a big step forward in its relationship with the traditional owners of the land.

“The value of this gesture by Boral in returning this site, which holds great significance to the Wadawurrung People, cannot be understated,” he said at the time. The traditional ceremony – which was part of Boral’s reconciliation plan – saw 3.6 hectares of the former cement works returned with a plan to turn it into a cultural and educational hub.

“We are thrilled to be the exclusive distributors of MDS heavy-duty rock trommels in key regions. We are excited to be working with such an innovative manufacturer and look forward to bringing their industry-leading equipment to our customers,” he said.

Lincom Group has an established network of sales and service centres to provide its customers with fast and effective support across the equipment lifecycle.

The first MDS M515 track trommel will arrive later this year. This model will come complete with fold- out stockpiling conveyors and is ideal for creating RipRap and recovering rocks that are mixed with clay and other sticky materials.

The initiative comes after Boral moved its operations.

Image credit: Benjamin Crone / Shutterstock.com

GREEN CONCRETE PAVES WAY FORWARD

Green concrete could be the way of the future after new studies into the product yielded promising results.

Concrete has become one of the most sought-after materials worldwide, highlighting the importance of the quarry industry. Green concrete has emerged as the quarry and construction industry search for low-carbon options. The product uses more recycled materials to reduce the amount of Portland cement.

Dr Ezgi Kaya — who conducted a report on the product — said the product had several benefits compared to regular cement.

“Unlike conventional concrete, which requires a considerable amount of energy and resources to produce, green concrete often uses recycled materials and minimises the use of Portland cement, a major contributor to carbon emissions,” Kaya said.

“To date, green concrete has been

KAYA BELIEVES IF THE CONSTRUCTION INDUSTRY MADE THE SWITCH TO THE NEW PRODUCT, THE BENEFITS WOULD BE SEEN ACROSS AUSTRALIA.

used in more than 60 projects across different sectors in Australia, including infrastructure, buildings, industrial, marine and geotechnical.

“Given that the carbon reduction achieved through its use can be as much as 80 per cent, the potential for green concrete to positively impact our emissions targets is monumental.”

The study highlights that the material is durable and has higher engineering properties and less shrinkage.

Global building projects have already started implementing the product into designs as seen in Amsterdam’s Schiphol Airport and Abu Dhabi’s version of the Louvre.

Kaya believes if the construction industry made the switch to the new product, the benefits would be seen across Australia.

“Replacing just 50 per cent of traditional concrete with green concrete could reduce Australia’s carbon emissions by approximately 17 million tonnes annually, which is equivalent to removing four million cars from the road,” Kaya said.

“By embracing this innovative and environmentally friendly construction material, Australia can not only reduce its carbon footprint but also create a more sustainable and resilient built environment.”

HEIDELBERG TARGETS CLAY FOR EMISSIONS REDUCTION

Heidelberg Materials has unveiled a major plan to invest €65 million into its cement production plant in France.

The cement plant – located in BussacForêt – will undergo an expansion with the investment set to fund a facility to produce calcined clay and boost its low-carbon production.

It comes at a time when the Australian sector is searching for ways to decarbonise its operations in the future with companies looking to innovate new ideas.

Heidelberg Materials chairman

Dr Dominik von Achten said the initiative will help cut the site’s carbon emissions by 20 per cent.

“Our most recent investment in innovative technologies in France

demonstrates Heidelberg Materials’ strong commitment to decarbonize our products,” von Achten said.

“The launch of the transformative project in Bussac-Forêt will be supported by a favourable administrative and regulatory environment.”

The company has started a pilot program of calcined clay in Ghana – home to one of the world’s largest calciners – which is set to inform their new project in France.

Ghana’s calciner is set to have a capacity of more than 400,000 tonnes per year.

The calcined clay will allow the company to produce a new and improved range of clay cement.

The cement will have less clinker because the calcined clay can replace elements of the CO2-intensive clinker in cement.

Heidelberg’s chief sustainability officer Dr Nicola Kimm said the replacement could yield a major reduction in CO2 emissions for the company.

“We are investing in a technology with great potential. It will allow us to significantly expand the range of lowcarbon products,” Kimm said.

“Using calcined clay as a clinker substitute is an important measure to reduce the carbon footprint of cement and concrete. In principle, a CO2 reduction of up to 40 per cent is possible when substituting cement clinker with calcined clay.”

Dr Ezgi Kaya

PRODUCT FOCUS

MAGOTTEAUX MAKES AN IMPACT

Magotteaux knows that any difference it can make to reduce the overall running cost of a quarry will have a positive impact on the bottom line. That’s why its impactor wear parts are designed with the customer in mind.

In addition to the horizontal shaft impactor (HSI) solutions, Magotteaux builds one of the most efficient vertical shaft impactors (VSI). The Mag’Impact has a high reduction ratio, high output in terms of cubicity in a single pass, and extreme versatility to suit any kind of application.

Magotteaux ceramic wear parts have been used to great effect at Hanson Wollert Quarry and Holcim Petrie Quarry. The site’s Canica VSI and Magotteaux’s ceramic technologies doubled the life at Petrie and improved the lifespan at Wollert by 45 per cent.

Improvement like this are potentially achievable in other high wear parts, including blow bars, impact plates, side liners and anvils.

Magotteaux is more than just a supplier. It invests continuously in innovation and develops a strong relationship with its partners to find the best possible solution prior to engineering and delivering the promised quality. It uses innovative and modern monitoring tools to prove its promise and optimise operations.

For more information, visit magotteaux.com

CLEAR RECYCLED MATERIALS OF METALS WITH A SMART MAGNET

Quarries across Australia are quickly getting on board with the circular economy revolution, by recycling construction demolition materials and concrete.

While this serves as a great area of diversification for quarries, it also comes with the challenge of sorting mixed materials such as metals.

Reinforcement steel and other metals found in construction waste can prove to be damaging for plants, conveyors and screening machines.

To meet this need, Tricon Equipment recommends installing a screening magnet as part of any quarry plant set up. Magnets can be suspended above a conveyor to extract ferrous metals from a conveyed stream of materials.

Tricon Equipment stock magnets of all types for all applications. The Conveyortek brand sold by Tricon are some of the most technologically advanced conveyor magnets on the market. With emphasis placed on innovation and efficiency, they are high-strength and performance guaranteed.

The permanent magnet boxes are charged with high strength Strontium Ferrite Magnetic Material and have the ability the extract ferrous metal from a wide range of belt conveyor applications. They range from as small as 400mm to 1200mm and above.

The range of different strength options will allow you to choose a suitable magnet for your application, taking into consideration, the shape, size and speed of

HARDOX HIACE FIGHTS CORROSIVE WEAR IN TIPPER BODIES

Abrasive loads that are acidic or have low pH levels can cause exceptional damage to steel. Even loads that are usually not aggressive can become corrosive in the presence of water. SSAB has researched the field of corrosive wear for several years and developed a new grade of steel more suitable for these environments: Hardox HiAce.

This steel has the benefit of resisting corrosive wear in tipper and trailer bodies. Loads such as minerals and wood chips can create an acidic environment, particularly when exposed to rain or humidity.

Hardox HiAce performs similar to a 450 HBW steel in a regular wear environment. At lower pH levels, it can extend service life up to 3 times compared to an AR400 steel. For more information, visit ssab.com/en/brands-and-products/hardox

ASTEC SCREENS DELIVER SUPERIOR EFFICIENCY

The Vari-Vibe technology incorporated into Astec’s range of high frequency screens delivers superior screening efficiency. The unique system introduces high-speed vibration, from 3600-4200 rpm, directly to the screen media and that, in turn, produces increased stratification and material separation. The level of gradation control achieved by direct-induced vibration is ideal for reclaiming fines in both damp and dry applications.

Astec products utilising Vari-Vibe technology include the two-deck GT2612V high frequency screen for tracked plants, and the 2618Vm and Next Gen 2818V models for fixed plant installations.

For more information, visitastecindustries.com.au

Blackwoods understands that some jobs require workwear that is built tougher, and more durable than lightweight or traditional workwear. Jobs that require hard work need workwear that is both up to the job in keeping workers safe and designed to last. Heavy industrial workwear has the added condition of being able to withstand industrial laundering.

Blackwoods has access to one of the largest ranges of heavyweight workwear options to keep workers safe on those tougher jobs.

Along with the foundations that 145 years of experience delivers, Blackwoods has a team of technical specialists and dedicated account managers who can conduct onsite visits to deliver in-depth fit-for-purpose product assessments, in-field technical support, product profile reviews and recommended stock profiles that are aligned directly to the needs of your business.

For more information, visit blackwoods.com.au/

KEEPING SUSTAINABILITY SIMPLE

The best ideas are often the simplest. Volvo Construction Equipment has taken this idea to heart to boost sustainability with its hybrid excavator range.

Scientists have reached a consensus –to avoid the worst impacts of climate change, global temperature increases need to be limited to 1.5°C above preindustrial levels.

In 2015 UN Nations signed the historic Paris Agreement, a legally binding international treaty to combat climate change. Recognising that accelerated and cooperative action is required to limit global warming, this agreement requires emissions to be reduced by up to 45 per cent by 2030 with a goal of net-zero by 2050.

Climate change represents one of the greatest challenges facing the planet and will require a fundamental transformation in how industries produce, consume, and transport. Achieving this goal will require stakeholders around the world to take bold, immediate steps towards reducing emissions.

Sustainability is at the forefront of decisions, and the energy and resources industries are driving a demand for machinery that is safer and more efficient, with reduced carbon  emissions.

Volvo Construction Equipment (Volvo CE) and its Australian distributor CJD Equipment are two companies that are already taking the necessary steps needed to address this monumental challenge. CJD Equipment’s thirty-year partnership with Volvo demonstrates the strength and trust between the two companies, and this unique relationship is crucial in helping the Australian quarrying industry shift to a more sustainable future.

In a pledge to reduce environmental impact, the Volvo Group announced its commitment to net-zero value chain emissions by 2040, set 10 years earlier than the Science-Based Targets initiative commitment.

Volvo CE has also set its own interim goal to be met by 2030, which includes halving emissions from its own operations, facilities and manufacturing processes, and achieving 30 per cent in absolute reductions in the use of its products, the indirect emissions of which account for the highest proportion of Volvo CE’s carbon footprint.

Volvo envisions that 35 per cent of its

product range will be electric by 2030 and intends to lead the industry in this transformation. The company has taken a holistic approach to achieving its sustainability goals embracing batteryelectric machines, hydrogen fuel-cellpowered equipment, and improved internal combustion engine solutions.

The Volvo EC300E hybrid excavator is the result of the company’s research and commitment to developing more sustainable solutions. A lot more work is continuing behind the scenes from Volvo CE around hybrid machines, motion systems and energy recuperation, which will undoubtedly lead to more significant savings in the future.

Volvo excavators are already well known in the quarrying industry for their impressive features, safety and comfort. What sets the EC300E hybrid apart from other hybrid excavators is Volvo’s unique hydraulic-hybrid technology. The 30-tonne hybrid excavator harvests and stores the energy generated by the machine’s boom-down motion to assist the engine system and support torque.

improvement in fuel efficiency by up to 17 percent, and up to 15 per cent fewer carbon emissions. The hybrid excavator is especially effective in quarry dig and dump applications, and offers rapid payback, especially when digging from a bench within a 90° swing.

Unlike other systems that capture the swing energy to electronically assist the engine, Volvo’s hydraulic-hybrid stores the energy of the powerful and repetitive boom-down motions to charge hydraulic accumulators, which then deliver energy to drive hydraulic assist motors to help power the engine system.

controllability, reliability, and performance of the new hybrid model hasn’t been compromised when compared to the conventional machine.

“Volvo’s hybrid solution is simple to use with just a handful of add-on components,” Grant said.

“The EC300E hybrid has the same performance as the standard EC300E, including the added feature to work in ECO mode and hybrid mode simultaneously. The hybrid function is automatically enabled in ECO mode, and all the operator sees on the dash is a small symbol stating that the hybrid

uncomplicated solution with reliable performance without any loss of performance in most operating conditions,” Grant said. “It’s a cleaner and greener choice delivering lower emissions, reduced fuel consumption and straightforward maintenance, without compromising on power.”

Volvo E-series excavator models also utilise a new D8M engine which combines advanced combustion technology and a fuel-efficient Stage 5 engine. The D8M Volvo engine reduces the rated RPM from 1800 down to 1600, whilst also delivering a five per cent increase in power.

Volvo’s hydraulic-hybrid stores the energy of the boom-down motions to charge hydraulic accumulators.

The EC300E hybrid harvests and stores the energy generated by the machine’s boom-down motion.

“The durable D8M Stage-5 engine produces a high amount of torque at low revolutions per minute, so you don’t have to rev the engine, saving fuel and keeping noise pollution down,” Grant said.

Inside the cab, the EC300E hybrid features boom and arm bounce reduction and Volvo CE’s new comfort drive control, which helps reduce operator fatigue by lessening machine shock and allows the operator to steer the machine with the machine’s joystick instead of the pedals.

The EC300E hybrid also stands out with its human interface design which streamlines all in-cab features ergonomically to increase operator productivity. The excavator is also available with Volvo CE’s intuitively designed Co-Pilot system. Volvo Co-Pilot enables access to a suite of connected technologies, including real-time machine monitoring, and insights into how the excavator is operating. Working alongside Volvo Assist software, the operator can easily access machine, job and material information to help maximise productivity, keep the job on schedule and establish a more sustainable site.

The EC300E hybrid excavator made its debut in the US at ConExpo 2020 in Las Vegas, Nevada. Thanks to CJD Equipment, the EC300E hybrid is available for Australian quarries to take advantage of the sustainability benefits. Along with the EC300E, Volvo’s hydraulic-hybrid technology

is also available on the 25-tonne EC250E and 35-tonne EC350E models, as indent orders.

CJD Equipment is a privately-owned Australian company with 20 branches nationally, from capital cities to regional country towns, and strives to deliver more sustainable and energy efficient equipment to the quarrying industry. The introduction of the EC300E hybrid excavator is an example of this commitment.

“We have over 100 field service staff

and 150 workshop staff, plus 15 resident field service technicians available to assist our customers any time,” Grant said. “Our aftersales support also includes 24-hour afterhours call out services.”

CJD’s team is well-trained and their partnership with international manufacturers like Volvo CE provides a diverse range of quality products for the quarrying industry. •

To learn more, visit cjd.com.au

Volvo E-series excavator models also utilise a new D8M engine.

The EC300E hybrid is the result of Volvo’s commitment to developing more sustainable solutions.

EXTRACT IT SUSTAINABLY

What does it mean to sustainably extract a quarry deposit? One of the best definitions I have seen is, “for a sustainable initiative to be meaningful, it must be environmentally and socially beneficial as well as economically viable.”

But what does that mean in practice?

GEOLOGY

You only get to know what’s in the ground through geological investigation and modelling.

Drilling, sampling, face mapping and other data, brought together in geological modelling tools help to provide a clear picture of what materials are in the ground and where they are, creating an ‘inventory’ of what’s in the ‘rock warehouse’, it’s quantity and location. Unlike a conventional warehouse where we know we have 1,000 units of product XY in aisle six, level five and can direct a forklift operator to move them from storage to despatch, the ‘rock warehouse’ is not like this. Instead of being stacked in shelves that allow access to items stored at any point high or low, we need to uncover items from top to bottom, hence the need to have a clear idea of their location, also realising that the materials at the top, are generally the lowest quality as well.

This knowledge helps us plan a quarry from scratch and better understand an existing one – it is the one factor that we cannot change.

MARKET, SALES AND PRICING

It’s one thing to have a potential quarry deposit, it’s another thing again to have a market for it and one without the other is rarely workable. It’s almost as if there are two types of exploration required – one to find the deposit and the other to find and understand the market.

If you take the time to understand both deposit and market (including the prices customers will pay and what the consumption is), you can determine the value

of extracting that particular deposit and how best to maximise its value.

Interestingly, we see few companies that work specifically on quarry market research and pricing, TKB being the only one that immediately comes to mind.

What we do know is that where a systematic approach to understanding what customers will buy, in what quantity, when and for how much, this information can dramatically improve planning and operational viability.

Steve Franklin, founder of Eltirus, looks at some factors that influence quarry sustainability.

Every hour that a machine is idling, it is consuming fuel and producing unnecessary emissions.

Sustainable operation is not just good for the environment, it is good for the bottom line as well.

OPTIMISATION

What can we do with our newfound deposit and market knowledge? How do we leverage this new information to make the most of it?

As the quarry operator, you need to know how best to extract the deposit is such a way as to match your production with market demand and you need to do this in a fashion that reduces your extraction costs and maximises the sales price.

The way to achieve this goal, is by using deposit optimisation tools such as Deswik. GO which are used to bring together practical extraction rules, operational costs, market and deposit data to determine what the optimal approach is to extraction.

Once these models are set up, they are easy to update and adjust to ensure that you have a dynamic approach to planning and budgeting. For example, if you know a big fill job was coming up, you could run the model to satisfy add this requirement and see where the best places to extract would be.

Likewise, if you were assessing a different haulage method (conveyor, electric, etc) you could program in the capital requirements and change in operating costs to determine what the impact would be on the bottom line. By bottom line, I mean the Net Present Value (NPV) of the operation, but you can also optimise for other things, like emissions.

A further step is to optimise a cluster of quarries. By this I mean that you could optimise three to five quarries simultaneously against the known major projects and demand likely to occur in the next five years to help understand which quarries should be developed and when to maximise the NPV of the cluster.

A good optimisation model provides confidence in how to best extract deposits.

A good optimisation model is the place that your data comes together in such a way that you have confidence in how best to extract deposits and how to quickly adapt tochanging circumstances.

OPERATIONAL SCHEDULING AND PLANNING

One of the truly useful things that we get out of the optimisation process is stage shells that help us with our short-term, detailed planning for how to extract the deposit. Without the use of an optimisation tool, the creation of extraction stages is at best “arbitrary” and often results in “pretty pictures” that have no real bearing in how the deposit will actually be extracted.

The conventional approach to the creation of stage shells (if they are to be truly representative) is highly iterative and can soak up engineering hours, to the point where compromise is the only real outcome.

The use of optimisation tool stage shells ensures that there is an effective basis for accurate medium-term planning that ensures that value identified in the optimisation process is not lost in poor or absent operational planning and control.

In short, it gives you a ‘real’ plan to judge actual vs. predicted performance against. Interestingly we are also seeing an increasing interest in this operational planning process from regulators and

company auditors, both of which are interested to see a structured approach that factors in the key variables.

EQUIPMENT PLANNING

One of the outputs that a good scheduling and planning process can give you is accurate estimates of mobile equipment hours. Most medium-term scheduling models can be run in such a way as to determine the likely loading tool and hauler hours to achieve the schedule. In fact, depending on the level of detail that you want to add, the models can detail out pretty much all the operational requirements from drill and blast, cleanup, extraction and through to rehabilitation planning with a good degree of accuracy. Use the mobile equipment that you have in the most efficient way possible. By this I mean, the right amount of equipment at the right time and working at the correct rate.

Yet again, if we are estimating this as part of our planning process, we then have something to compare with – in essence, the Plan – Do – Check – Act of quality control. Note however that if you don’t have the tools or methodology to Plan, then you can Do, but there is only historical performance to Check against and no way to know how (or if) your operations need to Act in a different way.

Where we see real opportunity is to budget not just for equipment operating hours, but to also budget for emissions as well.

Checking equipment operating hours and particularly idle hours is particularly important for as long as a site is running diesel powered equipment. Every hour that a machine is idling, it is consuming fuel, running up a maintenance bill, reducing its resale value and producing unnecessary emissions – none of which is helpful.

A further area for investigation in terms of planning is to look at the fuel consumption of older generation equipment vs. new machines to determine what the impact of this is on fuel consumption and emissions.

By way of example, a Cat 773B (1986) with a rated payload of 45t has a fuel burn of 25 - 69 litres per hour, vs. a current model 775G (2019) with a rated payload of 64t and a fuel burn of 24 - 47 litres per hour. While it may seem that the older truck is “cheap to run”, the reality can be very different once you sit down and look at all the factors in the owning and operating cost equation.

SUMMARY

Experience shows that sustainable operation is not just good for the environment, it is good for the bottom line as well. Take the time to put in place the knowledge and systems that allow you to ensure that you can Plan – Do – Check –Act to maximise operational value and improve sustainability. •

Use the mobile equipment that you have in the most efficient way possible.

Once models are set up, they are easy to update to ensure you have a dynamic approach to planning and budgeting.

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EXTRA CLEARANCE SCREENING

One of the world’s largest producers of modular, portable, and static mineral screening equipment has engineering a new horizontal screen with innovative features that sets it apart.

The ESX Series Horizontal 6 x 20, three deck screen is the latest addition to Terex Materials Processing Systems (MPS) range of vibratory solutions, available through Terex Jaques.

Named after the key feature, the ‘extra clearance’ ESX Series elliptical stroke screen, has taken the oval stroke screen to the next level.

The increased clearance between screen decks, compared to traditional horizontal screens, provides easy maintenance access to the media. There are 58cm between the top and middle deck and almost 70cm between the middle to bottom. The footprint of the ESX remains identical to traditional horizontal screens except for standing 55cm taller.

Glenn Forbes, machine sales manager for Terex Jaques, said the company’s experienced engineering team has designed the ESX series with the user in mind.

“Whether urethane media or specialty wire cloth is necessary, the ESX Extra Clearance feature is large enough to inspect and replace any type of media preferred, safely and with ease,” he said.

The ESX Series is designed to handle the heavy-duty applications typically found in Australia and New Zealand. It integrates more steel into the ‘rock zone’ and incorporates rugged computer-optimised decks with full length bracing.

Its patented gear case baffled lubrication system uses high tolerance machined eccentric weights, helping increase its lifespan. Longer suspension springs and a patented dual O-ring huck bolt construction that is ‘sealed for life’ means the screen can meet some of the most demanding applications.

Additional integrations focus on increasing production, while reducing cost of ownership. A variable slope installation from zero to 10°

allows the slope to match the application, minimising bed depth as well as enabling screening with apertures up to 150mm.

The high G-force, high efficiency oval stroke motion adjusts three ways to optimise performance. A patented optional bottom deck deflector plates boost screen efficiency by up to 12 per cent.

Maintenance-friendly features include the patented low maintenance surge damper system, bolt-on upper and lower spring guides, toolless oil check sight glasses, sidewall hand access system for wire cloth clamp bars and bottom deck feed curtain.

“The ESX Series is an illustration of our future product road maps focusing our efforts on offering customer solutions that are safe, reliable and provide dependable production,” Forbes said.

“The horizontal screen is built stronger, runs smoother, and will give customers peace of mind by providing industry leading durability.”

The screens are versatile and can be used for applications including quarried stone, river gravel, recycling concrete, fractured gravel and washing recycled

The ESX series includes several maintenance-friendly figures.

THE LITTLE DETAILS MATTER A LOT FOR KLEEMANN

When a customer needs a wear parts solution Kleemann likes to start at the end of the production process. The company works backward from the equipment and material the customer is producing to find the right wear or spare part required for the application.

It may seem like a small thing in the grand scheme of things, but it matters in the long run.

Kleemann’s national aftersales business development manager Dave Lefroy uses the example of two iron ore operations in Western Australia and South Australia as an example.

Both operations are in similar applications but the differing conditions ore bodies, and other variables mean they need differing wear parts.

After all, with aspects like feed material type, abrasiveness, moisture content and crushing ratio, there are plenty of factors that the customer may need help determining the correct wear parts to achieve the desired product and production rates.

Lefroy said unless a company is working in the same quarry or ore body as another, an

individualised, tailored approach is always best.

“We work closely with our customers to understand their application and try and reduce their operating costs,” Lefroy said.

“Once we can get an understanding of what the application is we can suggest the right wear product that is suitable for the best productivity and wear life, ultimately reducing operating costs.

“We are all about identifying the right wear items for the application.”

Kleemann aims to combine its staff’s industry experience alongside a technologysupported approach to ensure its customers choose the right wear parts and spare parts.

With branches in multiple states strategically located around Australia, Kleemann’s staff have plenty of knowledge to provide its customers at the point of sale.

It uses factory-backed wear rate calculators to provide a consumption rate based on the crusher’s settings, the feed size, annual running time and various other factors to provide a guide for the customer.

Downtime is the biggest impediment to a customer’s budgets, even for the metro quarries.

It delays projects, increases costs and often means paying for unscheduled or unexpected repairs.

This is why Wirtgen’s national parts manager John Richardson believes it is worth investing in the brand’s high-value parts.

“The key factor for the customer is downtime, it costs them more through downtime because they’re losing production,” Richardson said.

“If they’re using a cheaper part, what is that costing them in the long run with downtime where it could double or triple in a 12-month period, by utilising OEM parts they guarantee correct fitment, with local support and knowledge with factory OEM backing.”

Kleemann has tried to become more accessible to the remote customer which is why it provides a fleet view telematics solution that enables a manager to see a complete data-backed overview of their machines. It enables a manager to optimise the scheduling and planning process to reduce transport movements and expensive downtime periods.

“Customers that utilise this technology have found it beneficial for maintenance

Kleemann is matching technology with staff know-how to get the customer’s job done.

planning and mitigating downtime events, along with tailored parts packages that we have put together for customers in remote locations,” Lefroy said.

By melding the knowledge and digital

platforms together, Wirtgen sets up its customers to be self-sufficient with tailored wear solutions for their applications.

“Every client at the crushing end is treated in a unique way because at the end there

are no two applications that are exactly the same,” Richardson said.

“Once the machine arrives, understanding the application, that is where we come into play with our uniqueness in this sense to tailor the clients’ needs to suit their specific outcome.”

Then with the simplicity of online convenience, the maintenance manager or fleet manager can access the online store or parts and more platform.

The online platform enables the customer to see live prices and specials in the parts catalogue across the Wirtgen range and place orders.

“The (online store) is part of what makes us unique I feel,” Richardson said.

At the end of the day at Kleemann, it will always come down to one major factor in their service and sales approach, Lefroy said.

“We’re very customer-orientated and focused on building customer relationships and maintaining customer relationships,” Lefroy said.

“It’s been a core focus of our business for a very long time.” • To learn more, visit wirtgen-group.com/en-au

The online platform allows customers to see live prices and access products with the ease of a click of a button.

Kleeman likes to use an individualised approach for its customers to ensure they get the best product to suit their specific needs.

THE SECRET TO LOW EMISSIONS CONCRETE

Kayasand helps the construction industry be more sustainable with their manufactured sand plants.

Demand for concrete, the most widely used and versatile building material, is rising. However, it accounts for at least eight per cent of the world’s carbon emissions because of the way its key component, cement, is produced.

Sand is the second most consumed natural resource in the world behind water, according to the United Nations environment programme. Billions of tonnes are mined around the world every year from rivers, dunes and ocean dredging for use in construction. Much of it is used to make concrete and must be washed before use. This requires massive volumes of water, is expensive to clean up and creates a lot of waste.

The building industry is under considerable pressure to produce more sustainable building materials. As a result, organisations that are attempting to reach net zero greenhouse gas emissions are looking for new ways of producing more sustainable concrete.

There’s no magic bullet that will transform the industry overnight. Businesses have

begun implementing strategies like adopting supplementary cementitious and recycled materials, reducing freight emissions, and using alternative fuels.

Reducing the quantity of cement in concrete mix can also significantly help. Aggregate quality plays a major role in achieving this, and the secret lies in the sand. Finding an alternative to natural sand in concrete needs to be sustainable, have a low cost to produce, and improve the quality, durability, consistency of the final product. Importantly, it must require less cement to make concrete of the same strength.

Kayasand manufactured sand plants have been producing a quality alternative that ticks all these boxes since 2007.

In fact, manufactured sand has been around for years. When correctly designed and consistently produced, it can easily replace all the natural sand in concrete.

The perfect concrete sand is exactly what Kayasand’s founders set out to create. Its V7 plants consistently produce precisely graded

sand with a cuboidal shape that aims to make stronger concrete with less cement.

The way Kayasand manufactures sand is very environmentally friendly too. It combines ‘washing without water’ technology with a dust-free and low-noise process, and a compact footprint. The result is no wash plant tailings and reduced production costs.

Manufactured sand from a Kayasand plant has the potential to save concrete producers 6,000 tonnes of carbon emissions each year.

The V7 plants were originally developed to turn waste crusher dust into saleable premium product. However, the same technology works on slag and recycled materials such as glass and concrete to further reduce the industry’s carbon footprint.

For example, waste glass is recycled into premium concrete sand, concrete is recycled back into concrete, and cement substitutes are created from limestone filler and waste slag.

Kayasand’s unmanned plants are also designed to be reliable and cost-effective to run. Precision real-time control and advanced

remote monitoring capabilities mean the plant operates for long hours with minimal supervision to maximise capital utilisation.

At their heart is a specialist crusher and air screen technology developed by KEMCO in Japan. The technology was originally developed because of a ban on dredging that severely disrupted concrete sand supply in 1999. There are now over 300 plants in Japan, China and India.

In 2016 Kayasand installed and commissioned the first V7-60 plant outside of Asia in Holcim’s Albion Park Quarry. Holcim sells premium manufactured sand from the Kayasand plant to concrete

manufacturers in the Sydney area.

In June 2023 they received $3.5 million backing from New Zealand Green Investment Finance to reduce carbon emissions from concrete and opened their first V7 high-technology manufacturing demonstration plant in New Zealand.

NZGIF Chief Executive, Craig Weise, said the investment was an important step and a boost for the construction sector and consumers who are eagerly looking for more sustainable building materials. •

To learn more, visit kayasand.com

MEET THE BOAPOD: MONEY AND TIME SAVER

A new, mobile, all-terrain hydraulic hose repair unit is proving to be the silver bullet for quarries facing downtime costs due to hydraulic hose failures.

Critical damage to hydraulic hoses can spell critical disaster for most quarrying operations.

Production slows, downtime increases and the expenses can build up as the site waits for repairs.

And it’s not just the part that needs replacing that is the issue, but a range of other unseen costs can hurt quarry operations when machinery breaks down.

That’s why operations like Blue Ridge Quarry, located in Moruya in New South Wales, are turning to BOA Hydraulics

for a proactive approach to repairing and maintaining hydraulic hoses.

Blue Ridge quarry – like many others across Australia – is in a remote regional area, which presents its own set of challenges. Machines in need of repair would have to be taken on a 90-minute round trip into town to be serviced.

As Blue Ridge Quarry manager Aaron Millikin said to Quarry, the sales don’t wait, and trucks don’t stop just because one of its 21 hydraulic machines is in need of repair.

So having a machine on-site that can make needed repairs offers major advantages.

“Before we had the trailer (BOApod) on-site, we lost a lot of downtime,” Millikin said. “We would have to pull the hose off the machine, run it 45 minutes into town to get the hose made, and return to the quarry and put the hose back on.

“It is more the travel and downtime – 45 minutes into town and 45 minutes back to the quarry – but now we can take the hose off and have the hose fitted and the machine ready to run.

“It just increases the production time and consistency of running the machines.”

Since the BOApod arrived at Blue Ridge Quarry, workers have noticed how much the downtime has reduced and productivity has in turn been boosted.

The BOApod – the brainchild of company co-founders Simon and Greg Boakes – is a mobile, all-weather hose repair unit that features European precision crimping and cutting machinery, along with a large range of quality hoses and fittings. This unit is delivered with a full training and support program, to bring hydraulic hose repairs in-house.

With flexible finance options, companies can get a BOApod with minimal upfront cost, as well as ongoing training and support from the company.

The unit has created more solutions for Blue Ridge Quarry, with faster turnarounds on repairs and the chance to perform preventive maintenance. The latter has become increasingly important to the quarry, as operational costs have continued to increase and impact the business’ bottom line.

BOA Hydraulics’ downtime calculator,

which shows how much companies could lose due to critical hose failures in lost production, shows some companies can stand to lose up to $50,000 an hour. The company believes those expenses can be avoided through preventive maintenance and a proactive approach using the BOApod and its quality tools, hoses and fittings.

For Blue Ridge Quarry – where it is estimated 60 per cent of its breakdowns are related to hydraulic hoses – the BOApod has become a time- and money-saver.

One of the quarry’s eight mechanical operators or two diesel mechanics can, with BOA’s training, help repair the hose.

“It is a big plus being able to do it on-site,” Millikin said.

“(Most) of the hose failures are from wear or falling debris breaking a hose or hoses rubbing. Instead of taking off the hose, which is 3m long and runs through a wear spot, we can put different joins and re-route it in a different direction to prevent it from wearing through in the same spot again.”

After launching the BOApod in New Zealand in 2019, BOA’s introduction of this state-of-the-art mobile hose repair unit to Australian shores has earned rave reviews across the country.

With BOApods being used across quarrying, mining, forestry and civil operations, BOA has developed a strong reputation across Australian work sites.

“I would highly recommend the trailer to anyone, especially companies with a lot of hydraulic hoses,” Millikin said.

“Some days you might blow three or four hydraulic hoses. Just being able to have it on site is a big thing.

“The trailer is very user-friendly. There is plenty of space for storage. The crimper and the saw work great.

“We have had no issues with the product.” • For more information, visit boahydraulics.com

Blue Ridge Quarry have been using the BOApod to fix and repair its hydraulic hoses on-site.

Blue Ridge Quarry is located in Moruya in New South Wales and deals with issues of remoteness.

60 per cent or more of our breakdowns would be caused by hydraulic hoses, so it is a big plus being able to do it onsite.

SHELL LUBRIANTS KEEP CONSTRUCTION POWERED UP

The right oils and greases can help machines handle a booming construction industry.

There are plenty of things out there that can give a quarry an edge over the competition, but oils and greases are often left out.

Using the right lubricants and oils on machinery can help to reduce breakdowns and extend machine life.

It’s especially important to reduce any unexpected downtime as the construction industry booms.

Australia’s construction industry accounted for nine per cent of the country’s gross domestic product last year with $437 billion in revenue1

The sector is projected to have an annual growth rate of 2.4 per cent over the next five years2 which is expected to also impact the quarrying and aggregates industry as it supplies the raw materials for the construction boom.

On the global stage, the United States is tipped to grow its construction business by more than five per cent as part of the Infrastructure, Investments and Jobs Act3 while China has bolstered its construction industry by $2.3 trillion4

Elsewhere, India is looking to invest close to $840 billion in urban infrastructure to meet its population requirements over the next 15 years5

In Australia and abroad, there is an opportunity to grow business opportunities and interests with new construction projects.

And for the quarry industry, which is closely tied to the construction industry, that opportunity could present a flow-on effect.

Equipment reliability becomes vital when companies take on more projects which prioritise deadlines and budgets.

Viva Energy Australia, which is the Shell Lubricant Macro Distributor in Australia, can offer quarries a range of lubricants, oils and greases to help keep machinery running.

Shell’s survey from 2019 of lubricant decision-makers in the European construction industry, Powering Peak Performance, found 40 per cent of companies surveyed had suffered equipment breakdowns due to ineffective lubrication.6

It also found, more than seven out of 10 (73 per cent) of the responders believed their maintenance teams would benefit from additional training on lubricants.7

Often these breakdowns and equipment damage cannot be spotted until it is too late which creates unplanned downtime, cost blow-outs and missed deadlines.

Construction equipment maintenance contributes to about 40 per cent of total construction project overrun costs.8

This is why Viva Energy’s technical expert Silvana Farrugia believes companies would benefit from relying on Shell’s advanced lubricant technology but can also offer business expert advice from a local technical helpdesk.

“Shell invest significantly in technical collaboration and has over 350 product application specialists that work closely with OEM and customers to develop innovative lubricant solutions to optimise equipment uptime,” Farrugia said.

“Our lubricants products can deliver value but also improve business outcomes.”

When developing a new lubricant, Shell lubricants undergo rigorous rounds of tests, in the widest possible range of conditions to ensure products are developed for the real world.

With the convenience of Viva Energy’s online store, which launched earlier this year, purchasing the right oils, lubricants and greases has also never been as easy, with a simple click of a button.

Viva Energy’s technical desk, available to call or email on Monday to Friday between 8:30 am and 6pm EST, can help recommend the right lubricant product matched to a business’ specific needs and help them take advantage of the increased investment in construction.

Shell also offers a range of tools to help businesses including Shell LubeAnalyst to optimise lubrication practices which, alongside regular maintenance, oil monitoring and on-site assessments, can help extend the lifespan of machinery and keep it running in top condition.

The Shell LubeMatch and Shell LubeAnalyst digital tools allow customers to input the

Using the right oils, greases and lubrications can increase the lifespan of machinery on the site.

details of their equipment and access detailed lube matching information, as well as survey and monitor their engine health.

Using a sub-optimal lubricant may not display damaging results immediately but over time and with extensive usage, it can damage the machine.

“Our local technical help desk is available to answer your questions and provide expert equipment lubricant recommendations, as well as advice on rationalisation and lubricant storage,” Farrugia told Quarry previously.

“We make sure we recommend products with approved specifications and are the best fit for your quarrying, mining or construction equipment.”

With the construction industry on the rise, it is clear why using the right oils, greases and lubricants is one of the key factors to getting the job done on-site. •

For more information, visit vivaenergy.com.au/ shoplubricants

Power, Precision, Performance.

1 IBISWorld, Construction in Australia – Market Size 2007-2029, 2023

2 Quarry Magazine, Industry Leaders 2023 edition, 2023

3 GEP. “US Infrastructure Bill and its Impact on the Construction Industry.” 2022.

4 Global Times. “China to allocate more funding to support key new basic infrastructure projects.” 2023.

5 The World Bank. “India’s Urban Infrastructure

Needs to Cross $840 Billion Over Next 15 Years: New World Bank Report

6 Shell. “Predictive and Preventive Maintenance.”

N.D.

7 Shell. “Predictive and Preventive Maintenance.”

N.D.

8 International Journal of Engineering Science

Invention, Equipment Maintenance: An Effective Aspect of Enhancing Project Profitability, 2014.

According to a variety of reports, the construction industry is set to grow over the coming years.

MINIMISING DUST FOR A BETTER WORK SITE

Like many quarry operations, Stradacon Penna – located in Townsville, Queensland – was on the look-out for ways to minimise dust generation.

For owners David and Vivienne Penna, a clean and sustainable worksite was paramount.

“We’re very keen to get the dust out of our lives, to get the dust off our site,” David said.

“It causes mechanical issues, it causes health issues, and it causes productivity issues.”

This is where McLanahan entered the equation with a solution to Penna’s problems.

Penna was introduced to McLanahan through Lincom ¬– McLanahan’s dealer for wet aggregate processing equipment  in Australia.

“They’ve supplied us pretty much all our crushing equipment throughout the

years, and they maintain a very good relationship with us,” David said about his relationship with Lincom.

“We’re on a first-name basis with them and know the family very well, and being a family organisation ourselves, it means a lot to us.”

Through Lincom, Penna installed McLanahan’s UltraWASH modular wash plant. The UltraWASH produces up to three clean aggregate products and up to two washed sand products, which changed the dry screening process for Stradacon Penna.

“The UltraWASH is allowing us to operate without dust, that’s absolutely critical to us. Its reliability is just outstanding,” David said.

With some forward planning and the modularity of McLanahan’s products, the wash plant was set up quickly and easily.

A modular scrubbing system consisting primarily of a coarse material screw washer was also added to the plant for processing construction and demolition waste after it has been crushed.

The coarse material screw washer accepts the construction and demolition waste after it has been crushed and removes the lightweight debris and organic material from the aggregate before it is processed in the UltraWASH.

It has allowed Stradacon Penna to increase its product lines and produce some speciality sands without producing the dust usually associated with specification products.

“It’s been a real game-changer for us,” David said.

“We’re now producing aggregates and sands that are 10 per cent derived from recycled concrete from demolition waste.

“We’re cleaning it up, presenting it with new fresh material, giving it a spruce up, putting it back on the ground and you just can’t tell.

“Rather than crushing all that demolition waste up, sending it back to the industry, we’re tidying it up and presenting it back to the industry in an almost new state.”

The ability to reduce soft plastics, timber and paper in construction and demolition feeds and re-purpose the waste as new aggregate has been a hit with customers.

Customers know they can bring construction and demolition waste for recycling and leave with a clean, recycled

Stradacon Penna has benefitted greatly from its partnership with McLanahan through Lincom.

Stradacon Penna has used McLanahan’s products to minimise dust generation on its site to make it better for workers.

how we’re going about it, and they want to be a part of it,” said David.

“I’ve been in discussions with a lot of customers, and they all agree that it’s a very responsible thing to do, bring us concrete waste, we clean it up and send it back to  the industry.

“We’re very happy with the products coming out of the wash plant, and a key feature is the flexibility of the plant.”

With the addition of the McLanahan UltraWASH and modular scrubbing system, David can provide his customers with highquality aggregate products while creating a safer working environment for his team.

“The whole operation, the scrubber system coupled with the wash plant, enables us to treat this demolition waste and send it back into the industry like an asnew state,” David said.

“It also enables us to operate dustfree. There are fruit trees growing there because they can.

“It adds to the well-being of us all as people here, it’s healthy, it’s clean. It’s also environmentally sustainable because we’re not putting rubbish back out into the industry, we’re not belching dust out into the air, and it makes for a great work environment, it really does.”

Stradacon Penna – like most Australian quarries – ¬is in a remote part of Australia

can cost serious money.

This situation makes quick and reliable customer service crucial.

This is why Stradacon Penna has come to appreciate McLanahan’s controls and automation team, which can provide the plant with software updates and troubleshooting remotely.

It saves the expense of calling an electrician from town, which significantly reduces the potential downtime on site.

“The company being so far away, you feel a little remote here, you feel a little bit like you’re on another planet somewhere, but the remote access, that just makes us feel

David said.

“We feel like they’re right here with us.”

After his experience with McLanahan’s products and continued after-sales service, David believed they had created a partnership that will be continued long into the future.

“Having a relationship with someone supplying your equipment goes deeper than the actual equipment itself.

“It goes to the relationships you develop with the company, and I can’t say enough about the relationship that I’ve developed with McLanahan through Lincom and directly through McLanahan.” •

The McLanahan UltraWASH plant has helped improve the dry screening process at the Townsville business.

McLanahan is able to offer advice and troubleshooting help remotely to ensure the machinery runs smoothly.

SAFETY ON THE MIND AND IN THE WORKPLACE

Quarrying and Mining Safety and Health

For the Australian quarry sector, and the extractive industry broadly, there is nothing more imperative than ensuring all employees are kept safe while on the job.

The Quarrying and Mining Safety and Health Conference, featuring gold sponsors DWF, Groundwork Plus and Komatsu, is now in its 20th year, was back in Brisbane in June and brought together the best minds from across the quarrying and extractive industries.

The event organisers – Institute of Quarrying Australia (IQA), Cement Concrete and Aggregates Australia (CCAA) and Resources Safety and Health Queensland (RSHQ) – produced a diversified speaking list.

RSHQ’s deputy chief inspector of mines Trevor Brown delivered a special presentation on workplace fatalities followed by a look back at the past two decades of the conference.

The reflective session looked back at the past successes of the conference and how safety had changed during that time.

Caterpillar’s operational risk consultant Jenny Krasny explained how the conference

had evolved to encompass mental health and the environment as well as worker health.

“Certainly, over the years, the conversation has evolved from just the physicality of safety to a more holistic view, encompassing what it means to be healthy in body and mind,” Krasny said.

“More than ever before, the industry recognises the importance of leadership creating a culture where speaking up is encouraged, multiple perspectives are considered and where psychosocial safety issues can emerge and be addressed.

“More and more we’re looking at beyond physical health and into environmental safety as well.”

CCAA Queensland state director Aaron Johnstone said this conference showed the maturity of the industry to work together on important issues.

“It’s been really successful over the past 20 years in building the level of collaboration in the quarrying industry and between the industry and government,” Johnstone said.

“The industry has become more engaged in those matters and aware of its sustainability,

RSHQ’s chief inspector of mines Hermann Fasching and principal inspector of explosives Hayden Isaac delivered two sessions that provided a resource regulator update and incident reporting.

DWF principal lawyer Matthew Smith

The recent

Conference provided “an opportunity to share knowledge and challenge our current assumptions”.

discussed the positive duty to prevent sexual harassment which was followed by Josh Bryant’s discussion on the impacts of critical risk management.

Safe-Gauge founder and managing director Luke Dawson opened the conference with a focus on how to keep people from the line of fire in maintenance facilities.

Maranoa Regional Council chief executive officer Edwina Marks shed light on how to keep safety relevant by dealing with skill shortages and engaging safety within the workplace.

IQA chief executive office Kylie Fahey delivered an informative and educational session for the extractive industry before Kransy concluded the conference.

The conference focused on three key themes, including workplace culture, critical management and psycho-social issues.

New View Safety’s Kym Bancroft spoke to

Quarry ahead of the conference about the importance of safety in the sector, as well as tips to improve workplace culture.

“Conferences like these are so important for the industry, as they bring many minds together toward achieving the greater goals we have for workplace health, safety and

wellbeing,” Bancroft said.

“We all have busy schedules, but taking some time out for our own professional development provides a significant return on investment when we bring back valuable learnings to our organisation.”

For Bancroft, safety has been her calling

The conference featured gold sponsors DWF, Groundwork Plus and Komatsu.

card in a career that has spanned more than two decades and included stints as a member of the Safe Work Australia and the Heads of Workplace Safety Authorities.

She hopes the conference provided businesses in the quarry sector with the tools to positively contribute to the workplace culture.

“I started my safety career working in safety and wellbeing cultural transformation and it has served me very well throughout my entire (professional life),” Bancroft said.

“I get a huge amount of job satisfaction from empowering the frontline and middle management to take an active role in shaping workplace culture.”

A key aspect of workplace culture is staff retention. Data from the REMSMART and AREEA report Resources and energy workforce insights shows turnover is a “significant issue” for the resources and energy sector. The report noted that the industry found success when companies had invested in their overall employee value proposition.

The report, which included data from 115 companies, highlighted “non-wage” issues such as appropriate behaviour, including

workplace sexual harassment, as a key focus for companies in the future.

It is for reasons like this that Bancroft sees workplace culture as the next frontier for building productive and positive companies in the quarry sector.

“Workplace culture is so important because it is an implicit substitute for leadership,” she said. “In other words, a strong and coherent organisational culture takes the place of active monitoring and supervision by workplace leaders.

“Resources are then freed up to work on other areas like innovation and business management, rather than supervising and dealing with poor performance. When an organisational culture is managed strategically, it shapes workers’ behaviours in ways that align with company goals and priorities.

“Culture also sets unwritten rules around conduct and expectations for performance. Further, culture directly boosts workforce performance because it sends a signal regarding the value and importance placed on people, which workers interpret and reciprocate in the form of proactivity and proficiency.”

The best place to start with any change, but especially workplace culture, is at the top of a company’s leadership.

“If you want to change organisational culture, the best place to start is with management,” Bancroft said.

“What leaders reward and recognise, what they allow and permit to happen, what they measure, what they punish, and what they prioritise and talk about all contribute to the organisation’s culture.

“Therefore, the style and proficiency of senior leadership will influence organisational culture in the most efficient way.

“A ‘good’ workplace culture has been shown time and again to emphasise human relations – creating a sense of community, a supportive work environment, positivity and civility, collaboration and consultation, and investment in people.”

•

Dr Tristan Casey represented New View Safety at the conference

The IQA will be holding further health and safety conferences in Townsville in Northern Queensland on July 14 and Newcastle in New South Wales on August 3.

The conference brought together the best minds from across the quarrying and extractive industries.

LEAPING FORWARD ON SUSTAINABILITY

John Deere makes significant strides in reducing emissions and engine sustainability.

As businesses move to decarbonise their operations, John Deere is focused on improving its engine sustainability.

The company released its sustainability report last year which highlighted several goals and initiatives designed to help reduce its carbon footprint.

John Deere chief executive John C. May said the company was shifting its approach to meet these targets in his letter for the report.

“To achieve these targets, we are pursuing the expansion of renewable fuels across multiple products and geographies and are in various stages of development and launch on battery electric pavers, rollers, excavators, turf and utility equipment, and backhoes,” May said.

“Our efforts show the breadth and depth of our higher purpose: We run so life can leap forward.

“That means we run for the impact we can have when our products and people are involved. We run for food, shelter, fibre, and

fuel. We run for the environment and society.”

One of its fastest-growing initiatives was the remanufacturing business which saw “solid growth” despite weathering challenges over supplier capacity and material availability according to the report.

The company has set the benchmark for remanufacturing revenue by 50 per cent by 2030 to underline its commitment to sustainability across the organisation.

The program allows John Deere to rebuild and reuse engines rather than dispose of them. By going down this pathway, the company can provide a cost-effective solution for customers as well as reduce waste and support the circular economy.

This has been further bolstered by the company investing heavily in research and development to improve its engines with alternative fuels, better sustainability and efficiency.

John Deere has developed a hybrid-electric powertrain in its wheel loader machines

which reduces fuel consumption and emissions by more than 40 per cent in one key improvement which could also benefit the quarrying and aggregate industry.

The wheel loader features a 13.5L engine, gearbox, two three-phase alternating current (AC) permanent magnet generators, power electronics or inverters, four three-phase AC switched reluctance motors, four two-stage reduction final drives and two brake resistors.

The electric drive components are supported by an eight-year, 20,000-hour warranty.

The company’s push to develop alternative fuel technologies which use efficient technology has also seen it investigate hydrogen fuel cells, which can be used to power electric motors, and work on hydraulic pumps and construction equipment.

“This loader is unique in that it runs four electric wheeled motors, which allows the system to recover energy and send to the power electronics to manage where the most efficient path for energy to go,” John Deere’s

John Deere has significantly invested to improve its engine sustainability in recent years.

aggregate and material handling solutions manager Amy Asselin previously told Quarry “This allows the machine to be highly productive in the pit face while managing wheel slip. This means operations can process more material while burning less fuel. It also helps reduce the 944K’s overall environmental impact.”

Work is also underway to investigate the potential usage of biofuels, such as biodiesel, to further this aim.

It is this commitment to efficiency that has seen the company achieve a 16 per cent improvement in fuel efficiency for its construction equipment over the past decade.

The company aims to offer a range of electric construction equipment to its customers by 2026, including offering 20plus electric and hybrid models.

John Deere bolstered this ambition by investing in its partnership with Kreisel Electric earlier this year to help fund its expansion and increase its battery production capacity.

The partnership was designed to be a cornerstone of John Deere’s sustainability plans featuring increased electrification of its construction products.

As part of its sustainability goals and new partnership, a new facility will be opened at the John Deere Saran factory in France as well as assembly facilities in the United States.

“This investment will put a strong focus on the industrialisation and automation of the entire production process, as well as research and development capacities at Kreisel HQ in Rainbach,” John Deere electric power global director Jennifer Preston told Quarry previously.

“We are embarking toward a future with zero emissions propulsion and pursuing our sustainability goal to demonstrate viable lowand no-carbon alternative power solutions by 2026.” •

John Deere has made major gains in engine technology and efficiency in the past five years.

SHAPING TOMORROW, TODAY

More than two decades ago, Delta Group’s founder and managing director - Con Petropoulosknew it was essential to contribute to the recycled materials space, to ensure preservation, protection and sustainability for future generations.

Delta Group has been a central part in delivering many of Melbourne’s iconic landmarks - including the demolition of the Gas and Fuel Towers in Flinders Street, the Melbourne Cricket Ground (MCG) expansion, and more recently the Hazelwood Mine and Power Station demolition.

Delta’s recycling and logistics general manager Dominic Santullo said the company continues to evolve, embracing new technology, equipment and expertise to ensure optimal outcomes.

“With the Hazelwood project, we probably would have been able to deliver the project 20 years ago, but not as quickly or efficiently as we have”, Santullo said.

“Thanks to advances in all areas of demolition, and Delta Group’s ability to pool resources, machines and equipment from all over the country, we were able to deliver the entire project with zero lost time injuries.

“An incredible achievement for a project with over 1.1 million work hours.”

Delta is one of Australia’s largest processors of commercial and demolition waste streams, recycling close to 90 per cent of construction and demolition waste from their projects, including ferrous and nonferrous metals, timber, concrete and other construction materials.

Annually, Delta diverts over 2 million tonnes of landfill into the roads and building materials of the future.

Whelan the Warehouse is the timber recycling division of Delta Group. As the demand for timber products with unique provenance and sustainability principles soars, Whelan the Warehouse has established a strong reputation among Australia’s leading builders, architects and interior designers for high-quality salvaged and sustainably sourced new timber.

“With the MCG project, the timber from this historic site was all salvaged and recycledfurniture was made out of it – it ended up in people’s homes, people’s offices, shopping centres,” Santullo said.

“Demolition is often seen as a dirty industry – we’re making it clean because of what we do with the materials, we don’t just send it to landfill and bury it, we try to give it a second life.”

Delta displayed its ability to move recycled materials at scale during the successful completion of the Hazelwood project, which was shortlisted at the 2022 World Demolition Awards in the Industrial Demolition category.

“We were demolishing one of the biggest power stations in the Southern Hemisphere –it was massive,” Santullo said.

“Over 100,000 tonnes of steel was recycled, and over 100,000 tonnes of concrete waste was crushed and recycled on site.”

“It was re-used back on-site; it could have been sent away, but it was used to remediate the site, and utilised to help the new construction currently taking place out there.”

Delta’s ability to handle the logistics was another key aspect showcasing its expertise when it came to the state’s biggest

Delta Group is committed to diverting construction and demolition waste from landfills to help build a better tomorrow for everyone.

Delta Group recycles most of the waste from its demolition projects to give it a second life.

“That was the quiet achiever – the transport every day running in the background from the country to the city.”

substitute for crushed virgin quarry rock.

Envirocrete has been used in major infrastructure works like roadworks, as well as level crossing removals, freeway and highway upgrades and subdivision work.

The West Gate Tunnel project in Melbourne has utilised Delta’s recycled materials.

“With West Gate, Delta supplied the recycled material, so it’s a good feeling driving over that road knowing you’ve made a positive contribution to a sustainable future,” Delta’s concrete recycling and contract crushing project manager James Georgiou said.

Delta Group has come a long way since it was established over 50 years ago by Petropoulos, with one of his first projects in the Latrobe Valley in Victoria. Now with offices in every Australian state, the company prides itself on being able to handle any project, in any location from the metro, regional, remote or marine areas.

Georgiou said the company’s expertise in the recycled materials space had set it up to be able to tackle any job, big or small.

“A lot of government projects are required to use recycled materials first… we’re able to meet the demand and supply to many government infrastructure projects,” Georgiou said.

“Big highway upgrades, level crossing removals, freeway widenings and upgrades, a lot of those projects that have taken place over the last five years, the initiative and drive is for those projects to use recycled materials first.

“That’s where Delta Group can deliver, and demonstrates how we’re helping to shape tomorrow”.

strengths, sharing a partnership with Boral in Victoria. Delta moves in excess of 1.5 million tonnes annually of recycled concrete through

• Delta’s recycling and logistics general manager Dominic Santullo has been with the company for more than 25 years.

Delta’s recycling and logistics general manager Dominic Santullo has been with the company for more than 25 years.

KINDER CLEANS QUARRY CLEATS

Cleated belts are a common sight across Australia quarries. They stop freeflowing materials from rolling back down the conveyor and are especially useful in systems with high angles.

Due to their design, traditional belt scrapers cannot be used with the belts, leading to the question, how do you clean the conveyor?

Without the right cleaning systems in place, carryback can quickly build up on the belt. This build-up can migrate to the rollers, leading to mis-tracking and potentially damaging one of the most expensive components of a conveyor.

It can also lead to increased dust and spillage, creating hazards for nearby workers.

Peter Laskey, a field applications specialist at Kinder Australia, told Quarry that there is a solution – the K-Cleatscrape.

Fitted where a secondary belt cleaner would normally be installed, the K-Cleatscrape uses 200mm polyurethane blades with stainless steel or tungsten tips to reach stubborn carryback.

What makes the belt cleaner stand out is its finger-based design, allowing the cleaner

“Traditionally, to clean a cleated belt would require the use of a brush cleaner, but even then, if the cleats are higher than usual they are unlikely to be effective,” Laskey said.

“Motorised brush cleaners require a power source, and a static brush needs constant adjustment, leading to wear.

“In a lot of cases, constantly passing over a cleated belt at a certain angle can lead to a scraper losing its memory and flattening.”

There are several different levels of hardness available for the K-Cleatscrape to ensure they have the maximum cleaning effectiveness for cleats up to 100mm in height. The unique design is compatible with mechanical belt splices and helps to ensure old and worn belts are not damaged, further extending the service life of the conveyor belt.

The proprietary finger design ensures even and optimal belt scraping, with a double row of off-set combs to accommodate extreme ridges.

Old and worn belts avoid additional wear, as the cleaner is forgiving when it comes up against mechanically

Laskey said the effective and inexpensive cleaners have proved popular among Australian quarries.

“Our customers have been very satisfied with the K-Cleatscrape. They’ve gone from having no easy solution for cleaning cleated belts to a simple, easy solution,” he said.

“It’s saving them time and stopping carryback. It’s a simple design that’s strong enough to handle the job it needs to do.”

Kinder’s field application specialists work closely with quarries to find the right tool for the job.

Laskey said the company wants to support the quarrying industry as much as possible, and new components like the K-Cleatscrape is one way it can do that.

“Innovations help us solve the big problems we have found on sites,” he said.

“We’re a solutions-based company. That means we can come in and help quarries with the difficult engineering problems they’re facing.” •

To learn more, visit Kinder.com.au

The K-Cleatscrape uses 200mm polyurethane blades with stainless steel or tungsten tips.

BUY. SELL. HIRE. QUARRY MARKETPLACE

OUT AND ABOUT WITH THE IQA BRANCHES

VICTORIAN BRANCH YOUNG MEMBER NETWORK EVENT

The recent Victorian branch Young Member Network event, held on Friday April 28, provided an opportunity for education, networking, and professional development, incorporating three site tours and demonstrations.

The group’s first stop was at Burdett’s in Lang Lang, south-east of Melbourne, for a tour of the site and wash plant. This was followed by a trip to Langwarrin Quarry Equipment for a tour of the resource and discussion.

Following lunch, the group visited Kinder Australia for a tour of the facility and its workshop, before the day concluded with networking and refreshments.

SOUTH AUSTRALIA BRANCH PLANT AND EQUIPMENT WORKSHOP

It was a full house when the SA branch hosted the Plant and equipment: Safety, compliance and best practice workshop on Friday May 5. This half-day workshop covered four of the seven modules of the program, specifically legislation, safety, guarding and isolation, and mobile plant.

A total of 22 participants attended the workshop, which was facilitated by Peter Williams from Mining and Quarrying Occupational Health and Safety Committee (MAQOHSC). Participants came from organisations such as Adbri, Groundwork Plus, Hallett Group, Hanson, McMahon Services and Mining Plus – Tronox, and included quarry managers, supervisors, maintenance and general staff, along with operations and senior management.

The workshop was followed by the SA branch dinner.

compliance and best practice workshop is designed as a full-day event; however, it can modularised to allow specific modules to be delivered independently of each other. Note: it is recommended that the safety module is done prior to any other modules.

branch dinner held at the Adelaide Oval on Friday 5 May, with the 114 people in attendance representing the largest crowd ever at such an event.

A fitting farewell was given to the McDonald family who, after 60 years and three generations of quarrying experience in the state, recently sold their DK Quarries site in Port Lincoln to the Hallett Group.

The branch dinner was attended by 10 family members spanning the three generations. Tim and Mark McDonald gave a great speech highlighting their experiences in the sector, as well as their gratitude for the friendships made within the industry.

The SA branch also likes to welcome new members into the fold and was delighted to present Kasey Jury (Hanson) with her Technical Member certificate.

Isaac Lomman provided the evening’s

The event included a trip to Langwarrin Quarry Equipment.

The day kicked off with a stop at Burdett’s in Lang Lang.

to check out the Cleary Bros Museum and head office at Shellharbour.

Cleary Bros rolled out the welcome mat with refreshments and nibbles on arrival. The museum floor was awash with a variety of Caterpillar crawler tractors, as well as a canvas cab Mack truck with crawler, some US army items, several motorcycles, and a number of other nostalgic pieces.

The centre space was taken up with a beautifully restored Cat Sixty that was finished with glittery gold and silver paintwork, a simply stunning restoration. Indeed, all items on display were extremely well presented and we thank Cleary Bros for this unique opportunity.

Kasey Jury (left) was presented with her Technical Member certificate.

NSW attendees networking and discussing all things machines.

IQA NEWS

NSW ILLAWARRA SUB-BRANCH NETWORKING DINNER

For the dinner meeting, Anthony O’Grady, Vermeer Australia sales manager – South, and Greg Clayton, Vermeer Australia manager APAC region, were in attendance to present information on the T1255 Terrain Leveller. The Vermeer team also discussed some Australian case study data, as well as operational geological results from Sandy Point.

QUEENSLAND BRANCH 29TH ANNUAL GOLF DAY

Once again, the Queensland branch gathered for a fun-filled social day of spirited competition on the green. It was great to see so many familiar faces at the event, together with a few new ones, including two Young Member Network teams. The day featured plenty of camaraderie and a healthy level of competition; however,

there can be only one winner, with the RUD Chains team victorious on the day.

Thank you to our competition and hole sponsors for their support: Texcel, RUD Australia, Groundwork Plus, Saros International, Ausrocks, Mining Wear Parts, Komatsu, Orica, Astec Australia, MSC Group, Epiroc, Terex Jacques, Scope Geo, HE Parts, CJD Equipment, and Scope Engineering Services.

COURSE UNDER THE SPOTLIGHT

UNDERSTANDING PSYCHOSOCIAL HAZARDS AND THEIR OPPORTUNITIES

A person’s mental health includes their emotional, psychological and social wellbeing. It affects how we think, feel and act. It also helps determine how we handle stress, relate to others, and make healthy choices.

One in five Australians will experience a common mental illness every year, which means millions of people go to work each day while experiencing a mental health problem. And that includes people in the quarrying industry.

The impact is enormous, affecting workplace productivity, performance and employee wellbeing. Given that the average Australian worker will spend close to a third of their lives at work, the workplace is an ideal place for early intervention for mental wellbeing.

Under WHS legislation, the principal duty of employers is to ensure the health, safety, and welfare of their

workers. More workplaces are realising the importance of managing mental health at work and recognising the benefits of creating mentally healthy workplaces. A mentally healthy workplace is one that understands that work can play a large role in an individual’s mental health, and that such issues can have a huge impact on an individual. These workplaces promote education and adopt policies and practices that create a culture in which employees are encouraged to talk openly about mental health.

CPD HOURS: 1.5

IQA QCMS: General WHS

NSW MOC: 5. General WHS

This training can be offered as a corporate program and can be contextualised to a company’s policies and procedures, and specific incidence. The next ‘Understanding psychosocial hazards and their opportunities’ workshop is on Tuesday July 25. For corporate programs, contact the IQA.

UPCOMING COURSES AND EVENTS

L–R: Vermeer Australia’s Anthony O’Grady and Greg Clayton.

Two Young Member Network teams attended the gold day.

The RUD Chains team was victorious on the day.

BASALT COULD BE THE KEY TO THE CLIMATE CHANGE BATTLE

An innovative new project is casting this quarry by-product in a new light

Basalt is usually regarded as a simple by-product found across quarries and mines.

However, one enterprising business in Scotland is looking at finely crushed basalt in a new light using enhanced rock weathering (ERW) for CO2 removal.

After some academic study, Undo is using basalt as part of ERW to help capture CO2 with the potential of 100,000year permeance with billion-tonne volumes each year.

The weathering process involves the rock breaking down over time and, as it is exposed to rainwater, a chemical reaction helps remove CO2 from the atmosphere.

Undo founder and chief executive Jim Mann said CO2 removal needed more consideration in the fight against climate change.

“Even if we eliminate fossil fuel use and decarbonise all areas of our lives, such as transport, manufacturing, energy, infrastructure and food production,

we’re still going to have CO2 lingering at elevated levels in our atmosphere,” he wrote in a blog post.

“The problem with CO2 is that it hangs around for hundreds of thousands of years – and it will keep increasing the earth’s temperature unless we can remove it.

“For this reason, carbon removal technologies are so crucial to the future health of our planet.”

Undo has based its commercial application around the existing infrastructure sources and the quarries that have basalt in abundance.

Farmers can scatter the basalt across their fields and crops and while it weathers in the rain, it locks in CO2 from the atmosphere.

“For ethical and practical reasons, I believe we must make sure that the CDR market isn’t the exclusive realm of well-funded tech companies,” Man wrote on the blog.

“Real change will be inclusive –

of infrastructure, of talent, and regardless of geography.

“With ERW, we can scale carbon removal and distribute the benefits to people in rural communities.”

Undo used 27,000 tonnes of basalt across 1,350 hectares of farmland last year which they estimate will remove 6,750 tonnes of CO2 from the atmosphere.

The company said farmers who have used the mineral-rich volcanic rock on their crops have found improvements in soil fertility, crop health and soil’s pH levels.

“To be clear, there is no silver bullet when it comes to CDR technology. The biggest challenge we face is measuring and quantifying how many tonnes of CO₂ have been removed,” Mann wrote.

“We work within natural environments.

“So, while it will take time to drive down uncertainty, our team is stitching together what I see as the key components of success.” •

infrastructure in place:

• 2 x Weighbridges • Workshop • Offices & Associated Equipment

• Extensive Mobile Crushing & Screening Plant • Hercules Trommel

• Excavators

• Loaders• Dump Trucks• Water Truck• Generators

180,000,000

TONNE RESOURCE

GRAHAM MESSER INDUSTRIAL AUCTIONEERS & VALUERS

KEY RESOURCE AREA (KRA 119)

Location: 15km north west of Gladstone

A proven quarry resource plus approval for a Readymix Concrete Batching Plant & Asphalt Manufacturing Plant, the Yarwun Quarry is ideally positioned to supply material for the following upcoming projects:

• APPROVED ONE BILLION $$$ FITZROY TO GLADSTONE PIPELINE • GLADSTONE PORT UPGRADES

• FUTURE GAS COAL AND SUSTAINABLE ENERGY PROJECTS • ROCKHAMPTON RING ROAD