Quarry Apr 2020 by Prime Creative Media

‘COMBO’ PLANT REVAMPED FOR AUSSIE CONDITIONS

A family business transits from quarrying to landfill with a mobile, in-pit crushing solution

A portable ‘combo’ crushing/ screening plant has had an makeover to local standards

QUARRY-CUM-LANDFILL EMBRACES IN-PIT SOLUTION

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

APRIL 2020

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IN THIS ISSUE APRIL 2020

VOLUME 27, ISSUE 04

FEATURES 26 USER-FRIENDLY AUTOMATION What operators can expect from automation programs – and how they can overcome their doubts about them.

28 ECCENTRIC ROLL CRUSHER The ERC aims to improve quarrying capabilities through an advanced solution to hard rock crushing.

30 QUARRIES USE WATER TOO

IN-PIT SOLUTION A family business transits from quarrying to landfill with a mobile, in-pit crushing solution.

MODIFIED ‘COMBO’ A portable ‘combo’ plant has had a makeover for Australian conditions.

How equipment can now be optimised to close the loop of water processing and boost solutions and innovations.

35 A HOLISTIC APPROACH TO TYRE MAINTENANCE, SERVICE It’s not just the right tyre brand and pattern, but the service behind it, that may ensure optimum value.

36 KEY ACCOUNT PLANNING What makes a ‘good’ customer profile and how can producers can use that to achieve mutually beneficial ends?

43 PETER LASKEY: ON THE ROAD How a supplier’s personal touch helps to deliver effective customer solutions and training for producers.

A PLANT TO DO IT ALL? Could the wash plant, which has evolved to be more portable, cover all facets of operation?

APRIL 2020

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

A portable ‘combo’ crushing/ screening plant has had a makeover to local standards

QUARRY

‘COMBO’ PLANT REVAMPED FOR AUSSIE CONDITIONS

A family business transits from quarrying to landfill with a mobile, in-pit crushing solution

IQA Award a bonus for Andrew Hauser after triple challenges of work, education and family.

49 THE TRUST EQUATIONA MODIFIED APPROACH A trainer and coach applies his own variation of the Trust Equation to Australian working conditions.

APRIL 2020

www.quarrymagazine.com

QUARRY-CUM-LANDFILL EMBRACES IN-PIT SOLUTION

SETTING THE CULTURE

ECCENTRIC ROLL CRUSHER: A NEW DIMENSION How the ERC offers advanced solution to hard rock crushing

COVER ADVERTISER: The thyssenkrupp ERC aims to improve quarrying capabiities through an advanced solution to hard rock crushing. Turn to page 28 or visit: thyssenkrupp-industrialsolutions.com

EVERY MONTH 04 FROM THE EDITOR

46 IQA CALENDAR

06 FROM THE PRESIDENT

47 FROM THE IQA CEO

08 NEWS THIS MONTH

48 IQA NEWS

16 PRODUCT FOCUS

50 GEOLOGY TALK Victoria’s mountains grow taller

Quarry April 2020 3

EDITORIAL

A TIME TO STAY SAFE, POSITIVE – AND INFORMED

s we go to press, it seems utterly surreal for Australia to have so suddenly shut down large sectors of society in a bid to stave off the rapid rise of the coronavirus (aka COVID-19). As a nation, we now face very challenging times ahead – in both limiting the spread of the virus and also ensuring that our industries and our broader economy are equipped for the disquieting times ahead – and the positive era beyond it. As a result, unless you’re directly working in an extractive environment (albeit at a safe distance from each other), human contact with your peers will be limited. Certainly, I doubt many of us in communications, sales, administrative and management roles ever thought we’d be working from our home offices and studies for a protracted period. Thank goodness for portable technology and the internet! Fortunately, the responses of different levels of government, industry peak bodies and the publisher of this magazine have been positive. There is a determination by all of these parties (to use a nautical analogy) to navigate this tempest for calmer waters. For example, while its branch meetings and Young Members Network and Women in Quarrying events have been postponed indefinitely, the IQA will continue to provide webinar (wPDP) training to IQA members in the months ahead and will also launch materials to further educate the industry about the national exposure standards for respirable crystalline silica (see pages 46-47).

The Institute’s key message is that education opportunities for IQA members will continue. Participation in the wPDPs is highly encouraged and will assist members in their continuing professional development. The IQA secretariat (see page 6) is still available by phone or email for education- or training-related inquiries. Prime Creative Media (PCM), the publisher of Quarry, is also taking an optimistic approach to COVID-19. CEO John Murphy has stated that frequent communication with industries via print and digital platforms has never been more important at a time when businesses and individuals are having to withdraw from public life. PCM, through its media brands (including Quarry), is in a strong position to continue to support different industries. To that end, Quarry will continue to produce this magazine, our weekly enewsletter and our website (quarrymagazine.com) on schedule and with the same optimism and enthusiasm of old. We will continue to tell positive, informative stories about the industry and its people – and I invite everyone to pitch ideas at any time. Don’t hesitate to contact me via my email address – damian.christie@primecreative.com.au – if you have an idea that is just burning to see the light of day. Until next month, stay safe and stay positive – both on-site and in all facets of life. DAMIAN CHRISTIE Editor

Published by:

QUARRY WILL CONTINUE IN ALL ITS FORMS - AND CONTINUE TO TELL POSITIVE, INFORMATIVE STORIES ABOUT THE INDUSTRY AND ITS PEOPLE

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 Nickolas Zakharia nickolas.zakharia@primecreative.com.au

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

Client Success Manager Ruby Viju ruby.viju@primecreative.com.au

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

Art Director Blake Storey Graphic Design Jo De Bono Subscriptions T: 03 9690 8766 subscriptions@primecreative.com.au 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 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.

Quarry April 2020

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PRESIDENT’S REPORT

WHY SAFETY EDUCATION IS AN INVESTMENT IN THE FUTURE The Institute of Quarrying Australia

n 2019, the Department of Natural Resources, Mines and Energy (DNRME) commissioned a review of all fatal accidents in Queensland mines and quarries that occurred in the past 20 years. The report, authored by Dr Sean Brady, identified 11 recommendations to prevent fatalities or serious harm in the industry. The IQA welcomes this review (https:// www.parliament.qld.gov.au/documents/ tableOffice/TabledPapers/2020/5620T197. pdf) and encourages everyone associated with the industry to read it and to consider what they can do to prevent fatalities or serious harm. We simply must do more to prevent the rate of fatalities and serious injuries. A sobering point in Recommendation 1 was that the industry “should recognise that it has a fatality cycle. Unless it makes significant changes to how it operates, the rate of fatalities is likely to continue at current levels”. We have to do more and doing more is not that difficult.

Recommendation 2 states the causes of fatalities are typical everyday straightforward factors, such as failure of controls, lack of training and/or absent or inadequate supervision. In terms of training and ensuring supervisors and managers are adequately trained, the IQA is the organisation to approach for help. The first decision to make is that we have to do more to help ourselves and to commence the conversation at work, with your employer and your teammates. Every fatality could have been and can be avoided. In Recommendation 3, the industry was urged to “focus on ensuring workers are appropriately trained for the specific tasks they are undertaking”. It was reported that 17 of the 47 fatalities in Queensland from 2000 to 2019 “involved a lack of task-specific training and/or competencies for 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”. Task-specific training is also an area in which the IQA can assist. The IQA is able to provide training, or 6

Quarry April 2020

co-ordinate training, for all levels of the workforce, from operator level upwards (including Certificate III and Certificate IV in Surface Extraction Operations and Diploma of Surface Operations Management, as well as ongoing professional development). In Recommendation 4, the industry was told that it should focus on “ensuring workers are appropriately supervised for the tasks they are undertaking”. Again, this is where the IQA can help. The IQA’s Quarry Manager & Supervisor Certification System (QMCS) has been revamped and the CP Committee re-established. Why not engage the IQA to ensure that all your quarry managers and supervisors are Certified Practicing Quarry Managers (CPQM) or Certified Practicing Quarry Supervisors (CPQS) and to ensure that their ongoing professional development is verified and recorded? The IQA is working towards providing a training needs analysis (TNA) service to our members so that they can identify where there are deficiencies in terms of their training and how they can improve their professional development. Companies can also get behind the IQA to support the delivery of quality education and training, like respirable crystalline silica (RCS), that will be delivered throughout Australia, commencing in May 2020. As US scientist and political philosopher Benjamin Franklin said: “Wise men and women learn by others’ harms, fools by their own.” This is something we can control, this is something we can do to help ourselves and our teammates. Take responsibility for your training and education. From a company perspective, educating the workforce will not only help to prevent fatalities and serious harm, it will also help to improve productivity and reduce staff turnover. In summary, we cannot lose by educating ourselves and our employees. It is an investment in our future. SHANE BRADDY President Institute of Quarrying Australia

Educating and connecting our extractive industry

quarry.com.au THE IQA CAN CO-ORDINATE TRAINING FOR ALL LEVELS OF THE WORKFORCE, FROM OPERATOR LEVEL UPWARDS

The Institute of Quarrying Australia’s goals are: 1. To provide world class professional development for the extractive industries. 2. To establish an Australasian Academy of Quarrying. 3. To align service offerings with industry needs.

IQA CONTACTS: Chief Executive Officer Kylie Fahey PO Box 1779 Milton BC QLD 4064 Phone: 0477 444 328 ceo@quarry.com.au Company Secretary Rod Lester Phone: 0408 121 788 rgl@rlester.com.au Finance Officer Gemma Thursfield Phone: 0402 431 090 gemma@quarry.com.au General, membership and financial inquiries should be directed to admin@quarry.com.au or phone 02 9484 0577.

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INDUSTRY TO BENEFIT FROM NEW VICTORIAN GOVERNMENT GLASS KERBSIDE RECYCLING INITIATIVE ‘WE’RE PLEASED THAT VICTORIA’S NEW CIRCULAR ECONOMY STRATEGY WILL OVERHAUL THE STATE’S RECYCLING SECTOR’

“Consumers should understand that all these changes will cost them and the Government needs to educate us all to use these new waste arrangements properly to keep costs to a minimum.”

PETER MURPHY

Alex Fraser’s managing director, Peter Murphy told Quarry the Victorian Government’s decision was welcome.

ALEX FRASER GROUP

Alex Fraser is one of the companies leading the charge for supplying sustainable civil construction materials, including recycled glass sand.

The Victorian Government has announced $129 million in reforms to the state’s kerbside recycling initiatives. An additional purple-lidded recycling bin – specifically for glass – will be distributed to homes across the state from 2021. The bin will simplify the recovery of other recyclables, decreasing the amount of waste taken to landfills and improving the state’s recycling capabilities. The State Government expects glass jars and bottles from the new recycling bins will be transformed into road base and pavement products. The bins will bring welcome relief to the waste industry, but households

should also prepare for negative ramifications, according to the Australian Industry Group (Ai Group). “Four bins will reduce co-mingling contamination which will help with recycling which is positive,” Ai Group’s Victorian head Tim Piper said. “But, of course there will be trade-offs, whether it’s higher costs and higher council rates or fewer bin pick-ups or some other unintended consequence. “Ai Group has long called for the waste industry to be considered an essential service. Waste services are important to the consumer and our community needs a well-supported industry, so this is an important step by the Government.

Alex Fraser Group is one of the companies leading the market in the supply of sustainable civil construction materials. The company opened new asphalt and glass recycling plants at its Laverton site in 2019.

“We’re pleased that the Victorian Government has released its new circular economy strategy – Recycling Victoria – overhauling the state’s recycling sector and further reducing waste going to landfill,” he said. “The industry requires long term decisions, and the 10-year plan features reforms to accelerate Victoria’s shift to a circular economy, including supporting businesses and communities, creating local jobs, and leading the way in the use of recycled materials.” In prior publicity, Alex Fraser Group has estimated its glass recycling plant could, with a capacity to produce up to 200,000 tonnes per annum of recycled glass sand, significantly reduce glass waste stockpiles in Victoria. This is dependent on the extent of the glass waste stream, which is estimated to be about 150,000 tonnes every year. •

OCEAN REEF MARINA TO BOOST WA QUARRYING JOBS Construction of the Ocean Reef Marina has been greenlit by the Western Australian Government. Up to 800,000 tonnes of locally sourced limestone will be used to build two 2km long breakwaters located up to 18.5 metres from the ocean floor.

with that number set to increase as the project advances.

The limestone will be supplied by Neerabup Quarry, which has a history of boosting jobs after previously being contracted to a wide range of projects across WA, including the Perth to Darwin Highway.

“Quarrying the limestone and sand at Neerabup will allow new industrial land to be unlocked at Meridian Park and is a great example of how DevelopmentWA and the ILA (Industrial Lands Authority) are driving efficiencies and creating opportunities for WA businesses,” he said. “Thanks to a continual flow of new investment the industrial estate is currently

With construction beginning this year, the WA Government said 200 construction jobs will be initially created,

8 Quarry April 2020

According to Lands Minister Ben Wyatt, Neerabup Quarry, which is run by statutory body DevelopmentWA, could unlock new industrial land. The Ocean Reef Marina project will use 800,000 tonnes of locally sourced limestone.

experiencing a wave of new building activity, with one build completed recently and five new builds underway.” Once completed, the marina is expected to deliver more than 900 jobs to Western Australians. •

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NEWS

CONSTRUCTION INDUSTRY LIFTS PERFORMANCE AFTER UNSTEADY START TO THE YEAR The joint Australian Industry Group (Ai Group)/Housing Industry of Australia (HIA) Performance of Construction Index (PCI) has reported an ease to the industry’s decline in construction activity, after jumping by 1.4 points to 42.7 in February. Nonetheless, February marked the 18th consecutive month of contraction in the PCI. The PCI is a seasonally adjusted national composite index based on the diffusion indexes for activity, orders/new business, deliveries and employment with varying weights. A PCI reading above 50 points indicates that construction activity is generally expanding; if it is below 50, it is declining. The distance from 50 is indicative of the strength of the expansion or decline. The index found house building was the best performing sub-sector within the construction industry, reaching its highest numbers in almost two years (up 1.6 points to 55). This marked a slow but steady recovery from the December 2019 PCI, which marked the weakest construction performance in more than six years. “A further lift in the house building sector during February partially offset sluggish conditions across the rest of the construction sector,” said Ai’s Group head of policy Peter Burn. “Construction sector employment declined again as builders struggled in the face of lower selling prices, rising wage and non-wage costs and a further drop in new orders.” •

The latest Australian PCI reports the house building sector is still the construction industry’s saving grace.

Quarry April 2020

EARTH RESOURCES RELEASES REGULATIONS FOR QUARRIES A RISK MANAGEMENT PLAN MUST INCLUDE PERFORMANCE STANDARDS

Victoria’s quarry sector is set for a shake-up following an Earth Resources regulation update to the State’s extractive industries. Introduced in January, the regulations address requirements for work plans, rehabilitation and annual reporting. They also focus on infringement offences. Replacing the outgoing 2010 regulations, the new update will provide a modernised and streamlined approach to extractive industry regulation.

Earth Resources has revamped Victoria’s extraction industry regulations.

Earth Resources will make changes to the risk management area of work plans. The new regulations clarify that a risk management plan must include performance standards, requirements relating to sensitive receptors and noting the roles and responsibilities of workplace personnel accountable for implementing the plan.

Infringement notices that previously required full criminal prosecutions are now able to be issued by Earth Resources Regulation.

Changes to rehabilitation requirements aim to provide a sense of certainty to the community for the future uses of quarry sites. A total of 19 new infringement offences have been introduced in the January regulation changes.

Changes include extensions to cover people and corporations along with changes to penalty units.

There are minor changes to annual reports starting from the financial year commencing 1 July 2020. Reporting is now required to be completed at most 31 days after the end of the financial year (an extension can be granted in some circumstances). Statutory declarations are not needed under the new requirements. •

‘ONE-STOP SHOP’ HOTLINE TO ASSIST EXTRACTIVE WORKERS The Queensland Government has introduced a mine dust health service hotline for current and former quarrying and mine workers suffering from lung disease.

them expert advice and support on navigating the system – from prehealth screening to accessing postworkers’ compensation claim support services and everything in between.”

The Assistant State Development Minister Julieanne Gilbert said the Mine Dust Health Support Service hotline – 1300 445 715 – enables current and former workers to receive faster, easier access to “accurate workplace health information and free services”.

The hotline is also open to families of workers and doctors seeking screening and diagnosis information.

“My constituents, both past or current mine workers, tell me it can be a challenge to navigate various public and private sector organisations to find information and services,” Gilbert added. “The one-stop shop will provide

“The Government introduced laws in 2017 that deliver stronger workers’ compensation protections for Queenslanders suffering from black lung, silicosis or other forms of dust lung disease,” said Member for Rockhampton Barry O’Rourke. “For those who have developed these insidious diseases through their work, support is available.” Respirable crystalline silica is a major health concern for quarry workers. •

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REHAB STRATEGY FOR DECOMMISSIONED QUARRIES Victoria’s quarries may gain new leases of life post-operation after the state’s earth resources regulator unveiled a strategy to improve site rehabilitation. The new strategy released by Earth Resources Regulation seeks to deliver site rehabilitation across the entire life cycle of a quarry project, while also improving the sector’s public standing. The Regulatory Practice Strategy for the Rehabilitation of Earth Resources Sites will enable quarries to develop an effective rehabilitation plan. Planning will occur before extraction to guarantee land will be rehabilitated after quarrying activity. “Effective site rehabilitation underpins confidence in both the resources industry and the regulator – the commitments made upon approval of a project must be fulfilled when it is finished,” said Earth Resources Regulation’s executive director Anthony Hurst. “We’ll ensure rehabilitation is completed to protect communities and the environment, if an operator fails to meet their obligations.” Successful quarry rehabilitation has improved the safety and stability of decommissioned sites in the past. Niddrie’s Newport Lakes and Valley Lake, along with The Royal Botanic Gardens in Cranbourne, were all previously quarries. Under the new strategy, education and enforcement of environmental rehabilitation will also be introduced by regulators. The strategy also applies to Victorian mines and other resources sites. •

xxxRoyal Botanic Gardens in Cranbourne, The Victoria is a rehabilitated quarry.

Quarry April 2020

GYMPIE QUARRY EXPANSION PROJECT SECURES APPROVAL A 5M EMBANKMENT ON THE WEST SIDE WILL BE EXTENDED THROUGH AN ARC TO THE NORTH AND NORTH-EAST

On 22 January, the Gympie Regional Council (GRC) approved a development application for a material change of use for a Gympie quarry operation, on the Old Bruce Highway between Kybong and Traveston in Queensland, allowing it to extract up to 100,000 tonnes per annum. The site previously had planning permission for rural pursuits and small-scale extraction activities. It has previously supplied aggregates to council projects and has the capability to process material for other projects at present.

Gympie Regional Council has approved a smallscale operation, near the Bruce Highway.

The development, which courted eight submissions, including one petition with 53 signatures, will primarily extract gravel and crushed and screened rock.

Bruce Highway, as it was, would have provided a “masking’” effect during daytime hours and to some extent during the early evening hours due to motorists travelling home from work.

The decision ends a three-year wait for approval after the GRC requested an amended acoustic report. This was due to a nearby dwelling that had been omitted from an original noise assessment in February 2017.

A revised acoustic report was submitted in April 2018. In total it has been amended twice to address both issues.

The assessment was also based on “out of date background noise levels” taken prior to the opening of a new section of the Old Bruce Highway. According to the council, the Old

GRC councillors voted to approve the project, a key condition being that an existing 5m high earth embankment on the western side of the quarry is extended through an arc to the north and north-east, at the same height •

REPORT SHINES NEW LIGHT ON QUEENSLAND SITE FATALITIES A major review has provided a “sobering assessment” of the key factors that lead to on-site deaths in Queensland mines and quarries in the past two decades. Structural engineer Dr Sean Brady’s report – Review of all fatal accidents in Queensland mines and quarries from 2000 to 2019 – assessed 47 industry deaths during the 19.5-year period. The review was commissioned in July 2019 by Queensland Mines Minister Dr Anthony Lynham to identify changes to health and safety. This followed five fatalities in the 2018-19 financial year. Brady made 11 recommendations, highlighting a ‘fatality cycle’ that would only be broken with significant operational changes and elimination of fatalism attitudes. He also outlined a greater

role for the regulator to improve safety and argued the industry should move away from using Lost Time Injuries as a safety indicator. Cement Concrete & Aggregates Australia’s (CCAA) Queensland director Aaron Johnstone said the organisation welcomed the Brady review. “It is a comprehensive, accessible report providing a sobering assessment of factors leading to the fatalities in the mining and quarrying sector over the past 20 years,” he said. “We would urge anyone with an interest in safety in the quarrying industry to read the report. CCAA will work with its members and the State Government in the review and the implementation of the recommendations.” •

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NEWS

BRITISH STONE TO FINISH BASILICA AFTER 137 YEARS In the wake of Brexit, UKsourced stone has been chosen to complete part of Spain’s landmark Sagrada Familia Basilica. Marshalls Stone, the Yorkshirebased company whose claim to fame is that it has literally paved every London street on the Monopoly board, has been appointed to supply natural stone to help complete the Sagrada Familia in Barcelona after more than 100 years of development. Construction of the Spanish basilica began in 1882 and is slated for completion in 2026. Marshalls Stone has already supplied Sagrada Familia with 1000 tonnes of stone from its Stanton Moor Quarry since 2018. The majority of Marshalls’ stone will be used on the largest of the three “Glory Fačades” located outside the basilica. The company’s natural stone product is just one of three British stones to be chosen for the completion of the basilica. “We’re so proud to be working with the team at Sa Grada Familia to supply stone for this beautiful building,” Marshalls’ chief executive Martyn Coffey said. “The team at Sa Grada Familia are likely to start cutting the stone at the end of 2021, so it is a while until we will see it in situ but it will be a very proud moment when we do.” •

BREXIT USHERS IN BOOM FOR THE UK QUARRYING INDUSTRY INVESTMENT EARNINGS IN THE UK AGGREGATES MARKET HAVE SPIKED SINCE THE BREXIT VOTE

The earnings of the United Kingdom’s collective quarrying and mining sector have been boosted after billions of dollars in investments were pulled from the European Union following the Brexit vote. Figures released by the British Office for National Statistics show that total investment earnings in mining and aggregates have spiked from a negative £91 million ($AUD37 million) in 2015, to more than £2 billion ($AUD4 billion) in 2018. “The quarrying and mining sector’s earnings have gone from being £91 million in the red, to a whopping £2 billion in the black since the Brexit vote,” Catax’s chief executive of R&D tax reliefs Mark Tighe said. Tighe believes the bigger earnings have grown from UK quarrying and mining companies holding back on European Union (EU) investments.

Quarry April 2020

The earnings increase is expected to give the country a strong start after its exit from the EU. “This is more good news for British industry as the country starts to set its own course on the journey to become a new outward-looking nation outside the EU,” Tighe said. •

Sydney-based Karst Stone Paper is successfully extracting calcium carbonate from limestone and marble to produce a “stone paper” product, which is now being sold in more than 100 retailers across the UK, US and Australia. Co-founders Jon Tse and Kevin Garcia featured in a recent Forbes article and spoke of their “lightbulb moment” following an encounter with the original creator of the product in Taiwan.

The duo started making notebooks, mainly A5 hardcover notebooks. In the past two years they have sold more than 70,000 units across 80 countries, with more than two-thirds of their customers being Americans.

“For the past few years we’ve heard horror stories about what would happen to the UK following the vote to leave the EU,” Tighe said. “The quarrying and mining industry has clearly made some hard decisions about the future, with investment positions being wound down on both sides of the Channel.

AUSSIE FIRM TRANSFORMS ROCK INTO PAPER

“We thought it was crazy that no one had tried to disrupt the enormous traditional pulp paper industry with a more sustainable and eco-friendlier alternative in stone paper,” Tse told the publication.

xxxSagrada Familia in 2019. British stone The will be employed to complete the basilica.

EU investments from the UK quarrying and mining sector more than halved from £34.4 billion ($AUD66.6 billion) in 2015 to £16 billion ($AUD31 billion) in 2018.

According to its website, Karst Stone Paper is a “superior alternative” to traditional pulp paper

A Sydney company is turning waste stone into notebook paper products.

that uses no trees, water, wastes, acids or bleaches. It repurposes waste stone – containing calcium carbonate – produced by the quarrying and construction industries, which is crushed into a powder before being combined with a non-toxic, recyclable binding agent. “Not one drop of water and not one tree was harmed in the making of these notebooks,” the company stated. The paper is said to be whiter and smoother than traditional products. It’s also waterproof and tear-resistant. •

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POLY RIPPLE SCREENCLOTHS Locker’s Poly Ripple and Split Poly Ripple screencloths offer a lightweight and easy to install solution for quarry operations. Constructed from a combination of crimped and straight wires or crimped only that are held in position by abrasive resistant polyurethane, the screens’ construction reduces pegging or blinding due to the active wires not being woven together. Poly Ripples also provide an increase in open area above the traditional wire screen of up to 40 per cent with a reduction in weight against the traditional screen, also of benefit during installation. Poly Ripple screens also provide a longer life expectancy than the traditional woven wire and wire ripple construction.

More information: Locker, a Valmont company: locker.com.au

DURABLE PU FINE SCREENS Hong Hui’s polyurethane fine screens provide a range of benefits for quarries. The screens have high opening rates and provide a strong level of precision slot aperture. The polyurethane used in the fine screens is high quality and provides impressive levels of wear resistance. The apertures are available in a wide range of sizes, coming with high classification efficiency and energy savings. The screens will reduce long-term maintenance costs given their durable build quality. Hong Hui have a wide range of products available to suit a number of applications.

More information: Hong Hui JV, hhjv.com.au

LOKOTRACK MOBILE CONE The Metso Lokotrack LT4MX mobile cone crusher combines high performance, energy efficiency and safety. Designed with safety and reduced environmental impact in mind, the cone crusher provides dust suppression through its high pressure water spraying. Its direct v-belt drive improves energy efficiency, while its Caterpillar engine allows its emissions to meet Stage V regulations. The LT4MX also features large platforms and access to service locations along with emergency wires to increase overall safety. Metso also offer component quality and service support for peace of mind.

More information: Metso, metso.com Tutt Bryant Equipment, tuttbryant.com.au/tbe

Quarry April 2020

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CRUSHING

SITE SAFETY AND SAFER AGGREGATE CRUSHING OPERATIONS There are many key priorities to consider when ensuring overall site safety and safer crushing operations.

afety requires proactive intervention to prevent workplace accidents. Each company or site should have clear safety guidelines outlining best practices for the entire site, especially for crushers. Before even stepping on site to work with a crusher, employees and/or operators must be trained on all safety procedures for both the site and the crusher. For instance, is the operator clear on the warning signs to look for, emergency stop locations, and appropriate walkways? The operator or maintenance personnel should perform a hazard analysis before each new operation. Conditions such as the time of day, weather and the area around the piece of equipment can all affect the operation about to be performed. It is also a good idea to have a fresh set of eyes look at the conditions. Even when someone is experienced and well trained, it is very easy for them to miss something if they are looking for the same things day after day. While the safety aspects of a piece of equipment such as a crusher are extremely important and will be discussed further, companies should start by prioritising overall site safety. The aggregates industry is heavily regulated but regulations alone will not make managers, workers, contractors, etc safer or better safety stewards. To achieve high safety and environmental standards, companies cannot rely on the fear of retribution for noncompliance to achieve these goals. To be successful, the industry must rise above the regulations, inspections and penalties and focus on safety; achieving this goal is the right thing to do. Tips for keeping a safe site include ensuring effective signage, keeping the site clean, walking the site daily, and maintaining quarry faces and haul roads. No one should ever turn a blind eye to a hazard or hazardous situation. Do not say “It’s not my job”, or “I’m not the one who left it there”, or “someone else will fix it”. Every 18

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A fixed jaw crusher plant during the safety inspection process.

incident, accident or hazardous event should be investigated. Through these investigations, recommendations can be made to improve safety and to prevent the event, incident or accident from occurring again. It is vital that these recommendations are implemented, as without implementation sites are destined to repeat past mistakes.

PROMOTING CRUSHER SAFETY While new technologies and equipment to make the workplace safer are emerging every day, a company’s best resource is its workforce. It is important to make sure employees are not only trained on safety procedures within the workplace but also on proper use of the machine. Untrained, unknowledgeable staff can lead to an unsafe work environment. Just because a person on site works with other types of equipment does not necessarily mean he/she is trained on the proper use of a crusher or a breaker. For example, do they know the correct feed size and capacity? Not knowing these can lead to oversize material entering the crusher, causing a malfunction. Crusher safety starts with the person

feeding the plant. This person needs to be trained on crusher best practices specific to the machine he/she is working with. An operator may have years of experience of operating and loading a cone crusher but that does not translate into experience of loading and operating a jaw crusher. Operators also need to be trained on what to look for to prevent unnecessary maintenance. Spending time and resources to train the operator will not only lead to a safer workplace but ultimately will increase production too. When operators are proactive in keeping their crusher running safely and effectively, the more productive it will be. A couple of minutes spent on cleaning or maintenance can lead to hours of extra productivity later and an overall safer working machine. Operators should always keep detailed records of maintenance and other issues. Once confident that an operator is fully trained on his or her machine, as well as on site-specific safety policies, it is time to look at crushing safety in more detail. Some of main things to look for include ensuring the operator is wearing his/her protective clothing, and making sure all guards and

safety devices are in place, secured and functional before operating the crusher. It is important to ensure that operators review and follow all lock out, tag out and try out (LOTOTO) procedures for the crusher when performing equipment maintenance, repairs or adjustments, and keep the crusher working safely and efficiently by performing regular maintenance inspections. This will allow them to pinpoint any problems that may make the machine unsafe to use. Tips for keeping a safe crusher include operating the crusher at its appropriate capacity, keeping platforms and areas around machine clean, and ensuring lubrication, flow, temperature, wear and pressure are all monitored.

HOUSEKEEPING PRACTICES Safety is something that can be carried out and planned for daily, monthly and annually. Every day operators should try to make themselves and their workspaces safer. They should clean away any debris that may be a hazard and walk to their workstation by a

While new technologies and equipment to make the workplace safer are emerging every day, a companyâ&#x20AC;&#x2122;s best resource is its workforce.

different route to see if they notice anything unsafe. Good housekeeping is synonymous with a well organised, professional and safe workplace. Poor housekeeping is synonymous with a disorganised, less professional and hazardous workplace. In the aggregates industry, hazards are everywhere, owing to the nature of the business and the equipment and tools used. Less than desirable housekeeping practices add unnecessary hazards to the workplace. Housekeeping can take up a lot of time if it is carried out only once in a while but virtually no time at all if it takes place continuously. All employees should be expected to conduct good housekeeping on a daily basis to eliminate unnecessary hazards.

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It is important to make sure that crusher operators follow all operational guidelines and that all safety best practices are in place but also that the entire workforce is properly trained in site safety procedures and best practices. Regular safety meetings should be held to review new procedures or address any safety concerns. Yearly safety goals should be set and operators should be commended for years of safety excellence. Each person on site is responsible for safety and can improve the safety of their workplace. Properly trained operators will lead to a safer workplace and increased production. â&#x20AC;˘ Article courtesy of Quarry Management (UK). Visit agg-net.com

CRUSHING

The mobile crushing circuit at SBI Group’s Cranbourne Quarry. From far right: the J50 tracked jaw crusher; the R155 reclaimer; the C44 cone crusher; and the S190 screen.

QUARRY-TURNED-LANDFILL

EMBRACES IN-PIT CRUSHING SOLUTION A Victorian family run-business has made the transition from quarrying to recycling and landfill services – all with the assistance of a mobile, in-pit crushing solution. Damian Christie visited the SBI Group’s Cranbourne Quarry.

he SBI Group is a family-owned quarrying-cum-landfill business in Cranbourne, in the south-eastern suburbs between Melbourne and Frankston, and heading towards the Mornington Peninsula. Its quarry has been operating since the 1950s and for many years supplied sand and topsoil to the Victorian market. In the 1980s, the 64ha site began extracting the sedimentary rock beneath its sand reserves and much of this material has in the subsequent decades been sold to local infrastructure projects, including the Western Port Highway, the Eastlink tollway between Ringwood and Frankston, and Peninsula Link. Quarry first visited the site for a story in 2012 when the business was gradually moving from running a static plant to crushing and screening at the face of the 30-metre-deep pit. At the time, the company invested in a McCloskey J50 tracked jaw crusher and a 5m x 1.5m (16’ x 5’) R155 heavy-duty mobile screen, which were supplied by MSC Group, the eastern states dealer for McCloskey.1 Subsequently, the SBI Group was able to raise the throughput of its mobile operations by more than 30 per cent – from 400 tonnes per hour (tph) to 600 tph. Quarry visited the site again in 2017. At this point, SBI’s crushing operations were being completely managed from within the pit – with a mobile circuit comprising the J50, a C44 tracked cone crusher, the R155 and a 6m x 1.5m S190 mobile screen. The quarry was also in a state of transition. SBI Group was applying to transform the 20

Quarry April 2020

The McCloskey C44 cone crusher is one of the more recent additions to SBI Group’s mobile crushing circuit.

Cranbourne site’s operations from a working quarry to a landfill and recycling operation and had invested significant sums of funds into planning, designing and constructing a highly specialised, safe and environmentally responsible landfill at the bottom of the pit. That plan has now been realised, and at time of press, the SBI Group has formally begun accepting solid inert waste, construction and demolition materials, and commercial and industrial waste. It will not, however, be taking household, toxic or liquid wastes. Where possible, the group’s policy is to divert materials from the landfill for reclaiming or recycling for future re-use, eg rocks, soils, timbers, and clean concrete. Going forward, the operation’s end products

will include VicRoads-approved Class 3 and Class 4 recycled concrete, 20mm + 40mm road base, 100mm clean rubble, 40mm + 75mm VicRoads Type A products, and pugmilled wet mix. When the landfill area is eventually complete, SBI Group is proposing to rehabilitate the land for a public opening space that will either be controlled by the City of Casey or will be included in an expansion of the nearby Royal Botanic Gardens of Cranbourne – which also began life as a quarry.

A DECADE OF SUPPORT Throughout the past decade, MSC Group and its tracked McCloskey products

have been a constant of the SBI Group’s operations. Having assisted in taking over the burden of the crushing load from SBI’s old static plant, MSC and its mobile plant and equipment are well established to assist with processing reclaimed rock and recycled aggregates in the next phase of SBI Group’s operations. Indeed, the company has plenty of experience in rehabilitation operations at the former 142-year-old Lilydale Quarry to the north-east, crushing overburden rock and soil there for the eventual filling in of the quarry void. MSC Group has had a very similar closed crushing circuit in operation at Lilydale Quarry as it has had at Cranbourne. The McCloskey J50 V2 jaw crusher, with its high jaw speed, ensures better reduction and faster processing of material through the crushing chamber. The McCloskey C44 V2 secondary cone crusher has a high material capacity and throughput. The McCloskey R155 reclaimer has an open feed hopper and heavy-duty apron feeder, making it well suited to processing bulky material. The McCloskey S190 secondary screen features adjustable screenbox angles that allow adaptability to a wide range of material applications. Paul Williamson, the managing director of SBI Group, told Quarry that the company chose to move to a mobile crushing circuit at the quarry face for economical and practical reasons, including cartage. “Obviously, crushing at the face is far more viable, rather than putting it in the back of dump trucks and carting it up to crush it at the top of the pit,” he explained. “Here, we’ve had customers drive down to the face to pick it up – and depending on your cartage or the sort of trucks you’re using, that can cost between two and four dollars per tonne [of fuel] to get that rock up out of the hole.” Williamson said he expanded his in-pit crushing circuit in anticipation of the change from outright quarrying to recycled crushing. “I just needed a closed circuit in order to make road base,” he said. “Another part of it was that I knew we were going into concrete recycling. Mobile plant and gear is better suited for that. I’ve also found with fixed plant that you start throwing good money after the bad. In terms of throughput, our old plant was lucky by the end of its life to be generating about 100 tph. A mobile circuit with an open system can generate up to 300-plus tonne tph. Even in a closed recirculated system, you can still manage 240 tph.” Williamson also found that the R155

The McCloskey S190 secondary screen features adjustable screenbox angles that allow adaptability to a wide range of material applications.

reclaimer was a valuable, simple addition to the mobile circuit. “With the R155, you can make a rubble and a minus, which is ideal for concrete recycling. The R155 is also perfect for separating all of the contaminants from that concrete, and once you’ve got that clean base concrete, then you’re ready to put it into the cone to make your road base.” The reclaimer was also a good choice because he was reluctant to feed straight from the jaw into the cone. “You never want to put anything into the cone that you don’t have to. If the product is already reduced, why put it through the cone crusher and create extra wear? For me, the reclaimer worked out really well because it gives you that scalping product, which is quite a saleable product around here, and it just gives you a really clean cone feed.”

SELF-SUFFICIENT OPERATION Compared to a fixed plant crushing circuit, Williamson also said that a mobile circuit is autonomous enough and self-sufficient that it can be supervised by as few as two workers operating other machinery in the pit at any one time. They can monitor and stop and start the circuit accordingly with remote controls. “I can have an excavator feeding the plant at one end and another guy on the sales end,” he said. “That is the beauty of mobile crushing - as opposed to staying in a control room on a fixed plant, with a guy sitting there for eight hours, maybe pressing ‘start’ or ‘stop’ five times a day.” Williamson said that he chose MSC Group, represented by its Victorian sales manager Ian McCartney, and McCloskey for his mobile crushing circuit because MSC was,

like SBI Group, a family-run business and had a proven record of supplying parts when required. “For me, product support is huge,” he explained. “You can buy cheaper gear out there but you don’t want to be chasing parts around, especially when you have thousands of tonnes going out. At the end of the day it’s just a matter of ‘go, go, go’ and I hate saying ‘no’ to customers. For that reason, MSC ‘gets’ the support. It has a really good aftermarket service and it’s run by a couple of brothers [Kirwan and Philip Barr] who you can ring if you have any dramas. You can effectively talk to the bloke who runs the company, and that’s a big thing for me.” Williamson was also pleased with the performance of his mobile fleet. “They’ve been very good, no problems. I’ve probably hired most of the major brands at various times, I haven’t owned a lot of them, and by comparison, I find McCloskey to be a good, solid basic design. It’s like that C50 tracked cone. When you look at the cone, it has a big chassis, there’s the hopper that feeds into the cone, and then onto another conveyor. “Oh, and the machines are the same colour as SBI green, that made it easier to choose too!” Williamson quipped. On that basis, one can expect MSC’s mobile plant to be a mainstay of SBI Group’s operations as its landfill and recycling operations take root. • FOOTNOTE McCloskey’s mobile plant and equipment is available to the South Australian, Western Australian and Northern Territory markets through 888 Crushing & Screening Equipment.

Quarry April 2020 21

CRUSHING

POPULAR CLOSED CIRCUIT

CRUSHING PLANT MODIFIED FOR AUSTRALIAN CONDITIONS It’s been a mainstay of the Australian quarrying and recycled aggregates sectors for almost 15 years – but now a popular portable crushing and screening plant has had a makeover for Australian conditions. Damian Christie reports.

he portable ProSizer plant, by Astec, is no stranger to the Australian construction landscape. In fact, it has been a popular recycled aggregates and asphalt solution here for more than a decade. The ProSizer has also been successfully applied in the quarrying environment, particularly as a wheeled mobile option. “The ProSizer has been out now for about 14 years. It’s a mature product for us,” Patrick Reaver, the product sales director for Astec, told Quarry. The ProSizer – named for its “product sizer” application – incorporates a horizontal shaft impact (HSI) crusher and screen on a portable chassis and trailer. Traditionally, the ProSizer has been available in three models – the ProSizer 3100, 3600 and 4200. The average dimensions of each of these models is around 20.4m x 3.4m (length by width). “Every ProSizer we’ve ever built is a closed circuit,” Reaver said. “It has a feeder, a crusher and a screen. Ideally, we screen the product first, especially if we’re talking about recycled asphalt. We take out as much of the minus product as we can, so we don’t over crush that product, then we send the overs back to the crusher and knock that last little bit of product back to the size that’s needed. Since we’re operating a closed circuit, everything that you put into that machine comes out as a sized product. “Our main target with the ProSizer has always been recycled asphalt (RAP). RAP is sticky and tough to deal with, and it can often be slabby,” Reaver said. “To handle slabby material, we’ve developed an open conveyor design, so it can handle large slabby material. The overs conveyor can be operated remotely so if there’s a lot of reject material, you can remotely stop the feeder, swing the conveyor out, dump the reject material off to the side, swing the conveyor back in, turn the feeder back on and keep on going. It’s an easy way 22

Quarry April 2020

The ProSizer 3100 has been fitted with a multi-frequency twin-deck screen and adapted for Australian conditions.

of getting reject material out of the system. “We work hard to ensure our equipment performs well in tough environments and the ProSizer is no exception. Take the engine package for example,” Reaver said. “The ProSizer’s remote swing out radiator allows for easy maintenance and cleaning. The all-hydraulic drive also allows us to vary speeds. For example, on the impactor, we don’t want to over crush, we want to crush only as much as is needed to break the RAP back to its original size. Some equipment doesn’t break the product all the way down to the original sized rock, but we deliver a nice, coated rock at its original size. The ProSizer’s variable speed impactor allows us to dial in the requirement for the given conditions and makes sure we’re crushing it to the right size.” Reaver added that the ProSizer can be programmed for different applications. “And there’s essentially an overload protection system that will slow the feeder down if

necessary, so you don’t have to dig out the machine or end up with a product that’s out of spec.”

MULTI-FREQUENCY ADDITION In late 2019, Astec Australia incorporated multi-frequency screening technology into its ProSizer 3100 for the Australian market. It has been repurposed and resized for a range of recycling applications and has been adapted for universal roads access across all parts of the country. Australian transport regulations had been a limitation for earlier USmanufactured versions of the ProSizer. “In the past, some of the road regulations that apply in Australia haven’t lent themselves to the easy transportation of the unit around the country,” Reaver explained. “So, in conjunction with Astec Australia, we came up with the product – still employing our multi-frequency technology – that offers really good capacities and meets the regulation and transport needs of the Australian market.”

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CRUSHING

The ProSizer 3100 with multi-frequency technology is suitable for sizing and screening products, including RAP, concrete, bricks, tiles, plasterboard, gypsum, limestone and glass. It is the first of the ProSizer range to include a twin-deck 4.2m x 1.5m multifrequency screen in closed circuit with an Andreas 3136 HSI. The feed hopper offers 5m3 of capacity with a heavy-duty, sloped grizzly with 125mm openings. The twin-deck screen can resize materials from 25mm down to 0.5mm, with two standard product conveyors and a returns conveyor that can be converted to a third product conveyor via radio remote control. The ProSizer’s carrier frame features a 533mm wide I-beam frame with an Australian-style kingpin, and hydraulic landing gear. The frame comprises a tripleaxle assembly with 12 11R22.5 tyres, fenders and mud flaps, an air bag-type suspension with air brakes and an Australian standard lights package. In recent years, Astec has sold several multifrequency portable screens into the Australian market. One of these – a GT205MF – has successfully processed glass, plasterboard, gypsum, topsoil, crusher dust and manufactured sand. The first GT165MF arrived on Australian soil in the last quarter of 2019. A particular advantage of multi-frequency screens is their ability to simultaneously screen both light and tough materials on separate decks. Adam Gordon, Astec Australia’s national account manager for aggregates and mining, told Quarry that on a traditional twindeck scalper, 600mm rock can be screened on the top deck and 20mm on the bottom. However, different masses of material require different forces to achieve the most efficient screening outcomes. “Having the multi-frequency vibrators at the bottom, with five adjustable settings, means you can fine-tune them for the load over that section of the screen media, independent of the screenbox that’s taking care of the bigger material,” Gordon said. “With the benefits of the scalper on top, you can do flexible things with large rock there, while on the bottom you can get into those tougher 20mm and below applications, where it’s a finer or high moisture application. You can use the high frequency vibrators to better screen in those tough applications. So the multi-frequency bottom deck gives you a lot more throughput, efficiency and accuracy.” Reaver explained that on Astec’s 35-tonne GT165MF, the standard top deck features a lower speed adjustable amplitude of about 24

Quarry April 2020

The ProSizer 3100’s carrier frame features an Andreas horizontal impact crusher and a multi-frequency twin-deck screen. It also includes a triple-axle assembly with tyres, fenders, mudflaps, air brakes and lights package.

950 revolutions per minute (rpm), an increased stroke rate of 6mm to almost 10mm, and hydraulic controls for variable angle operation. The multi-frequency bottom deck has six independently-controlled exciters that can each apply an additional frequency of up to 4200 rpm to the screen media. This contributes to increased stratification and higher separation, with sizing down to as low as 400µm. The multi-frequency screen on the ProSizer 3100 operates on similar specs and delivers the same high quality outcomes.

VIABLE ALTERNATIVE While the ProSizer plant was originally developed by Astec for the asphalt market and has been used for more than a decade by recycling and asphalt producers to separate bituminous asphalt content from cement, Reaver said the machine has been proven time and again to be a useful asset for quarrying operations, as well as mobile contractors. “Our ProSizer series, as a whole, is a

horizontal shaft impact crusher so, within limits, it will crush any material that a horizontal impact crusher will crush,” he said. “We’ve tried to make it extra friendly for the recycled asphalt market, but we do have units that crush virgin aggregates, sand and gravel, and concretes. In Peru, they’re even crushing seashells with it! “We have a customer in Colombia who has three ProSizers crushing sand and gravel every day. That’s all they do. The customer is an asphalt producer, but they wanted to screen and process sand and gravel themselves, and now they do, with the ProSizer. So the ProSizer can act as a lone horizontal shaft impactor. It will crush. “In the RAP environment we try not to over crush the product, we just want to break it down to its constituent elements for reuse in other roads. But, at the end of the day, the ProSizer is a horizontal shaft impactor that’s meant to crush, and it will crush virgin rock.” The ProSizer 3100 with multi-frequency technology is now available to purchase from Astec Australia. •

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CRUSHING

The Vantage Automation System has been previously utilised on predecessors of the Patriot P500 cone crusher.

USER-FRIENDLY AUTOMATION

DRIVES NEXT LEVEL CRUSHING EFFICIENCY As the crushing circuit becomes automated, personnel need to be brought up to speed with the latest advances. Brian Weiss provides tips for what operators can expect from automation programs – and how they can overcome their reservations about automation.

verall plant systems integration and crushing circuit automation will continue to grow, expanding quickly in capabilities every year. For some people, adapting to a new cone crusher automation program fuels fears of frustrating learning curves, operational failures and troubleshooting headaches. However, the right automation program is designed with true simplicity and safety at the forefront. From a simple set-up to safe start-ups and shutdowns, crusher automation systems should be easy to install, easy to understand, and easy to monitor by any member of the quarrying crew. Most importantly, optimum automation ensures safe, reliable, and profitable material processing. 26

Quarry April 2020

SIMPLE SET-UP Operators should look for an automation system with a simple, user-friendly sensor communication network. Past systems may feature dozens of separate conductor wires running from the programmable logic controller to each component, which is a complicated, time-consuming network to set up, and a major hassle to maintain over time. A simple sensor communication network accesses a standard four-wire cable system from the cone crusher to all auxiliary systems. It’s a quick, easy set-up that streamlines diagnostics and troubleshooting, while minimising the downtime associated with common conventional systems. SAFE START-UP AND SHUTDOWN A major advantage is safely controlling motor

starts and stops with one touch on the screen. This ensures that the crusher always safely starts and shuts down in the proper sequence (without operator intervention) to protect machine performance. A one-touch start and stop feature eliminates the need for an additional box for electrical push buttons in the tower. For a safe start-up, the automation system will monitor the lubrication system for proper temperature and flow before allowing the crusher to start – and should an event occur, it will automatically shut off the crusher as well as the crusher feed. For a safe shutdown, the operator hits the one-touch stop feature and proper sequencing automatically starts with shutting off the feed, followed by the cone and the discharge. The lubrication will run for an additional five minutes

until all the oil flushes through and the cone comes to a complete stop. At that time, the lubrication system will shut down. Notably, the system tracks how long it takes the crusher to shut down – from full revolutions per minute to a full stop. By tracking shutdown times, operators have a way to help diagnose abnormal bushing wear. The right automation system is all about simplicity – and end users find there’s nothing to fear – and everything to gain in peace of mind and optimum crushing performance. • Bryan Weiss is the automation manager for Superior Industries.

The Patriot P500HD cone crusher has undergone significant design improvements.

FIELD-PROVEN AUTOMATION In both portable and stationary operations, user-friendly automation systems are impacting crushing efficiency, and ensuring lower operating costs per tonne. The latter has proven true for an Idaho, USA-based contract crusher who is operating a Superior Industries Patriot P300 cone crusher plant, equipped with Superior’s Vantage Automation System. As Matthew Voigt, Superior Industries’ product manager for portable plants, explained, the crushing plant combines a 225kW cone, a triple-deck screen and seven feed and discharge conveyors – all on one chassis and configured for both open and closed circuits. The plant also features new patent-pending “level assist” technology as an innovation that further streamlines crushing plant portability. Voigt explains that after lowering the hydraulic cylinders to get the plant to the desired operating height, the level assist system automatically levels the plant. “One worker can get the job done in less than five minutes. It saves a lot of time in set-up,” he said. On the portable plant, Voigt stressed that the Vantage Automation System monitors all the vital functions of the crusher. “It’s simple, easy to use, and acts as a warning system that alerts operators to conditions such as bowl float, excessive amperage or temperatures, and lubrication issues,” he said, adding that, “since it’s built completely in-house, the system is more affordable, and offers the user a one-call service and support package.” On older crushers, Voigt said maintenance crews had to constantly rely upon gauges to monitor operating parameters. “Also, it

material feed levels in the cone, while also maintaining the desired amperage on the motor to ensure optimum crushing efficiency.

was such a hassle to change settings on older crushers, causing crews to check the settings less often than necessary,” he added. “Today, crews operate the new plant from a touchscreen control panel that allows them to easily adjust crusher settings, or to start and stop the plant in sequence with the push of a button.” Operating an automated Patriot P500 cone crusher, the Tulsa Rock Quarry in Oklahoma, US, has had a decrease in operating costs, and an increase in plant uptime. The plant’s processing team likes a number of the automation system’s features, particularly the simplicity of the sensor communication network, which accesses a standard fourwire cable system from the cone crusher to all auxiliary systems. Other big benefits include the capability of making setting adjustments on the fly, which gives them greater flexibility for changes in material feed; and allows them to easily tweak processing within all circuits of the plant. Tulsa Rock’s processing engineer Mike Neal said the automation system’s auto-feed function is one of its biggest advantages. Regardless of changes in the feed, the system will always maintain the desired

WHAT IS VANTAGE AUTOMATION? Superior Industries’ Vantage Automation software monitors and controls crusher parameters, automatically adjusting unit settings or shutting down the machine when harmful conditions occur. Designed for simple, straightforward operation, the software maintains optimum crusher production without operator interruption. It is applicable for the Patriot range of P200, P300, P400 and P500HD crushers. The software is available on an HMI touchscreen, which comes as part of the package, along with a 10-metre tether cord for remote locating. The touchscreen virtually eliminates the need for electrical push buttons and operator intervention, meaning motor starts and stops can be safely controlled from the pad itself. The software monitors CSS, amperage draw in real time, liner wear conditions, and the counter-shaft RPM sensor, and can generate performance analysis reports. It will also alert users to potentially harmful conditions, such as lube oil temperature and pressure, lube filter condition, hydraulic clamp and tramp releases, ring bounce/ bowl float, lube oil and hydraulic tank levels, and the eccentric bushing temperature. Vantage Automation also provides access to Superior’s in-house engineering team, allowing users to directly ask questions of the source developers. • Source: Superior Industries

Quarry April 2020 27

CRUSHING

ECCENTRIC ROLL CRUSHER SHRUGS OFF THE ‘AIN’T BROKE, DON’T FIX IT’ TAG

roductivity is one of the key facets to operating a successful quarry. In a bid to provide quarries and mines with technology that enhances throughput, a German OEM has crammed a lot of power into a compact eccentric roll crusher. While some might argue the “if it ain’t broke don’t fix it” maxim to decades of conventional quarry machinery is applicable, industry demand for faster and more efficient technology has taken charge. thyssenkrupp’s eccentric roll crusher (ERC) aims to improve the capabilities of quarries by providing an innovative, advanced solution to hard rock crushing. The ERC combines improved power, efficiency and size to provide an alternative to conventional gyratory and jaw crushers. The unit is available in five models: the ERC 18-14, ERC 20-20, ERC 25-25, ERC 25-30 and ERC 25-34. In the larger models, the feed opening into the crushing chamber is an average 2500mm wide and 1280mm high. Suitable for hard rock crushing in both underground and surface operations, thyssenkrupp has engineered the ERC to provide a rock crushing solution that boosts productivity. The machine features an integrated grizzly that bypasses fine materials to help increase liner lifetime and capacity while reducing energy consumption. Capacities of up to 10,000 tonnes per hour are achievable with the integrated grizzly. Coarse material is crushed between the oscillating roll and jaw of the machine. The ERC’s kinematic design allows the stroke to be equal throughout the entire crushing chamber. During the crushing process, the ERC is able to roll backwards to distribute the material over its entire circumference. thyssenkrupp engineered this to prevent uneven wear zones. As a result, the crusher’s kinematics provide high comminution intensity and high throughput rates. The ERC has been designed to have a weight balance through its oscillating roll to avoid the risk of machine overloading. This reduces machine vibrations and loads, giving it the much needed benefit of use in mobile and semi-mobile crushing systems in quarries. The machine’s flywheel and 28

Quarry April 2020

The thyssenkrupp ERC is a worthy alternative to conventional gyratory and cone crushers.

V-belt pulleys have a significant inertia which reduces the amount of energy peaks needed during the comminution process. Featuring a compact design not normally found on rock crushers, the ERC’s installation height has been reduced by between 20 and 50 per cent, compared to similar performing gyratory or jaw crusher options that require high headroom in confined spaces. Its smaller size and reduced number of components also assists with maintenance time and allows it to be transported around the site. This is achieved through the crusher’s removable hood that can be dismounted with ease. The crusher also features a hydraulic gap/ retraction system that reduces liner wear. This allows the swing jaw to be adjustable and adapted to suit a specific product. It features an adjustment range of up to 200mm. Uncrushable materials, such as tramp metal, are expelled from the machine through this system which ensures the machine is robust and long-lasting. The higher service life of the ERC’s wear elements and a reduction of energy peaks also improve its reliability. Machine stress is also reduced through the addition of balancing the rotating crushing element, resulting in low machine vibrations during

a no-load operation. There is a notable amount of rigidity in the crusher’s design which allows it to have a strong resistance to large chunks of feed material. The chunks of sediment that are fed into the crushing chamber hit the hood, rather than falling on the natural element. For all of its advanced features, thyssenkrupp has the numbers to prove its machine is a viable alternative to conventional crushers. The first prototype was tested in a German quarry in 2017 to test its ability to process operating parameters and data processing. The crusher then had an output of 250 to 300 tonnes of hard andesite per hour during testing. This gives the ERC an advantage over conventional jaw crushers and even rivals the throughput of some gyratory crushers. The ERC’s power consumption was proven to be highly efficient in the test, achieving a power draw of 200 to 500kW, depending on speed and gap width variables. With a significantly smaller footprint, thyssenkrupp has developed a machine that is not only portable but highly competitive and economical. • By Nickolas Zakharia

QUARRIES FOR SALE GROMAC CENTRAL DIVISION

• SARINA • HATFIELD • BLUE MOUNTAIN, QLD OFFERS INVITED FOR THE SALE OF QUARRY SITES AT SARINA, HATFIELD AND BLUE MOUNTAIN, CENTRAL QUEENSLAND

SARINA

HATFIELD

BLUE MOUNTAIN

Located on the Bruce Highway, approximately 5kms south of Sarina, Queensland.

Located on Bolingbroke Road, Koumala, approximately 35km from Sarina, Queensland.

Located approximately 40kms south west of Mackay, QLD and is accessed via the Peak Downs Highway.

Owned under freehold title

Operated under a licence agreement

Owned free hold

Development approval 5000t – 100,000t

Weighbridge including computer and software

Development approval for 100,000t – 1,000,000t

Licence renegotiation March 2022

Access via a road easement

Weighbridge including computer and software

Office building with fixed desks and cupboards

Sale of a parcel of freehold land encompassing the quarry or licence agreement

Weighbridge including computer and software

Demountable office building

Shipping container adjoined to office building used as store room

Office building with fixed desks and cupboards

Workshop building

Two water tanks adjacent to office with pressure pump

n n

Bore pump and water lines Pugmill with Genset

Workers camp consisting of four demountable buildings, cement tank, pressure pump, roof structure

Bore pump and water lines

Two access grids

Underground fuel tank

Jaques Jaw crusher

Shipping container containing fuel pump

Pugmill with Genset

High quality mineral resources across all quarry sites, capable of meeting market demand across all quarry products. n n n n n n n

Ballast Precoated Aggregate Road Base Armour Rock Flood Rock Crusher Dust Cement treated base “Pugged”

Concrete Aggregate

Aggregate

Gabion Rock

Drainage Rock

Mattress Rock

Shot Rock/Blast Rock

Note: All sites are capable of producing the full range of quarry products

All quarries benefit from close proximity to the Hay Point Port, one of the largest coal ports globally, the Goonyella rail system and the growing central Queensland city of Mackay. There are no operational constraints at the sites, with the exception of development and environmental restrictions.

Contact Ray Gross for further details Mobile 0407 595 253 | Email: ray@gromac.com.au

SAND PROCESSING

QUARRIES USE WATER TOO:

EFFICIENT WATER MANAGEMENT SOLUTIONS Water and its usage is as vital as the aggregates quarries produce – particularly in practices such as sand processing. However, equipment can now be optimised to close the loop of water processing without impacting on productivity and profits and indeed boosting product solutions and innovations.

or an outsider, water management might not be the first thing that comes to mind when thinking about quarries. However, water availability and wastewater management have been a strong focus for quarrying and mining operators since the early 2000s when the states introduced mandatory licences for previously unlicensed water use for quarries. Restrictions on water extraction from the natural environment have made the recycling of process water a must for quarrying operators. Operators must now compete for licences in fully utilised systems or in rural areas where there are no new water licences available for industry to expand, or where the total licensed extraction is actually being reduced. The management of process water, reclaim systems, dust suppression and pit dewatering is essential to the success of a sand and aggregates project. By managing these processes efficiently, quarry sites can process more product faster, while lowering their water bill and eliminating the need for double handling. Most quarries use water in the washing and processing of their products. For example, sand washing, a necessary step for producing high quality sand, utilises both recycled and clear water. Once the sand has been processed, wastewater containing product fines and additional wastewater run-off from the stockpiles make their way to storage or tailings dams. All these water sources need to be managed effectively for 30

Quarry April 2020

Weir Minerals’ equipment can manage water more efficiently to provide a drier end product.

the quarry to keep their operational costs under control.

FROM A TO B “Maintaining the water level balance on site is very important to everyone,” Darren Van der Westhuizen, Weir Minerals’ territory manager for dewatering, explained. “No matter what you’re processing, you’ll always need to move water from point A to point B.” The new decade has brought to light new problems for fluid transport, from the introduction of water restrictions on urban water supplies to climate change affecting the supplies of non-potable groundwater (rainwater, groundwater and stormwater).

By transporting and making use of water already available on-site, quarries can reduce the cost of water licences and make their investment go further. “Increased awareness of the positive outcomes achievable with efficient water management provides us the opportunity to partner with customers to explore and develop new and safer water management systems,” van der Westhuizen said. “We target the challenges the quarries are facing with regards to pumping water around the site with the focus to champion and provide the most optimum solution for each specific and unique application.” Pumps designed to handle increased

suspended solids in water while operating at high discharge head pressures could be the answer. With the Warman DWU pump, Weir Minerals provides a pump built to transport surface water from dams and ponds on-site back to the washing circuit for recycling. Other onsite water sources, such as tailings dams, might make better use of a pump house or a customised Multiflo barge solution. “There is more than one way to reclaim water at a quarry,” van der Westhuizen said. “We engineer our solutions in-house, so no matter the customer’s needs or budget, we can create a custom solution to get the most out of the water they already have on site.”

CLOSING THE LOOP In 2020 it’s no longer just about moving water around site, now quarries need to work toward closing the loop of water use in their processes. Regulatory and government bodies around the world have begun implementing guidelines for the management of water in quarries. These guidelines promote site water management proposals founded on the principles of waste minimisation and active promotion of the reduction, reuse and recycling of wastewater. “More and more quarries are looking for equipment that will help them to reduce their water usage on site,” Steve Barnett, Weir Minerals’ sand and aggregates sales manager, said. “With the new guidelines, sites are re-evaluating their water management plans and seeing how an effective plan and change of equipment can contribute to their success.” The new planning and allocation of water resources covers reducing, reusing, recycling and recovering water wherever possible. Equipment optimised to handle water not only reduces its losses and boosts efficiency but also frees up water resources that can be used elsewhere in the process for necessary site duties such as dust suppression. Installing equipment like the Weir Minerals sand wash plant, specifically designed to produce a drier end product, can improve water recovery by up to 35 per cent compared to common sand screw plants. “We’re out on site with our customers every day,” Barnett said. “We see how hard they work, and we know how precious each and every recoverable resource is. Installing a custom-engineered solution such as the Weir Minerals sand wash plant doesn’t just provide customers with a drier aggregates product after processing but creates a whole new by-product in ready to use recycled water.” THE NEW ECONOMY The conservation of water is a major consideration for a circular economy. As restrictions tighten, quarries are faced with a new question of how to close the loop and get the most from the water available. Weir Minerals’ solutions make it easy to optimise any site for efficient water management. With years of water transport expertise, and a portfolio of products designed to manage water efficiently, the Weir Minerals team works with quarries across the entire process to produce a high quality product while saving time and money, as well as water. • Source: Weir Minerals

Weir’s Multiflo pump units can transport water to where it is needed.

Superior Industries’ new portable Spirit washing plant was recently unveiled at CONEXPO/CONAGG.

SAND PROCESSING

PORTABLE, MOBILE, MODULAR, FIXED – COULD ONE PLANT DO IT ALL? Wash plants have traditionally been static or modular, with limited mobility around the quarry. Jim Hankins explains how recent iterations of the wash plant have evolved to become more portable and flexible – and may one day be capable of covering all facets of operation.

ortable plants have been utilised in the quarrying industry for decades. In the US, portable wash plants became popular in the 1960s and generally consisted of a vibrating screen mounted over a sand screw. The various configurations were typically used for projects with short to medium term contracts, requiring screening and washing on-site, and the ultimate removal of equipment at the end of the project. With developments leading to more flexibility, portable plants are now found in a broad range of applications. In the past decade, Superior Industries acquired washing, crushing and screening, as well as portable equipment, manufacturing firms. With these acquisitions, its range of portable processing plants – dry or wet, crushing, screening and integrated washing plants – has grown immensely.

PORTABLE AGGREDRY The first Superior Industries Aggredry portable wash plant was imported into Australia in late 2017. This was a standard configuration, with Australian requested modifications to suit local conditions, described as a 2m x 6m (6’ x 20’) Aggredry. It combines a Guardian horizontal triple-deck 6m x 2m (20’ x 6’) screen, with a pan feeding a 91cm (36”) twin Aggredry dewatering washer makes a powerful and flexible plant. Two reversing and roll-out cross conveyors, made from the Superior Industries product 32

Quarry April 2020

The original Australian portable Aggredry wash plant in operation.

range, accommodate the product of the screen decks on either side of the plant, with the third screen discharge to a chute at the end. An arrangement of stackers, appropriate to the site requirements, will stockpile the various products. This unit has been in operation for close to two years, processing a sand with minimal bottom end with some organics. The washing process is cleaning the organics out, while producing sand in grade at a high production rate. The second portable Aggredry wash plant to come to Australia had considerable Aussie input to modifications to make the plant more versatile. Both technical and operational modifications were involved. For the first time, Superior Industries built a twin 112cm (44”) Aggredry with removal flared sides, for travel, again making use of the Guardian 6m x 2m

horizontal triple deck screen. The water manifold was reconfigured, valve changes, electrical components were altered for road travel within Australia. With the changes, what can the newly configured portable plant do? The Guardian screen can process in excess of 500 tonnes, depending on feed and aperture sizes. The twin 112cm Aggredry can produce a nominal 275 tonnes per hour, depending on the raw feed grading of the –4.75 mm material.1 Based on river rock (or pebble) and sand in a typical alluvial deposit, the Aussie Aggredry wash plant could take a 45:55 ratio of rock to sand, of the material fed to this plant.1 If a feed hopper is used with a grizzly, the plant can produce one oversize, threescreen washed rock or pebble size ranges, depending on preferred screening apertures,

in addition to a washed sand. Washing pebbles for the landscaping market is an art or science in itself. Removal of difficult surface coatings may require further processing. If the river rocks are crushed to make aggregates, and require washing after crushing, the same processes could be followed, while the crusher dust could be blended with the natural sand, if blending ratios were acceptable.2 If a hard rock site was looking at washing aggregates, three washed aggregate ranges could be produced, while washing crusher dust to make a local manufactured sand. The versatility of this plant is only limited by the site-specific products and required feed rates.

ALL-ROUND OPERATION While portable and easy to move within a site and from location to location, the plant can be set up in position for permanent operation. With regards to modularity, plants can be set up to operate in tandem, once a second one is added (or more, as required). Is it possible for

The versatility of the “Aussie” Aggredry portable wash plant is only limited by site-specific products and feed.

one plant to cover all facets of portable, mobile, modular and fixed operations? Within reason, yes. With experience in operation and expertise in sizing plants it is possible to base an initial operation around the use of the Aggredry wash plant, with expansion in multiples of these added to the process, with some materials handling additions or modifications, as well as inputs such as water and power. With level assist technology, to efficiently utilise hydraulic levelling of the plant, the Superior Industries portable range can be brought on site and set up in a matter of days, with supply of electricity and water (if required). With Superior Industries’ foundation in conveying and stacking, needless to say, there is a vast range of options for conveyors and stackers, ranging from fixed, to radials, to the Telestacker

telescopic radial with automated controls. Superior Industries continues to innovate in the portable field, recently unveiling the latest development in portable washing – the Portable Spirit Wash Plant, which was on show at CONEXPO-CON/AGG Las Vegas in March 2020. • Jim Hankins is the principal of Rivergum Industries. FOOTNOTES: 1. The basic operation of an Aggredry washer is determined by the water requirements and the speed of the shafts, which are directly related to the raw material feed grading. The throughput will depend on sitespecific parameters. 2. Ratios for blending of natural sand and manufactured sand are dependent on a number of issues related to the ultimate end product.

SAND PROCESSING

PORTABLE CAPTURES STATIC COUSIN’S ‘SPIRIT’ Superior Industries, the US-based manufacturer and global supplier of bulk material processing and handling systems, showcased its newly configured portable wash plant at CONEXPO-CON/AGG 2020 in Las Vegas in March. Based on the company’s successful brand of static Spirit sand plants, the Portable Spirit Wash Plant is capable of producing as many as five products. It carries a 6m x 2m (20’ x 6’) Guardian Horizontal Screen, plus a sand production module and ultrafines recovery module. As part of the sand washing process, material is fed to a slurry box, which liquifies it to improve the screening and stratification processes. The three-deck horizontal screen washes and sizes three products from a top, middle or bottom deck. Leftover sand is then processed through one of two Spirit wash modules, which comprise of one or more Helix cyclones followed by a dewatering screen. The first wash module uses a cyclone to size and separate material for a traditional sand product. A dewatering screen ensures it is instantly saleable off the discharge chute.

P L A N T

The Portable Spirit Washer Plant.

Depending on the deposit, an optional ultrafines recovery module washes out -100 to -400 fines for microfine material, which is saved from being lost to a waste pond. “It’s the first time such a configuration has been created for the portable market in North America,” Matt Voigt, Superior’s manager of portable plants, said. “We incorporated our low profile dewatering screens and a series of hydraulically-powered components to ensure the plant is road permissible and quick to deploy.” Applications for the new portable plant include operations with settling ponds, crushed aggregate, sand and

E Q U I P M E N T

P A R T S

gravel, dredging and frac sand. The Portable Spirit Wash Plant was one of a dozen new products for crushing, screening, washing and conveying applications that Superior Industries launched at CONEXPOCON/AGG 2020. The new equipment included the brand new Sentry Horizontal Shaft Impact (HSI) crusher, the Fusion Modular Platform, the Valor Vertical Shaft Impact (VSI) crusher, the bolted model Liberty Jaw Crusher, and the Alliance Low Water Washer. Additional equipment with new features included the Anthem Inclined Screen, the Valor Vertical Shaft Impact (VSI) crusher, the P500 Patriot Cone Crusher, the Aggredry Dewatering Washer and the TeleStacker conveyor. Superior also displayed aftermarket solutions for new conveyor idlers, pulleys and accessories, plus crushing rotors, cone bushings, cone heads and jaw dies, alongside a multimedia experience showcasing several turnkey projects completed by the company’s construction management division. • Source: Superior Industries

S E R V I C E

S U P P O R T

ASTEC AUSTRALIA PAVING SOLUTIONS

EQUIPMENT TO BUILD AND RESTORE THE WORLD’S INFRASTRUCTURE ASTEC AUSTRALIA.

an Astec Industries Company

PO BOX 142, ACACIA RIDGE, QLD, 4110 • 1300 278 322 • astecaustralia.com.au

TYRE MAINTENANCE

A HOLISTIC APPROACH TO TYRE MAINTENANCE AND SERVICE

hoosing the right tyre brand and pattern for quarry-spec machines can be the first step in ensuring optimum cost and operational management. After all, not all tyres are created equal. The right tyre can deliver improved productivity, cost management and tyre life performance, reducing tyre consumption, spend and replacement service costs, as well as subsequently reducing downtime. Other performance benefits that come with choosing the right tyre include safety, grip, traction, damage resistance, etc. However, while tyre choice is crucially important, the other part of the equation which mustn’t be overlooked is the services around this tyre choice. This is where Michelin’s Quarry Productivity Solutions come into play. While baseline recommendations can include product and pressure advice, ensuring the optimum product and pressure to carry the load, and resulting in optimised safety, performance, and wear, other numerous added value opportunities are encompassed within Michelin’s Quarry Productivity Solutions. These include consulting services tailored for quarries to provide additional levels of collaboration. For too long, the relationship between tyre manufacturers and quarries have revolved around price (rather than value), or increasing tyre life as much as possible. Today, Michelin’s Productivity Solutions can help producers optimise the value of their tyre choices by optimising their quarry’s output. To make this happen, Michelin representatives have extremely innovative and powerful analytical tools to support their quarrying customers. Whether the goal is to safely maximise productivity (through use of a tyre which allows you to carry more load), better use of the tyre’s thermal potential (by increasing average speed), increasing tyre life and achieving subsequent cost reductions (through reduced consumption or fitting) or downtime reductions, Michelin Productivity Solutions can help producers achieve their objectives through a tailored consultancy approach.

Michelin’s core objective is to work with its extractive customers to optimise the value and work performed by its tyre products in their operations.

In collaboration with Michelin representatives, Productivity Solutions can provide quarrying producers with the necessary expertise, tyre and operational analysis, to support their objectives, managing the proposal and implementation of the productivity actions. Michelin’s core objective is to work with its customers to optimise the value and work performed by the tyre in their operations, eg: • What contribution is the tyre making in your operation today? • What additional contribution could be made by the tyre in terms of safety, value, productivity and efficiency? Michelin’s strategic vision is to improve an operation’s productivity by utilising the full potential of Michelin tyres. It seeks to implement this vision through: • People who work closely with customers to understand their businesses and objectives, providing expertise in the science of tyres. • Data that draws from a broad and comprehensive global experience in tyre usage. • Powerful tools to capture and analyse critical operational data. Michelin Productivity Solutions utilises the following tools to provide customised advice,

to implement recommendations and actions to deliver on safety, productivity and efficiency objectives, eg: • V Box – A GPS measurement tool that captures cycles, cycle mapping, speed, and distance. • D Box – A Michelin measurement tool, using GPS and accelerometers, to capture cycles, cycle mapping, speed, distance, strut pressures and other dynamic characteristics of vehicles and an operation. • Weight studies – The use of adapted scales to get real load distribution by vehicle position, by tyre. • TKPH + – A Michelin reporting tool, capturing real TKPH realised for each tyre, based on Fleet Management System data. In summary, Michelin’s Quarry Productivity Solutions can help producers achieve their operational objectives of safety, reduced tyre-related costs and downtime, increased productivity and efficiency, and optimised results for today – and beyond. For more information, email michelin. earthmover@michelin.com or visit michelinearthmover.com • Source: Michelin Quarry Productivity Solutions

Quarry April 2020 35

SMART BUSINESS

KEY ACCOUNT PLANNING:

THE PROFILE OF AN ‘IDEAL’ CUSTOMER? Achieving new sales of your business product or service solutions requires care and finesse, especially in lean times. Mike Cameron explains what makes a ‘good’ customer and how producers can use that profile to achieve mutually beneficial ends.

hink about your ideal customers – the people you enjoy working with and the companies who value the relationship that they have with both you and your organisation – and then compare that thought with the people and customers associated with your most difficult and/or challenging accounts. You may ask yourself: • Is it easier doing business with our best accounts? • Do our ideal customers share similar values to our own? Is their culture one where they seek to create valued partnerships rather than chasing a lower price? • Can we clearly identify the key characteristics of both our best and worst accounts? Successful sales professionals don’t look at every sale in the same way; they plan well, aligning their strategy with their customer’s profile, in order to establish a realistic Key Account Plan (KAP), with action steps and a clearly defined sales objective.

KINDRED SPIRITS An effective KAP isn’t just about winning business or creating a product/service/ price fit; it is about establishing whether the organisations share similar values while creating long term, and mutually beneficial, relationships. A KAP has six important components: objective; strategic focus; target contacts; core strategy; competitors’ reaction; and action steps (see Table 1, opposite page). Key account plans are an integral part of the total business planning process (see Figure 1). The impact of change is clearly evident in today’s fast-paced business, requiring you, as a sales professional, to develop specific skills that will lead to reliable selling strategies. Remember: • Selling strategies and the tactics that 36 Quarry April 2020

BUDGET CAPITAL PLANS BUSINESS PLANS MARKETING PLANS SALES PLANS TRAINING PLANS

KET ACCOUNT PLAN • Objective KET ACCOUNT PLAN • Strategic FocusPLAN • Objective KET ACCOUNT • Contacts • Strategic FocusPLAN • Target Objective KET ACCOUNT • Core Strategy • Contacts • Strategic FocusPLAN • Target Objective KET ACCOUNT • Competitors’ Reaction • Core Strategy • Target Contacts • Strategic FocusPLAN • Objective KET ACCOUNT • Action Steps Reaction • Competitors’ • Core Strategy • Target Contacts • Strategic FocusPLAN • Objective KET ACCOUNT • Steps Reaction • Action Competitors’ • Strategy • Target Contacts • Core Strategic Focus • Core Strategy • Strategic Target Contacts • Focus • Objective • Action Steps Reaction • Competitors’ • Core Strategy • Contacts • Target Strategic Focus • Action Steps • Competitors’ Reaction • Core Strategy • Target Contacts • Action Steps Reaction • • Competitors’ Core Strategy • Steps Reaction • Action Competitors’ • Action Steps

• Objective KET ACCOUNT PLAN • Steps Reaction • Action Competitors’

Figure 1. The considerations that underpin a Key Account Plan.

have delivered your current success will not necessarily guarantee future success and/or business growth. • To succeed in tomorrow’s world, you need to continuously review your position to know what you are doing, why you are doing it and how to implement your tactical sales plan. •A good tactical sales plan is only as good as the strategy that led to its creation, supported by realistic action steps and a regular reviewing and monitoring process.

AN ‘IDEAL’ CUSTOMER PROFILE As a sales professional, you are employed to generate revenue through sales, so obviously, you can’t always pick the ideal customers. However, through utilising a structured planning and monitored account management process, you will know where and how to

spend your time more effectively – which is often the best investment you can make. Ideal customers and prospects are the accounts with the highest value return on your effort. You should be nurturing them with a passion since, apart from the obvious enjoyment of working with people you like and respect, when an account is not ideal the impact on you can be: • Longer sales cycles. • Challenging relationships. • Lower margin business. • No referral-ability. • No reference-ability. • No repeat business. • Difficult to manage. • A source of frustration. In managing a sales process, especially when dealing with prospects and/or substantially growing an existing account,

you need to focus on personal wins for each of the target contacts that you have identified within your KAP. These wins are intangible and nonquantifiable but when you focus on identifying and addressing them, you start to work on meeting their individual needs, establishing rapport and building a relationship rather than filling a procurement requirement.

WIN-LOSE SCENARIOS It is important to understand that your attitude, behaviour and credibility during this initial sale will largely determine your customer’s perceptions and impact on how they will treat you and your organisation in the future. As a strategic and sales professional, you need to think in terms of: • Shared values. • Long term relationships. • A source of enjoyment. • Projectable sales cycles. • Equitable margin business. • Good referral-ability.

Objective

A clear, specific and realistic statement of the sales outcome to be achieved for this particular customer.

Strategic focus

How broadly will this sales objective be achieved?

Target contacts

Whom will you need to influence in order to achieve this sale objective?

Core strategy

The specific benefits that you will promote so that this prospect/customer will use your organisation rather than your competitors.

Competitors’ reaction

What are your competitors likely to do?

Action steps

What must be done to achieve your sales objective, by whom and by when?

Table 1. The six important components of a Key Account Plan.

• Good reference-ability. • Repeat business. One way to achieve the above outcomes is to ensure that the sale is seen as a “win-win”.

There are perils in other approaches that leave you either stronger or weaker than your customer, eg: • You may obtain an order through unethical and/or deceptive behaviour and,

SMART BUSINESS

OVERVIEW OF THE KEY ACCOUNT MANAGEMENT PROCESS

The seven steps in the Key Account Planning process.

THE CHARACTERISTICS OF WINS VS LOSSES CHARACTERISTICS OF A RESULT n A result is the impact of your

product/service/solution on one or more of your customer’s business processes. A result improves something or fixes something. A result is measurable, tangible and quantifiable. A result is corporate/ organisational.

thereby, generate a short term revenue gain. However, in the longer term, your reputation will be tarnished and your organisation will be excluded from future business opportunities. • You should also be aware that, rather than gain respect, you can quickly lose credibility when you succumb to pressure from your customer to (i) trim your margin in order to make a sale or (ii) have your proposal shared with other product/ service providers. Your customer doesn’t see the value you offer; they see you only as a cost or a commodity. Note: Buying the business, or gaining a partial share of it, may seem like reasonable strategies at times, but usually they are not. 38 Quarry April 2020

Characteristics of a win n

A win is the fulfilment of a promise made to oneself. A win changes and reflects the individual’s current perceptions, wants and needs. A win is intangible, not measured and not quantifiable. A win is personal. It is not a group goal. It benefits only the person involved.

You should never negotiate giving something away without receiving something in return. There are four possible outcomes with every sales encounter between a customer and a provider/supplier. They are: •W IN-WIN: Both of you – the salesperson and the customer – win. You both appreciate that you have each achieved what you needed from the transaction, but not at the expense of the other. •W IN-LOSE: You win at the expense of the customer. It is a short term scenario, because that person, or their organisation, will always find out with the likelihood of repeat business being minimal. •L OSE-WIN: The customer wins at your expense. You are subsequently

categorised as a commodity because you ‘bought’ their business. • LOSE-LOSE: Both you and the customer lose. You make the sale but neither one of you feels good about what happened to make the sale occur. Many sales professionals work on the premise that people buy when you demonstrate to them that you can meet their immediate business needs. However, this is a product-orientated process focusing on features and benefits that frequently require the salesperson to carry out demonstrations in order to obtain orders. It is not a relationship or partnership scenario. People buy for one of two major reasons: • To gain a benefit or avoid a loss. • To gain a feeling or avoid a feeling. In a practical sense, it may be that the customer perceives an opportunity to meet a new goal or exceed a pre-determined revenue target, or the customer sees an issue in achieving their budget and can rectify the situation by applying and using your product/ service or solution. The result, in either case – the impact on both the customer’s business and the opportunity for relationship development – is positive.

BUYING PSYCHOLOGY Obviously, as a sales professional, your role is to sell but you will also want to do more than just sell, you will want to create a “winwin” situation or “partnership” scenario. The “win” is buying psychology. It’s a personal gain that satisfies the personal self-interest of the many “buyers” within your customer’s organisation. “Win results” are tied together and are the real reason why people buy. The “win result” concept rests on the following terms: • Selling. Selling is a professional, interactive process directed toward demonstrating to all the “buyers” within your customer’s organisation how your product or service assists their individual self-interest. • Product. A product or service or solution that is designed to fix or improve one of your customer’s business processes. • Process. A process is an activity or series of activities that converts what exists right now into something else. • Result. A result is the measurable impact that a product has on one or more of your customer’s business processes. Results are objective and corporate, and they

affect many people at the same time. • Win. A win is the fulfilment of a subjective, personal promise made to oneself to serve one’s self-interest in some special way. Wins are always different for different people. • Win result. A win result is an objective business, a result that gives one or more of the “buyers” within your customer’s organisation a subjective, personal win. Note: It is important to understand both halves of the “win results” concept. A result must take place before a “buyer” will perceive a “win”. A result is the precondition to any win. You may think that a result you bring to a “buyer” is exceptional but if you don’t think about the personal win, it may be irrelevant to his/her situation or it could even be interpreted as a personal loss. A win-lose situation frequently arises due to the salesperson not appreciating the motives that drive the individuals who are involved in the buying/sales process. To

avoid this problem, always remember the following key point: Companies get results – people get wins.

DETERMINING WINS You can: • Use deductive reasoning. • Appraise lifestyle. • Evaluate attitude. • Consider what is communicated. • What grabs each individual’s attention. You can ask open questions, like the following examples, without creating embarrassment, eg: • How do you feel about our proposal? • What is your opinion on the product/ service/solution? • Do you believe that our product/ service/solution will support you in the achievement of your goals? • Does our proposal meet your personal objectives? • When we deliver, as promised, what does

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our proposal do for you? Additional questioning, done correctly and face-to-face, will assist you to identify any difficulties that any individual “buyer” may be having in making a direct connection between your proposal and their own personal wins. Remember that the main reason for asking questions, such as those above, is to ensure that you identify any/all issues that may hinder your achieving the sales objective within this particular customer’s Key Account Plan. So, don’t feel uncomfortable, it is a necessary part of the sales process. Finally: • Ask about results first then, when appropriate, ask “win” questions. • Don’t interpret results as the “win”. • Don’t assume that your own “win” is the same as an individual “buyer’s” “win”. • Mike Cameron is an IQA member and the principal of Strategically Yours. Visit strategically.com.au

IQA AWARDS

ANDREW HAUSER:

SETTING A WORKPLACE CULTURE The Alec Northover Award has been a bonus for Andrew Hauser after juggling the triple challenges of managing a quarry, undertaking professional education and raising a young family.

he Oxford Dictionary defines culture as “the beliefs and attitudes about something that people in a particular group or organisation share”. Yet this is only the tip of the iceberg for what culture means to the 2019 Alec Northover award winner Andrew Hauser. “The culture is the environment that surrounds us at work,” the 38-year-old told Quarry. “It’s a powerful element that shapes the work environment, the work relationships and the work process. “But the culture is something you can’t actually see. It’s something that physically manifests in the workplace and the organisation’s culture is made up of the life experience each employee brings.” Hauser is the most recent recipient of the Alec Northover award – an accolade he has brought to Barro Group’s Seymour Quarry where he now works as quarry manager. “We are a basalt quarry, we are two-bench single flow and we supply aggregates and rock mixers to the industry,” he said. “This operation has been here for 20 years.” Located about 100km out of Melbourne, Seymour Quarries has been extracting basalt for decades and was first purchased by Barro Group in 1964. The site has had several years of successful operations, and after working at Barro for almost 14 years, Hauser decided it was time for a change of pace. “With Barro, I started as a machine operator, so working through from the face to the sales,” he said. “I had a Certificate III in Civil Construction before I started.” Hauser later worked as a quarry supervisor and decided to expand his knowledge in 2018 by studying a Diploma of Surface Operations Management. The diploma teaches students the necessary skills to manage an open cut quarry and for Hauser this meant an opportunity to expand his seasoned understanding of the industry. “I wanted to expand my knowledge in all aspects of quarrying,” he said. “All the subjects and workload covered in the diploma set the bar to a level where I think the industry needs to be heading.” 40

Quarry April 2020

Alec Northover Award recipient Andrew Hauser has brought his learnings to Barro Group’s Seymour Quarry where he works as the quarry manager.

TIME MANAGEMENT For each month of the course, Hauser drove two hours from Seymour to study at Box Hill Institute, where he would stay for a week. Hauser would then return to Seymour Quarries to apply what he had learned to practical situations at the site. “I would travel to Melbourne and do my studies for the week,” he said. “And then you would get piled with all the work that needs to be done over the [next] month,” he said. Leaving a patient family behind, Hauser said his biggest challenge was finding time to do anything besides study and work at the quarry. “I had a very supportive family – and a very supportive wife,” he said. “On top of work, I was doing at least another 30 hours a week.

Movie nights were out – but you see the light at the end of the tunnel.” Thankfully, it was all worth it. On the back of completing his diploma with straight A grades, Hauser went on to become the full-time quarry manager for Barro’s Seymour site in 2019. “I was employed as quarry manager in 2019,” he said. “Since then I’ve had the responsibility of implementing all the facets of the business. Things like managing our financial budgets, maintenance scheduling, managing major incidents and emergencies, implementing environmental plans, implementing the pit plans, side operations, stockpile management – yeah, lots.” “I’ve had the opportunity to apply my knowledge and obtain in my studies a diploma, but also gain how policies and

procedures are an important factor to support quarry operation and implementation.â&#x20AC;? Hauser believes it has been a big jump from his previous role as a quarry supervisor. â&#x20AC;&#x153;Within the supervision role, I was more about following up on the implementation. I was moving from [a place of] supervision and overseeing the implementation to actually implementing the new procedures.â&#x20AC;? Hauserâ&#x20AC;&#x2122;s advice to people undertaking similar diplomas and courses is simple: donâ&#x20AC;&#x2122;t procrastinate and know when to take a break. â&#x20AC;&#x153;The first tip would be donâ&#x20AC;&#x2122;t procrastinate. If you delay the things that are coming, theyâ&#x20AC;&#x2122;ll pile up and youâ&#x20AC;&#x2122;ll have more work in the end,â&#x20AC;? he said. â&#x20AC;&#x153;Time management is very important.Â With the study and work balance, youâ&#x20AC;&#x2122;ve got to consider having a day off. For me, it just clears the head. Whether itâ&#x20AC;&#x2122;s going out to golf on a Sunday afternoon or something like that, itâ&#x20AC;&#x2122;s important just to clear your head and keep yourself grounded.Â â&#x20AC;&#x153;All the family time had to get put on the back burner but my young kids were playing footy so my â&#x20AC;&#x2DC;outâ&#x20AC;&#x2122; was on the Sunday morning â&#x20AC;&#x201C; it

was to get a coffee, go watch the kids play football, and talk to other parents â&#x20AC;&#x201C; thatâ&#x20AC;&#x2122;s how I got through it.â&#x20AC;?

TEAM CULTURE Since becoming quarry manager, Hauser has taken on the role as a mentor where he encourages a team-orientated culture at Seymour. â&#x20AC;&#x153;A key aspect of Seymourâ&#x20AC;&#x2122;s environment is teamwork,â&#x20AC;? he said. â&#x20AC;&#x153;I like to mentor people during the day-to-day tasks they are faced with.â&#x20AC;? Last year Hauserâ&#x20AC;&#x2122;s near perfect scores for his diploma granted him another opportunity â&#x20AC;&#x201C; a nomination for the Alec Northover award. â&#x20AC;&#x153;Andrew has been able to put into practice in the workplace many of the competencies introduced,â&#x20AC;? said Barroâ&#x20AC;&#x2122;s quarry operations manager Victoria Craig Banthorpe in a statement for Hauserâ&#x20AC;&#x2122;s Alec Northover nomination. â&#x20AC;&#x153;The module â&#x20AC;&#x2DC;Manage People Performanceâ&#x20AC;&#x2122; has given Andrew the tools he required to manage the people at and connected to the site.â&#x20AC;?

In his own nomination statement, Hauser noted his excitement to make a difference in the industry as quarry manager. â&#x20AC;&#x153;My interests have always been in quarrying and to be in such a role where our team can make a difference to the industry has me excited to the possibilities,â&#x20AC;? he said. And with that attitude, Hauser received the 2019 Alex Northover Award. Hauser is planning to use the $2500 in prize money to further his studies. â&#x20AC;&#x153;I was happy, over the moon,â&#x20AC;? he said about receiving the award. â&#x20AC;&#x153;It was good to see that the hard work was acknowledged. I would say itâ&#x20AC;&#x2122;s a great recognition of your knowledge, the hard work and learning capabilities.â&#x20AC;? Regardless of the award, Hauser was just happy to gain a new level of self-fulfilment. â&#x20AC;&#x153;Itâ&#x20AC;&#x2122;s more of an award within myself,â&#x20AC;? he said. â&#x20AC;&#x153;When I was doing the studies, I wasnâ&#x20AC;&#x2122;t really aiming for the Alec Northover (Award) â&#x20AC;&#x201C; I just wanted to set the bar for me. â&#x20AC;&#x153;For it to be at a standard where the Alec Northover award came into it, I was just blown away.â&#x20AC;? â&#x20AC;˘

4HE BENEFITS OF 4UFFLEX s ,ONGER LIFE OVER WIRE SCREENS UP TO X s ,ESS SCREENING DOWNTIME REDUCED NUMBER OF SCREEN CHANGES s /(3 2EDUCED WEIGHT OVER WIRE SCREENS 2EDUCTION IN NOISE s %ASIEST SCREEN TO REPLACE IN END TENSION MOBILE SCREENS LIGHTER COMPACT AND EASIER TO PLACE INTO POSITION #ONTACT A ,OCKER REPRESENTATIVE FOR PRICING AND ADVICE TODAY

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IQA AWARDS

ALEC NORTHOVER AWARD The Alec Northover Training award (also referred to as the Alex Northover Award) acknowledges the best prepared portfolio of evidence given to a registered training organisation (RTO) by an applicant seeking recognition for the Certificate IV, Diploma or Advanced Diploma programs in extractive surface operations or extractive industries management. Sponsored by the Australian Institute of Quarrying Education Foundation (AIQEF), the successful recipient is provided with a prize of $2500. The AIQEF provides the three award finalists with a $2000 allowance catering for registration, accommodation and travel expenses to attend the IQA’s national conference (where the award is presented).

During the second quarter of the year, the IQA asks RTOs to select one candidate for each qualification. The selected candidate must be a successful graduate within the 12 months prior to 30 June. All nominations must be submitted by 31 August in the prior year. A panel of judges assess the successful applications against specific criteria, including: • Evidence that supports the competence of the applicant.

• A useful reference system. • Mentioning company policies and procedures (except where the applicant has developed, implemented or revised them). • Evidence that the applicant is committed to other learning and ongoing learning. • Testimonials from management, team members and third parties.

• Predominantly self-prepared evidence (some RTO assistance is allowed). • An individual’s own knowledge and skills applied alongside the RTO assessment guide.

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IQA AWARDS

PETER LASKEY:

ON THE ROAD CUSTOMER SOLUTIONS In today’s busy, competitive environment, conveying downtime is the bane of the quarrying process, especially in remote locations. The experience of 2019 Supplier of the Year recipient Peter Laskey is that the personal touch is still integral to delivering effective customer solutions.

eter Laskey is on his way to work. Usually, people would be complaining about their one-hour commute in Melbourne’s congested traffic – but not Laskey. With his car serving as a makeshift office, Laskey is travelling eight hours from Melbourne to Broken Hill in New South Wales. This is not out of the ordinary for Laskey, who has worked as a field applications specialist for Kinder Australia since 2016. Laskey, who was previously involved with construction work, has been at Kinder since 2011. The 59-year-old now has the responsibility of looking after customers in the quarrying and extractive industry to help fix and improve site equipment. Laskey helps his clients using the wide range of technology Kinder offers to the industry. His role at Kinder also extends to the mining industry and grain handlers. “We’re mainly looking at situations at the transfer sites with skirting issues, if they’ve got spillage there,” Laskey said. “We also help with belt tracking as well. “I started [at Kinder] in 2011 as a warehouse supervisor and that’s where I gained a lot of product knowledge.” Between 2018 and 2019, Laskey visited more than 100 customer sites – with most being from the from quarrying and extractive industries. His work is primarily focused in parts of Victoria and South Australia, but he has driven as far as Broken Hill, NSW. “Melbourne to Broken Hill was my longest trip,” Laskey said. “That was about 13 hours. Going as far as Broken Hill and offering solutions with their belt cleaning in a mine site there was a pretty huge moment for me. They were having a lot of issues and we seem to have solved those issues. That was really good.”

SUPPLIER OF THE YEAR Due to his dedication, professionalism and

IQA CEO Kylie Fahey presents Peter Laskey with the IQA Supplier of the Year Award.

strong work ethic, Laskey was nominated for the IQA’s 2019 Supplier of the Year Award. Laskey considers it one of the proudest moments in his nine years at Kinder. “To be involved and to be recognised was something out of the blue and something that I was really chuffed about,” he said. “I believe in the company that I work for and the industry that we’re in. Both of those are very progressive and it’s a good place to be at this time because I think the expansion

[at Kinder] and everything that’s going on – I really like that situation. “Honestly, it was a shock. I thought it was good of the company to put me up there.” With a new accolade on the wall, Laskey believes his passion pushes him to go further. “I guess I’m very driven because I want to help people and I want to help this company,” he said. “It’s a family-run business, so I like those initiatives. Quarry April 2020 43

IQA AWARDS

“What motivates me is being able to represent the company and myself in a good light.” Positive feedback from customers is a rewarding experience in Laskey’s line of work. This has been one of the driving forces behind his business. “We might suggest something, and they go for that idea – and the next month they’re saying, ‘Can we look at getting another one of these installed?’ or ‘That’s worked really well in that area’,” he said. “It’s offering the solutions and getting customers to come back to us and say ‘Yes, we want to add more of those in’.” Laskey’s support extends beyond supplying solutions to customers – he also helps run maintenance training programs at sites. “We also offer conveyor maintenance training in house and also out on site,” he said. “So that’s always worthwhile when you get the feedback there from the customers saying, ‘Yes, that was really worthwhile doing

and beneficial for us’, and that’s something I can take back to the field and implement.”

COMPELLING BUSINESS CASE In Laskey’s eyes, making a business case to customers is the most challenging part of the job. This means he must explain why his solutions are worthwhile. “I know our company is very innovative in keeping up with the latest solutions,” he said. “But making a business case for our products means we as an organisation are highly attuned to industry pain points, our customers are challenged by constant on-site dust emissions and material spillage issues.” A combined conveyor skirting and sealing, conveyor belt support and conveyor belt cover system is offered by Kinder Australia. “The Essential Seal combination transforms high risk dust and material spillage transfer points into productive, efficient, safe and clean workspaces,” he said. For Laskey, his mantra is simple – be yourself and be honest.

Laskey enjoys looking after customers in the quarrying and extractive industry to help fix and improve site equipment.

“I reckon its vital because I think a lot of what I do is just myself being myself and if people can see that you’re an open book it’s easy to relate to that person,” he said. “They know what they’re going to get each time you see them and a lot of what I do is getting to know people too.” “It’s also important that I do get to know the person so that it makes it easier and they feel relaxed and I feel relaxed as well. “It’s not just ‘Hi, how are you going?’ but just digging a little deeper and getting to know the person. And being a sports nut is pretty easy in Victoria and South Australia where we talk about the football. “Open and honest communication is paramount for people to trust you.” Since starting his career at Kinder in 2011, Laskey has grown to be one of the company’s brightest and successful employees. As he continues to drive around quarries both near and far, his goal is to continue learning as much as he can about the industry he helps to keep operating. •

SUPPLIER OF THE YEAR AWARD The IQA awards recognise the industry’s highest achievers who demonstrate leadership and excellence. The Supplier of the Year Award acknowledges an IQA member that works for a quarry supplier organisation. The winner will demonstrate all facets of the IQA’s code of conduct, values and professional standards. They will also need to exhibit the highest amount of professionalism as a supplier. According to the IQA, applicants for the award will be judged based on the following criteria: • Broad engagement with the IQA through branches, events and committees. • Demonstrating the highest

standards of professionalism, IQA code of conduct and values. • Excellence against reaching KPI targets in their work and outcomes. • A broad range of industry knowledge. • Participating in and contributing to the extractive industry. • Exhibiting commitment and leadership in their area of responsibility. • Letters of recommendation from suppliers, managers and colleagues. The winner of the IQA Supplier of the Year award receives a framed certificate and recognition through IQA marketing.

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2020 IQA EVENTS NSW CENTRAL WEST SUB-BRANCH • Dinner meeting

NSW HUNTER SUB-BRANCH • Breakfast meeting

NSW ILLAWARRA SUB-BRANCH • Dinner meeting

NSW NORTHERN REGION SUBBRANCH • Dinner meeting

QUEENSLAND BRANCH

• Annual Golf Day, Cairns • Dinner Meeting & Branch AGM, Townsville • Annual Golf Day, Townsville • Dinner Meeting, Cairns/Tablelands • Dinner Meeting, Mackay • Christmas Function, Townsville

SOUTH AUSTRALIAN BRANCH • Dinner meeting/Site tours/Partners Mystery Tour, Rowland Flat, SA • WIQ SA Conference, Adelaide Pavilion

TASMANIA • Dinner meeting

• Quarrying Safety & Health Conference, Brisbane • Dinner Meeting & Branch AGM, Brisbane • Annual Breakfast Meeting, Brisbane

VICTORIAN BRANCH

CENTRAL QUEENSLAND SUB-BRANCH

• Dinner meeting

• Quarrying Safety & Health Seminar, Rockhampton

WESTERN AUSTRALIAN BRANCH

NORTH QUEENSLAND BRANCH

• Student Presentation Night

VICTORIAN SUB-BRANCH

• WA Branch WIQ Beyond Diversity Conference

A NOTE ABOUT UPCOMING IQA EVENTS To support Australian and global strategies aimed at preventing the spread of COVID-19, the IQA Board has postponed all IQA face to face events scheduled up to and including 31 July, 2020. This includes education workshops, conferences and branch events (such as technical evenings, dinners, lunches, etc). While the IQA will postpone face to face events in the coming months, it will monitor the situation and work closely with industry to reschedule events and ensure access to education is maintained. Dates will be announced when it is safe to do so. The IQA was due to release face to face training on new exposure standards relating to respirable crystalline silica (RCS). This face to face training will be delayed. However, the IQA will release RCS general awareness material and will be available to support any questions on RCS. Members and suppliers will continue to have access to IQA staff via email and phone. See page 6 for further details.

• Quarrying Safety & Health Seminar, Townsville

WPDP WORKSHOPS & EVENTS To register for the courses below and for further information, visit: quarry.com.au/Education/ProfessionalDevelopmentProgramsCalendar.aspx

WPDP WEBINARS The IQA is working closely with industry and government representatives to manage the unprecedented response to the COVID‑19 outbreak. The IQA’s focus remains the safety of our members, staff, presenters and sponsors. For more information on the IQA’s position on events, education and training, visit quarry.com.au.The IQA is proud to be the industry leader in accredited training and we will continue to deliver webinars and virtual training sessions to meet your needs. To discuss your online training, email education@quarry.com.au

INTRO TO SAFETY MANAGEMENT SYSTEMS WPDP 23 April, 2020 This webinar provides an introduction to Safety and Health Management Systems (SHMS) for small mines and quarries. Attendees will gain an understanding of what a SHMS should look like for a small quarry, 46

Quarry April 2020

share ideas with other quarry operators, receive help with SHMS elements, and receive information on how to improve their site SHMS.

EMERGENCY MANAGEMENT WPDP 14 May, 2020 All Australian and New Zealand quarrying legislation either implies or specifies that quarrying operations must have a plan to respond to emergency situations. Those plans must be appropriately comprehensive, resourced, tested and updated. This webinar is designed to introduce principles and methodologies of quarry emergency planning and response, including: definitions, interpretations and legislative requirements; developing emergency management and response plans; resourcing emergency management and response; testing emergency management and response plans; and emergency management and response plan review and update.

IQA BRANCH CONTACTS ACT

Peter Hewson: 0429 001 476

NSW

Gemma Thursfield: 0402 431 090

Northern Gemma Thursfield: 0402 431 090 Hunter Gemma Thursfield: 0402 431 090 Illawarra Dylan Treadwell: 0418 632 057 Central West Mitchell Bland: 0428 462 987 NT

Darren McKenna: 08 8988 4520

QLD

Jennifer Milward: 0419 782 688

Gladstone Jennifer Milward: 0419 782 688 Townsville Jennifer Milward: 0419 782 688 Cairns SA

Chris Wilson: 0438 134 752 Marie Cunningham: 08 8243 2505

Tasmania Nicholas Palmer: 0418 126 253 Victoria

Eli Carbone: 03 8637 4723

VIC Sub-branch Craig Staggard: 0407 509 424 WA

Celia Pavri: 0417 027 928

FROM THE CEO

ENSURING ACCESS TO ONLINE EDUCATION AND TRAINING NEEDS Amid the COVID-19 pandemic, the IQA takes the well-being of members, staff, presenters, suppliers and hosts seriously and is conscious of the instructions being given by government and health officials. While there has been a disruption to a number of IQA events, our top priority is everyone’s health and well-being and supporting strategies to that will help stop the spread of the disease. We will work closely with industry to reschedule events and ensure access to education is maintained. The IQA is constantly increasing its online offerings. If you have urgent training needs, please contact us and we can discuss online options during the COVID-19 pandemic. The IQA has been proactive in the past few months identifying and responding to specific training needs across all states. To date a number of targeted training events have been held responding to local needs including: • Alcohol and drug awareness training.

• Learning from disasters. • Accredited training from Certificate III to Diploma. • Introduction to Safety Management Systems. • Effective risk management. • Incident investigation. • Slope stability and more. Last month I had the pleasure of visiting Tasmania and meeting with the Acting Chief Inspector of Mines for Worksafe Tasmania. This was an extremely productive meeting and the IQA will be working with Worksafe Tasmania to develop and deliver specific training on risk for the state. This type of engagement will continue to ensure training is targeted. We have also started working with a number of businesses to undertake training needs analysis and will be expanding our capability in this area. The focus is to offer training that is relevant and

supports business outcomes. A key part of ensuring relevance is the alignment with state regulation, business objectives and individual learner needs. Please take all precautions to keep yourself and others safe. KYLIE FAHEY CEO Institute of Quarrying Australia

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IQA NEWS

Australia’s leading designer and manufacturer of rubber torsion spring motor bases.

NEW SOUTH WALES ILLAWARRA SUB-BRANCH NEWS The IQA held its first Learning from Disasters course on Thursday, 5 March, which was hosted at Holcim Albion Park.

Motorbase - Crushers

The IQA has been approved by the NSW Resources Regulator to deliver this course, which is required under the Maintenance of Competence scheme for those holding a NSW Practicing Certificate – Quarry Manager (without conditions). The learning outcomes of the course include recognising patterns of failure, identifying and managing principal hazards, and recognising the organisational and human factors which contribute to work health and safety incidents. Sixteen participants from a range of sites attended the full day face to face program which was delivered by Tony Ferrazza, a former senior mining engineer with WorkSafe Victoria. In that role, Tony had oversight of quarries and open cut mines in Victoria and contributed his extensive experience to facilitate the course.

Motorbase - Screens, Feeders

Throughout the day, participants reviewed a number of case studies related to mining incidents that involved fatalities and the outcomes of subsequent investigations. The important lessons which may be learned from these devastating events can assist in improving the health and safety of the quarrying industry. The IQA will be scheduling further delivery of this program in the coming months. If you are interested in completing the course, email Facilitator Tony Ferrazza with some of education@quarry.com.au By Emily Logan

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the 16 course participants at the full day face-to-face program.

IQA NEW MEMBERS GRADE NAME BRANCH ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE ASSOCIATE MEMBER MEMBER MEMBER OPERATOR STUDENT TECHNICAL MEMBER

Troy Crisp Kim Soei Matthew Frost Kelera Livia Grant Soper Mark Standing Craig Baillie Sheree Kidziak David Dixon John Delbridge Angie Garzon Jakeb Barry Robert Ryan Peter Harper Scott Wiseman Michael Todd Brendan Coad Luke McNeilage Nicholas Dunstan Shane Hillhouse

NSW NSW NSW NSW NSW NSW QLD QLD QLD QLD SA SA VIC VIC NSW NSW TAS NSW VIC QLD

SMART BUSINESS

A MODIFIED VERSION OF THE TRUST EQUATION

Mike Cameron has previously discussed the Trust Equation, and how it plays a significant role in building an organisational culture of belief and confidence. He applies his own variation of the equation to Australian working conditions.

n my article on trust1, I highlighted the Trust Equation, a scientifically-based, deconstructive model offering an analytical, actionable framework for evaluating trustworthiness which was first described in The Trusted Advisor, co-written by Charles H Green and David Maister (2000). They also introduced the term “Trust Quotient”2 (TQ). As a coach and trainer, I’ve used the Green/ Maister model, together with a simple story to gain my clients’ understanding of how important and useful this model can be when used appropriately and in a timely fashion. However, after feedback, I’ve modified the model to reflect the most common Australian meaning of words associated with trustworthiness, trust and Green/ Maister’s own selection of words for their Trust Equation (without, I believe, losing the intention, research and science of their original work). The modified Trust Equation uses four objective variables which I’ve described as: • Believability. • Dependability. • Relatability. • Self-interest. These are combined to create the following equation – the TQ (see Figure 1) – which evaluates an individual’s trustworthiness with four variables: 1. Believability (Credibility*), ie your having confidence in the truth, the existence, or the reliability of something (although without absolute proof that you are right in so doing). 2. Dependability (Reliability*), ie on the other person’s actions and their displaying honesty, economy, faithfulness and a capacity for finishing what has been started. 3. Relatability (Intimacy*), ie your feeling connected to the other person, appreciating their ease of communication, identifying with their ability to understand and be understood, and recognising/appreciating when they display empathy towards you and others. 4. Self-interest (Self-orientation*), ie the other person’s focus. Are they focused

TQ = B + D + R S-I Figure 1. The Trust Quotient evaluates an individual’s trustworthiness with four variables.

on themselves, or on you when making decisions and advising on what is best for you? * Note: The asterisked words are the formal terms used by Green and Maister. What is important to remember is that the meaning of the words I’ve selected are almost entirely personal, not organisational. People rarely give over their trust to a company or business but they tend to assess the situation when, right or wrong, they decide to either trust or not trust other people. While people within a company make it what it is, a company (or its marketing image) may be described as “Believable” and “Dependable” (the first two components of my revised model). However, “Relatability” and “Self-Interest” are solely people-based. Many of us make a quick judgement, based on our “gut feeling”, whereas the assessment of trustworthiness requires an objective, nonemotive rating for each of the four variables, since you are seeking high believability, dependability and relatability, and low selfinterest scores to establish a credible TQ.

THE RATING PROCESS Self-interest, which sits alone, is the most important variable in the Trust Equation because by increasing the number that you apply (one to five, with five being for a person most focused on themselves) it will decrease the value of trust. In other words, the more you trust that person, the lower the rating you will give self-interest (with one being for a person most focused on you). However, increasing the rating to any of the three variables in the top line of the equation (one to five, with five representing

your highest level of confidence) increases the value of trust. In other words, the more comfortable you feel about these variables the higher the score you will give to each of them. For example, in a recent TV advert about a couple looking for a home mortgage, the financial advisor initially would have been rated 5 (excellent) + 4 (good) + 3 (fair) = 12 (out of a maximum of 15) on the top line, divided by 2, from the bottom line (showing low self-interest and a keen focus on the couple), giving an overall TQ of six. This means the customers felt reasonably comfortable with this individual, given that it was a commercial transaction. However, when suddenly he is shown counting a fist full of dollars (his commission), how would they rate his self-interest now? Let’s assume the couple assessed the financial advisor as a five (showing little or no concern/interest for his clients’ well-being), a revised TQ of 2.4 would be the result (12 divided by 5 = 2.4).** **Note: With the highest TQ rating being 15, any score at five or less means questionable to low trustworthiness. The TV couple certainly didn’t want to take up his offer to provide them with additional services having lost their previous feeling of trust for this man! In conclusion, this model is an important tool that, when used correctly, will assist you to evaluate the “trustworthiness” of individuals rather than relying on your “gut instinct” or less reliable methodologies. • Mike Cameron is an IQA member and the principal of Strategically Yours. Visit strategically.com.au

ENDNOTES 1 Cameron M. Building and sustaining the environment of trust in business. In: Quarry 28(3); March 2020: 39-41. 2 Green CH, Founder, Trusted Advisor, Associates LLC. The trust quotient and the science behind it. https://trustedadvisor.com/why-trust-matters/ understanding-trust/the-trust-quotient-and-thescience-behind-it

Quarry April 2020 49

GEOLOGY TALK

VICTORIA’S MOUNTAINS GROWING TALLER

View of the Bogong plains, taken from Mt Feathertop, in the Victorian Alps. According to a recent Victorian Government survey, the Alps are rising by 0.1mm per year.

Everlastings on Mt Hotham looking towards Mt Feathertop.

A survey has discovered Victoria’s mountain ranges are increasing in height each year due to a tectonic plate boundary collision in New Zealand. Nickolas Zakharia reports.

understanding of southeast Australia’s underlying geological “architecture” from the surface to 60km deep within the Earth’s crust and includes the acquisition of fundamental geoscience datasets and applied geoscientific research. The findings will assist government to make better informed land management decisions to benefit the community, identify natural geological hazards, protect state infrastructure and manage earth resources. The scientific results of the Initiative will be married up with results from a similar project in southeast New South Wales, providing a key geological reference for southeast Australia in terms of its geology and evolution over the past 500 million years. •

he Victorian Alps are rising each year according to a 18-month survey conducted by the Eastern Victoria Geoscience Initiative. The 629km stretch of mountains from Benalla, Victoria to Eden, New South Wales is being pushed up by 0.1mm a year, the survey revealed. This is believed to be a side effect of New Zealand’s ongoing tectonic plate boundary collision, which moves its mountain regions up by 12mm every year. The 18-month survey went from the surface to 60km deep into the Earth’s crust. While Victoria’s growth spurt may seem small, it has provided geoscientists with a number of practical insights. Ross Cayley, of the Geological Survey of Victoria (GSV), told connection.vic.gov.au it will now be easier for earthquake threats to be detected in Victoria due to the survey’s findings. It is also expected to help with infrastructure planning and management plans. “The research can work out which regions

Quarry April 2020

of Eastern Victoria lie above and below major tilted faults, and so better estimate potential earthquake risk from these structures should they reactivate,” Cayley said. Earthquakes reaching near magnitude 6.0 on the Richter scale have hit Victoria in the past, with regions in the state’s east lying above and below major tilted faults. Mineral exploration will also receive a potential boost, with the survey expected to help locate geological deposits connected between NSW and Victoria. Despite the data being unable to pinpoint the specific location of a mineral deposit, it will be able to help geologists locate the correct district for mineral exploration. Farming productivity and environmental management is also expected to be improved with the survey’s geological information. The Eastern Victoria Geoscience Initiative began mapping the Victorian component of the Southeast Lachlan Crustal Transect in 2018. The project aims to improve

A ground level view of the Bogong Plains.

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Quarry Apr 2020

Articles inside

PETER LASKEY

QUARRIES USE WATER TOO

THE TRUST EQUATION

A HOLISTIC APPROACH TO