Quarry September 2021

OEM RESTRUCTURES UNDER ONE BANNER

A business committed to sustainable quarrying practices trials a new wheel loader

Astec Industries announces a major restructuring of the company’s business model

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LOADER COMPLEMENTS PILLARS OF SUSTAINABILITY

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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

SEPTEMBER 2021

NON-TRADITIONAL OEM PUSHES ENVELOPE Superior Industries’ Mike Schultz champions innovation in the crushing space

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IN THIS ISSUE SEPTEMBER 2021

VOLUME 29, ISSUE 09

FEATURES 22 GC SERIES NOT JUST TRIMMED DOWN MODELS An excavator range offers a downsized machine without sacrificing performance.

24 CALIBRATING YOUR SCALES REGULARLY Why having your industrial scales calibrated regularly helps maintain their accuracy and has cost benefits.

33 CONTRACTOR EAGER FOR INFRASTRUCTURE WORK

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SUSTAINABILITY TRIAL A business committed to sustainable quarrying practices has trialled a new wheel loader.

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DOZER REASSEMBLED A dozer has been transported in sections over kilometres of terrain and reassembled.

A crushing contractor could yet leverage off the opportunities the 2032 Olympic Games provides for South East Queensland.

39 ROCKS PUT TO THE TEST: A PROFICIENCY PROGRAM Nearly 30 laboratories have participated in a rocks proficiency testing program to assess the strengths of construction materials.

42 THE KEY MESSAGES OF THE BRADY REVIEW Jodi Goodhall revisits the learnings that arose out of a comprehensive review of fatal accidents in Queensland mines and quarries.

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ONE BANNER Astec Industries has announced a restructuring of its business model.

OEM RESTRUCTURES UNDER ONE BANNER

A business committed to sustainable quarrying practices trials a new wheel loader

Astec Industries announces a major restructuring of the company’s business model

28

LOADER COMPLIMENTS PILLARS OF SUSTAINABILITY

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16

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

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43 EFFECTIVE LEADERS AND EMPATHETIC RELATIONSHIPS CRUSHER SOLUTIONS Superior Industries’ Mike Schultz discusses innovative thinking in the crushing space.

Hy-tec Northern Territory’s Ryan Low highlights the importance of empathy in management roles.

SEPTEMBER 2021

NON-TRADITIONAL OEM PUSHES ENVELOPE Superior Industries’ Mike Schultz champions innovation in the crushing space

COVER ADVERTISER: Brand new to the Australian market and weighing in at 36 tonnes, the versatile GT205S3D mobile screen can be deployed in multiple applications. Turn to page 26 or visit astecaustralia.com.au

EVERY MONTH 04 FROM THE EDITOR

46 IQA NEWS

06 FROM THE PRESIDENT

49 FROM THE IQA CEO

08 NEWS THIS MONTH

50 GEOLOGY TALK

15 PRODUCT FOCUS

Quarry September 2021 3

EDITORIAL

ARE THE PANDEMIC, CLIMATE CHANGE JUST NATURAL COGS IN HUMAN DEVELOPMENT?

T

hroughout history, humanity has pivoted into many eras of transformation. There was the Renaissance and the Industrial Revolution, which promoted new innovations and ideas. The two world wars of the 20th century spurred spin-offs out of the military-industrial complex. The development of civilisation has also been furthered – somewhat paradoxically - by plagues and pandemics. To paraphrase business author Kumar Mehta, the Black Death may have killed up to 60 per cent of Europe’s population in the 14th century but it ushered in labour and modern medicine. The survivors were not only paid for working harder and longer, they relied on clocks to plot their work days.

In an article he wrote for Forbes last year at the beginning of the COVID-19 pandemic, Mehta also mentioned how a debate about the first vaccines in response to the Boston smallpox contributed to the evolution of the modern media. James Franklin, the brother of one of America’s founding fathers Benjamin Franklin, was so disgusted by the notion of injecting pus from an infected patient into a healthy one that he wrote an opinion piece opposing inoculation for one of the first newspapers. As the debate raged incessantly, the publication grew to incorporate other news and opinions in addition to medicine, eg local politics, events, humour and satire, thus inspiring the development of the newspaper.

Why do I raise this? It’s clear that as tragic as COVID-19 and the lockdowns associated with it are, the way we work and interact has irrevocably changed.

Hopefully it will be for the positive but we are already seeing incremental changes and innovations that will drive us in the decades ahead. When I interviewed a captain of industry earlier this year, he marvelled at how it is possible to tutor someone on a

completely different continent about operating a piece of machinery in real time via video link. This form of training was born out of necessity because of restrictions on international travel and wasn’t necessarily convenient in terms of language or time (particularly in Australia, where time differences are often to our disadvantage). However, in a decade from now it may well be the norm. Add virtual and augmented reality to this form of training, and the days of sending people abroad to train customers for weeks at a time may become a distant memory.

Similarly, the climate debate (reinvigorated in Australia last month after the release of the United Nations Intergovernmental Panel on Climate Change) is itself driving industries to pursue net zero strategies by 2050, regardless of the thoughts of politicians and governments. In the extractive space, OEMs are exploring the notion of the “emissions-free quarry” by trialling electrical or hybrid versions of their machines. In other parts of the world, quarries have experimented with alternate energy sources to power their operations, from wind turbines to solar energy to hydroelectricity. Closer to home, companies like Boral, Holcim and Wagners are developing environmentally friendlier concrete products. Australian industries may adapt much faster to more climate-friendly solutions simply because it is more economical, leaving politicians in their wake.

COVID-19 and climate change are undoubtedly the latest turning points in human development. Rather than fearing innovation and ingenuity, we should embrace them. That way, perhaps there will be long-term benefits to the costs and sacrifices of this pandemic era.

Published by:

IT’S CLEAR THAT AS TRAGIC AS COVID-19 AND ITS ASSOCIATED LOCKDOWNS ARE, THE WAY WE WORK AND INTERACT HAS IRREVOCABLY CHANGED. HOPEFULLY IT WILL BE FOR THE POSITIVE

11-15 Buckhurst Street South Melbourne VIC 3205 T: 03 9690 8766 www.primecreativemedia.com.au Publisher John Murphy john.murphy@primecreative.com.au

Editor Damian Christie damian.christie@primecreative.com.au

Journalist Henry Ballard henry.ballard@primecreative.com.au

Business Development Manager Les Ilyefalvy les.ilyefalvy@primecreative.com.au

Client Success Co-ordinator Janine Clements janine.clements@primecreative.com.au

Design Production Manager Michelle Weston michelle.weston@primecreative.com.au

Art Director Blake Storey Subscriptions T: 03 9690 8766 subscriptions@primecreative.com.au Follow Quarry online: Facebook: facebook.com/quarrymagazine Twitter: twitter.com/2021Quarry LinkedIN: linkedin.com/groups/4314906/ Web: quarrymagazine.com The Publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from the advertisers and contributors against damages or

DAMIAN CHRISTIE Editor

liabilities that may arise from material published. © Copyright – No part of this publication may be reproduced, stored in a retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.

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Quarry September 2021

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PRESIDENT’S REPORT

IQA CONFERENCE DELAYED BUT NOT DEFEATED The Institute of Quarrying Australia

I

trust everyone is safe and well. It is a frustrating time for our industry which has been stymied by the ongoing COVID-19 lockdowns in New South Wales and Victoria.

In Sydney, the restrictions in several local government areas (LGA) mean people cannot work because they are not permitted to leave their LGA. Consequently, construction materials companies have had to stand down workers and suspend projects.

The NSW, Victoria and ACT lockdowns are a reminder that our industry must be vigilant. If we’re to be the mainstay of economic activity, then we must be COVID-safe in all we do. We must treat COVID-19 like any other safety aspect in our operations, eg safe distancing, wearing of masks, hygiene practices, modernising and enhancing operations.

Due to the escalation of the Delta strain in NSW, the IQA Board last month chose to reschedule the IQA’s 63rd annual conference in Newcastle from early October to 29 to 31 March, 2022.

It’s a shame the event has had to be moved, as James Collings and his organising committee devised a fantastic plenary program and registrations in the early bird phase were strong. However, it became clear in early August that Sydney’s lockdown would be ongoing. It would also be problematic for our members to travel to Newcastle while the states and territories designated the city and many NSW regional centres “red zones” without being forced into quarantine on return to their home states.

We’re disappointed about the delay but optimistic the conference will proceed at the end of the first quarter of 2022. It’s important to minimise the risks now and ensure everyone’s

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Quarry September 2021

safety. Vaccination rates should ramp up later this year and in line with national cabinet’s four-phase plan, each jurisdiction can reopen with fewer restrictions once 70 to 80 per cent of their adult populations are vaccinated. On current projections, all states and territories should reach their targets by Christmas. By March next year, we would expect to be in the clear and our conference participants to be fully vaccinated.

If you haven’t already registered for the Newcastle conference, I encourage you to turn to pages 13 and 46 for more information.

While Australia’s events have taken a hit, it was a relief to follow (albeit remotely) the Institute of Quarrying New Zealand’s annual conference in Wellington in July. In conjunction with the other International IQ Presidents, I judged the submissions for the annual Caernarfon Award, the highest international honour for an IQ member.

For the second year running, it was great to present the award to a member of the Antipodes – Blackhead Quarries manager Gavin Hartley, for his work with his team in establishing a quarry in Antarctica. It was pleasing to also award five commendations for other high calibre submissions from the UK and South Africa.

Congratulations to Gavin Hartley for his prestigious award, and IQNZ President Dean Torstonson and the IQNZ organising committee for a very successful conference.

I implore everyone to stay safe and well. The rest of this year will be challenging but as an industry we have shown time and again we are resilient.

SHANE BRADDY President Institute of Quarrying Australia

Educating and connecting the extractive and associated industries

quarry.com.au THE IQA IS OPTIMISTIC THAT ITS 63RD ANNUAL NATIONAL CONFERENCE WILL PROCEED IN NEWCASTLE IN LATE MARCH 2022.

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

NEWS

HANSON TO MAKE ALTERATIONS TO PLANS FOR HARKAWAY AND WHITE ROCK QUARRIES and delivering safe environments at their former sites.”

‘HANSON HAS WORKED ON A MODERN REMEDIATION PLAN FOR HARKAWAY QUARRY THAT WILL DELIVER A SAFE, STABLE AND SUSTAINABLE OUTCOME’

The work variation plan would reduce the number of truck movements involved in the rehabilitation by 170,000, subsequently reducing emissions, noise, and wear on local roads.

The building materials supplier expressed its disappointment in the decision in a statement.

“For the past two years Hanson has been working with its consultants and external stakeholders to develop a contemporary rehabilitation plan for the Harkaway Quarry that will deliver a safe, stable and sustainable visually acceptable outcome in line with its legal requirements,” the company stated.

HANSON AUSTRALIA STATEMENT

An aerial view of Hanson Construction Materials’ Harkaway Quarry, Victoria.

Hanson Construction Materials has had a work variation plan refused by the Victorian Earth Resources Regulator for the rehabilitation of the former Harkaway Quarry.

Since ceasing operations in 2010, the 100-year-old quarry has undergone partial rehabilitation, most recently in 2015.

But as the current rehabilitation plan was developed in 1987, Hanson applied for a work plan variation which would reduce the carbon emissions and amenity impacts for the local community.

Earth Resources Regulation executive director Anthony Hurst broadly stated the responsibilities of regulators and operators in such contexts.

“When it comes to site rehabilitation operators are obliged to deliver restoration work to the required standard in order to protect the environment and future site users,” Hurst said.

“While most quarry operators do the right thing, we’ll step in and hold companies accountable if they seek to reduce rehabilitation standards.

“Public confidence in the quarry sector and the jobs it creates depends on operators fulfilling their rehabilitation obligations 8

Quarry September 2021

“After minimal engagement with Hanson and a significant delay post its statutory decision-making timeframe, the Regulator refused to approve the revised plan and issued Hanson with a notice requiring Hanson to specify what steps it will be taking to deliver the 1987 rehabilitation plan.”

In the statement, Hanson emphasised its commitment to rehabilitation and responsible operating, saying it takes its obligations very seriously.

The company has appealed the decision to the Victorian Civil and Administrative Tribunal.

WHITE ROCK QUARRY Hanson Construction Materials must also make significant alterations to its Mine Operations Plan (MOP) review for its White Rock Quarry in Horsnell Gully, 10km outside Adelaide.

Hanson submitted the MOP review to the South Australian Department for Energy and Mining (DEM) in late December 2020, after a significant community consultation process.

The company then received notice from the DEM that it must re-submit a plan which better considers the risk and scope of the mine life extension.

“Following submission of a Mine Operations Plan on 23 December 2020, the Department for Energy and

Mining has carefully assessed the MOP,” a statement on the DEM website reads.

“Government has determined that alterations are required and additional information necessary to enable further assessment of the proposed future operations of the White Rock Quarry.”

Hanson stated its consultation with all relevant stakeholders was very positive.

“All landowners immediately adjacent to White Rock Quarry were invited to attend information sessions held in October 2020 in relation to the Mine Operations Plan Review,” the company explained in a statement received by Quarry.

“State Government representatives, local councils and various other interest groups were also invited to these sessions.”

The quarry has been in operation since 1946 and under Hanson’s ownership since 2007.

The DEM stipulated the areas in which Hanson was required to provide more information in the new MOP review.

“This involves analysing potential areas of impact including air quality, noise, blasting, public safety, Aboriginal and non-Aboriginal heritage, native vegetation and fauna, groundwater, surface water, hours of operation, visual amenity, traffic impacts at the mine access points, and third party property,” the DEM stated.

Hanson has also released a letter to residents and businesses dated July 2021, which provides relevant stakeholders with an update on the progress of the MOP review.

“As a result of consultation to date, and in tandem with our continuing review, we have already taken the decision to reduce the planned operational footprint of the quarry,” Hanson stated in the letter.

“In addition, we have made a commitment to bring forward rehabilitation works, including the planting of native species across part of the southern and eastern faces of the site.” •

BORAL ANNOUNCES BOARD CHANGES AFTER SEVEN GROUP ACQUIRES MAJORITY OWNERSHIP Boral Limited has announced changes to its Board of Directors after Seven Group Holdings secured a 69.6 per cent holding in the construction materials giant.

The Boral share price on 29 July closed at $7.34, slightly down on the final cash per share Offer of $7.40 that Seven Group Holdings (SGH) paid. After mounting the Offer on 10 May, SGH gradually increased the price from $6.50 as each of its conditions were met. The off-market takeover offer closed at $7.40 and was not extended beyond 29 July.

As part of changes to the Boral Board’s composition announced on 30 July, SGH’s managing director and chief executive officer Ryan Stokes has, with immediate effect, been appointed as the chairman of the Board of Directors.

Stokes was SGH’s sole representative on the Boral Board prior to the off-market takeover offer and recused himself from the Boral Board once the Offer was mounted.

Former Boral chairman Kathryn Fagg has retired from the Board with immediate effect.

Stokes paid tribute to his predecessor, thanking Fagg for her contribution. “She has served Boral shareholders over multiple terms, overseeing significant changes and challenges in that time,” he said.

“Kathryn leaves Boral in a strong position, with an actionable transformation strategy and a wellprogressed program of strategic

interests of all shareholders”.

Boral also announced the establishment of a standing Independent Directors’ Committee.

This will be chaired by a Lead Independent Director who will be appointed in due course.

Seven Group, owner of WesTrac, has acquired a 69.6 per cent holding in Boral.

divestments for its US businesses, including continuing to assess options for the fly ash business. The Board is very grateful for her service.”

Stokes also welcomed the appointment of SGH’s chief financial officer Richard Richards as a Board director. “I look forward to working with the Board and Management Team to realise the potential through transformation and strong operating disciplines to deliver sustainable returns for Boral shareholders,” Stokes said.

Throughout the off-market takeover offer process, SGH insisted it would retain a majority of the independent directors on the Boral Board and continue to support the Board’s “current publically disclosed strategy” and “collectively drive Boral’s renewed strategy and maximise value for all shareholders”.

In announcing changes to its Board, Boral has confirmed that the Board will retain a majority of independent directors and the governance framework will continue to be consistent with “promoting the best

The shake-up to Boral’s Board structure is unlikely to impact Boral CEO Zlatko Todorcevski who commenced his role on 1 July, 2020.

In the past 13 months, Todorcevski has overseen a number of sales and divestments as Boral sought to return to profitability after a number of disappointing international ventures and a decline in domestic performance.

‘KATHRYN FAGG LEAVES BORAL IN A STRONG POSITION ...

THE BOARD IS VERY GRATEFUL FOR HER SERVICE’ RYAN STOKES, INCOMING BORAL BOARD CHAIRMAN

In that time, Todorcevski has offloaded Boral’s stake in the former USG Boral plasterboard joint venture to Knauf for $1.4 billion and has sold Boral North America’s building construction business to Westlake for $2.9 billion.

Todorcevski also oversaw the recent buyback of $860 million of 122 million shares in late April at an average price of $7.01 per share. The buyback ironically assisted SGH with gradually increasing its stake in Boral while the Offer was under way.

The next major sale on Todorcevski’s list is Boral’s US fly ash business, which is estimated to be worth up to $USD1 billion. It is attracting the interest of various suitors, including construction materials multinationals Holcim, HeidelbergCement and Waste Management. •

CLEAN AIR, CLEAR LUNGS CAMPAIGN BEGINS Safe Work Australia has launched the Clean Air. Clear Lungs. campaign to raise awareness about occupational lung disease in dusty workplaces.

The campaign runs until December 2021 and largely targets managers responsible for workforce health.

Safe Work Australia chief executive officer Michelle Baxter stressed the importance of lung disease awareness.

“Occupational lung disease continues to

be a major work health and safety concern in Australia,” Baxter said.

“Not all hazards in the workplace are visible. Dusts, gases, fumes, or vapours can be invisible to the naked eye but can cause serious lung diseases. It’s incredibly important to know what hazards exist at your workplace and how to eliminate and manage them.”

The campaign includes a kit on the Safe Work website, informing people on the hazards of dirty air and what to do if you

think you may be at risk.

For more information visit www.swa.gov.au/clearlungs The acceptable Work Exposure Standard (WES) for respirable crystalline silica in nearly all jurisdictions across Australia is the eight-hour time-weighted average (TWA) of 0.05mg/m3 under the Work Health and Safety Regulations 2011. Tasmania is the only jurisdiction to not lower the WES from a TWA of 0.1mg/m3.•

Quarry September 2021 9

NEWS

VICTORIAN EXTRACTIVE INDUSTRY FLOURISHES – IN SPITE OF COVID-19 Victoria has recorded its highest level of extractive production in more than 10 years, according to the annual Earth Resources Sector Indicators Report. It found Victoria’s quarry production had increased by 25 per cent in the past six years, hitting 63 million tonnes of sand, rock and gravel for FY2020.

The Victorian Minister for Resources Jaclyn Symes said record production through a global pandemic was thanks to a government that facilitates growth.

“This government’s policies and programs are delivering results, with record high infrastructure investment stimulating demand for raw materials from our quarrying sector,” Symes said.

“An expanding resources sector is a crucial part of the government’s approach to delivering investment opportunities and well paid local jobs in regional Victoria.”

CONTRACT CONTRIBUTES TO NATION-BUILDING INLAND RAIL ‘HOLCIM HAS DELIVERED MORE THAN 22,000 TONNES OF CARBON NEUTRAL CALVERTS FOR INLAND RAIL - SAVING MORE THAN 7000 TONNES OF CARBON EMISSIONS’ GEORGE AGRIOGIANNIS, HOLCIM CEO’

Humes Tamworth has been awarded a $67 million contract for the Narrabri to North Star, New South Wales section of the Inland Rail Project.

The engineering construction business, owned by Holcim, was visited by Deputy Prime Minister Barnaby Joyce and Humes executive general manager Guido DeWilde who announced the contract.

Holcim Australia and New Zealand chief executive officer George Agriogiannis said Humes’ product was vital to the project.

“Holcim has already delivered more than 22,000 tonnes of carbon neutral culverts for Inland Rail, saving more than 7000 tonnes of carbon emissions, equivalent to removing 1350 vehicles from the road for one year,” Agriogiannis said.

“The new $67 million contract announced by Australia’s Deputy Prime Minister, includes 9400 products ranging from precast concrete culverts to drainage pipes, weighing more than 70,000 tonnes.

Deputy PM Barnaby Joyce at the Narrabri to North Star section of Inland Rail.

regional NSW, supporting local jobs.”

Joyce emphasised Australia’s ability to manufacture its own product without a reliance on competing foreign suppliers.

“We have the capacity to be respected because people can see that we’re doers that can get things done, and that we are strong in our own right,” he said.

About 5100 culverts from Tamworth will support 116,396 concrete sleepers from Mittagong, 224,939 sleepers from Wagga Wagga, and 2474 165m-long lengths of steel from Whyalla in South Australia. •

The 63 million tonnes (mt) of materials extracted in FY2020 had a production value of $1.06 billion, which allows for future investment into the sector. Of this amount, 40.37mt was hard rock, with basalt making up 25.9mt and granite 7.06mt.

CONSTRUCTION FEELS FIRST CONTRACTION IN NINE MONTHS

These materials allowed $40.4 billion worth of building work to be done in FY2020 – a 1.3 per cent increase on the previous year, despite COVID-19 restrictions in the final quarter.

The Australian construction industry has fallen into decline for the first time since September 2020, following COVID-19 lockdowns in Victoria and New South Wales.

It is likely, however, that the effects of COVID-19 on construction will be seen more prominently in reports over the coming years, as the sector’s results have a tendency to lag compared to others.•

The Performance of Construction Index by the Australian Industry Group (Ai Group) and the Housing Industry Association (HIA) dropped 6.8 points to 48.7 seasonally adjusted (where scores above 50 indicate growth) in July.

“Over 19 months, most of these products will be manufactured in

“With Australia’s two largest states affected by COVID-19 outbreaks and associated restrictions, the construction industry slipped into contraction in July after a robust ninemonth expansion,” Ai Group head of policy Peter Burn said.

The Victorian quarry sector continues to have a significant role in supporting the state’s infrastructure and construction.

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“The negative national result masked continued growth outside of NSW and Victoria and further

expansions in both house building and commercial construction.”

Overall activity fell 14.4 points – down to 40.4 – as apartments were the hardest hit of the four sectors, down 5.3 points to 35.

The CPI report stated that many construction businesses reported workers having to take leave, being stood down or temporarily moved offsite while the lull in activity took hold.

HIA chief economist Tim Reardon said the pain would hopefully be short-lived as COVID-19 restrictions eased, but the return to growth would be slow.

Employment was the only segment of the Index to trend upward, adding 2.5 points for a score of 60.8.

The result came as more builders nationwide sought skilled workers. •

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NEWS

MASTER PLAN EDGES OLD HORNSBY QUARRY CLOSER TO NEW LIFE Hornsby Shire Council has formally established a Master Plan for the $130 million Hornsby Park project, north of Sydney, after a period of extensive community consultation.

‘COMMUNITY FEEDBACK SUPPORTS THE DRAFT MASTER PLAN’S VISION FOR THE PARK’

The project aims to transform a former quarry into “the Centennial Park of the north,” according to Hornsby Shire Mayor Philip Ruddock.

Latest announcements have included a canopy skywalk and walking tracks to minimise the impact on the environment, passive recreation spaces and bushland areas, and adventure- and waterbased recreation opportunities aimed at young locals.

“A project of this scale requires commitments and contributions from many sources and is being partly funded by the NSW Government through the NSW Stronger Communities grant scheme and also

A projected image of Hornsby Park, with old pit bench and diatreme walls.

PHILLIP RUDDOCK, HORNSBY SHIRE COUNCIL MAYOR

by developer contributions,” Ruddock said.

Since Quarry last reported on the project’s developments in April, a further $35 million has been sourced to fund the project, with $50 million still to go.

Ruddock said feedback from the

community had been largely positive, as the project gets closer and closer to being a reality.

“The community feedback expressed a high level of support for the draft Master Plan’s vision for the park, particularly its balance of ‘active’ and ‘passive’ recreation activities and its restoring and protecting the natural environment,” Ruddock said.

“This excellent outcome has been, of course, the result of good planning, extensive consultation with the community and support from both State and Commonwealth governments, creating an exceptional opportunity for Hornsby Shire.”

The first stage of the project is due to open in late 2023 with early settler relics, remnant buildings of the crushing plant and the existing Hornsby Aquatic & Leisure Centre to all play a part. •

HOLCIM SAILS AWAY FOR OCEAN PLASTIC RECOVERY Holcim has assisted with the launch of a plastic recovering, solar-powered catamaran, with the ability to recover four tonnes of plastic per day for use in new products and alternative energy.

The Circular Explorer was launched in Germany by Holcim, in collaboration with One Earth – One Ocean and endorsed by the Solar Impulse Foundation, all of which have shown a vested interest in the cleaning of habitats and recycling of resources.

Circular Explorer is not just a catamaran, however. It also includes education and science programs to engage with young people in the environmental space.

Holcim chief executive officer Jan Jenisch said Holcim was just playing its part, as all companies should.

“Everyone has a role to play to preserve our ocean. We are proud supporters of the Circular Explorer to be part of the solution,” Jenisch said.

“I am inspired to see how young changemakers can act as catalysts to solve some of our world’s greatest challenges. The Circular Explorer’s education and science

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programs are designed to mobilise them to take action.”

One Earth – One Ocean founder Günther Bonin said this was a small step for his company, and a big part of why he began in the field.

“One Earth – One Ocean has been working to protect marine ecosystems since 2011,” Bonin said. “The Circular Explorer is our most advanced experiment to date.

“Fully powered by solar energy and designed to recover four tonnes of plastic waste per day, I look forward to seeing it make a real difference.”

The initiative came just months after Holcim released its green concrete ECOPact to the Australian market, to improve its standing as a world leader in recycled materials.

Holcim Australia and New Zealand chief executive officer George Agriogiannis said the Circular Explorer and Holcim’s wider efforts in sustainability added to a bigger picture.

“Construction materials have the extraordinary advantage of being

The Circular Explorer catamaran sucks plastic underneath and on-board for sorting.

recyclable, with potential to contribute to a more circular economy resulting in less waste,” Agriogiannis said.

“Holcim launched ECOPact green concrete in Australia earlier this year, with 30 per cent to 60 per cent less embodied carbon.

“We are proud to be directly contributing to a more sustainable environment through local innovations and inspired global projects such as the Circular Explorer.”

Holcim currently recycles about 50 million tonnes of material worldwide, with a goal of doubling that by 2030. •

63RD IQA NATIONAL CONFERENCE NEWCASTLE, NSW 29 – 31 MARCH 2022 To register or for further information visit the Conference Website https://iqa.eventsair.com/conference

The Institute of Quarrying Australia

NEWS

STONEHENGE THEORY ROCKS BRITISH EXPERTS A British enthusiast has put forth his theory on the transportation of the infamous stones of Stonehenge.

Carpet fitter Steven Tasker has suggested a rocking platform could be the answer to one of modern man’s greatest mysteries. Using wood, ball bearings and simple physics, Tasker built a prototype of the machine in 2004 as he indulged a similar interest in the transportation of Egyptian statues.

“I tied rockers below a plank of wood to try and work out how they could have been used,” Tasker told the BBC. “By using pivot points, I could counterbalance a 60kg roll of carpet on top and by using the rockers, walk it across the road.”

Tasker revisited the prototype in 2018. Inspired by an old Bible passage about a similar machine, Tasker considered his machine’s place in the Stonehenge legend. The similar mysteries of transportation in Egypt and Britain lead Tasker to believe the machine was created in the former and recreated in the latter.

The theory has caused multiple experts to comment. Mike Parker Pearson from the University College London’s Institute of Archaeology suggested Tasker has used modern intuition to solve ancient issues.

GLASS-LIKE GRAINS CAN CONSTANTLY CREEP, RESEARCH SAYS AN UNDISTURBED HILL REMAINS LOOSE AND FRAGILE UNTIL A DISTURBANCE CAUSES STRAIN BETWEEN SOIL PARTICLES HOLDING IT IN PLACE

A study has found sand and soil in downhill formations can “creep”, despite a lack of disturbance, with an almost liquid-like nature. This has posed a raft of questions for those building, working or living near such materials and geographies.

For the paper published in Nature Communications, researchers used a laboratory hillslope where disturbances can be monitored and mitigated to observe how the granular material behaved.

“Surprisingly, we find that even an undisturbed sandpile creeps indefinitely, with rates and styles comparable to natural hillslopes,” the study stated. “Our observations suggest a new model for soil as a creeping glass, wherein environmental disturbances maintain soil in a perpetually fragile state.”

The authors found this comparison between grains and glasses to reveal “deep similarities”.

One interesting finding related to the relaxation and strain of a hillslope.

In layman’s terms, an undisturbed hill remains loose and fragile until a disturbance causes strain between the soil particles holding it in place.

Quarry September 2021

“An improved model of soil creep is not only useful for predicting hillslope sediment transport; it will also help us to better understand how creeping soil accelerates to the yield point, which leads to catastrophic landslides.” •

mines, archaeological sites, historical settlements, gardens, ports, harbours, quays, railways and roads.

It also encouraged the upbringing of many skilled workers over its centennial tenure, providing a blueprint for how similar regions around the world should operate.

North Wales’ famous slate landscape has received UNESCO World Heritage status.

14

“While vibrations in our experiments excited surficial flow, the underlying bulk became more rigid and less susceptible to future fluidisation.

This finding may have relevance for landslide development from earthquakes and should be explored further,” the researchers stated.

WORLD-BUILDING WELSH SLATE GETS HERITAGE LISTING

“It’s a failure to understand megalith builders, past and present, used vast amounts of labour,” Pearson told the BBC.“One of my researchers has calculated the amount of person power it would take to move the stones from Wales to Stonehenge. It’s not as much as you might think.” •

A Stonehenge enthusiast has suggested the famous stones may have been transported by a machine of ancient Egyptian design.

A landslide in the east wall of Dubbo Quarry, circa 2019. Photo courtesy of Alasdair Webb.

The Slate Landscape of Northwest Wales has been added to the UNESCO World Heritage List as the region of quarries and mines was recognised for helping to build much of 19th century Europe.

The region was industrialised from the 1780s to the early 20th century.

The site includes relic quarries,

“[The Slate Landscape] offers an important and remarkable example of interchange of materials, technology and human values,” a UNESCO spokesperson said.

Other inductees to the World Heritage List were Italy’s Porticoes of Bologna; Slovenia’s works of Jože Plečnik in Ljubljana; Russia’s Petroglyphs of Lake Onega and the White Sea; and Gabon’s Ivindo National Park. •

PRODUCT FOCUS

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

SMARTGRADE TECHNOLOGY John Deere’s SmartGrade technology, available on its earthmoving equipment from compact track loaders to motor graders, offers intelligent and intuitive automated features that help maximise productivity and lessen the operator’s workload. SmartGrade technology delivers a first of its kind mastless integrated grade control as a factory option on new machines and field kit for equipment already on the job. The system is fully incorporated into the machine’s structures and software, delivering precise grading performance while eliminating vulnerable masts and cables.

More information: John Deere Australia, deere.com.au

ROBUST TRACKED CONE CRUSHER The Astec tracked FT200DF cone crusher plant features the Kodiak K200+ cone crusher, with a large range of liners for various applications. The patented tramp iron relief system minimises crusher overload impact shock loads transmitted to the components. This machine, with its geometry, stroke and speed, delivers an aggressive crushing action and increased capacity. The Astec mobile cone plants are engineered for maximum cone crushing productivity, with internal counterweights balanced for life.

More information: Astec Australia, astecindustries.com/products/details/mobile-cone-plants

SMART HAUL TRACKING SOFTWARE Load and haul operations represent opportunities to improve material moved per shift and lower cost per tonne. With Trimble Smart Haul, quarry producers can track the productivity and progress of their load and haul operations to ensure they are on target to achieve the site’s goals. Trimble Smart Haul combines payload data from the excavator scale with haul fleet monitoring and cloud reporting to identify opportunities to move material with greater speed and efficiency.

More information: Trimble, heavyindustry.trimble.com/en/products/smart-haul-load-and-haultracking

DUST-FREE, CONTACTLESS CONVEYOR BELT SKIRTING The AirScrape is a specialised contact-free conveyor skirting and sealing system, which acts as a side seal, suspended over the conveyor belt. It can reduce the spill and dust formation at transfer points and other critical sections in the conveyor chain. The system’s hardened steel blades are effective in reducing skirt wear. The service life of other conveyor components may also be extended, as well as a significant reduction of maintenance and replacement costs.

More information: Kinder Australia, kinder.com.au

Quarry September 2021 15

LOAD & HAUL

The Liebherr XPower L 580 has served Isaac Group well, with fuel efficiency of 14 litres per hour and a 230kW engine.

LOADER COMPLEMENTS PILLARS OF SUSTAINABILITY

A quarrying business committed to undertaking sustainable quarrying practices has completed a three-year trial of a wheel loader that best suits its objectives.

T

he Isaac Group has helped to build the South Island of New Zealand since the 1950s, when its founders Sir Neil and Lady Diana Isaac combined their love of construction and conservation.

After forming solid foundations in earthmoving and civil construction, Isaac Construction began quarrying its own material from the Isaacs’ home.

Soon after, as their land disturbance grew, the couple looked to satiate their interest in land conservation and set up the Isaac Conservation and Wildlife Trust, which still runs in conjunction with the company’s four quarries.

The Isaac Group’s chief executive officer Jeremy Dixon told Quarry how the Trust and construction group came to co-habitate.

“What’s differentiated the business since

16

Quarry September 2021

that point is the Isaacs had a passion for conservation which was unusual for people in the 1970s,” Dixon said. “They quarried out a lot of land which is one of our biggest assets.

“As they had that passion for conservation, they decided to set up a conservation park and rehabilitate some of the quarried land back into wetlands, native bush and the conservation park for the breeding of endangered New Zealand animals.

“It evolved to a point where it was put into a Trust, along with the land and the Trust owns the company.”

COMPLEMENTING TRUST VALUES To advocate for environmental responsibility while constructing half a nation takes a great deal of balance and the tools to match.

That’s why three years ago the company

decided to trial one of Liebherr’s L 580 XPower wheel loaders to complement its pillars of sustainability and productivity.

Dixon said the machine has performed well ever since, with a fuel efficiency of about 14 litres per hour and a 230kW engine supporting his decision to buy.

“We heard some good things about the L 580 XPower’s fuel efficiency. We didn’t know how it would go for maintenance or how it would perform against our traditional loaders.

But the L 580 XPower has performed really, really well,” Dixon said.

“It’s shown a massive reduction of fuel usage compared to our usual loaders in the fleet.

“We’ve owned it now for around three years and it’s performed really well maintenancewise – probably better than some of our

loaders – and its noise is also lower.”

“The guys really enjoy driving it as well. It’s got some good grunt, good power, it’s really smooth and it’s well set up.”

POWER AND EFFICIENCY Noel Tosolini, the national sales manager for Liebherr-Australia’s and New Zealand’s Earthmoving Division, told Quarry this balance of power and efficiency is achieved using the Liebherr XPower dual driveline, which combines the hydrostatic and mechanical drive.

The driveline provides better acceleration and travel speeds among other important benefits.

“The interaction between these two drives is continuously adjusted automatically,” Tosolini said. “As the result, XPower offers the optimal level of efficiency during material loading and transport, as well as providing maximum acceleration and performance along all loading cycles – including long routes.”

Liebherr has incorporated an improved bucket design for faster filling, while an intuitive counterweight at the back continues to uphold that balance which Liebherr and Isaac have strived for.

“Together, the innovative features help to increase the handling capacity per hour of operation, save time and therefore, increase productivity while optimising running costs,” Tosolini said.

Liebherr has ensured the Isaac Group was provided with the highest quality service throughout its ownership of the trial unit, which speaks to the longevity of the threeyear trial.

With sales, parts and service availability seven days per week, Liebherr lives its core values promise: “We are a trustworthy partner”.

Dixon attested to the amicable partnership held with Liebherr over the past few years.

While the Isaac Group isn’t currently in the market for any more machines at this stage, he said Liebherr would be a front-runner for Isaac’s business in the future.

“I think we were the first ones to get the L 580 XPower locally and Liebherr have been brilliant,” he said.

“We took a bit of a punt and they’ve been really good around the technical support from overseas and the local support in sales.

We’ve had no problems whatsoever.”

Adding to its value , the 580 XPower’s fuel efficiency and reduced noise can provide significant selling points when quarries

consult with their customers.

Dixon explained how important this was when Isaac considered going with Liebherr.

“It saves us money but it’s also something we can use when our customers are inquiring to let them know they’re buying product which has been obtained in a more sustainable way with lower use of carbon-based fuels,” Dixon said.

“Quarries aren’t traditionally seen in a great light around how they behave and look with dust control and how they operate.

“But our business with the conservation park, the quarry rehabilitation projects we do and then this investment in machinery which has lower fuel use and less noise really adds to the story of what we’re trying to achieve.”

For more information about the Isaac Conservation and Wildlife Trust, visit isaacconservation.org.nz • More information about the XPower L 580 wheel loader can be found on the Liebherr website: liebherr.com

LIEBHERR XPOWER 580 WHEEL LOADER – SPECS MAIN FEATURES Tipping load

15 - 19.5 tonnes

Bucket capacity

4.5m3 – 14m3

Specific bulk weight of material

0.45 t/m3 – 1.8t/m3

Operating weight

27 – 30 tonnes

Output (ISO 9249/ECE R24)

230kW

Rated output (ISO 14396/ECE R120)

233kW

Emission stages

Stages IV and V

FEATURES • Adaptive working lighting.

• Active personnel detection rear sensor.

• Roof camera for front area monitoring.

• Tyre pressure monitoring system.

• Joystick steering (optional).

• Key with remote control and Coming/Leaving Home functions (optional).

• Skyview 360o – Four additional cameras give the operator a 360o view of the entire machine environment (optional).

• Weighing system with Truck Load Assist (optional).

For more information, visit liebherr.com

Quarry September 2021 17

LOAD & HAUL

MONSTER DOZER

TRANSPORTED, REASSEMBLED ON-SITE The largest dozer in an OEM’s inventory has been transported in sections over kilometres of terrain and reassembled in a glacier region of New Zealand’s South Island.

W

est coast miner Whyte Gold has taken delivery of one of the largest and most sophisticated bulldozers in New Zealand to service its new claim in the glacier region behind Greymouth.

A five-truck convoy carrying the 115-tonne machine broken down into transportable capsules made the 500km journey from Lyttleton outside Christchurch to its new base at Rimu. Reassembly took two weeks.

The machine marked the start of a new phase in the development of the veteran gold mining company on a long-established site until recently believed to have been worked out.

Company principal Iain Whyte conducted tests which convinced him there was plentiful new material lying deeper into the substructure.

18

Quarry September 2021

Whyte believes the claim can be worked for at least another eight years, using techniques he has developed to access the site under increasingly stringent ecological controls.

He purchased the Komatsu D475A-8, one of the first delivered by the Japanese OEM in the Southern Hemisphere, to anchor his operations.

ELECTRONIC CONTROLS The bulldozer is the largest in Komatsu’s range with levels of emission control at the leading edge of heavy machine capability.

It is fitted with such sophisticated electronic controls that its essential operations are monitored by telemetry flowing constantly to Japan and Australia.

The new bulldozer is capable of extracting and crushing material with unmatched

efficiency of time and materials, which will limit and manage impact on the land.

The operation is made easier with electronic control of the work equipment, including blade auto pitch and ripper auto return.

There’s the potential for future expansion to intelligent Machine Control (aka iMC), incorporating remote control and automation.

“Some say I would be better served with a smaller machine, but this bulldozer can extract substantial material with a single pass, so it is actually in use far less than any alternative method,” Whyte said.

Whyte Gold had wound back its operations on a nearby site at Dungaville to comply with directions of New Zealand’s Department of Conservation and The Crown Minerals Act, and it had sold its first D475

The 115-tonne D475A bulldozer is the largest in Komatsu’s range, with leading emission control levels.

The rebuild commenced within hours of the 75-tonne main frame arriving on a low loader.

The D475A arrived at the site in sections and was reassembled within a fortnight.

bulldozer, a previous model, to a local coal mining company.

“I was left with enough to keep ticking over,” Whyte said, “but I’ve worked with a lot of good local people and I felt I owed it to them, and to their future, to keep prospecting.

“I tested a lot of claims, mainly on old workings – I figured the old guys didn’t tunnel for nothing.”

Whyte Gold’s new site was believed to have been mined out.

“But the previous miners worked only the top level,” Whyte explained. “Further down there’s a wash with strong content.”

Whyte Gold will use its new Komatsu dozer to open cut between 25 and 35 metres into the site to reach the new level.

TRANSPORT AND REASSEMBLY Komatsu positioned technicians at Whyte Gold’s purpose-built hard stand to assist with the final construction of the massive machine.

“It was fully built and tested in Japan before it was shipped to New Zealand,” Len Higgins, Komatsu’s territory sales manager for the west coast of New Zealand’s South Island, said.

“We had to semi-knock it down at Lyttleton to be able to transport it across Arthur’s Pass.”

The rebuild commenced within hours of the 75-tonne main frame arriving at Whyte Gold on a low loader accompanied by another four trucks of essential components.• Source: Komatsu NZ

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LOAD & HAUL

PINK BUCKET LOADER RAISES FUNDS FOR BREAST CANCER SUPPORT

I

n late February 2021, Kalgoorlie-based crushing and milling specialist Axis Mineral Services took delivery of a Komatsu WA500-7 wheel loader, fitted with a specially made pink bucket to raise funds and awareness for breast cancer. The cancer has affected a family member of one of the company’s directors and owners.

Seven years ago, Kylie Birkin, sister-in-law of Axis Minerals director Mark Thompson and sister of site administrator Leanne Thompson, was diagnosed with breast cancer at the age of 43. Her treatment included a double mastectomy.

Kylie Birkin is now in her fifth year of remission, and to celebrate this – and to raise funds for breast cancer research – Leanne and Mark Thompson decided they would like to dedicate the company’s fifth Komatsu WA500 to Kylie.

Komatsu and bucket manufacturer Contatore Engineering were only too happy to support this. Each donated $5000 – matched

by Axis Minerals – to Breast Cancer Care Western Australia. Additional in-kind support was provided by local signwriting company Sign-Here signs.

Leanne Thompson said that with Kylie Birkin celebrating her fifth year of being in remission, and the company’s fifth WA500-7 being delivered, it was an opportunity to do something different, and to support others with breast cancer.

“We were delighted that Komatsu and Contatore threw their support behind our proposal, and we’ve all been able to work together to provide more funds to Breast Cancer Care WA,” she said.

The day it was delivered, the new loader went straight out to Axis Minerals customer Golden Mile Milling, where it is feeding Axis Mineral Services’ on-site crusher, and then feeding the crushed material to the milling plant.

“It certainly turned some heads at the customer’s,” Leanne Thompson said. “It was the conversation of the morning when it rolled up.”

Axis Minerals was formed in October 2016

by Mark Thompson and fellow partners/ directors Joel Alman, Steve Alman and Steve Sutton, to provide rock and ore crushing

20

Quarry September 2021

The Komatsu WA500-7 wheel loader feeds Axis Mineral Services’ on-site crusher.

services for mining operations throughout the Eastern Goldfields of Western Australia.

The pink bucket WA500-7 is the seventh Komatsu loader in the company’s fleet, with another on the way. Other Komatsu machines owned by Axis Minerals include a WA4708, four other WA500-7s, a WA500-8 and a PC300LC-8MO.

“Axis Minerals has had a relationship with Komatsu since they started the company,” Leanne Thompson said. “And Mark’s had a long association with Lindsay Nelligan (Komatsu business development manager in Perth) for some years before that.”• To learn more about the WA500-7, visit komatsu.com.au

WA500-7 WHEEL LOADERS – SPECS ENGINE Model

Komatsu SAA6D140E-6

Horsepower (Gross)

266kW

Horsepower (Net)

263kW

Rated RPM

1900

Emissions certification

EPA Tier 4 Interim

OPERATION Bucket capacity

5.6 - 7.0m3

Standard bucket capacity

6.4m3

Bucket description

General purpose bucket

Bucket width

3400mm

Dump clearance at 45° dump angle

3235mm

Dump reach at 45° dump angle

1600mm

Static tipping load, straight

28035kg

Static tipping load, full turn

24885kg

Breakout force

267kN/27200kgf

OPERATING WEIGHT

37 tonnes

RECYCLED PLASTIC BOTTLES CONTINUE SUSTAINABLE PRACTICES

K

omatsu has introduced a sustainable packaging initiative to ensure plastic bottles for its oil wear analysis samples contribute as little as possible to landfill.

The initiative will also employ workers with disabilities through Brisbane’s Endeavour Foundation, as part of the company’s corporate responsibility commitments.

“From July 2021 the yellow outer plastic bottles used for collecting Komatsu Oil Wear Analysis (KOWA) oil samples from our Australian east coast customers will be made from 100 per cent recycled plastic,” Komatsu Australia’s executive general manager for supply chain Russell Hodson said.

“As well, the sample registration card and

delivery boxes will be of 100 per cent recycled paper/cardboard.Our new recycled plastic bottles can be cleaned and re-used up to six times, further reducing the unnecessary use of resources,” Hodson added. “Once bottles can no longer be re-used, the plastic can be recycled again.”

The Endeavour Foundation provides people with intellectual disabilities the support they need in-home, at work and in life.

Hodson said the company was excited to partner with such a respected organisation.

Apprentices from the Endeavour Foundation will be involved in the collection of the KOWA recyclable bottles.

“We are delighted to partner with the

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Endeavour Foundation, in a move which will provide its employees with meaningful and sustainable work,” Hodson said.

Komatsu’s east coast customers use about 100,000 sample kits every year. By moving to recycled plastics and packaging, Komatsu will be removing nearly 10 tonnes of packaging materials each year.

The initiative adds to Komatsu’s efforts to be environmentally sustainable. The OEM has a range of technologies in the market and in development to aid the reduction of carbon emissions.

“Initiatives such as our recycled, reusable KOWA bottles are another step on this journey,” Hodson said. •

LOAD & HAUL

GC SERIES EXCAVATORS

ARE NOT JUST TRIMMED DOWN MODELS Thinking about right-sizing your fleet in an effort to keep costs down, but don’t want to sacrifice on performance? The good news is quarry producers can save with the Cat GC Series excavator, which offers cab comfort, ease of operation and fuel savings.

C

aterpillar machines with the GC decal are designed to be economical and offer an attractive total cost of ownership. They are reliable, fuel-efficient and built to the same Cat production system standards. They are easy to operate and equipped with all of the brand promises supported by the Cat dealer network and services with Cat genuine parts and quality.

The Cat GC excavator product line-up offers a new value proposition for the more cost-conscious customers who do not want to pay for a solution they do not need. The GC range complements the traditional product offering Caterpillar calls its performance range, as well as Caterpillar’s technically advanced XE premium range, thus enabling customers to choose across

It may have an operating weight of 42 tonnes but the Caterpillar 345 GC excavator is powered by a 258kW engine and has a digging depth of 7200mm.

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Quarry September 2021

a spectrum of machines that precisely matches their work and budget.

Much like the automotive industry offers different “trim” levels of the same car model, heavy equipment manufacturers are now providing similar options. Caterpillar has introduced several GC models in the past few years. These include excavators, medium wheel loaders, articulated dump trucks and soil compactors.

WHY GC? Caterpillar has stated that its customers in consultations had expressed a preference for earthmoving vehicles equipped with the latest technology to give their businesses a competitive edge or to compensate for a lack of skilled operators. Others also prioritised owning and operating costs over technology. The GC standard models deliver high performing machines that are simple to operate and easy to maintain.

Caterpillar’s range of GC excavators will include: • The 315 GC. • The 320 GC. • The 330 GC. • The 336 GC. • The 345GC. When a producer chooses a GC machine, they will receive a well-designed product that offers high fuel efficiency and low owning and operating costs, all at an affordable price. GC models are reliable, with no compromises made in terms of quality or safety. They are built with the “same Cat DNA”, and have the best dealer network support.

Caterpillar insists quality and reliability are not compromised.

The Cat GC models are ideal for applications that do not require the use of cutting-edge technology like grade control or on-board payload weighing. Therefore, a GC excavator is suitable in a range of applications, be it in construction, demolition

or quarrying. The GC range also meets the emission standards without the use of Diesel Exhaust Fluid (AdBlue).

FUEL COMPETITIVENESS With the GC range, Caterpillar aims to set a new standard for customers who value reliability at a low cost per hour. As a result, the OEM is standing behind fuel efficiency to improve the producer’s return on investment get from their GC construction equipment.

For example, if an extractive producer purchases a qualifying Cat excavator machine with Product Link enabled from a participating Cat dealer, and if they burn more than the committed fuel consumption thresholds, they will receive a parts credit from that dealer.

Full program terms and conditions including qualifying machines, program period, fuel consumption threshold calculations, fuel consumption measurements, parts voucher calculations and process for any

reimbursement will be available from your local participating Cat dealer.

Caterpillar insists that right-sizing a fleet doesn’t mean producers have to compromise on their business concerns. Caterpillar’s range of GC solutions will be expanded across the product lines to better serve the market needs. The GC models offer producers dozens of options, and there will be a model with proven affordable, reliable and low cost per hour solution for your job and budget.

Caterpillar dealers throughout Australia will be able to assist producers with making the best purchasing decisions. Caterpillar products are distributed by WesTrac (New South Wales, ACT, Western Australia), William Adams (Victoria and Tasmania), Hastings Deering (Queensland and the Northern Territory), and Cavpower (South Australia).• For more information about the GC range, visit cat. com/en_AU/campaigns/awareness/new-gc-range. html

Caterpillar machines with the GC decal are designed to be economical and offer an attractive total cost of ownership.

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LOAD & HAUL

WHY SHOULD YOU HAVE

YOUR SCALES CALIBRATED REGULARLY? Having your industrial scales calibrated regularly helps maintain their accuracy, complies with trade measurement law, and has cost benefits.

T

he National Measurement Institute (NMI) advises that industrial scales should be calibrated every six to 12 months depending on the stresses applied to the scale, or after major hydraulic work is completed on the scale. This is for maintaining accuracy, fairness, and to comply with regulations that could otherwise cost producers.

No matter how robust an industrial scale is, over time it becomes less accurate from natural wear and tear. Maintaining accuracy is important for both trade and non-trade purposes, including adhering to the load-bearing capacity of a machine, or ensuring you have enough of a certain material for a construction project. When measuring large quantities of material, even a small discrepancy in the scale’s accuracy can result in large deficits or unnecessary surpluses in material being transported.

In some cases it’s impossible to tell whether a business is under-charging or over-charging its clients until you view a yearly report.

24

Quarry September 2021

If you’re charging for aggregate per kilogram, then having accurate scales ensures the price is fair.

Maintaining the accuracy of earthmoving machinery’s load-bearing calculations is essential to preventing overloading-related accidents, or moving material in inefficiently small amounts. Scale inaccuracy often causes product quality to decrease.

In situations where there is an underlying problem beyond natural wear and tear that causes scale inaccuracy, putting off scale calibration can cause unscheduled downtime and even product recalls.

COMPLYING WITH TRADE MEASUREMENT LAW Trade measurement law requires “an unbroken chain of calibrations to primary measurement standards … to ensure that measurements are comparable to each other and give industry, researchers, regulators[,] and consumers confidence in the accuracy of measurement results”.

Basically, scales should be accurate so we know how much of a thing we’re getting each time we get it.

Australia’s trade measurement transactions are estimated to be worth more than $750 billion each year, so maintaining their accuracy has high monetary value.

As a result, the NMI says instruments must be accurate at all times when used for trade.

The NMI enforces this broad law by sending trade measurement inspectors to conduct audits at places of business with industrial scales, requiring licenced operators like Position Partners to help businesses use accurate measuring instruments, and requiring industrial scales be reverified after repair or adjustment.

If for no other reason, it’s important to calibrate and re-calibrate your industrial scale because keeping it accurate keeps your business within the law.

Maintaining the accuracy of earthmoving machinery’s load-bearing calculations is essential to preventing overloading-related accidents, or moving material in inefficiently small amounts.

FAIRNESS FOR YOU AND THE CUSTOMER Where measuring amounts of material to determine how you charge a customer whether that be charging for aggregate per kilogram, or charging someone to dispose of material at the dump - accurate scales ensure the price is fair. An inaccurate scale means someone is getting ripped off, and

in some cases it’s impossible to tell whether you’re under-charging or over-charging until you view a yearly report. That surprise can be prevented by calibrating your industrial scale.

Where your industrial scale sits on the six to 12 month re-calibration schedule depends on how much stress it’s subjected to. Factors like how much the scale is used,

how old it is, and whether it’s moved around regularly can affect how often it needs to be calibrated.

If your industrial scale is kept in a place with dust, fluids, vibrations, static electricity, mechanical shock, temperature variations, power surges, or humidity, it will need calibration more often.

If your industrial scale moves around regularly, it should be re-calibrated regularly, to ensure its location’s differing angle to magnetic north and barometric pressure doesn’t impact how it accommodates to the acceleration of gravity in the area it works within.

A Position Partners technician will be able to evaluate how often this is, but if you’re unsure, it’s also a good idea to consult the manufacturer.

For a regular industrial scale calibration schedule, Position Partners can supply an obligation-free quote. Visit positionpartners.com.au •

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CRUSHING & SCREENING

The 36-tonne GT205S-3D mobile screen is launched at the Astec Industries factory in Omagh, Northern Ireland.

OEM RESTRUCTURES

UNDER ONE BANNER FOR PRODUCERS In a move designed to deliver benefits to extractive producers and change the way its products are presented to the market, Astec Industries has announced a major restructuring of the company’s business model.

T

he change to the organisation’s structure sees all its well known subsidiary companies brought together under the new OneASTEC banner.

Former brands including JCI, KPI, AMS, BTI, Telsmith, Roadtec, Carlson, Osborn, Heatec, Astec Inc, Powerflame, Peterson and Rexcon, and two new concrete plant manufacturing acquisitions – Con-E-Co and BMH Systems – will no longer operate as separate subsidiary businesses and will take on the Astec name.

Coinciding with the restructure, Astec has launched an international rebranding initiative, the first since the company was founded in 1972.

Astec Industries’ president and CEO Barry Ruffalo announced the changes from the company’s head office in Chattanooga, Tennessee, USA. According to Ruffalo, the restructure is part of the company’s OneASTEC business model, including its “Simplify, Focus and Grow” strategy.

“The unification will make it easier for dealers and customers to work with the company,” Ruffalo said. “By coming together

26

Quarry September 2021

as one organisation, we can offer greater customer service and drive innovation. The rebrand enables us to build our strength together under one common name and purpose. We can better leverage growth as one Astec team rather than individual brands.”

Astec Australia’s regional managing director David Smale has welcomed the changes.

“Astec was founded in 1972 by Dr Don Brock who was known and respected globally for his ingenuity and focus on developing high quality products and leading technologies,” Smale explained. “Brock had an unparalleled passion for his customers and for hard work, expanding his business – one company at a time – until it became the global organisation it is today. That growth was achieved both through acquisitions and by building businesses like Astec Inc, Roadtec and Heatec from scratch. Don Brock’s legacy has truly survived.

“While Astec’s development has been remarkable, it’s the core values on which the company was founded that have sustained the business for almost 50 years,” Smale

continued. “Devotion to the customer, safety, integrity, respect and innovation; they’re the values we’ve lived and worked by and they’re as important today as they were in 1972. The OneASTEC business model is underpinned by these strong values.

“The pillars created by Barry Ruffalo – ‘Simplify, Focus and Grow’ – weren’t simply dreamed up. In his first two months as CEO, Barry visited all Astec factories around the world, talking directly to our employees and customers. It was their feedback that convinced him the business needed to be less complex so we could focus more effectively on our customers and the products, service and support we provide them.

“This simplified structure means we will be more able to finetune our product range, be more competitive and offer our customers even better value,” Smale said.

IDENTICAL STRUCTURE Astec has rolled out the new structure globally so the company’s business operations are identical in every region.

“In the previous model, 16 companies

operated on a range of different systems.

Under OneASTEC we are already seeing huge benefits from working together under common operating systems across the entire business,” Smale said.

“Simplifying our internal structure makes for greatly enhanced information transfer between different parts of the business, no matter where we are in the world. And that gives us a superior ability to meet and respond to our customers’ needs.”

While Astec strengthens its global network, Smale said the company recognises the need to maintain a local perspective.

“We fully understand that our customers in different regions around the world have different requirements. That’s why we’ve established a hub at the centre of every region, in the same time zone as our customers. Our teams have expertise around the products and they know the local market, so there’s a detailed understanding of local standards and regulations, and potential impacts of the physical environment.”

Astec Australia customers will soon become familiar with the company’s newly-released branding. The streamlined grey and blue ‘A’ will be standardised across all Astec products, and those products will become more readily available to the market.

“Wherever you are, when you operate remotely, logistics is always a critical issue and it’s no different for us here in Australia,” Smale said. “One thing that will reduce the impact of that is the decision by the company to locate our factories regionally, closer to our markets and the customers we serve.”

As part of the restructure, Astec Australia has taken over its dealer networks operating in the country. Smale said the move has opened up new market segments for Astec.

“We’re expanding our product offering, particularly in terms of innovative modular equipment. As well as our new Astec BG series of modular asphalt batch plants, we now provide a very successful range of concrete plant products.

“In the concrete sector, Con-E-Co and BMH were acquired last year to complement our Rexcon brand, all of which have been united under our OneASTEC umbrella. We now have 60 concrete plants operating for our customers throughout Australia and New Zealand, so that’s a significant addition to the business,” Smale said.

“Again, it’s about giving customers more options to add portable equipment to their existing facility when peak production periods demand it. Ultimately, our goal is to design and build state of the art equipment which makes it possible for our customers to supply their customers with industry-leading results, profitably.”

NEW MOBILE SCREENING PLANT One product Astec says will do just that is the GT205S-3D mobile screening plant from the Global Track Series. Brand new to the Australian market and weighing in at over 36 tonnes, the versatile GT205S-3D can be deployed in multiple applications.

Featuring a 6m x 1.5m (20’ x 5’) triple-deck inclined screen in a bolted track frame design, the mobile screen has been engineered to

deliver a higher production capacity and more efficient sizing than comparable screens. The side-tensioned top and middle decks, with end-tensioned bottom deck, gives producers options at 950 revolutions per minute with adjustable amplitude and aggregate spreader.

As well as being decked out in the new Astec branding, the self-contained unit includes a hydraulic angle adjust and simple to use hydraulic plant controls.

These features, coupled with the flexibility and mobility of the track unit and wireless track remote capability, make the GT205S the right screen for Astec customers to quickly and easily produce the material they need.

Depending on conditions, this mobile screen plant can process up to 600 tonnes per hour independently.

Astec’s manufacturing facilities around the world produce a wide range of mobile handling equipment including mobile ship loaders, ship unloaders, hopper feeders, truck unloaders, bulk reception feeders, stockpiling conveyors, link conveyors and telescopic stackers.

“Whether you operate in a mine, quarry, port or plant, Astec offers the most comprehensive and accomplished range of mobile material handling solutions in the marketplace,” Smale said.

OneASTEC, Smale concluded, is an exciting time for Astec and its customers.

“Our company is ‘Built to Connect’ – that’s our purpose. We’re committed to connecting people, processes and products, advancing innovative solutions from rock to road,” he said. “OneASTEC helps us achieve that purpose.” •

With a 6m x 1.5m triple-deck inclined screen, the GT205S-3D is designed for a higher production capacity and more efficient sizing.

Quarry September 2021 27

CRUSHING & SCREENING

NON-TRADITIONAL MANUFACTURER

PUSHES THE CRUSHER ENVELOPE While the base technology that underpins crushers has not dramatically changed for more than a century, there are still manufacturers that seek to think outside the box. Quarry spoke to Superior Industries’ Mike Schultz who is championing more innovative thinking in the crushing space.

Two Patriot P400s in operation. The Patriot Cone has been the most popular of Superior’s four crusher product lines in the USA.

T

he COVID-19 pandemic of the past 18 months has shaken industry. It has impacted supply chains and forced many countries that had decades ago wound down their manufacturing bases (including Australia) to reconsider the importance of restoring a local manufacturing base.

Even before the pandemic started, the quarrying industry and its suppliers around the world were consolidating resources.

“Over the last 10 years, we’ve seen a domination of the larger producers buying up the smaller producers, and some smaller producers sold out to the big guys, and the same thing is happening with the manufacturers,” Mike Schultz of Superior Industries, told Quarry.

Certainly, in Australia, some family-run and independent quarrying producers have not completely given up their identities but

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Quarry September 2021

have continued to trade under the wings of larger blue-chip companies, with the likes of the Mawsons Group being part-owned by Adbri Limited. Abroad, we’ve also seen large OEMs bring former competitors under their wings, including Metso Outotec acquiring McCloskey International, Wirtgen becoming a John Deere company and Terex MPS recently buying MDS International. Seven Group, which owns WesTrac, a distributor of Caterpillar equipment in New South Wales, ACT and Western Australia, has most recently diversified by assuming majority ownership in Boral Limited.

A risk perceived of OEMs consolidating is that there is less competition and choice of plant, equipment and services for quarrying producers. But there is also another concern that innovation could be a casualty of consolidation and that there is little, if

any, product differentiation that will enable quarries to raise efficiency and productivity in their operations.

“I did 20 years with a large OEM as a product manager and most of the designs that were there when I started were still the designs when I left,” Schultz said. “A lot of the time when you see development in those companies which have product lines for a long time, you just see an upgrade to an existing product.”

This is particularly pertinent in a segment in which the base technology – eg the crusher – has not remarkably changed in more than a century.

Superior Industries, headquartered in Minnesota, USA, is seeking to change this global narrative, both in its homeland and Australia. The 50-year-old company engineers, manufactures and supplies bulk crushing, screening, washing and conveying systems plus all related parts and services for the quarrying and mining industries.

In Australia, its distributors include Tricon Equipment and 888 Crushing & Screening Equipment.

“If we go all the way back to the beginning of Superior, it was a fabrication shop that was servicing the aggregates and mining industries,” Schultz told Quarry. “Then our folks decided to jump into the crushing and screening market. The depth of Superior in the past 50 years was the conveying market.

It was serving all of these customers but only providing one segment of the equipment that was necessary.”

VOICE OF CUSTOMER Superior Industries began developing products for the crushing and screening market in 2016. With more than 25 years’ experience in the crushing segment,

including 20 years on Terex brands such as Cedarapids, Pegson and Jaques, Schultz said he was “attracted to the Superior team because we were starting with a clean sheet of paper. Having been in the industry for as long as I had been, I knew the advantages and disadvantages, and pitfalls and issues that people have had along the way.

“To paint it with a broad stroke,” he explained, “the advantage is that you start with something that you design from the ground up, being able to avoid the pitfalls that we know exist with other manufacturers’ designs. It’s about developing something with a team with fresh eyes and fresh perspective, not a team of engineers that has been designing plant for 30 years and has its own way of doing things. All of that translates into very innovative, cost-effective, efficient product lines that are safe and easy to work on. We have tried to blend all of those things into whatever product line we sell. I think our task is easier because we don’t have to fight

the old historical machine battle.”

Today, Schultz is in Superior’s specially titled position of crushing and screening product champion. Schultz described his position as an “amalgamation of different roles. I’m a technical liaison between the sales teams and the customer, and the sales teams and the engineering teams. There is mentoring that goes on with that, there’s some teaching and learning responsibilities, and there’s some direct customer relationship responsibilities. It’s a combination of different roles, geared more at the technical aspects of crushing and screening”.

“The mindset was Superior wanted a ‘one-stop’ solution for the customers and we wanted to provide equipment from the rockface to the load out,” Schultz explained.

“In order to do that, we had to develop the products. Obviously crushers, vibratory equipment, screens and feeders, and washing equipment was a huge part of that.

“I would say our streamlined approach to

these was defined by our customers. Before we develop any products we have a process called the ‘Voice of customer’. We go out and talk to the customers and we ask: ‘Hey, listen, we are going to go into in this market.

What part of this market is important to you?

What do you use the most? Where would you like to see significant developments in this market?’ And so that’s what we use as our guideline. Our streamlined approach really is determined by our market and our customers’ voice telling us where we need to be at in that space.”

Schultz added that producers to an extent require and like a “level of standardisation”, especially if there are full plant builds required. It is easier for them if they are negotiating with a single company. “Our market asked us – given we are privately held, not as large as some of our competitors and not solely focused on our product lines – to build crushing and screening products so they don’t have to deal with the downsides

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of larger companies. That’s been a feather in our cap because we’re smaller and more versatile, and able to be at our market’s beck and call.”

CUSTOM DESIGNS FOR MULTIPLE CUSTOMERS What distinguishes Superior Industries is its capacity to custom design, manufacture and assemble plant and equipment to suit the producer’s needs. “We have a construction management team within our group that do turnkey installations of full plants, completely designed, erected, started up and run by us.

That’s odd for a manufacturer to offer that kind of service,” Schultz explained.

Superior Industries has in the past five years introduced four crusher product lines – the Liberty jaw crusher, the Patriot cone crusher, the Valor vertical shaft impact crusher and the Sentry horizontal shaft impact crusher. These four lines cater to what Schultz describes as the company’s three market segments – the smaller, mid-range and larger quarrying producers.

The smaller producer, he said, is more of the “mobile guy, that runs fairly small production machines, and maybe does contract crushing”. The mid-range producer has machines that are “larger versions of the small producer, maybe numerous crushing plants on wheels or tracks, all the way up A Patriot Cone as part of a modular plant set-up.

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Quarry September 2021

Mike Schultz is Superior’s crushing and screening product champion, with more than 25 years in the crushing segment.

to a quarry that’s producing half a million to 750,000 tonnes per year”. The large producer is “always in fixed plant production, high power, high tonnage machines, probably producing three quarters of a million to multimillion tonnes per year”.

Schultz said the Liberty Jaw, Patriot Cone, Valor VSI and Sentry HSI can all be designed to suit each segment. “We design all of our products for applications in all three of those markets, and we’ll have horsepower ranges that will suit for each one. Within the Liberty

Jaw, we’ll have a horsepower range that suits the small guy, the middle guy and the big guy. Within the Patriot Cone, it will be small guy, middle guy, big guy.”

To that end, there are more than a dozen models of the Liberty jaw crusher available.

These models range from 16 tonnes to 135 tonnes, with feed openings from 510mm x 1400mm to 1500mm x 2000mm, closed side settings (CSS) from 38mm to 304mm, maximum feed sizes from 406mm to 1200mm, and power from 110kW to 400kW. Similarly, the Patriot Cone, which is designed as a secondary or tertiary crusher, has five models – the P200, P300, P400, P500, P600 – weighing nine tonnes through 51 tonnes, maximum feed openings of 236mm to 356mm, with power ranges between 150kW and 450kW. All four product lines can be installed for fixed, semi-portable and mobile applications, with a view to providing the best added value for the producer. “We’ve worked with other companies where we’ve built parts and pieces of our plants that really help to maximise production,” Schultz said. “An example would be a rotary cone feeder.

There’s a company that builds one, so we try to implement these rotary cone feeders into our plants because they do such a good job of feeding material into the centre of the crusher. We try to standardise on those

products, in designs that are going to mean the most for the customer, from an efficiency perspective. I don’t think there’s a lot of other folks that pay close attention to that amount of detail.”

Schultz added the Superior Industries team also strives to tie automation into all of its product lines, again with the view to make production as efficient as possible for the producer.

“Within our business, having the capability to build plants from the ground up has taught our teams where we can maximise efficiencies. I would say, far and away, it’s important to introduce automation where and when you can, giving the machine the best ability to perform as efficiently as you can.

“For example, a cone crusher is designed for maximum amounts of volume, power and force. That force, power and volume is all going to be determined by what you put into it, how much you put into it, and how effectively you can get material to the crusher.

So, as the plant designer, we can say ‘I want that machine fed with a belt feeder with a variable speed drive on it’. The variable speed drive will run in conjunction with the cone’s drive motor, and we will want that cone drive motor to run at 100 per cent at all times. So what we’ll do is develop the technology for those two machines to talk to each other, so the feeder either speeds up or slows down to ensure the crusher is running at full capacity at all times.

“These are things we can do as a plant designer and fabricator that leads to more efficiency for the end user. Lots of people can design plants and put up the structures and they can set the machines but we take a more in-depth look and try to maximise the potential of the equipment that we are installing through automation.

“We do this often. It doesn’t matter if it’s a crushing plant, a washing system, a screening system or a conveying system.

We try to implement that automation as often

as we can, and we help the end user design it, with the functionality and the capabilities they want it to have, whether it’s a single point person in the control room, or two or three control rooms to capture everything that is going on. The point is that we design it custom for your needs.”

BREAKING INTO THE AUSTRALIAN MARKET To date, the most popular of Superior Industries’ product lines in the United States has been the high speed Patriot cone crusher. “It’s been well received by our customers, it has a history of performing very well and it is highly competitive with the other manufacturers on the market,” Schultz said.

In Superior’s other product lines, notably its vibrating screen products, the Guardian triple shaft horizontal screen is the next most popular. “It’s a tried and true machine, we’ve done very well in capturing some of that market share that had been dominated

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CRUSHING & SCREENING

A Patriot Cone on a portable trailer at Hopkins Sand & Gravel.

by a few manufacturers for many years,” Schultz said. “The Guardian Screen has been accepted by the industry as equal or better than the machines that have been out there prior to its development. So the Guardian screen and Patriot cones are two of our flagship product lines, for sure.”

While Superior Industries has had a presence in Australia through a number of distributors over the years, the company has found the Australian quarrying industry a challenging market. Schultz, who has dealt with Australian customers on and off over two decades through his involvement with Terex and Superior, said Australia is “a prove it to me type of market” whose quarrying producers “want to see results with our machines that they wanted from their machines”.

“For us, it’s a matter of focusing on the Australian market and building a name for ourselves,” he continued. “It’s about aligning ourselves with good dealers and representatives that support us in those marketplaces, and that’s an evolution.

There’s definitely a plan to promote our products in Australia, our names, and our plant designs. It’s an evolutionary process that’s going to take some time but we’re already making strides in selling pieces of equipment and establishing a flagship installation which people can visit and see our equipment run.”

Schultz added that Australian quarrying producers should consider Superior Industries precisely because it is not a traditional manufacturer. “When quarrying producers deal with Superior, they will deal

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Quarry September 2021

with a manufacturer that is different from the manufacturers they’ve dealt with in the past. We listen, we’re open to ideas and suggestions, and at the end of the day we take away all that information, and we come back with a plant that’s going to work for you, that is going to be supported for you and there’s going to be parts on the ground for you. It’s a process for us to get ourselves up to a point in Australia where folks will think of us but we aim to make an impression over time.”

THE FUTURE Schultz agreed with a question put by Quarry that, given the disruptions caused to the international supply chain by COVID-19, perhaps the key to opening that door to the elusive Australian market is through the manufacture of some parts and components in Australia.

“I agree with that statement,” Schultz reflected. “Maybe next time it’s not a biological issue that we’re dealing with like COVID-19, maybe it’s a geopolitical issue that disrupts the manufacturing process, for example you can’t source steel from China or manufactured parts from India. What happens is everyone pulls back and you start to look at what is around you to get the job done. We’re seeing that in the States already and I’m sure you see that in Australia where there could be a guy down the road who is a local fabricator. He could be 50 cents in the dollar more expensive than the guys overseas but you can walk down the road and you can look at the product and talk to him and there’s value from that which is more

important than the dollar. I think this industry in particular has a very good view on what the actual value is.

“I don’t see local fabricators and manufacturers going away. I think they provide a service that is necessary for our producers out there. So while I think global manufacturers will stay strong, I don’t think they will still dominate and put smaller manufacturers out of business. I think there is always going to be a need for those folks.

“I think there will be a return of the smaller producer, and there will also be more focus on the smaller manufacturers, the more customisable folks that we’ve tried to pattern our business after, the people that will sit down with you at the table and talk about a plant for a day or two rather than hand you a portfolio of plants and ask you to pick.

“I think the more and more we become a global market, companies that align themselves with countries and technologies that are going to be used in other countries, they are going to be on the forefront of the global perspective. Superior is a smaller, privately held business that is really hyperfocused on our closer markets but we’re reaching out to those smaller markets now. So it’s times like these when we’re really having to put resources and investment into developing those markets and it’s something that’s going to be extremely important for our future. The global market perspective is going to drive our business for the foreseeable future.”

Schultz concluded that the crushing equipment itself won’t necessarily change radically but there will still be ongoing innovation. “There’s only so many ways you are going to make small rocks out of big rocks, and I think at Superior we’ve done a fair job of evolving the equipment that we have. There will be new products that come out, and some of them will be good, some of them won’t work, and some might succeed a little but never catch on. But there will be no end to the amount of innovation that happens, it’s just whether it catches on is the big question. We are constantly having development meetings every month where we discuss new ideas and sooner or later one of those is bound to catch on. So I think that’s coming.”

To view Superior Industries’ product lines, including its crusher range, visit superior-ind. com • For further inquiries in Australia about Superior products, visit triconequipment.com.au and 888cse.com.au

CONTRACTOR EAGER

FOR MORE INFRASTRUCTURE WORK Glendun Group’s mobile plant fleet principally consists of Terex Finlay machines.

T

he Glendun Group in 2022 will celebrate 10 years of operation – and with Brisbane set to host the 2032 Olympic Games, the contract crusher could yet leverage off the infrastructure opportunities that the Games will provide for southeast Queensland.

Glendun Group, which is headquartered in Banyo, Brisbane, has been operating since 2012. It boasts a contract fleet of mobile plant and equipment, including mobile crushers, screening plant and conveyors, and a fleet of earthmoving plant and equipment.

Its inventory includes excavators, wheel loaders and dump trucks. Notably, some of its earthmoving machines include some impressive iron: the 102-tonne Caterpillar 773G rigid dump truck, the Volvo Construction Equipment L260 wheel loader, the 48-tonne Volvo EC480DL excavator, Volvo 750D excavator, and the Volvo A40F articulated dump truck.

Glendun Group specialises in the supply of mobile crushing and screening plant and equipment for short- and long-term jobs. Its mobiles include the Terex Finlay, the J-1175 jaw crusher, J-1480 jaw crusher the C-1540 and C-1550 cone crushers, and the Finlay 693+ Supertrak. Glendun has a close working relationship with Finlay Crushing & Screening Systems, the east coast dealer for the Terex Finlay range of mobile crushers, screens and wheeled conveyors.

Although based in Queensland, Glendun Group operates nationwide. “We’re working in Western Australia, Victoria and Queensland at the moment. We’ve worked in the Northern Territory , and we’re looking to expand into South Australia,” Glendun manager Sarah Emery told Quarry.

“Quarries are the biggest part of the business,” Emery continued. “We’re a contract crushing business that provides a quality service to our clients. and provides crushing services. We work in the quarries to produce the required rock.”

Glendun Group has also worked in mine projects and participated in large infrastructure projects.

“We have been involved in many road projects, including the Toowoomba By-Pass,” Emery said. “That job wasn’t in a quarry, we were crushing on the site. For most of those big projects, we will source the materials from a quarry. If it’s a council road, and they have a quarry nearby, we will crush in the quarry.”

In addition to its work with regional councils across Australia, Glendun Group has assisted some of the larger construction materials producers with meeting demand. Where a site’s fixed plant is preoccupied with a larger job, a contractor can provide some relief by crushing and processing at the face of the pit and meeting smaller and additional orders.

Glendun Group has crushed in quarries for Hanson Australia, Holcim Australia, Boral and Hy-Tec Concrete & Aggregates, the subsidiary

of Adbri Limited.

Regardless of the quarry producer and the job, Emery said one of Glendun’s strengths is its ability to be “super-flexible”.

“We can reconfigure our machines to produce in-spec materials,” she explained.

“Our machines can process hard rock, soft rocks, and sand and gravel. The great thing about our mobile crushers and screens is that they are tried and trusted. The designs of our crushers haven’t really changed much since we started, there haven’t been any major advancements, so they are relatively straightforward to operate.”

Emery added that Glendun can also provide experienced, reliable operators for jobs. While an advantage of modern mobile crushing and screening plant is that it is designed to be operated by fewer hands and requires minimal supervision, Glendun is prepared to provide as much expertise as a given job needs.

“We pride ourselves on getting the jobs done,” Emery added.

For the foreseeable future, Glendun Group will continue to build on its contract crushing fleet. “We’re striving to be more innovative by harnessing a lot of the technologies that are coming out and we’re going to focus on more environmental and modern technologies,” Emery said.

She is also excited by the long-term prospects of Brisbane becoming the host of the 2032 Olympic Games for a small, yet growing company like Glendun.

“We would absolutely love to be involved,” Emery said of the potential quarrying and construction opportunities that an event like the Olympics offers. “We would definitely get on-board, if we could. We do a lot of concrete aggregate, and I’m sure there will be plenty of demand for materials.” • For more information about Glendun Group, visit glendun.com.au

Glendun’s earthmoving fleet includes the Volvo CE L180G wheel loader and A40F articulated truck.

Quarry September 2021 33

CRUSHING & SCREENING

The CH400 and CH600 series cone crushers are fitted with the ASRi control system to match variations in feed and material hardness.

ROCK PROCESSING DIVISION ADDRESSES QUARRYING NEEDS

S

andvik has continued to march to the beat of its own drum in 2021, with the unveiling and growth of its Rock Processing Solutions business.

With a dedicated focus on largely quarryrelated applications, this new business was announced at the start of the year to cater more effectively to a slice of its customers which deserved more focus.

Sandvik Rock Processing Solutions’ (RPS) vice-president for sales in the Asia-Pacific region Caroline Robinson explained the thinking behind the new business area.

“There was a bit of a disconnect in terms of the other products offered by Sandvik Mining and Rock Technology which had the load and haul and the drills, and it was really about the mining process,” Robinson said.

“So a decision was made to split our business away from the rest of the Sandvik mining business and it was really to allow us to be more customer-focused.

“We know when we’re talking to our RPS customers because they’re different to the Sandvik mining customers – at least, the contacts on-site are different people.”

One specific product area which has benefitted from the new business area is Sandvik’s range of cone crushers.

With a dedicated business area, Sandvik RPS representatives can really get to know who is using its products and in what applications, before matching them up with the perfect crushing partner.

This is the benefit of offering 16 stationary, 13 tracked, and six wheeled cone crushers: there is sure to be one suited to every Australian quarry.

The range is tough, flexible and agile, according to Robinson, who described some of its key features.

“They offer long life and reliability, they’re built with the highest quality materials and a proven design, including unibody mainframe

34

Quarry September 2021

for optimal strength and less components requiring maintenance,” she said.

“We also build our crushers using recycled materials in line with circular thinking. It’s a uniform product range with the same technical levels throughout for safe and easy servicing guaranteeing reliability.”

The cone crusher range also has the technology to streamline quarry operations, such as Sandvik’s Automation Setting Regulation (ASRi) control system.

“ASRi comes as standard,” Robinson said. “It automatically controls the crusher in real time to match variations in feed and material hardness.

“It maintains optimal crushing and protects the crusher from overloading by automatically regulating the closed side setting.”

In addition, Sandvik’s products remain adaptable, thanks to the Hydroset system and a range of options to suit the array of needs demanded by the quarrying sector.

“Our Hydroset system protects the system from overloads by letting tramp iron pass through the crusher before automatically returning to the original setting,” Robinson said.

“We also have a large range of different liners that are designed to suit our customers’ different conditions and circumstances so that they’re getting the shape and size to be more profitable.”

It’s features like these that underline Sandvik’s customer-focused attitude – from simplifying maintenance duties to consulting to find the right fit for purpose, Sandvik’s RPS business has made this multinational manufacturer feel relatable and reliable.

Robinson said such attitudes were at the heart of the business.

“At the foundation of what we do, we want to build relationships with our customers, we want to understand what their problems are and then, if we have a product to help solve their problems, that’s where we want to be,” Robinson said.

Not even the noise of the competition can distract Sandvik from offering its reliable product ranges.

“I’m happy for our competitors to be themselves, but I want to be Sandvik,” Robinson said. “Part of being innovative isn’t about following the competition, it’s about listening to our customers and hearing what problems they have.

“Our goal is be the leader in the market rather than us following them.”

Robinson also said Sandvik RPS appreciates what quarries are most concerned with.

That competitive spirit doesn’t stop at the manufacturers, as businesses of all size work to maintain healthy quarries and the communities they serve.

“It seems like total cost of operation is really important to the quarrying sector, they’re very focused on cost-effective solutions, so Sandvik is certainly looking at aligning its premium brand with customer’s needs,” Robinson said. • For more information about Sandvik’s Rock Processing Solutions, visit www.rockprocessing.sandvik

Caroline Robinson, Sandvik RPS’s Asia-Pacific region sales vice-president.

SANDVIK ACQUIRES SCREENS AND FEEDERS MANUFACTURER KWATANI

S

andvik has acquired the South African-based company Kwatani, a supplier of screens and feeders for the mining industry. The product offering includes screens, feeders, fine separators, drives and services. The company will be reported in Stationary Crushing and Screening, a division in Sandvik RPS. “I am pleased that we are continuing to execute on our strategy to grow through acquisitions and at the same time strengthening our position in rock processing,” Sandvik President and CEO Stefan Widing said.

The acquisition of Kwatani, the first since the Sandvik RPS business area was established in 2021, is expected to expand Sandvik’s equipment range and complement the existing aftermarket product and services portfolio. Kwatani’s offering in large multi-slope screens adds to Sandvik’s existing portfolio.

“Kwatani’s offering of large vibrating screens and feeders is in line with our strategy to strengthen our capabilities in comminution and will complement Sandvik’s strong competence and experience within stationary crushing and screening”, Sandvik RPS President Anders Svensson said. Kwatani is headquartered in Johannesburg, South Africa, and has about 150 employees. In 2020 Kwatani had revenues of about SEK175 million ($AUD27.4 million).

The transaction is expected to close in the fourth quarter of 2021. •

Source: Sandvik Rock Processing Solutions

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UPGRADE RAISES SITE’S PRODUCTIVITY A high resilience rubber screening media has helped a South American family-owned aggregates business to almost eliminate contamination and fines and increase its operational efficiency.

S

anta Isabel Quarry has been in operation since 1959 and is part of Votorantim Cimentos, one of the largest business groups in Brazil. Located in Mogi das Cruzes, in Greater São Paulo, the quarry serves customers in the metropolitan region of the largest Brazilian city and provides aggregates for civil construction, major works and cement block producers.

However, the company’s positive story was jeopardised in 2018.

Votorantim’s Santa Isabel Quarry faced two major challenges. In addition to the retraction in civil construction, the plant was having problems due to aggregate contamination and an above average presence of fines.

Both had a negative impact on buyers’ perception of the final quality and on

Screen adjustments and the use of rubber media were considered key factors in the increased production quality.

Santa Isabel Quarry has adopted a LEAN approach in operations, increasing its productivity by 4000 tonnes per employee from 2018 to 2019.

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Quarry September 2021

Santa Isabel’s sales. On the sand and gravel market, buyers prefer materials with controlled levels of contaminants and dust – that is, “cleaner” aggregates.

With the arrival of Votorantim Cimentos’ new regional manager Carlos José Barbosa Silva, the quarry began to implement operational changes, including training employees and addressing the main technical problem – the improvements needed in the aggregate screening process. Specialists from original equipment manufacturer Metso Outotec were invited to assess the operational efficiency of the screens. “We had already faced a similar problem at the Araçariguama Quarry and achieved good results with the solution presented,” Silva said. “The screens were retrofitted and the wire media was replaced with Metso Outotec’s high resilience rubber screening media.”

IMPROVED PERFORMANCE FROM SCREENING OPTIMISATION The tests conducted at the Araçariguama Quarry plant were replicated at the Santa Isabel Quarry. “In Araçariguama, the tests involved simultaneous operation of two screens – one with wire media and another with rubber media,” Metso Outotec’s screening specialist André Rosa said. “When the media change-out was made, an analysis was performed in the quarry laboratory. We discovered that the use of rubber screening media nearly eliminated the final product contamination and reduced the presence of fines. Even with a smaller open area, the high resilience rubber media is much more efficient than the wire media.”

The tests played a decisive role in the selection of Metso Outotec as a partner for Araçariguama, and later for Santa Isabel.

While the screens alone were not the reason for the improved operational performance, the screen adjustments and the use of rubber media were considered key factors in the increased production quality. This is

An example of Metso’s Trellex 300TS screen media.

supported by an analysis of the end-user feedback. The quarry index of one complaint for every 37 thousand tonnes produced (2018) decreased to one complaint for every 700 thousand tonnes produced — an improvement of 20 times better than planned.

The current assessment parameter is 10 times higher than the specified target of one complaint per 67 thousand tonnes. “It was a fantastic leap that surprised everyone. We didn’t miscalculate our goal. The results of the changes were significant,” Silva added.

COMPETITIVE ADVANTAGES The challenge of the above average presence of fines was addressed by optimising the screening solution. In addition, the main action to address the internal contamination – the unwanted mixture of different products – was training. Internal contamination was reduced by correcting the improper procedures of the loader operators that were moving products in both operating shifts. Mistakes in the transportation stage from the quarry to the customers – performed by third parties – were also corrected. The errors were identified, and the drivers were given the appropriate guidance.

However, the best indicator of success was the pricing. In July 2019, for example, the price of stone powder had been increased seven times in a row. The recovery of the price negotiated between local customers and the increase in production were complemented with an even bolder plan in 2020 – screening changes that allowed

for the supply of an intermediary product between fine and medium gravel. It improved the quality of concrete block production with lower cement consumption and higher mechanical strength and visual quality.

“There is pent-up demand already being seen, but our production should be able to keep up by making screening adjustments,” Silva said. The executive added the quarry already takes a LEAN approach in operations, having increased its productivity by 4000 tonnes per employee from 2018 and 2019.

“Some of the buyers of our sand and fine gravel are concrete block producers, who have automated machines and demand a high homogeneity standard,” he said. “They were the first to observe the change in the quality and the appearance of our final product.”• To learn more about Metso Outotec products and services, visit mogroup.com/aggregates or find your nearest distributor at mogroup.com/contact

CRUSHING & SCREENING

ENHANCED MOBILE CONVEYOR RANGE DEBUTS IN BULK HANDLING SECTOR The Telson range of radial telescopic conveyors is available from 42m up to 58m in length, with capacities of up to 1500 tph in standard specification.

I

n 2020, Terex MPS launched the ProStack range which offers a comprehensive portfolio of products to address the needs of the bulk materials handling and product stockpiling industries.

Introduced into the Australian market through Terex Jaques, ProStack offers operators in these industries high performance equipment that is simple to operate and maintain, automated during operation and requiring minimal set-up time. High performance is at the heart of the brand, with a focus on moving the most amount of material, cost-effectively in the shortest time possible.

The ProStack range of products includes feeders, telescopic conveyors and truck unloaders. These products have been specifically developed and built for largerscale bulk handling environments.

The ProStack portfolio consists of the Hornet bulk reception feeder series, the Telson telescopic conveyor series and the Ranger tracked conveyor series. All are designed to include a multitude of options

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Quarry September 2021

to tailor these machines to meet customer demands.

The Telson range of radial telescopic conveyors is available from 42m up to 58m in length, with capacities of up to 1500 tonnes per hour (tph) in standard specification. They come in a portable wheeled format and are further enhanced with on-board hydraulic systems, allowing for quick and efficient site deployment. Advanced PLC automation and radio remote control of the radial, telescopic and luffing movements allow creation of large precise desegregated stockpiles and seamless integration into existing bulk handling operations.

The ProStack Ranger series is made up of tracked conveyors in both high level and low level specifications. Heavy-duty tracks as standard make these conveyors highly portable and versatile enough for many different applications. Each machine is easily transported while select models feature rotating undercarriages. A wide variety of options are available so that each

track-mounted conveyor can be tailored to individual users’ needs.

The Hornet bulk reception feeders are capable of receiving high volume material feeds, delivering a steady uniformed material flow onto secondary material handling systems. The 10-12 feeder has a 1200mm wide belt design that can handle up to 1000 tph and discharge the material at a maximum height of 3.1m. The larger 15-18 feeder has an 1800mm belt and can handle 1500 tph, discharging at a height of 3.5m.

A high level of versatility and a wide range of customisation options means that ProStack conveyors are ideally suited for use in the quarrying, mining, recycling and sand industries.

The ProStack conveyor is backed by more than 100 years of Terex engineering experience to deliver a product of the highest quality, providing high capacity, intelligent machines to the bulk handling market.• For more information, visit terex.com/prostack

QUALITY ASSURANCE

ROCKS PUT TO THE TEST:

A PROFICIENCY TESTING PROGRAM

Nearly 30 laboratories affiliated with quarrying operations have recently participated in the third round of a rocks proficiency testing program to assess the strengths and purities of construction materials. Proficiency Testing Australia co-ordinated the program and analysed the results.

P

roficiency testing is a means of determining the performance of individual laboratories for specific tests or measurement and an external audit of their quality control procedures. A standard proficiency testing program compares the measuring results of different laboratories on identical samples.

Proficiency Testing Australia (PTA), one of Australia’s largest proficiency testing providers, can service the construction materials industry by offering proficiency testing programs for aggregate, soils, concrete, rocks, cement, asphalt and bitumen.

PTA recently announced the completion of its third Rocks Proficiency Testing Program.

The program was approved by International Accreditation New Zealand and organised with the technical assistance and sample supply of Gayani Samaradiwakara of Golder Associates’ Melbourne Laboratory.

The aim of the program was to assess laboratories’ abilities to competently perform the prescribed analyses.

Twenty-nine participating laboratories participated in this program in April 2021. All but two of the laboratories were in Australia, with the overseas participants in Bulgaria and Peru.

All of the laboratories submitted their results by the due date. Each laboratory was allocated a unique code number for the program to ensure confidentiality of results.

All participants performed the required testing by either Australian Standards or ASTM methods, eg: • AS 4133.4.1 Determination of point load strength index - (clause 3.3 Axial test).

• AS 4133.4.2.2/1.1.1 Determination of Uniaxial Compressive Strength/ Determination of the moisture content.

• AS 4133.4.3.2 Determination of deformability of rock in uniaxial compression.

• ASTM D3967 Splitting tensile strength on

intact rock specimen.

Laboratories were requested to perform the tests as per PTA instructions and record their findings on a PTA-supplied results sheet. Two or four cylinders (nominally 50mm diameter x 150mm length) were supplied to each laboratory. Cylinders had the identification A or B, depending on the tests performed by each laboratory.

Prior to sample distribution, a number of randomly selected samples were analysed for homogeneity. Based on the results of this testing, the homogeneity of the samples was established.

STATISTICAL ANALYSIS OF PARTICIPANTS’ RESULTS PTA used a robust statistical approach to assess the laboratories’ testing performance.

A list of summary statistics appears at the bottom of each of the tables of results and consists of: • The number of results for that test/sample (No. of Results).

• The median of these results, ie the middle value (Median).

• The uncertainty of the median; a robust

Up to four 50mm (dia) x 150mm (l) rock cylinders were supplied to each laboratory.

estimate of the standard deviation of the Median.

• The normalised interquartile range of the results (Normalised IQR).

The results by lab of the Rocks Deformability – Density test as per AS 4133.4.3.2.

Quarry September 2021 39

QUALITY ASSURANCE

• The robust co-efficient of variation, expressed as a percentage (Robust CV), ie 100 x Normalised IQR / Median.

• The minimum and maximum laboratory results.

• The range (Maximum - Minimum).

Z-scores measure how far a result is from the median consensus value and create a “score” for each result relative to the others in the group.

A z-score close to zero indicates the result is in agreeance with those from other laboratories. A z-score with an absolute value greater than or equal to 3.0 is considered an outlier and is marked by the symbol §.

On the Ordered Z-Score Charts, each laboratory’s robust z-score was shown in order of magnitude and marked with its code number. From these charts, each laboratory can compare its performance relative to its peers.

Table A below summarises the results that were submitted by the program participants.

LABORATORY PERFORMANCE AND TECHNICAL COMMENTS There were 17 outliers (or 8.85 per cent) from the 192 results analysed across the 29 TEST

laboratories. All laboratories with outliers or an absolute z-score between 2.0 and 3.0 have been encouraged to review their procedures.

In this round, the results for Uniaxial Compressive Strength Moisture Content, Rock Moisture Content and Rock Deformability Moisture Content were not analysed. About 34 of the 44 submitted results were under 40 per cent.

The pre-testing of the samples showed that the Moisture Content of PTA Sample B was between 41.1 per cent and 43.2 per cent.

However, the correct moisture percentage was obtained only after drying the samples for four days.

As the rock samples used in this round were artificial and a four-day drying of natural rocks is uncommon, a decision was made to not analyse the Moisture results in this round.

However, as this is the third round of the Rocks program (with 50 to 58 per cent Moisture content obtained in previous rounds), the incorrect results are considered outliers and it is suggested that the multi-day drying of samples be considered in future rounds.

As stated in Australian Standard AS 4133.1.1.1 Methods of testing rocks for

NO. OF RESULTS

MEDIAN

NORMALISED IQR

POINT LOAD STRENGTH INDEX Average P-Load at Failure

33

3.1820

0.3855

Is - Average Uncorrected Point Load Strength

33

1.500

0.230

Is(50) - Average Point Load Strength

33

1.436

0.297

Uniaxial Compressive Strength

17

16.880

1.483

Moisture Content

18

N/C

N/C

Density

15

1.860

0.026

15

N/C

N/C

11

16.000

2.409

Tangent Young’s Modulus

9

5.400

0.787

Secant Young’s Modulus

11

6.200

1.735

Poisson’s Ratio

9

0.216

0.105

Density

10

1.855

0.017

Moisture Content

11

N/C

N/C

11

1.800

0.345

UNIAXIAL COMPRESSIVE STRENGTH

ROCK MOISTURE CONTENT Moisture Content ROCK DEFORMABILITY Uniaxial Compressive Strength

SPLITTING TENSILE STRENGTH Mean Splitting Tensile Strength

Table A: Summary statistics. Note: N/C = ‘not calculated.

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Quarry September 2021

engineering purposes Rock moisture content tests - Determination of the moisture content of rock - Oven drying method (standard method), the drying process should continue until the loss in the mass of the rock between successive drying periods is less than 0.1 per cent of the initial mass of the wet rock.

Thus, participants have been recommended to review their Rock Moisture determination processes.

A few laboratory results were excluded from the statistical analyses and identified as non-statistical outliers. Laboratories were encouraged to investigate their procedures for these tests.

The areas for improvement included Uniaxial Compressive Strength (UCS), UCS Density, Poisson’s Ratio, and Rock Deformability Density.

Other possible sources of error that might have affected the outcome of the proficiency testing program included but were not limited to: • Interpretation of test methods and procedures.

• Calibration/condition of equipment.

• Incorrect calculations.

• Transcription errors.

• Technician competency.

• Precision in calculations and reporting.

HOMOGENEITY AND STABILITY TESTING The samples utilised in this program were supplied by Golder Associates’ Melbourne Laboratory. For this program, samples were cast on two separate days: Samples A on Day 1 and Samples B on Day 2.

Eight random samples from each day were selected and tested for homogeneity.

Statistical analysis showed that the samples were sufficiently homogeneous so that any results identified as outliers could not be attributed to sample variability.

The homogeneity acceptance criteria was: three per cent CV for the Density test and five per cent CV for the Uniaxial Compression Strength test.

As testing was performed on the same day by all participants, stability testing was not considered necessary.

ADVICE TO PARTICIPANTS The Rocks Proficiency Testing Program was developed to offer laboratories the opportunity to evaluate their testing capabilities in comparison to other laboratories, and to provide an opportunity for participants to improve their performance

after the identification of outlier results.

Participants with outliers in Rounds 1 and/ or 2 were encouraged to investigate their performance in the current round to see if any improvement had been made.

A comparison of laboratory performance in Rounds 1 and 2 with Round 3 showed that five participants that obtained outlier results in Rounds 1 and 2 improved their performance and reported correct results in Round 3.

One laboratory did not improve its performance. Some participants from the earlier rounds did not participate in Round 3, and were therefore excluded from analysis.

The final program report for Round 3 of the Rocks Proficiency Testing Program can be found on the PTA website: pta.asn.au Round 4 of the Rocks Proficiency Testing Program is scheduled for March 2022. • For more information about the program and to register, contact the PTA, via email ptaenquiry@pta.asn.au or visit https://www.pta.asn. au/index.php/programs/request-form

Determination of deformability of rock in uniaxial compression as per AS 4133.4.3.2.

Determination of the uniaxial compressive strength/determination of the moisture content, as per AS 4133.4.2.2/1.1.1.

GLENDUN

Group Pty Ltd

Quality

. Reliability . Service

WWW.GLENDUN.COM.AU

CRUSHING AND SCREENING SPECIALISTS

(07) 3256 7271

SAFETY

REVISITING THE KEY

MESSAGES FROM THE BRADY REVIEW Jodi Goodall, of Brady Heywood, reviews some of the key concepts and learnings that arose out of a comprehensive review of fatal accidents in Queensland mines and quarries released in early 2020 – and why quarries should heed those learnings.

T

he Review of all fatal accidents in Queensland mines and quarries from 2000 to 2019, conducted by forensic structural engineer Dr Sean Brady, provided an independent analysis of Queensland’s mining and quarrying fatalities, serious accidents and high potential incidents (HPIs) across a 20-year period.

The report, which was released in February 2020, assessed 47 of Queensland’s mining and quarrying industry-related deaths between 2000 to 2019. There were six fatalities in quarrying across a 20-year period, four being employees and two being contractors. A total of 35,000 incidents were also analysed. Dr Brady calculated the frequency of the deaths, serious accidents and HPIs in terms of incidents per million hours worked.

There were numerous key messages which arose from the Brady Review.

FATALITY CYCLE The industry is moving in a fatality cycle.

Past behaviour suggests that in the order of 12 fatalities are likely to occur over any five-year period. This pattern has been evident over the past 19½ years and is characterised by periods where a significant number of fatalities occur, followed by periods where there are few to none. This

Sean Brady, managing director at Brady Heywood.

suggests that the industry goes through periods of increasing and decreasing vigilance (see Figure 1).

The cycle further suggests that the periods with few to no fatalities should be viewed as simply part of the fatality cycle – they are not evidence of the industry becoming safer over the long term. Instead, further fatalities should be expected as the cycle continues.

As a standardised rate, quarrying has the

Figure 1. Periods of significant numbers of fatalities are often preceded or succeeded by periods with few to no fatalities.

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Quarry September 2021

most amount of fatalities by hours worked (Figure 2).

FATALITIES ARE AVOIDABLE There are no smoking guns. A superficial examination of the causes of the 47 fatalities analysed as part of this review gives the impression that many were freak accidents, that events transpired in such a way that could never have been anticipated. This

Figure 2. The frequency rate of fatal accidents by sector by worker type. As a standardised rate, quarrying has the most number of fatalities by hours worked.

industry, are some of the least effective controls available.

impression can inspire fatalism: how can we possibly protect workers against such freak accidents? It can reinforce the notion that mining is a hazardous industry and fatalities simply cannot be avoided. However, the majority of fatalities were not freak accidents.

Almost all were preventable, via hazards the industry is aware of, and there was rarely a single significant cause.

Fifteen of the 47 deaths were from vehicle accidents, 12 were machinery-related (struck by moving objects, entanglement, crushing), 10 were strata failures, four falls from height, four tyre failures, one from a fire and one irrespirable atmosphere.

INTERNAL INCIDENT INVESTIGATIONS The causes of fatalities are typically a combination of everyday, straightforward factors, such as a failure of controls, a lack of training, and/or absent or inadequate supervision. Internal incident investigations in extractive companies must strive to capture these combinations of causal factors, and avoid simplifying them to a single cause, such as human error, bad luck or freak accidents, which has the potential to mask the underlying system failures.

At a practical level, many of the fatal incidents involved a worker being in a situation that they were inadequately trained for, with the controls meant to prevent harm being ineffective, unenforced or absent, with no or inadequate supervision to identify and remedy these shortfalls. It then took an initiating event – that is, in the form of a freak incident or bad luck – to result in a fatality.

SYSTEMIC FAILURES Human error alone would not have caused these fatalities. They were all the result of systemic, organisational, supervision or training failures – either with or without the presence of human error. Seventeen fatalities involved no human error at all on the part of the deceased. There were 10 incidents involving known faults, where individuals were aware of them, but no action was taken. Nine fatalities had known near misses occur prior to the fatality. In some cases, prior fatalities had occurred in a similar manner.

SUITABLE TRAINING The industry needs to focus on ensuring workers are appropriately trained for the specific tasks they are undertaking. A total of 17 of the 47 fatalities involved a lack of task-specific training and/or competencies for

Jodi Goodall, expert in HRO, Brady Heywood.

the tasks being undertaken. A further nine had inadequate training. These tasks were often undertaken at the direction of supervisors or others who were aware of these deficiencies.

In many cases this lack of training resulted in the worker being unaware of the hazards involved in completing the task or the worker operating equipment in a manner that exposed them to hazards.

SUPERVISION The industry needs to focus on ensuring workers are appropriately supervised for the tasks they are undertaking. In 32 of the 47 fatalities, the worker was required to be supervised when undertaking the task – that is, the 32 did not include routine tasks, such as driving. Twenty-five of these 32 fatalities involved inadequate or absent supervision.

Seventeen of these involved both inadequate or absent supervision and a lack of training for the specific task being undertaken. Not only does absent or inadequate supervision allow tasks to be approached in an unsafe manner but it greatly amplifies the consequences of a lack of training or ineffective or unenforced controls.

MANAGING HAZARDS The industry needs to focus on ensuring the effectiveness and enforcement of controls to manage hazards. A significant number – 62 per cent – of highest level of controls put in place in the aftermath of a serious accident were administrative in nature. These types of controls do little to treat the hazard but rather treat the person interacting with the hazard.

The majority of the 47 fatalities involved at least one failed or absent control that could have prevented the fatality. Administrative controls, despite having their place in the

HIGH RELIABILITY ORGANISATION Businesses should follow the principles of High Reliability Organisational theory to reduce the rate of serious accidents and fatalities. At its most fundamental level, High Reliability Organisational theory focuses on identifying the incidents that are the precursors to larger failures and uses this information to prevent these failures occurring.

The concept of drift into failure, where the industry exhibits a greater acceptance of risk over time, is potentially evident in the Queensland mining industry at both macro and micro levels. While the Mining and Quarrying Safety and Health Act 1999 (Qld) has made significant progress in making the industry safer, despite this progress, the current approach has not been sufficient to reduce the fatality rate to zero in the long term. No single change to the mining industry will reduce this rate. What is instead required is a change in approach to how the industry identifies and controls hazards, as well as how it recognises and addresses them when these controls are eroding or ineffective.

A High Reliability Organisation, or HRO, understands that periods of success breed complacency, which can lead to failures and fatalities. Periods where there are few to no fatalities are typically periods where a drift into failure occurs. Safety is compromised for a variety of reasons, often benign, over time. These compromises typically result in a series of minor near-miss incidents. HROs actively seek out these near-miss signals, which are typically the precursors to failure.

HROs believe that these signals provide an opportunity to identify and act on existing hazards in order to remove them from the workplace. This is the key step that helps prevent the drift into failure. • Jodi Goodall is Head of Organisational Reliability at Brady Heywood, Brisbane, Queensland.

Dr Sean Brady’s report – Review of all fatal accidents in Queensland mines and quarries from 2000 to 2019 – can be downloaded via the Brady Heywood website: bradyheywood.com.au/brady-review Brady Heywood also has also developed the Queensland Mining and Quarrying Podcast as part of the Brady Fatality Review. This podcast contains interviews with key industry leaders, the Regulator and union about key challenges.

Visit bradyheywood.com.au/podcasts Sean Brady and Jodi Goodall’s thoughts about serious accidents, mine safety and High Reliability Organisations can also be found at bradyheywood.com.au/articles

Quarry September 2021 43

EDUCATION

EFFECTIVE LEADERS

AND EMPATHETIC RELATIONSHIPS In chapter six of a seven-part series on the characteristics of effective leadership, Hy-tec Northern Territory’s Ryan Low highlights the importance of empathy in management roles.

I

have written a companion book to my first title The Emerging Leader, entitled Effective Leaders: Four attributes that underpin the core characteristics of effective leadership, which will be published next month.

Apart from offering many additional stories from the seven core characteristics of effective leadership (see diagram on opposite page), it has interesting articles from local and international authors on: • RESPECT: (Diversity/Gender Equality and Inclusion & Culture).

• COURAGE: (Personal & Public).

• INTEGRITY: (Accountability & Transparency/Authenticity).

• AGILITY: (Alignment & Agility Leadership/Emotional/Management).

It has been an inspirational experience, during the past few months, to have received so many interesting stories, with several having been published in Quarry.

The Seven Core Characteristics of Effective Leadership are: 1. Know yourself.

2. Emotional resilience.

3. Empathetic relationships.

4. Vision and values.

5. Effective communication.

6. Motivation and teamwork.

7. Trust in your leadership.

This month’s article from Ryan Low, is based on Empathetic Relationships, which I have “defined” as: Empathetic leaders have the ability to recognise, understand and share the thoughts and feelings of another person.

They acknowledge the story without judgement.

Mike Cameron

RYAN LOW’S STORY Developing and maintaining empathetic relationships was definitely NOT a focus for me when I started my career in

44

Quarry September 2021

Hy-Tec Industries’ NT area manager Ryan Low.

management/leadership roles.

At 22, I became the manager of a busy concrete plant with 15 employees and had little to no idea of what it took to be an effective leader. My team had an average age of about 55, so my first task (self-assigned) was to ensure that under no circumstances would I be viewed as a pushover or easy target due to my young age and inexperience. So, for the next few years I yelled, pointed fingers, and held people to impossible standards - all the while showing everybody involved exactly how young and inexperienced I actually was.

I cringe when I think back to these times but through my misguided attempts at earning respect I did manage to learn a lesson which I have kept front of mind for all my subsequent roles, ie: • Management success is highly dependent on successful people management.

Sounds like an obvious point, but it is often overlooked for other “priorities”. Developing and maintaining strong relationships with your co-workers and employees should

always be a focus if you are striving to get the best out of a team.

I have worked for my current organisation for more than 10 years and in that time I have worked in four different states and territories, multiple divisions and in numerous operating environments. The one constant through it all has been the people.

People who want to be heard, people who want to be respected and people who want to be empathised with.

By attempting to give a strong focus to these areas I have managed to develop many long-lasting relationships which I believe have subsequently improved the overall performance of every team I’ve been involved with. But I haven’t always hit the mark.

Out of the blue, around seven years ago, I received a resignation letter from a team member who I had a high degree of respect for and I really valued their contribution.

Naturally, I sat down with the employee to try and gauge what the reasons were and if there was some way, I could salvage the situation. Turns out that the team member had been reporting on his daily pre-start about a faulty air valve on one of his dump truck’s tyres. I was aware of the issue but a faulty tyre valve was the least of my concerns at the time and I hadn’t actioned it for repair.

When they pointed this out as the reason for the resignation, to be honest I was astounded. However, they then went on to point out that they had been reporting the issue for more than four months and that due to my inaction on the matter, they had been starting each day pumping up said tyre and essentially feeling fed-up.

I tell this story because quite simply I wasn’t empathetic to the situation. It was a very minor concern for me but to the employee it was having a direct and daily impact that had pushed them to the point of resignation.

Forming empathetic workplace

Courage, respect, integrity and agility underpin the seven core characteristics of effective leadership.

relationships has, at times, been an almost taboo topic in the manager/employee space.

The old motto of “leave your personal life at

home” was frequently upheld as being a key component to a successful working career.

Not only is this an outdated mindset, it is also unrealistic and an unhealthy expectation to place on someone with no long-term benefits to be gained.

The introduction of assistance programs for employees cannot be understated since it has not only opened previously shut doors for employees, it also encourages leaders to engage and to show genuine care and understanding towards those they lead.

Let’s be clear, there is not an expectation that all leaders must now become full-time counsellors. In fact, too much empathy can come with its own downsides. But something as simple as the ability to recognise emotional change in an employee, and being able to guide them to the support programs in place, is a strong indicator that empathetic relationships have been formed.

To be empathetic is to be understanding, to be supportive, to be encouraging, and to always act with integrity. These attributes

are of value in any workplace and are what I believe to be a core characteristic of any modern day, effective leader. The ability to build empathetic relationships is a requirement if you intend to coach your team to further development.

By creating this environment and encouraging an empathetic culture, you will be supporting staff satisfaction which, in turn, will lead to greater staff productivity and staff retention.

I challenge you to consider the above traits, and empathetic relationships as a whole, the next time you look to apply an “arm’s length” approach to a challenging leadership situation. With confidence in your ability to apply them, you can build relationships based on trust and appreciation that will contribute to the overall success of your team. Without them, you risk a culture of apathy and disconnection.• Ryan Low is the area manager of Hy-Tec Industries in the Northern Territory.

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IN CONJUNCTION WITH

IQA NEWS

IQA NATIONAL CONFERENCE MOVES TO MARCH 2022 The Institute of Quarrying Australia has announced the rescheduling of its 63rd National Conference in Newcastle, New South Wales.

The conference will now be held at the Newcastle Exhibition and Convention Centre (NEX) in Newcastle from 29 to 31 March, 2022.

The IQA was set to host IQA2021 from 5 to 7 October. However, due to the uncertainties and travel restrictions caused by the COVID-19 pandemic, and in consideration of the health and safety of delegates, sponsors and exhibitors, the Institute has postponed the conference.

Sydney has been in lockdown due to spiraling COVID-19 case numbers since late June. Newcastle and the neighbouring Hunter region went into lockdown at the beginning of August, followed by other regions of NSW. Until that time, Newcastle and Hunter had experienced zero cases.

“This decision has been made after discussion with key stakeholders, in consideration of the latest Government health advice and to ensure the conference delivers value for delegates and sponsors,” IQA President Shane Braddy, IQA2021 Conference Chair James Collings and IQA CEO Kylie Fahey said in a joint statement.

“We are determined to run the National Conference Re-Think, Re-Source, Re-Engage as a face to face event and are optimistic that the current travel restrictions will have eased by March 2022 to allow us to deliver a comprehensive and informative program in an environment which enables delegates and stakeholders to network, build relationships and share knowledge.

“We would like to acknowledge and thank our sponsors, exhibitors and registered delegates for their support of the IQA’s 63rd

46

Quarry September 2021

NEX, in Newcastle, will now host IQA2022 from 29 to 31 March, 2022.

National Conference,” Braddy, Collings and Fahey added. “We have been overwhelmed by the level of support from our industry, particularly in such unprecedented times.

All existing bookings will be transferred to the new dates, however for those that have committed to IQA2021 and are unable to attend in March 2022, any fees paid will be refunded.”

For further information, contact the IQA’s Conference Manager Ned Worboys, on tel 0431 021 193, email events@quarry.com.au or visit iqa.eventsair.com/conference The October issue of Quarry, which would have been launched at the conference as a satchel insert, will be mailed out as per normal to IQA members.

Exhibitors and sponsors keen to promote their products and services between now and the rescheduled March conference are encouraged to contact Quarry BDM Les Ilyefalvy, tel 0402 177 966 or email les.ilyefalvy@primecreative.com.au

2021 IQA AWARDS EXTENDED With the national conference date now moved to the end of March 2022, the Institute has extended the IQA Award submission deadline from August to 5:00pm on Friday 22 October, 2021.

This will provide IQA members with additional time to prepare their own submissions or to nominate colleagues that they believe are worthy of an award and recognition of their endeavours.

“Showcase the many good people and ideas in the industry by nominating yourself or someone else today,” Fahey said.

“Winning an IQA Award reflects talent across the quarrying and associated industries and validates the passion in the industry.”

To learn more about the IQA Awards, visit the IQA website: quarry.com.au (then scroll down on ‘Events’ in the top right hand corner, and click ‘IQA Awards’).

The recipients of the IQA Awards will be announced at the IQA Conference in Newcastle from 29 to 31 March, 2022. •

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IQA NEWS

The Institute of Quarrying Australia

2021 IQA AWARDS EXTENDED With the national conference date now moved to the end of March 2022, the Institute has extended the IQA Award submission deadline from August to 5:00pm on Friday 22 October, 2021.

This will provide IQA members with additional time to prepare their own submissions or to nominate colleagues that they believe are worthy of an award and recognition of their endeavours.

“Showcase the many good people and ideas in the industry by nominating yourself or someone else today,” IQA CEO Fahey says.

“Winning an IQA Award reflects talent across the quarrying and associated industries and validates the passion in the industry.”

To learn more about the IQA Awards, visit quarry.com.au The recipients of the IQA Awards will be announced at the IQA Conference in Newcastle from 29 to 31 March, 2022.

The winners of the Cairns Annual Golf Day: Nordev Contractors members Greg Rains, Tim Lowy, Nathan Timms, Sam Pao and Lisa Took.

NORTH QUEENSLAND BRANCH NEWS

CENTRAL QUEENSLAND SUBBRANCH NEWS

Cairns Annual Golf Day

Annual Golf Day

Cairns was blessed with a beautiful day to hold its annual golf day at Cairns Golf Club on Friday, 23 July. After a barbeque lunch, a group of 48 players took on 18 holes, followed by the post-game presentations and celebrations.

The Central Queensland branch held its annual golf day on Friday, 30 July at the Rockhampton Golf Club. The day started with a barbeque lunch, and thereafter 63 players took to the course to cover nine holes. This was follwed by the post-game presentations and celebrations.

The winning team was Nordev Contractors with team members Greg Rains, Tim Lowy, Lisa Took, Nathan Timms and Sam Pao. Second place went to Pioneer North Queensland and third to Top End Truck Align.

The auspicious NAGA prize of four concrete shovels were raffled off by winning team Brown & Hurley, with $325 being raised and donated to Ronald McDonald House.

Thanks are in order to the Cairns subbranch and all participants for making the Cairns Annual Golf Day a success. This year’s sponsors included: • • • • • • • • •

48

Orica.

Komatsu.

Pioneer North Qld (PNQ).

SmartTech.

Hastings Deering.

BSC Bearing & Power Transmission.

Finlay Screening & Crushing.

Tuff Tyres.

Insurance Advisernet.

Quarry September 2021

This year’s sponsors included: • Hastings Deering.

• Orica.

James Meakin, of Brown & Hurley, raffled off four concrete shovels, the proceeds of which went to Ronald McDonald House.

• • • • • •

REO Heavy Equipment Repairs.

Inline Drilling (QLD).

Komatsu Australia.

Blackwater Quarries.

Finlay Screening & Crushing.

Coffey Testing.

IQA ANNUAL GENERAL MEETING The Institute of Quarrying Australia’s Annual General Meeting (AGM) will be held Tuesday, 5th October 2021 from 4.00pm AEST via a video conference. For more information, visit the IQA website: quarry.com.au •

UPCOMING BRANCH EVENTS • 2 Sept

Queensland WIQ 5th Annual Conference, Brisbane

• 3 Sept

Victorian Branch Student Presentation Night, Bulleen

• 7 Sept

Tasmanian Branch Plant Tour, Dinner Meeting & AGM, Launceston

• 8 Sept

Cairns Technical Dinner Meeting, Cairns

• 9 Sept

Hunter Sub-Branch Networking Dinner & AGM, Wickham

• 10 Sept

North Queensland Annual Golf Day, Townsville

• 13 Oct

Central Queensland Sub-Branch Technical Dinner Meeting, Rockhampton

• 10 Nov

Tasmanian Branch Industry Update Workshop & Dinner Meeting, Launceston

• 26-28 Nov Tasmanian Technical & Social Weekend, Bruny Island • 29 – 31 Mar 63rd IQA National Conference, Newcastle To register for these events, email admin@quarry.com.au or visit the “Networking & Branches” section of the IQA website: quarry.com.au

The Institute of Quarrying Australia

CONFERENCE DELAY

FOR BEST AS INDUSTRY BRACES FOR TOUGH TIMES AHEAD Recent lockdowns have had a significant impact on the construction materials industry.

Non-urgent construction in Greater Sydney was paused and further snap lockdowns occurred in Queensland and Victoria. At the time of writing this, the daily cases in New South Wales were not trending in the right direction and the economic impacts on the industry will certainly be felt in the coming months.

However, due to the economic impacts, uncertainties and travel restrictions caused by the COVID-19 pandemic, and in consideration of the health and safety of delegates, sponsors and exhibitors, the IQA conference has been

postponed. It will now be held at the Newcastle Exhibition and Convention Centre (NEX) in Newcastle from 29 to 31 March, 2022.

IQA conference chair James Collings and the Conference Organising Committee are working hard to ensure the conference will be a fantastic program and provide a much-needed opportunity for the industry to network and interact.

We would like to acknowledge and thank our sponsors, exhibitors and registered delegates for their support of the IQA’s 63rd National Conference to date. The IQA Awards have been moved back to coincide with the conference. I

encourage you to submit a nomination for the outstanding work occurring across the industry.

KYLIE FAHEY Chief Executive Officer Institute of Quarrying Australia

IQA ONLINE WORKSHOPS & WEBINARS – SEPTEMBER & OCTOBER ELECTRICAL AWARENESS TRAINING IN QUARRYING 15 September 2021 There is significant focus on electrical awareness in quarrying by state regulators.

Quarry owners, managers and senior staff should understand their responsibilities and the relationship between legislation, standards, guidelines. This four-hour online workshop will provide an understanding of the basic electrical principles and how to manage risk relating to electrical installations. Students will obtain quarry certification of completion contributing to CPD Hours. For more information, tel 02 9484 0577 or email admin@ quarry.com.au

subject to collapse. Geotechnical awareness and skills to recognise and manage potential rockfall and batter collapse hazards are necessary to achieve an acceptable level of risk. Registrations close on 20 September, 2021. Students will obtain quarry certification of completion contributing to CPD Hours. For more information, tel 02 9484 0577 or email admin@quarry.com.au

QUARRY PRODUCTS TECHNICAL TRAINING 21 October 2021 The Quarry Products Technical Training workshop, hosted by the IQA, has been designed to provide participants with

knowledge relating to specifications, quarry product test methods, quality control, basic statistical measures, technical characteristics, and the influence of quarry products on concrete, asphalt, seals, bases and fills, and other rock products. Students will obtain quarry certification of completion contributing to CPD Hours. Registrations close on 14 October, 2021. Students will obtain quarry certification of completion contributing to CPD Hours. For more information, tel 02 9484 0577 or email admin@quarry.com.au For more information about the IQA’s professional development activities and its online workshops and webinars, visit quarry.com.au •

QUARRY SLOPE STABILITY TRAINING

EDUCATION AND PROFESSIONAL DEVELOPMENT COURSES

23 September 2021

Professional Development

The potential for rockfalls and slope failures makes working near quarry walls, stockpiles and dump faces a hazardous task. As quarries develop over time, they usually get deeper and the overall slope angle becomes steeper which can increase the risk of rockfalls. Stockpiles and waste dumps contain unconsolidated material which can be

• Electrical Awareness – 15 September, 2021 • Online courses - Effective Risk Management – Self-paced Fully Online Course.

- Incident Investigation – Self-paced Fully Online Course.

To register for these courses and/or to organise training, email admin@quarry.com.au or visit the “Education” section of the IQA website: quarry.com.au Quarry September 2021 49

GEOLOGY TALK

BASALT BOOSTS CARBON CAPTURE AND SOIL FERTILITY

Basalt stone could be the answer to more effective carbon sequestration.

Plants growing on the soil of ash, lapilli and basalt.

A multinational research team has discussed the use of finely ground silicate rock, such as basalt, in removing carbon dioxide from the atmosphere.

L

ed by the Laboratory for Climate and Environment Science (LSCE) and involving several researchers from the International Institute for Applied Systems Analysis (IIASA) – both based in Europe – the research spread the powder in impoverished soils and assessed the effects on carbon dioxide (CO2) levels.

Where previous studies had studied similar techniques on fertile land, the study used impoverished soil and found the largest rates of sequestration were in regions which were previously considered unsuitable for the experiment.

Basalt was a key mineral candidate and the study found up to 2.5 gigatonnes of CO2 could be removed every year, with 50 per cent due to the rock powder.

Co-author and IIASA researcher Sibel Eker explained the process.

“In a wide range of ecosystems, the fixation of CO2 during photosynthesis by plants and its storage in biomass and soils

50

Quarry September 2021

is constrained by low soil fertility,” Eker said.

“By spraying nutrient deficient ecosystems with basalt powder, which slowly releases nutrients during weathering, the nutrient constraints could theoretically be lifted, and ecosystem carbon storage promoted.”

Senior IIASA researcher and director of the Environmental Change Institute at Oxford University, Michael Obersteiner, indicated the team didn’t expect to find such positive results.

“Our findings render the global physical and economic CO2 removal potential of basalt substantially larger than previously suggested,” Obersteiner said.

As the rock powder is administered by aeroplane, the cost of carbon dioxide removal equated to about $USD150 per tonne.

The researchers suggested a number of factors which could make the process

more cost- and resource-efficient.

These included increased basalt mining, low carbon deployment systems such as drones or airships, and low carbon energy sources.

“Pilot studies should focus on degraded systems and afforestation projects to test for potential negative side effects,” said lead author Daniel Goll.

“If rock powder can enhance the CO2 removal in existing managed systems, it will help to reduce pressure on natural ecosystems elsewhere.”

The study has been published in the most recent issue of Nature Geoscience.1

REFERENCE & FURTHER READING: 1. Goll DS, Ciais P, Amann T, Buermann W, Jinfeng C, Eker S, et al. Potential CO2 removal from enhanced weathering by ecosystem responses to powdered rock.

Nat Geosci (2021). https://doi.org/10.1038/s41561-021-00798-x

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2021

AUSTRALIAN MINING PROSPECT AWARDS

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