These two businesses’ shared values have helped both flourish.
22 Jaws for life
McLanahan’s Donal McNicholl shares his tips for optimising a jaw crusher’s size
26 Crushing for a Cardinal
A business has turned to 888 Crushing and Screening to support its quarry.
28 Unlock cone liner potential
Curt Theisen explains how operators can maximise the lifetime of their cone liners.
30 Quadruple-threat evolution
Metso is set to unveil the latest entry into its cone crusher range.
32 New vibrations
Liebherr is set for a major showcase at bauma 2025.
56 Meet your ambassadors
Quarry talks to Greg Dressler about the benefits of being an IQA member.
THE BEATING HEART
It’s hard to overstate the value of a good crusher. Central to most quarry operations, they have the difficult job of taking raw materials and turning them into a sellable product.
The process is often brutal on the equipment, especially in Australia’s often harsh environments.
There’s much more to the process than just turning big rocks into slightly smaller rocks.
A lot of complex design and engineering has gone into ensuring the end product meets highly specific requirements. There are also vital safety, dust minimisation, and productivity concerns that need to be addressed.
Maintenance also plays a vital role in keeping the heart of a quarry beating.
Without the right care, crushers can suffer unplanned downtime, and work will grind to a halt. For all these reasons and more, this edition of Quarry highlights crushing equipment.
Inside you will find articles that highlight the latest machinery and technology that quarries are using for crushing and screening.
We speak to original equipment manufacturers, quarries, and technology providers to find out the latest happenings in the sector.
This edition also highlights some of the new technologies that are helping quarries turn crushing waste into a valuable resource.
Innovative companies like Kayasand are implementing crushing technology that is helping to transform crusher dust into a sand replacement, improving sustainability and benefiting bottom lines.
Quarry also covers the latest business moves in the sector, featuring a breakdown on how a deal between Astec and Mineral Processing Solutions will support quarry customers.
Read on to learn more about what is an especially important aspect of the modern quarrying industry.
William Arnott Editor
MAINTENANCE ALSO PLAYS A VITAL ROLE IN KEEPING THE HEART OF A QUARRY BEATING. WITHOUT THE RIGHT CARE, CRUSHERS CAN SUFFER UNPLANNED DOWNTIME, AND WORK WILL GRIND TO A HALT.
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www.primecreativemedia.com.au
Chief Executive Officer
John Murphy john.murphy@primecreative.com.au
Group Managing Editor
Paul Hayes paul.hayes@primecreative.com.au
Editor
William Arnott william.arnott@primecreative.com.au
PERFORMANCE, PRECISION AND SUSTAINABILITY. The MOBIREX MR 130 PRO mobile impact crusher excels with outstanding performance in a diverse range of applications. With its double-deck post screening unit, the plant ensures top product quality with up to two graded end-products, while achieving impressive throughput rates of up to 600 t/h in natural stone and recycling. The all-electric E-DRIVE is not only efficient, it can also be operated with zero local emissions. Operation is intuitive thanks to SPECTIVE components. The MOBIREX MR 130 PRO – the sustainable powerhouse.
www.kleemann.info
DRIVING INNOVATION AND CONNECTION ACROSS THE SECTOR
The first quarter of 2025 has demonstrated remarkable momentum across our IQA community, with strong engagement in both educational offerings and branch events nationwide.
All branches across the country are actively developing their 2025 event calendars, promising a year filled with valuable networking, professional development, and technical learning opportunities. The Queensland and North Queensland teams have already hosted successful site tours and networking events, while the Victorian Branch has secured an impressive calendar for 2025, including their April Autumn technical event featuring insights on geospatial technology in quarries.
Our Strategic Growth Webinar Series in partnership with William Buck has been particularly well-received by members, providing practical business development resources specifically tailored for quarry businesses. I encourage you to register for the final session on 29 April focused on succession planning – an important topic for many in our sector.
EDUCATION AND PROFESSIONAL DEVELOPMENT
We continue to expand our professional development offerings with a comprehensive range of courses including introduction to quarrying, critical control management, mental health and wellbeing, contractor safety management, and specialised technical training programs. These educational opportunities provide valuable CPD points while enhancing the skills and knowledge essential for career advancement in our sector.
MEMBERSHIP GROWTH
I’m pleased to report we’ve had 141 new professionals joining our community since the beginning of the financial year. This strong interest,
particularly from Queensland and Victoria, demonstrates the continued value of IQA membership to quarrying professionals.
As our membership base continues to grow, we’re enhancing our member benefits through our comprehensive 12-month member journey plan. This initiative focuses on improving your experience at every touchpoint with the IQA, from professional development opportunities to networking events and digital resources.
LOOKING FORWARD
www.quarry.com.au
The IQA’s Strategic Plan 2023 to 2026 embodies the following vision, values and strategic priorities:
Vision:
Thriving communities supported by a sustainable industry
Operational Priorities:
As we move into the second quarter, preparations are intensifying for our state-wide Quarrying and Mining Safety & Health Conferences in Queensland, North Queensland and NSW Hunter Valley in June and July. These flagship events will bring together sector leaders, regulators, and practitioners to share knowledge and drive safety innovation across our sector.
Work is also progressing on our national public awareness campaign. This comprehensive initiative will highlight the essential role quarrying plays in building Australia’s infrastructure while showcasing our commitment to sustainability, safety, and community engagement. By raising the profile of our sector, we aim to attract new talent, strengthen community relationships, and ensure continued support for responsible quarrying operations nationwide.
I encourage all members to engage with our expanding range of initiatives and opportunities and to consider active involvement in our branch activities and committees. Your participation strengthens not only your own professional journey but our entire quarrying community.
Michael Close, FIQ President Institute of Quarrying Australia
SECTOR, WE AIM TO ATTRACT NEW TALENT, STRENGTHEN COMMUNITY RELATIONSHIPS, AND ENSURE CONTINUED SUPPORT FOR RESPONSIBLE QUARRYING OPERATIONS NATIONWIDE.
• Deepen industry participation
• Sustainable revenue streams
• Highly capable team
• Technological innovation
• Effective engagement
• Great governance
Strategic Priorities:
• Support industry participants with compliance and regulation
• Build a diverse and skilled industry workforce
• Foster strong industry connectivity
IQA Contacts:
For all education, member and branch enquiries:
Phone: 02 9484 0577
Email: iqa@quarry.com.au
Chief Executive Officer
Jane Schmitt
President Michael Close
Company Secretary
David Cowie Follow the IQA on our social media pages:
quarrying/ iqaus
The Institute of Quarrying Australia
Educating and connecting our extractive industry
GEOLOGY
IS GEOLOGICAL UNCERTAINTY INCREASING YOUR RISK?
Eltirus Exploration, Geological Modelling, and Resource Assessment services.
We work with quarry operators to explore, model, and assess your resource, increasing certainty of operation and reducing risk. Our experienced geological team help identify gaps in understanding, create exploration programs, and manage the program for you. Whether it be field mapping or blast hole, RC, aircore or diamond drilling, we not only help you explore and assess your deposit, but also ensure outputs are accessible through the use of world-class geological modelling software that provides you with interactive models that truly make a difference on the ground and in the field.
IQA NEWS
OUT AND ABOUT WITH THE IQA BRANCHES
IQA VISITS HY-TEC QUEENSLAND OPERATIONS
The IQA team recently conducted a valuable site visit to Hy-Tec Concrete and Aggregates’ Queensland operations, alongside IQA President, Michael Close.
The visit provided an excellent opportunity for IQA staff members Jane Schmitt, Donna Turner and Rebecca Farnes to gain firsthand insights into Hy-Tec’s Queensland facilities and strengthen connections with members in the field.
These on-site engagements play an important role in helping the IQA team better understand sector operations and maintain strong relationships with the IQA quarrying community.
VICTORIAN SUB-BRANCH KICKS OFF 2025 WITH
SOLD-OUT NETWORKING EVENT
The Victorian sub-branch started the year strong with a sold-out networking dinner in Geelong on 20 February, drawing 80 quarry professionals to the Grovedale Hotel.
The evening’s highlight was an engaging presentation by Heidelberg Construction Materials regional general manager southern region Sarah Bellman.
Bellman shared valuable insights from her impressive 15-year journey in the mining and quarrying industry, drawing from her diverse experience as a former deputy president of the IQA and chair of the Cement Concrete and Aggregates Association in South Australia.
The event also featured informative presentations from sector partners, with Cliff Hutchings discussing Hitachi Construction
Machinery’s Building the Future 2025 initiative, and Franco Harkins representing Coffey Testing.
The networking dinner received enthusiastic feedback from attendees, with Steve Hopper from Komatsu praising Bellman’s presentation as “amazing”, while John O’Reilly from Metso echoed the sentiment about the event’s success. This well-attended gathering demonstrates the Victorian sub-branch’s commitment to promoting connections and professional development, setting a positive tone for the year ahead.
QUEENSLAND BRANCH SITE TOUR DELIVERS PRACTICAL KNOWLEDGE AND NETWORKING OPPORTUNITIES
The Queensland branch and Central Queensland sub-branch started 2025 with a successful site tour at Currumbin Minerals on Thursday, 27 February, drawing more than 65 quarrying professionals.
Attendees gained practical insights touring the gravity separation facility and the wet table, electrostatic and magnetic separation facility. The tour showcased realworld applications that participants could immediately apply to their own operations.
“Being able to see these processes firsthand and discuss challenges with peers is invaluable,” one attendee said. “You simply can’t get this level of practical knowledge from a webinar or textbook.”
Brett Hoyle guided the group through each facility, sharing industry expertise and answering questions from participants.
“We’re extremely pleased with the strong attendance at our first event of the year,” Queensland branch chair Blake Ardrey said.
“The combination of technical learning and networking opportunities is exactly what our members value, and we look forward to delivering more quality events throughout 2025.”
The day wrapped up with a barbecue lunch that created the perfect setting for sector connections. Conversations ranged from equipment specifications to operational challenges, with many exchanging contact information for future collaboration.
The Queensland branch is planning several similar events throughout 2025. Members consistently report these tours are among their most valuable IQA benefits, providing both technical knowledge and careerenhancing connections.
Register early, as these popular site tours typically fill quickly.
NORTH QUEENSLAND BRANCH HOSTS SOLD-OUT WOMEN IN QUARRYING EVENT
The North Queensland branch kicked off its Women in Quarrying (WIQ) initiatives for 2025 with a creative networking evening on Friday 28 February in Townsville.
The sold-out event brought together women from across the sector for an evening that combined networking with artistic expression. Attendees enjoyed drinks and grazing platters while creating unique pieces of art at Tipsy Doodle in Townsville.
The sold-out event attracted 80 quarry professionals to the Grovedale Hotel.
IQA NEWS
North Queensland branch
WIQ coordinator Deanne Lewty facilitated the successful evening, which provided an excellent opportunity for women in the quarrying sector to connect in a relaxed and creative environment.
Event sponsor Finlay Screening and Crushing provided valuable support for this initiative, demonstrating their
commitment to promoting diversity within the industry.
The strong attendance signals growing interest in WIQ events across the region. The North Queensland branch is planning additional events throughout 2025 across both the North Queensland and Far North Queensland regions, with details to be announced in the coming months.
UPCOMING COURSES AND EVENTS
PRODUCT FOCUS
KLE
Kleemann has unveiled the first screening plant in its PRO line, the MOBISCREEN MSS 1102 PRO. Mainly used in natural stone, the plant can work as a standalone machine or interlinked with other crushing and screening plants.
The MOBISCREEN MSS 1102 PRO has a feed size of 880x550x330mm and a feed capacity of up to 750 tons per hour. The large range of screen surfaces and the simple setting of screening parameters make it possible to adapt the MSS 1102 PRO easily to new application conditions or feed material.
If a fine end-product needs to be screened from very coarse feed material, the plant can be quickly converted from three to two final product sizes.
Further advantages of the plant include its simple operability thanks to its intuitive control system, easy access to all relevant machine components and its drive concept H-DRIVE with the option of an external power supply for operation with zero local emissions and therefore environmentally friendly work.
This machine will be presented to visitors at the Wirtgen Group exhibition stand at bauma 2025.
For more information, visit wirtgen-group.com
KINDER SUPPORT AT THE TRANSFER POINT
When it comes to providing conveyor belt support, Kinder Australia have a solution to suit any transfer point regardless of any configuration or application.
These factors can include:
• product
• belt width
• duty
• belt speed
• budget.
Rollers alone with spacious gaps, do not give ample support to the critical transfer point. If support is not provided adequately, belt sag can occur – along with detrimental productivity issues such as material spillage and excessive dust. The product loss, equipment damage and downtime issues caused by poor conveyor belt support is inconvenient, unsafe and expensive.
Kinder Australia’s K-Sure belt support system is engineered to provide the heavyduty support that your transfer point requires.
It utilises the existing conveyor idler frames and load, carrying the centre conveyor roller. The wing rollers are then replaced by the K-Sure belt support system’s universal adaptor brackets and low friction polymer belt support rails. It is available in a standard two metre length assembly kit. Other lengths can be modified upon request.
Effectively, it is designed to provide a consistent and stable support for the troughed belt profile by reducing the number of rotating components. K-Sure belt support system eliminates any belt edge sag and therefore increases the effectiveness of the skirting seal.
To ensure a precise fit, a specialised universal adaptor stud has been engineered by Kinder Australia. This allows for adjustment to suit three different size roller diameters, offset/inline frames, and manufacturing tolerances in trough frames. Since its introduction, this innovative technology has transformed the industry benchmark, in delivering greater flexibility in conveyor transfer point configuration.
For more information, visit kinder.com.au
Image: Kleemann
Image: Kinder
PRODUCT FOCUS
UNLOCK LOKOTRACK’S VERSATILITY
Tutt Bryant Equipment’s Lokotrack range can provide quarries with options ranging from compact mobile crushers to combined crushers and screens. The Lokotrack LT220D mobile crusher is designed to be a powerful crusher and screen, with a cone crusher and three-deck screen on the same chassis. It is ideal for the secondary or tertiary crushing stage, in combination with a Lokotrack jaw crusher capable of producing up to three calibrated end products. The Lokotrack LT220D is suitable for road construction and railroad ballast. It can be combined with the LT106 and LT116 jaw crushers, the LR200HP, LT200HPX, and LT220GP cone crushers, and the LT7150 VSI crusher and ST2.8 mobile screen. Key features are: The three-deck screen is a widescreen designed for high capacity with efficient separation with a high stroke rate.
• Choice of a high-capacity HP200 or GP220 cone crusher suited to hard rock crushing. Different cavities are available.
• IC process control is available for connectivity. The feeder and tracking are controlled by a radio remote.
• Fuel- efficient CAT C9.3B power transmission. The direct drive for the crusher is a purposely designed gearbox, and the hydraulic clutch achieves high reliability.
• The conveyors can be hydraulically lowered for transportability, including the H10-7 screen feed conveyor, H10-6 lifting conveyor and the threedeck screen.
The Lokotrack LT106 mobile jaw crusher is better suited as a primary crusher for aggregate production and demolition recycling applications.
Designed for easy transport between sites, the LT106 allows for quick set-up, helping to reduce overall operating costs. It is suited for recycling demolition, such as crushing concrete and medium-sized aggregates, as well as road construction and railroad ballast.The Lokotrack LT106 mobile jaw crusherIt can be used in combination with LT200HP, LT200HPX, and LT220D cone crushers. It can also be used in combination with ST2.3, 2T3.8, and ST4.8 mobile screens.
For more information, visit tuttbryant.com.au
NEW RAMMER E COMPACT RANGE ANNOUNCED
Rammer has unveiled the new E Compact range of hydraulic rockbreakers which provide a considerable power-to-weight ratio while maintaining performance.
Due to their efficiency and durability, compact and powerful rock breakers can be reliably used across a wide range of applications.
“With their lightweight design and advanced features, the Rammer E Compact Range provides operators with greater flexibility while reducing carrier stress and maintenance requirements,” Walkers Hammers Victorian service technician Carlo Costanzo said. “These rockbreakers are engineered to enhance productivity while ensuring the durability Rammer is known for.”
Key features of the Rammer E Compact range:
• Lightweight design
• Minimised equipment stress
• Plug-and-play operation
• Quick and s afe tool change
• Versatile performance
Smart construction
Three-year factory warranty
The Rammer E-Compact range is designed for operators looking for a powerful yet compact solution that ensures efficiency, safety and durability in demanding work environments.
For more information, visit attachmentspecialists.com.au/rammer or rammer.com
Image:
Tutt Bryant
Image:
Rammer
Explore the IQA Education Hub
IQA Learning Management System offers a central repository for courses, Continued Professional Development (CPD) points tracking, instant access to online programs, immediate certificates upon course completion, and more! VISIT QUARRY.COM.AU / EDUCATION HUB
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TURN WASTE INTO SALES
Crusher Screen Sale and Hire is helping quarries turn waste into valuable sellable materials.
As demand for construction materials has risen in recent years, so too has the demand for recycled materials. Recycled materials can enable producers to reduce landfill costs, produce more materials and lower capital costs.
IMS and Crusher Screen Sales Hire have collaborated to deliver the IMS-BP120048TB blender, which provides producers with a versatile option for reusing their waste materials and turning them into sellable materials.
Crusher Screen Sales and Hire co-owner John Andersen said the IMS BP120048TB can transform waste into another revenue source.
“IMS and Crusher Screen Sales have been working together for some years designing plants for the Australian conditions and the changing requirements of blending quarry and construction products to meet the tighter specifications in the quarry industry with increased accuracy and reporting systems to support the sale of their products there for reducing prevention claims downstream,” Andersen said.
“It is not unusual when a construction site project has problems for all parties involved to try to distance themself from potential claims, so the more accurate the product is to specification with supporting documentation, the better. Construction companies will generally gravitate to product supplies with
proven records reducing potential problems for them, and the blender does offer a lot more confidence than watching a quarry bucket mix.”
four feed hoppers, each five meters long and capable of holding 12m³. The centre wall can be removed to create two 24-meter-long hoppers. Each feed hopper has separate conveyor belts, all fitted with belt scales, variable speed controls, and adjustable flow gates at the front. The BP1200-48TB can also feed directly into the IMS modular electric pugmill, allowing for the addition of powders and liquids.
The blender operates using a Cat C7 generator, which can be connected to mains power and allows for production of up to
blender includes a PLC control and recording system that can connect to an iPad in a loader and link directly to an office through its own Wi-Fi system. The PLC control and recording system manages the entire plant; if one product does not meet the programmed percentage, the entire plant will stop.
Crusher Screen Sales and Hire is the official distributor of IMS equipment in Australia. The two companies have been long-time partners, with CSSH being a key part of IMS’s global network of dealers.
“IMS produces a range of mobile track and modular pugmills and blenders, both
diesel-hydraulic and dual power and electric options,” Andersen said.
The IMS PM1200-20TB features two five-metre-long feed hoppers, each with a capacity of 10m3 and designed to accommodate vibrating hydraulic tipping grids. Each feed hopper is equipped with belt scales and variable speed controls. The pugmill blender can hold one or two cement hoppers, simultaneously blending two powders. This setup facilitates processing materials such as reinforced cement concrete with significant amounts of cement, where one cement hopper can dispense while the other refills. Alternatively, it provides the option to automate the dispensing of one or two liquids.
IMS also produces the IMS-BP1200-9TB track twin hopper blender with a flow-through mixer, twin hopper electric blenders on jacking legs that can be transported on a
2.5-metre-wide drop deck and operate with an electric modular pugmill that offers two or four feed hoppers fitted with belt scales and fully PLC automated.
Andersen said the IMS-PM1200-20TB was a versatile option for Australian producers of construction materials providers.
“The new IMS-PM1200-20TB Track Pugmill Blender is a game-changer in the industry,” he said.
“The mobility of the blender is ideal when operating at multiple sites, reducing the capital costs associated with having fixed plants at each location when they are not always in use.
“The future of blending waste products with virgin quarry material decreases reliance on landfills and quarry products, which benefits both the environment and the economy.”•
For more information, visit crusherscreen.com
The BP1200-48TB can help operators turn waste into sales.
The BP1200-48TB can blend four recycled products.
The BP1200-48TB Blender feeding an IMS electric Modular Pugmill.
The IMS-PM1200-20TB Twin Feed Hopper Pugmill Blender with three silos and two powder hoppers.
MAWSON MOTORS ON
E. B Mawson and Sons Pty Ltd managing director John Mawson reflects on his career and being named a Fellow of the Institute of Quarrying Australia.
In many ways, John Mawson was likely destined to become the managing director of the family business.
He remembers visiting his family’s quarries during school holidays and watching as the many skilled operators worked their machines, which included cable shovels, jackhammers and old trucks with “crash box” transmissions. Back then, high-visibility clothing was something only people at airports wore. Most loaders had no cabins, and air conditioning was unheard of. No scales or reversing cameras, no seat belts or rollover protective structures; some machines had rearview mirrors.
“My involvement with quarries goes back as far as I can remember, and you just grew into it from there,” John told Quarry “I can remember going to the quarries and watching the dropball work. I recall when we used to fire pops to reduce oversize so they would fit into the 36x24-inch jaw crushers, which we thought were really big.
“Once the jackhammer crew drilled the oversize, the oversize boulders would be loaded with half a stick of gelly and a safety fuse inserted; then all the safety fuse was tied together so each ‘Pop’ would fire one at a time. Everyone would come out of the pit and stand what we thought was a safe
distance away from the blasting and count each explosion to ensure there were no live explosives left. It was always a bit of relief when the last pop went off.”
Mawsons has been part of the quarrying industry since 1952. Today, the company employs more than 580 people and operates a network of hard rock and sand quarries and premixed concrete plants across regional Victoria and Southern NSW. The company’s name is well respected within the industry.
John’s pathway to running the family business, which was started by his grandfather, E.B (Barney) Mawson in 1912, was not direct. He completed a Commerce
John Mawson and the Pyramid Hill Quarry team celebrating the 50th anniversary of Mawsons Quarrying in 1992.
Image: Mawsons
Degree at Melbourne University and then spent a few years working in corporate banking in Collins Street in the Melbourne CBD. Following his stint in the corporate sector, John returned to the family business and quarrying. He started work in 1989 at the Lake Cooper Quarry, near Rochester in Northern Victoria, as an operator.
“I don’t think many people had a CV that included a Heavy Articulated Truck Licence, a Shot Firer’s ticket and a Commerce Degree,” he said.
“Returning home to quarrying was quite a change, but it was something that has always been close to my heart, and I was keen to do it. I was lucky enough to work with a great team at Lake Cooper; everyone was more than happy to share their knowledge and experience.
“I had a whole different set of skills from what those guys did. I drove road tippers during university holidays, but the quarries are different. Most of our team had been at Lake Cooper for 10 or 20 years. It was nice
was very lucky and had great fun.”
Swapping a suit and tie for the quarry’s hard hats was always going to be a big change. Still, in some ways, his previous work on Collins Street supported his ambition to progress in quarrying.
John pursued a Quarry Manager’s Ticket, previously known as a Superintendent’s
TRUSTED RELIABILITY. CONTINUED SUPPORT.
a week at Box Hill TAFE. His background in corporate finance earned him two subject exemptions.
“When I started quarrying, I was just an operator. It wasn’t until a couple of years later that I got my Quarry Manager’s Certificate and moved to manage our Pyramid Hill Quarry that the financial experience kicked in,” he said.
• Heavy duty, apron or incline belt feeder with hydraulic folding hopper sides
• Jack up screen facility to aid mesh changes
• Hydraulic folding conveyors with excellent stockpiling capacity
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“I majored in economics and commercial law. In my role today, the practical knowhow gained at the quarries remains critical, but the commercial law, economics and accounting knowledge probably apply more.”
In reflecting on his 36 years in the industry, John said, “There’s a lot more focus on compliance now. We were always safety conscious and aware of looking after each other and managing risks, but now it is done in a much more formalised manner.”
John has witnessed a time of significant change within the quarrying industry. The advent and increased adoption of technology has re-shaped the sector dramatically to the point where very little would be familiar to his grandfather.
“Almost every aspect of drilling, blasting, loading, hauling, crushing, and screening has changed in my 30-odd years in the industry. But we do still work with people,” he said.
“Today the mobile plant is more sophisticated, the fixed plant is more sophisticated, and all the equipment is more efficient. We monitor things more closely to optimise performance, and there are many more tools available through electronics and drone and satellite technology to make the work safer, reduce environmental impacts and optimise outputs.”
“The technology we employ now is so different from what it was 30 years ago. The rate of change has accelerated as technology has become more sophisticated and more
As the industry has changed, Mawsons has continued to be a key producer of construction materials. It operates more than 80 sites, including over 30 quarries, 40 concrete plants, as well as some landscaping centres. Its operations feature smart systems and advanced equipment, including mobile crushing and screening plants and a fleet of concrete, cement and tip trucks. According to John, the business has grown five-fold in the last 18 years.
In 2007, Adelaide Brighton Limited purchased ex-IQA Australia president, Ken Mawson’s 50 per cent of the family company. This made Mawsons a joint venture between the listed Adelaide entity and Mawson’s family. It was at this time that John became managing director.
“The business is much bigger and more complex than 18 years ago. We are lucky enough to have dedicated specialists in several critical areas, such as workplace health and safety, IT, human resources, quality assurance, engineering and blasting. Moreover, we have these skilled people spread across our regional workshops, offices and labs. So that they can enjoy country living and better serve our customers,” John said.
“It has meant that we’re able to survive and flourish in an industry that is much more complex than 36 years ago. We’re still working with our people, for our customers, crushing rock, but there are so many more
business which bears his family’s name. Despite the company’s growth, it has always stayed true to its roots.
“You understand that it’s not just the Mawson family legacy. There are many people I work with now whose grandparents, parents, aunties and uncles worked with us, so the Mawson legacy is a shared legacy between the multiple generations of staff,” he said.
“We have over 120 men and women in our 25-year club. We’ve all been in this together for a long while, and a lot of people, regardless of how long they have been part of our team, feel personal ownership and pride in what we have achieved and what the people that went before us built and what we’ve all achieved together.”
The latest in the line of achievements at Mawsons belongs to John himself after being designated as a Fellow of the Institute of Quarrying Australia (FIQ). Institute of Quarrying Australia chief executive officer Jane Schmitt attended the Victorian branch’s end-of-year meeting to present John with a certificate and the FIQ badge.
The recognition was another step in his long association with the IQA, which began when he was an affiliate member.
“That was a nice moment,” he said.
“It was very nice to be recognised as a Fellow after a long period of time as part of the IQA. It is nice to have that recognition from your peers and acknowledgement of your achievements.” •
Mawsons Lake Cooper Quarry
Image: Mawsons
ELECTRIC CRUSHING IN WA
Striker Crushing and Screening and WA Limestone’s shared values have helped both businesses flourish in Western Australia.
Striker Crushing and Screening and WA Limestone have spent decades working alongside each other, but there is one thing that binds them together – family.
Located in Western Australia, just down the road from each other, the two family businesses have been run by members of their respective families for generations.
WA Limestone director Steven Della Bona said these family values are invaluable.
“When you create these relationships with family businesses, most of these people are going to be there for a long time,” he told Quarry.
“You can ring any time of the day or night and know that they’ll answer the phone and resolve the issue, and you can’t beat that.
“Their knowledge and experience within the crushing industry and the understanding of our business in crushing aggregates and crushing limestone stands out.
“Their ability to understand the requirements of what is needed by us as a customer is always the focus, and they can deliver it.”
Della Bona remembers the rockbreaker that Striker Crushing and Screening founder Craig Pedley fabricated for the crushing plant for WA Limestone and some general modification work. It was the first job and the start of a long and productive partnership between the two businesses.
Della Bona estimated his business now has more than 50 bits of plant and equipment
across WA Limestone’s sites from Striker Crushing and Screening.
The latest innovations, including electric drive crushing and screening equipment, have come long since WA Limestone’s first crusher from Striker, the 11- 10 Impact Crusher.
Traditionally, most crushing plants, or crushing trains in some cases, have been diesel-hydraulic in Australia.
Every piece of the crushing train gets its power from a diesel engine that runs on diesel fuel. When considering a crushing system that may include several crushers connected to stackers or screens, a lot of diesel could be used in a conventional set-up.
WA Limestone has been impressed with the performance of Striker’s equipment.
Della Bona said WA Limestone had noticed that the diesel-hydraulic equipment developed maintenance and reliability issues after a few thousand hours of use.
The constant engine maintenance, fuel costs, and repair downtime of these diesel hydraulic machines were costly headaches for the WA-based construction materials provider. So it engaged Striker to design electric-drive crushing and screening equipment that could run off mains power or equivalent. The result was the Striker range.
Della Bona and his team run the Striker equipment off a Cummins Powerbox generator.
“The reliability of this Striker equipment and the tonnes it produces is through the roof, and you don’t have to worry about all the individual engines like you do in a diesel set-up,” he said. “The Striker range is a game-changer in that sense and the way it is designed. It has been a great thing.”
conventional diesel-hydraulic plants.”
WA Limestone’s hard rock quarry sites of Port Headland, Onslow and Karratha now all feature Striker equipment. Della Bona’s staff have provided positive reviews since the company rolled out Striker equipment.
“The Striker range makes it easy for the blokes who work for us. They don’t have to stress about maintenance all the time because we’re able to get far more run time out of the electric plant,” he said.
“The productivity is phenomenal. It has improved out of sight compared to the
WA Limestone’s sites are in the northwest of Western Australia, so they are remote and need strong customer support from the company’s chosen manufacturers and suppliers.
When a customer deals with Striker, the benefit is that they deal directly with the company that has designed, manufactured, and likely installed the equipment, so they know it inside out.
According to Della Bona, Striker Crushing has always provided high-level service.
“You can talk to them and are on the same wave length. They’ll work to solve any issues straight away.
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If we need to procure parts, it is never an issue; everything just happens instantly,” Della Bona said. “When you’re running sites in the northwest, remote locations, and all of that, it is so good to get the issue sorted over the phone.
“And they’re not just good to me; they’re good to my staff, too. If my quarry manager is on-site, they can call Striker at any time of the day or night, and they’ll answer and resolve the problem.
“They go far and beyond any other supplier that I know, and they’ll bend over backwards.”
For more information, visit strikercrushing.com
JAWS FOR LIFE
McLanahan director of sales for the UK and Ireland Donal McNicholl shares his tips for optimising a jaw crusher’s size and feed to support long-term crushing.
Quarries working with resources such as dolomite, limestone, and sandstone or in emerging sectors like recycled and demolition materials rely on jaw crushers.
As a result, selecting the right size of jaw crusher is crucial.
“Jaw crushers are effective for crushing a wide range of materials and are a top choice for primary crushing in a variety of applications as well as in stationary, portable or modular plants,” McLanahan director of sales for the UK and Ireland Donal McNicholl said.
“They provide a 6:1 reduction ratio and can handle small and large tonnages. Jaw crushers are a low-wear, low-operationcost option for material size reduction with minimal maintenance requirements.”
The fundamental considerations are the materials to be processed, their characteristics, the maximum feed size, the product size, and the feed rate.
“The characteristics of the feed material are extremely important. Not only do they help to determine the size of the jaw crusher required to do the job, but they also help to determine the materials of construction of the wear components,” McNicholl said.
also help to determine if a jaw crusher is
even the best type of crusher for the job or if another type of crusher would be better suited.
“Lab testing can provide an analysis of the material that can be shared with the equipment manufacturer for sizing the crusher.”
McNicholl said the best practice for sizing the jaw crusher was for the maximum feed size to be 80 per cent of the gape and width opening. This method reduces the likelihood of large feed sizes stuck in the crushing chamber and stalling production.
The site environment is also likely to influence the selection of the right jaw crusher for a quarry application. Key environmental factors include the method of extracting the raw material, the process of feeding the raw material, potential production increases, the site footprint, plant height restrictions, and site operating hours.
“You also want to consider if tramp metal relief is necessary. If there is a chance you could accidentally process a large piece of metal, such as a bucket tooth, on through to
material enters the chamber, whereas the hydraulics on a hydraulic-adjust jaw crusher will relieve to pass the material.
“Another consideration is the method of adjusting the closed-side setting: manually with shims or hydraulically with the push of a button. Shim-adjust jaw crushers are lower in capital cost, but they require a complete plant shutdown when product-size adjustments need to be made, as well as someone to physically make the adjustments.”
Using the correct sizing and feeding methods can significantly enhance a jaw crusher’s performance.
Quarries can improve the maintenance and operation of their jaw crushers by using the best feeding practices.
Jaw crushers are often fed in line by a feeder or scalping screen where the feeding machine lines up with the feed opening of the jaw crushers. The in-line feeding method helps limit the possibility of materials clogging the jaw crusher and slowing production.
McNicholl said choke feeding was considered one of the best feeding methods for jaw crushers.
“Jaw crushers work best when the entire crushing chamber is used for material size reduction. Choke feed a Jaw crusher to maintain a crushing chamber that is at least 80 per cent full,” he said.
“This will help to draw the material down into the crushing chamber, as well as create a better material shape and improve overall efficiency.”
Beyond employing a choke feeding method, quarries can implement a series of actions to support their jaw crusher operation. These include pre-screening the feed to remove fines and removing oversized material from the feed.
“Removing oversize ahead of the Jaw crusher will help to avoid blocking and clogging of the crusher opening. A good rule of thumb is that the maximum feed size should be 80 per cent of the crusher opening. If the crusher opening is 30 inches, a 24-inch feed top size is recommended,” McNicholl said. “Fines in the feed can limit production for several reasons. They can clog
McLanahan’s team works with the customer to find the ideal solution.
the crushing chamber, reducing the tons per hour and efficiency of the crusher.
They can also prevent even distribution of particle sizes and generate an inconsistent product shape.
“Fines can also create unnecessary wear on crusher components. Scalping out this material ahead of time will help to prolong the life of wear components [jaw dies and side plates], as well as help to reduce the downtime required to change out worn components.”
Material characteristics, including the type, quality, and presence of tramp material, can impact the jaw crusher’s performance.
McNicholl said limiting the presence of steel or other materials in the feed and avoiding lightweight, sticky materials would support the jaw crusher’s performance.
“While jaw crushers can handle metal, such as steel, in a feed, and can even pass the steel without harm to the crusher if equipped with an automatic tramp relief system, it is best to limit the amount metal that enters the crusher,” he said.
“If the crusher does not feature a tramp relief system, the toggle that maintains the closed-side setting can break, potentially damaging other components in the plant as it falls out of the crusher as well as causing unplanned downtime to replace the toggle.
“Jaw crushers are known for being able to handle a wide variety of materials, specifically those that are very hard, very abrasive and non-friable. They can even handle some wet materials. Jaws are not designed for handling lightweight or sticky materials, however. Sticky materials can build up on the jaw plates and reduce efficiency. Lightweight materials don’t draw down into the crushing chamber well, which also reduces efficiency.”
By implementing these best practices, quarries can maximise the efficiency,
lifespan, and productivity of their jaw crushers. Proper sizing, feeding, and maintenance not only improve overall performance but also help reduce downtime and operational costs, ensuring a more sustainable and profitable crushing operation.
As the demands of the industry continue to evolve, staying informed about innovative crushing solutions and best practices will be key to maintaining a competitive edge. For those looking to optimise their crushing operations, McLanahan offers a range of solutions designed to enhance efficiency and reliability in material processing.
For more information, visit mclanahan.com
GET PUMPED
NEW DAWN FOR OLD SOLAR PANELS
Boral has embraced innovation with novel sources of recycled and low-carbon construction materials, including end-of-life solar panels.
Sustainability has become an important part of doing business, especially when it comes to winning multi-million government contracts.
This has led the construction materials industry to find new ways of reducing cement and increasing recycled content.
Boral has recently partnerships with industry stakeholders to do just that by repurposing end-of-life solar panels to develop ‘sand’ for concrete and introducing innovative concrete mixes.
Boral recently showcased its latest development on Victoria’s North East Link project.
The Spark North East Link Design & Construct Joint Venture approached the construction materials producer to discuss the feasibility of creating concrete from sand made of solar panel glass.
The solution could solve the problem of two birds with one glass stone: according to the United Nations, the world faces a shortage of sand, and there are few uses for glass from end-of-life and damaged solar panels.
“The success of this sustainable concrete mix in a commercial project provides an effective pathway for recycling of end-oflife solar panels and contributes further to sustainability of the construction and building industry,” Boral head of sustainability and innovation Dr Ali Nezhad said.
“We’re excited to be leading the development of concrete mixes containing solar glass sand.”
Boral worked alongside Spark, Australian solar panel upcycle business Elecsome and the University of Melbourne to develop the ‘sand’ for a trial slab to be laid within the North East Link Project.
The glass from solar panels was crushed and processed at Elecsome’s recycling facility, then blended with up to 50 per cent natural sand. From there, Boral created a range of concrete mixes using the sand, with test loads transported from its Tullamarine plant to its Bulleen Concrete Plant, which supplies concrete for the North East Link project.
The construction materials provider has evaluated the plastic properties, including consistency and finish, and has conducted hardened property testing to ensure compliance with relevant standards.
Nezhad said the results so far have been promising.
“We are committed to finding ways to be more sustainable and push the boundaries of innovation. Our solar glass sand concrete trial demonstrates the ability and strength of reusing materials to create a circular economy,” he said.
“We are excited about the next generation of work being done around new and innovative building construction materials.”
This came after Boral partnered with key stakeholders to develop lower-carbon concrete in a trial announced last year.
The construction materials provider wanted to reduce its reliance on blast furnace slag and fly ash, which it says are already in limited supply. Therefore, it tested whether calcined clay concrete was feasible for use in building and infrastructure projects.
The calcined clay project builds on the UTS Boral Centre’s research, which has spent the past three years investigating the suitability of several Australian clay sources.
Boral worked with the University of Technology Sydney (UTS), Transport for
NSW, and Calix, with project support from SmartCrete CRC. As part of the validation stage, the project partners will conduct accelerated lab testing and field trials.
“We are continuously improving and diversifying our lower carbon concrete offering by identifying new ways to reduce the cementitious intensity of our products,” Boral’s chief executive officer Vik Bansal said.
“The strong demand and take-up of our lower carbon concrete range can be seen across many major Australian buildings and construction projects that use our Envisia and Envirocrete products.
“We are excited about the next generation of work being done in lower carbon concrete and Boral’s ability to support the decarbonisation of Australia’s building and infrastructure for many years to come.”
In testing, the first batch of Boral’s clay has been calcined using the renewably powered electric calcination technology from Calix.
The project has been co-funded through the Federal Government’s CRC program.
“It’s an exciting time to be at the forefront of the research and development being done on lower carbon concrete,” Nezhad said.
“The industry is constantly looking for ways to innovate, push the boundaries and find ways to be more sustainable. Given the abundance of clay in Australia, using Australian calcined clay was a natural decision for us.
“We have been impressed with the work done to date and initial testing in this project is promising. We look forward to the building and construction industry in Australia embracing these new innovations.” •
Boral used end-of-life solar panels to develop ‘sand’ for concrete.
Image: Boral
CRUSHING FOR A CARDINAL
A WA-based business has turned to 888 Crushing and Screening to support its crucial quarry.
Cardinal Contractors has been entrenched in the Western Australian earthmoving industry since three young men established it in the 1960s.
The trio started the business by focusing on bulldozing and bulk earthworks, which supported infrastructure work around Collie’s mining heartland.
The company grew alongside the demand from the region and now has a second office in Bunbury and operations spanning dam building, bulk earthworks, mine rehabilitation, landfill, tailings dams and road building across Australia.
The company’s quarry, which produces thousands of tonnes of aggregates daily, is supported by a McCloskey I4CR impact crusher and a TS4065 tracked stacker. Dealer 888 Crushing & Screening Equipment supplied this combination, which has proven successful for producing roadbase material.
Cardinal Contractors general manager Bill Berry said his business prioritised finding a dealer who could deliver a high level of aftermarket service with simple machinery to operate and manoeuvre capable of high throughput.
Cardinal Contractors discovered the ideal partnership in 888 Crushing & Screening Equipment (888CSE), a WA-based dealer that exclusively supplies McCloskey’s crushers, screens, stackers, reclaimers, conveyors, and trommels to WA, SA, and the NT.
The McCloskey I4CR impact crusher and a TS4065 tracked stacker marked the first time Cardinal Contractors had used McCloskey equipment. Berry told Quarry he was impressed machines’ performance in the quarry, especially the I4CR.
“It’s a really good machine that’s easy to use and produces a consistent material,” he said. “The operator likes the remote control of the machine, and it’s easy to move around the site.”
The I4CR impact crusher has a compact footprint but with an impressively sized impact chamber on-board at 1050mm (diameter) by 1125mm (width) and a 375hp (280kW) Cat engine.
Weighing around 42 tonnes, the I4CR is a fully contained crushing, screening and stockpiling plant. McCloskey designed the blow bar to have a larger contact area for high-capacity crushing, while a Tough-Flex heavy-duty conveyor belt increases durability.
The McCloskey TS4065 tracked stacker can stockpile aggregate at a rate of up to 600 tonnes per hour and can be connected to the hydraulics of the I4CR impact crusher, eliminating the need to run the engine.
888CSE’s base is in Oldbury, south of Perth, which enables its team to provide a high level of service to its WA-based clients, including Cardinal Contractors.
“They’re very responsive and easy to deal with,” Berry said.
“They’re local, and they support local businesses really well.
“Downtime is a major concern and they’ve been very responsive in that aspect. They also have a large supply of parts, so we’re not waiting on parts.”
With more than 30 years of experience in the industry, 888CSE provides its customers with one of the broadest and most diverse selections of crushing and screening equipment. The company’s varied offerings have helped clients tackle projects of all types, ranging from compact crushing and recycling in urban areas to extensive operations in large quarries. •
For more information, visit 888CSE.com.au
The McCloskey I4CR impact crusher and a TS4065 tracked stacker.
UNLOCK CONE LINER POTENTIAL
Superior Industries’ Curt Theisen shares tips on how operators can maximise the lifetime of their cone liners.
Optimising cone liner utilisation cuts maintenance costs, boosts uptime, and enhances throughput. When all those factors are combined, a quarry’s overall profitability can be improved.
Utilising effective strategies is crucial for production success. Superior Industries technical support engineer Curt Theisen has shared his insights with Quarry on the key strategies that can be implemented to achieve this type of success.
Theisen is part of Superior Industries’ rockface to loadout solutions team, which helps producers achieve greater efficiency throughout their plants. Based on his industry experience and on-the-ground work with producers, Thiesen said a wellthought-out approach to cone liners could yield major benefits.
“By considering several key strategies, producers can boost cone liner lifespan by up to 30 per cent, depending upon the application,” he said.
Manganese is a popular choice for manufacturing cone liners due to its ability to “work harden” over time. This means that a new manganese liner will harden when its outer surface is impacted by rock. Engineering
“green” manganese from 25 Rockwell (250 Brinell) to a hardness of up to 60 Rockwell (660 Brinell).
Theisen said that recent industry data showed that applying proper “work-hardening” methods can boost cone liner utilisation by up to 30 per cent more cone liner life. This applies to most quarry applications except when the application is highly abrasive.
The technical support engineer recommended a gradual approach when hardening a new manganese cone liner. This can be achieved by starting at a 50 per cent power rate while running with a full cavity for about six hours. During this period, rock is still being crushed while the new liners are hardening. After this period, operators can
with a full cavity for two hours.
Theisen said the liners should be fully workhardened, and operation can continue near or at a full 100 per cent rate of power from that point forward.
Another fundamental element to maximising the lifetime of cone liners and manganese wear is maintaining a continuous feed to the crusher.
“Choke feeding means keeping the cone head covered with at least 150mm of consistent, homogenous feed material,” Theisen said.
“Most operations use a combination of hoppers, feeders, and surge bins to achieve optimum feeding processes within the cone crushing circuit.”
In his experience, Theisen said it was best never to run the cone crusher empty or with sudden surges in the feed material.
“This causes the head to spin from one direction to the other at a range from 200 to 300rpm with inertia and momentum that leads to potential component damage and accelerated and excessive liner wear.
“Bottom line, avoid feeding a crusher on and off all day long. Instead, supply an ongoing, even material load to the crusher throughout the work shift.”
By employing effective work-hardening and choke-feeding techniques, operators can maximise the lifespan of their cone liners.
“These are the two ‘best practices’ that lead to more crushing efficiency, more manganese wear life, more product output, and a consistent yield of a more cubicle product,” Theisen said.•
For more information, visit superior-ind.com
QUADRUPLE-THREAT EVOLUTION
Metso is set to unveil the latest entry into its cone crusher range, the Nordberg HP with the HP350e.
How do you evolve a recognised brand to become even better?
That question challenged Metso as it sought to develop the Nordberg HP, which was reviewing the classic workhorse from the “ground up.” The result is the Nordberg HPe.
The Nordberg HPe series aims to provide improved performance, uptime, application coverage, and serviceability more sustainably than its predecessor.
“Nordberg HP cone crushers are globally accepted as the go-to crusher for aggregates and mining,” Metso’s cone crusher product range Ilkka Somero said.
“The range continues to evolve and align with customer and industry needs and demands. Today there are drivers pushing for ever higher efficiency in productivity.
maintenance as well as with enhanced application flexibility.”
When Metso examined the key mining and aggregates industries it serves worldwide, it noticed efficiency is the central focus of many operations. Quarry and mining businesses are looking to achieve maximum performance in throughput, reduction, or higher yield of certain aggregate fractions.
The new Nordberg HPe series needed to meet all of these requirements while also addressing the sustainability challenges that many businesses face every day.
Metso has further developed the kinematical crushing action and crusher chamber. The improvements balance kinematics, chambers, release force, and power rating. The redesign enables the HPe series to deliver more head
and application-specific options to select from. Metso’s team can assist customers in creating the optimal chamber for their needs.
According to Metso’s data, the new HP350e crusher delivers ten per cent performance compared to the traditional HP300 crusher in secondary or tertiary applications.
“Our development engineers and manufacturing facilities have provided a full range of eRange cones from 200 to 900kW, following a full redesign of a classic workhorse. We are excited to bring these products to the market to increase our customer’s bottom line,” Metso’s business development manager for aggregates, John O’Reilly, said.
“The evolution enables us to meet industry needs where you want more production
Images: Metso
The HP350e is a new innovation from Metso.
this may seem minor, the update significantly simplifies liner changes, making them easier and safer for operators.
This reduces the need for quarries to source, store and transport backing compounds. Operators will also not need to handle, mix and pour the backing material, making operations safer and line changeouts faster. Metso can also tailor the liners to suit particular applications, including manufactured sand or specific aggregate fractions with its NF liner.
The anti-spin brake and ring bounce monitoring feature help extend the lifespan of the liners while also safeguarding the machine.
These upgrades will help operators increase machine uptime and productivity in the quarry. Metso has designed the HPe range, including the HP350e, to fit within the HP300 footprint while delivering more power.
“It is an evolution, but it is not just that we’ve put more power onto the machine and redesigned the cavity kinematics; there are more safety features, which is very important and simpler maintenance,” O’Reilly said.
“It has the same footprint as its predecessors. For example, the HP450e replaces the existing HP400 but is the same size on the outside. Because it is the same size envelope, there is no extra structural work to replace it. You can switch one in and one out.”
The HPe series is set to be unveiled progressively throughout the year by Metso at the world’s biggest quarrying trade shows.
The original equipment manufacturer is set to launch the HP450e at AGG-1 in St Louis. Attendees to bauma 2025 in Munich, Germany, can witness the debut of the HP600e. Other launches with the Nordberg HPe range will include the 600e later in 2025.
Metso’s Australian team and service and support network will fully support the introduction of the HPe series into Australia. With extensive industry experience, the team
can help optimise a Nordberg HPe series crusher to suit the customer’s application.
“Metso is strongly focused on supporting the Australian quarry industry with worldclass aggregate-producing solutions. The Nordberg HPe range is the evolution we believe our customers have been asking for,” O’Reilly said. • For
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Metso will feature the HPe range at international trade shows throughout 2025.
NEW VIBRATIONS
Multotec is helping quarries rethink vibration analysis with equipment from the UK.
The old-school methods of vibration analysis rely on sight, sounds, touch and guesswork. Multotec product manager Marc Barraclough has seen how old-school methods can fail quarries. In one case, a customer usually conducted a vibration analysis audit once a month. A week after their most recent audit, a bearing failed, causing unplanned downtime while maintenance was performed to repair it.
“Even though all their assets get tested every month by a vibration analyst, failures can happen in that period,” he told Quarry Multotec plans to reshape vibration analysis into the next frontier for quarries seeking to optimise their operations’ efficiency.
Multotec has partnered with UK-based wireless machine health provider Sensoteq to provide vibration analysis solutions. Multotec is offering these solutions to the Australian quarrying industry, helping quarries make more informed decisions about their equipment.
“Using something like Sensoteq in comparison, where it is updated all the time, that is much less likely to happen,” Barraclough said.
“Your Sensoteq solution is updated live, so if a bearing starts to fail, you have an early warning.”
Vibration analysis is a predictive testing method that measures the overall health of a machine or components of that machine. To do this, the minute vibrations of the machine are compared from when the machine is running well to the vibrations during operation. Changes in vibrations, including emitting high-frequency vibrations, can indicate possible future failure as bearings, brushes, and lubricants lose their effectiveness. The method can be used to monitor any quarry equipment except for static screens, which are solitary. All of the equipment’s vibrations can be measured and monitored, and the data can be used to make informed decisions about maintenance.
However, the manual methods used by vibration analysts can create room for failure between the periods of the analyst’s audit.
Few quarries can afford unplanned downtime, and even fewer want to pay for avoidable maintenance. That’s where real-time vibration analysis from Multotec and Sensoteq can help.
“By the time a bearing gets warm or noisy, it is nearly going to fail. By that time, it is too late to plan something to have the bearing changed out without affecting production,” Barraclough said.
“Whereas if you can pick it up early and see that something is wrong, then you can start to plan a shutdown in advance.”
Multotec supplies the quarrying sector in Australia with two main solutions from Sensoteq: the Kappa X and the Tau E.
The Kappa X enables quarries to monitor non-moving machinery with rotating elements, such as motors, pumps, gearboxes, fans, and compressors. It has a 10KHz bandwidth for detecting vibrations and is powered by a replaceable battery, which has a lifespan of five years. The recording parameters can be adjusted to suit the machine and is versatile due to its small footprint and mounting methods.
The Tau E is designed to measure and monitor the responses of machinery that moves during operation through orbit or stroke. The Tau E also has a bearing version to detect bearing faults in the machine’s moving parts. Customers can also access a boltable version of the Tau E if it suits their application.
Barraclough said these two solutions moved vibration analysis from being a maintenance application to a productivity enhancer.
“Everyone is seeing vibration analysis as machine health and how to keep the machine working as long as possible. But these solutions allow you to access data which over time will give you great insights,” he said.
“The technology is advanced in terms of the vibrations that we can pick up, but it is the data itself that will be important in the long term.
“They’ll be able to compare the vibration analysis on a screen or conveyor, for example, and then compare it with their data about how the plant was running at that particular time and understand their machines.
“They’ll be able to understand how their machines perform under different circumstances as well as all the maintenance data. It will provide a greater insight into how their site works.”
Sensoteq’s solutions can be run via the GSM/ethernet gateway or Wi-Fi/ethernet gateway. The GSM gateway uses 4G GSM to communicate with the Sensoteq Cloud or ethernet when GSM is unavailable.
The Wi-Fi gateway can connect to the local network via Wi-Fi or ethernet for internet access or to the site’s SCADA network via Modbus or Profinet.
The Analytix online platform showcases all of the site data, from the overall site health to the numbers on individual machines. Operators can also set alarms when machine numbers fall outside set parameters.
Sensoteq protects all cloud information through industry-standard secure measures. This ensures quarry operators have peace of mind knowing their data is safe and accessible when needed.
Barraclough said Multotec wanted to work with more quarries to show them the benefits they could unlock through Sensoteq equipment.
“The sensor’s abilities are at the top of industry standards, and they’re unparalleled for features,” he said. •
For more information, visit multotec.com.
Sensoteq’s solutions conduct vibration analysis in real-time.
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DRILL AND BLAST AI
AI is coming to drill and blasting operations to help improve fragmentation and reduce costs. Eltirus founder Steve Franklin explains how.
When I was new to the industry, an old hand told me that the best crusher you have is the one in the pit, by which he meant effective drill and blast.
Drill and blast can be challenging. Holes not being drilled to design, missing holes, short holes, excessive fallback, damaged or destroyed drill holes, drill holes not being loaded, misfires, ground vibrations, air blasts, fly rock, back break and more can provide no end of trouble. These obstacles not only impact the efficiency and safety of the drilling and blasting process, but also the results.
Surprisingly, even though there are a lot of tools in the drill and blast space, up until now there hasn’t been an integrated system that can take you all the way from drone survey through blast design, drill, load and fire and then tie back the analysis of the results – in essence a quarry blast to primary crusher feedback loop.
After some research internationally, we found that such a system does exist in the form of the Strayos AI analytics platform.
THE VALUE OF DATA
Data is a company’s greatest asset. This is the era of big data. There is so much of it that companies are being buried under it or
leaving the rich resource untapped because they don’t know what to do with it or because it’s just too much to deal with right now.
That’s where AI and analytics come in. They sift through the mountains of data and pull out the nuggets in an easily accessible and usable
form and the more data they get, the better they get at analysing it for you.
Strayos takes all the data gathered from drones, from satellites, from smart drills, from sensors, from lasers, from cameras and processes it for you, giving you accessible
Strayos aims to makes it easy to visualise and integrate measure while drilling data with blast design.
Strayos takes data gathered from drones, satellites, smart drills, sensors, lasers, cameras and processes.
insights and usable models. More data allows you to analyse workflows, identify areas for improvement, increase efficiencies, etc. and companies who use this newfound insight can make better decisions and provide a competitive edge.
So, what can we do to help improve drill and blast performance through the application of tools such as drone and AI analytics software?
BENCHMARKING
The first thing you need to have is a good idea of current drill and blast performance. Understanding current performance is critical to providing a baseline you can measure improvement against.
Benchmarking success in drill and blast operations crucially hinges on several key performance indicators. Efficiency, safety, cost-effectiveness, and environmental impact stand as the primary metrics.
A successful operation is marked by optimised drilling rates that maximise rock fragmentation, adapt to geological variations and minimise the use of explosives, ensuring cost savings and a reduced environmental impact. Safety metrics are paramount, with the aim to minimise accidents and ensure compliance with all regulatory standards.
Once you understand your baseline, you can start to employ technology for more precise blasting and use data analytics and AI for continuous improvement - modern hallmarks of excellence in drill and blast operations.
BENCH MAPPING USING DRONES
Drones are a great way to map a bench ready for planning. Initially this was not considered the case as when a drone was used to only take photos vertically, underhanging areas
would be missed with consequent issues around front row burden.
Drones such as the DJI M3E and M4E have superior object avoidance and terrain following technology and can be used to fly with the camera at an oblique angle in terrain following mode to ensure that a face is captured exactly, ensuring that you can have full confidence that the front row can be accurately planned.
Strayos can deal with whole-of-site drone flights or just a single blast area and given that the pricing model is fixed fee, this can be done without worrying about upload costs.
In addition to physical survey of the area, the rock mass classification AI can automatically detect and analyse critical geological features such as bedding planes, joints, spacing, and fractures to further improve drill and blast design, even to the point of being able to
automatically map the structures directly onto a 3D model for geotechnical insights.
BLAST DESIGN AI
One the key values of Strayos is that everything is done in one platform.
When you begin interacting with the 3D models the real power becomes apparent. Shotfirers can plan their shots by inputting their blast designs into the bench model and the algorithm will generate the face profile, blast volume, rock fragmentation and even muck pile shape. If you don’t like what you get, just enter a different blast plan.
Once you have designed the pattern, ensuring that the holes have the exact burden, spacing, depth, inclination, and azimuth, you can then provide this as an IREDES file for a smart rig to execute.
MEASURE WHILE DRILLING ANALYTICS
Data from smart drills on what they encounter while drilling the blast holes is captured and brought into Strayos for analysis. This measure while drilling (MWD) data can be difficult to use and interpret. Strayos makes it easy to visualise and integrate MWD data with blast design.
Information such as the hardness of the rock layers encountered, the burden, the declination of the hole, and the final collar position of the hole allows the shot firer to adjust the charge in the moments right up to the actual blast.
If your rigs don’t have MWD capability, the Strayos Fielder App can be used to manually log the data, allowing data to be logged faster, while making it easier to save and share the data in operations. In addition, having the
Strayos has worked with some of the largest and smallest drilling and blasting companies in North America.
Strayos automates fragmentation analysis in real time.
drillers’ logged data instantly appear on your 3D models allows shotfirers to better visualise the logged data in parallel to loading. Tracking overburden, seams, voids and geological changes has never been easier. On top of drilling data and performance, tracking man hours, drill bits, consumables and fuel consumed and compiling the needed information in one place, makes daily, weekly and monthly drill tracking an automated task.
HOLE DEVIATION ANALYTICS
Boretrak data can be read and visualised in 3D, providing quality control assessment of the drilling as well as a clear model of hole collar and toe locations. This data brings tremendous value to the shotfirer, as knowing the exact face burden will dictate how the face holes are loaded, ultimately reducing the risk of fly rock and excessive vibration and air blast.
FRAGMENTATION AI
Once a drill and blast design that is complete, Strayos has the capabilities to provide
fragmentation, muck pile profile, and vibration models. To fully apply the optimal workflow, comparing these predictions to post-blast data will feed the machine learning algorithms within the platform to produce more accurate predictions for future blasts. Strayos automates fragmentation analysis in three primary ways:
1. Flying a drone over the shot post blast and uploading the data for analysis in Strayos.
2. Using the Strayos FragR app on a mobile device.
3. Employing the Strayos Netra 3D machine vision system to assess material size and shape as it is being tipped into the primary crusher.
Whichever method is used, the results can be fed back into the system, improving results as more and more data is collected. In essence, after each blast is fired, a comparison between predicted and actual performance is carried out by the system analytics and AI to provide analysis on how a particular design performed and what could be improved.
SWITCHING TO AI
Switching to an AI platform can be intimidating at first, but its surprisingly easy to do and the benefits make it well worth it. In one case study, a site achieved a 30 per cent reduction in secondary breakage and a 25 per cent decrease in overall operational costs through adoption of the Strayos AI analytic platform and drill and blast tools.
Strayos has worked with some of the largest and smallest drilling and blasting companies in the North American industry and it is now used by a majority of the drill and blast contractors in that region.
Our experience is that they listen to their user based and proactively work to improve the platform on a continual basis, and if you run into any issues, they you will get to work with a human, to resolve any and all questions you have. •
Eltirus is a Strayos reseller. For more information, contact steve.franklin@eltirus.com
SIZING UP KOMATSU CRUSHERS
Komatsu crushers are helping to redefine performance standards and expand the boundaries of where sizers can be applied for maximum impact.
In the competitive world of mining and material processing, efficiency, reliability and cost-effectiveness are paramount.
Komatsu sizers offer a robust solution that’s designed to handle a variety of materials with high efficiency and minimal downtime.
The machines are high performance double-roll crushers designed to excel in both hard and soft rock applications. With a capacity of up to 3000 metric tonnes per hour, they can be used as a primary or secondary crusher to reduce material size and prepare it for further processing.
Equipped with crushing blocks or picks, depending on the specific application, Komatsu sizers are engineered to efficiently crush material using compression, tension and shear forces.
CRUSHING EFFICIENCY
Proven to manage even the toughest materials, the sizers operate effectively in mine sites with compressive strengths exceeding 260 MPa.
Primary sizers incorporate wear-resistant pick technology, built from Komatsu’s extensive experience with feeder breakers, shearers and continuous miners.
Material is processed using a combination of gravity and rotational downforce from the heavy-duty centre sizing shafts.
Additionally, the sizers feature a breaker bar beneath the rolls to control product sizing in three dimensions. A key benefit of this technology is its ability to efficiently screen undersized material through the rolls, preventing over-crushing, reducing fines generation and minimising waste.
DURABLE DESIGN
Komatsu offers a range of primary and secondary sizers tailored to meet the specific needs of an operation.
Primary sizers are designed to handle large lumps and produce a consistent product size that can be easily transported. These machines are particularly effective with wet, sticky materials that often cause problems for other types of crushers. Secondary sizers are optimised for reducing fines while
maintaining high throughput, due to their matched velocity technology and replaceable teeth segments, helping to extend the machine’s lifespan.
Sealed outboard bearings help to minimise water and dust ingress, reducing the need for water sprays and helping to maintain a cleaner work environment.
The no-clog performance of Komatsu’s primary sizers, even with challenging materials, enables consistent production and reduces the risk of operational delays.
COST EFFECTIVE OPERATION
One of the standout benefits of Komatsu sizers is their low total cost of ownership. The robust design and durable wear components help extend operational productivity between scheduled maintenance periods, resulting in lower running costs and longer machine life.
Komatsu sizers feature replaceable teeth and segmented wear parts, allowing quarries to replace the worn components instead of the entire unit. Customers can also rotate high-wear areas with low-wear areas within the crushing chamber.
SMART TECHNOLOGY
Komatsu sizers are equipped with smart machine LINCS technology that provides
Image:
Komatsu
MOVING ON UP
ODE Materials is expanding its dredging operations beyond the private sector in Australia.
ODE Materials, a relative newcomer to the industry, was one of a handful of companies shortlisted after an expression of interest process with Transport NSW (Maritime).
The tender is primarily for a road-
across the state for coastal remediation and rehabilitation.
The company is competing against some well-regarded dredging manufacturers that have been established for decades.
While at the time of writing, the
said being part of the process was a major achievement.
“For our company to have been approached is significant,” she told Quarry.
“Designing a dredge for government use means the standard of compliance is much higher than a dredge used in a private sector setting.
“That alone is a significant indication of the recognition of our work so far and a significant compliment for us.”
The GC21 tender allows the parties involved in some cases to discuss and negotiate the terms.
While ODE Materials is confident it could supply a cutter-suction dredge within the tender’s guidelines, it also believes it could show a dredge that requires less maintenance and less power for the same production rate, which would be more sustainable and environmentally friendly.
“It will be interesting to see whether we are selected and whether we can discuss with the government about using our technology rather than a traditional cutter suction dredge,” Simone said.
“It would lead to a reduction in operating costs and a reduction in most costs.
“If we were selected, it would be a massive milestone. To be the chosen or selected supplier for NSW Transport (Maritime) would put us on the map.”
ODE Materials is an Australian business.
ODE Materials has primarily earned its reputation by supplying dredge technology and producing construction materials. Some of Australia’s largest construction material providers use its sand, which has been used to create roads and buildings.
It has taken a long journey to get to this position, but now that the foundations of the business have been laid, ODE Materials is not content to rest on its laurels. To do this, Simone and fellow co-founder Brendan O’Dowd are thankful it has a series of quality suppliers that support its vision.
“You have to have the courage to not step back and not be overwhelmed. As part of that, you must take your key suppliers on the journey with you,” Simone said.
“The supplier of our pumps is a small-tomedium business just like us, but they have the same culture, and they want to give things a go.”
The challenge of growing a smallto-medium (SME) business cannot be overstated. Fewer resources may require juggling a heavy workload, especially when competition for contracts is fierce. Brendan continues to run O’Dowd Engineering, which provides servicing and maintenance on “yellow machines”, as well as contract work for advanced manufacturing companies, while also being a co-founder of the expanding ODE Materials. While
ODE Materials specialises in dredging equipment.
juggling the tender and additional work, ODE Materials is in the process of working on the ‘holy grail’ of sand management projects, according to Simone.
“Juggling all of that is part of being an SME,” Simone said.
“We’ve experienced several years of steady growth, stable income, and consistent expansion. However, 2024 was a year for us to consolidate our expertise and diversify away from a single income stream.”
“I think we achieved that successfully because we created a level of stability and financial standing from which we can now build. It’s important to have a platform like that, and it took an incredible amount of hard work.”
Looking ahead to the rest of 2025, Simone is excited about ODE Materials’ future trajectory.
“I think we’ve got three strong likelihoods in front of us. All three of them will require a significant dredge build, whether it’s the government tender or one of the other two jobs we’re looking at,” Simone said.
“We are busy, but it speaks to the fact that we’re well enough known for other parties to think it is worth working with us, and that is tremendous.” •
For more information, call Brendan on 0414 506 430.
FUTURE DRIVEN
Tesmec has launched the 1475XL EVO Dynamic Drive to address the critical needs of the modern quarrying operation.
Quarries face the daily challenge of balancing efficiency with essential safety and environmental protection requirements.
With the launch of 1475XL EVO Dynamic Drive, Tesmec has, in its own words, delivered a “significant leap forward” for quarries seeking to address these critical requirements.
The 100-tonne class machine has been designed to be a productive addition to a quarry and an environmentally friendly solution.
Tesmec’s design and advanced technology make the 1475XL EVO Dynamic Drive useful in various mineral extraction activities for quarrying operations.
The Tesmec 1475XL EVO Dynamic Drive features a 630HP (470 kW) engine in available in Tier 4, Stage V, or Tier 3 versions. It is equipped with a cutting drum capable of digging up to 45cm deep and 380cm wide.
Tesmec general manager of Australia and New Zealand Adrien Merceron said these features made the machine productive in various applications.
“This robust machine ensures optimal performance when working with extremely weak to medium-hard rock formations, making it ideal for minerals such as coal, gypsum, bauxite, phosphates, salt, potash, and marly limestone,” Tesmec general manager Australia and New Zealand Adrien Merceron said.
“One of the most significant benefits of the 1475XL EVO Dynamic Drive is its ability to ensure extreme cutting precision and versatility. This solution allows for control of digging depth, ensuring that material from different layers doesn’t mix. This process is crucial in maximising productivity and improving the stripping ratio. It also reduces the need for further processing, leading to cost savings in the long run.
“By combining digging and crushing into a single phase, Tesmec eliminates the need for primary crushing equipment, leading to fewer machines, reduced operational complexity, and lower logistics expenses.”
The fundamental feature of the Tesmec 1475XL EVO is its direct drive, which Tesmec has labelled as “revolutionary” for the quarrying industry.
The direct drive integrates a planetary gearbox into the cutting drum, removing the need for sprockets, digging chains, and baseplates.
“This results in higher efficiency without power losses, eliminating wear in key components and reducing maintenance costs. With no limit to the maximum cutting speed (RPM) of the drum, operators can achieve higher cutting power and efficiency,” Merceron said.
“This translates into a 60 per cent to 100 per cent increase in productivity and reduced operational costs by up to 45 per cent.
“The 1475XL EVO Dynamic Drive isn’t just about raw power. Its modularity is a key differentiator. Depending on the digging attachment that is equipped, it can adapt to suit various applications. Its quickswap backend makes it the perfect fit for multiple projects, reducing downtime and enhancing flexibility.”
It is no secret that safety is the priority of all Australian quarries. Tesmec has equipped the 1475XL EVO Dynamic Drive with a pressurised cabin, including air conditioning, heating, and sound suppression, for a comfortable operator environment. The cabin’s roll over protection system and falling object protection system help protect operators from potential hazards.
“Its low noise levels, minimised dust emission and reduced vibration ensure that the environmental footprint is minimal. By replacing several conventional machines, it reduces fuel consumption, leading to lower
CO2 emissions and a more sustainable process,” Merceron said.
Tesmec has equipped the 1475XL EVO Dynamic Drive with new technology to make it easier for operators to complete tasks.
The new Tesmec machine includes TrenchTronic 5.0, an automatic trenching and self-diagnostic system, and the TrenchIntel 3D-GPS automatic guidance system. TrenchTronic 5.0 allows operators to make precise adjustments to pressure and speed and makes it easier to navigate the job site. The TrenchIntel 3D-GPS ensures that machine steering, trajectory, and trenching depth are controlled accurately, improving alignment and reducing the need for rework.
Merceron said the Re.M monitoring system and SmartTracker system rounded out innovative features.
“The Re.M remote monitoring system provides real-time data on machine performance, helping operators optimise productivity and reduce maintenance costs. The SmartTracker system allows for digitalisation of the job site, automatically collecting as-built data during trenching operations, which reduces survey time and costs,” he said.
Merceron said the Tesmec 1475XL EVO Dynamic Drive could help quarries unlock a new standard of productivity.
“It combines power, precision, and flexibility with cutting-edge technology to deliver unmatched productivity and efficiency. By simplifying operations, reducing maintenance costs, and enhancing safety, it is an invaluable asset in any job site,” he said.
“As the industry moves toward more sustainable and efficient solutions, this machine stands at the forefront of innovation, offering a safer, more costeffective, and environmentally responsible approach to quarrying.”•
For more information, visit tesmec.com.au
Image:
Tesmec
Mobile crusher with compact dimensions
Lokotrack LT106 mobile jaw crusher is a primary crusher for aggregates production and recycling demolition as well as other crushable waste. It is ideal for medium-sized aggregates production, as well as recycling demolition waste such as crushing concrete, which can be re-used as base material for sidewalks, for example. It is designed to be easily transported between sites, quick to set up and to cut overall operating costs with its reliable performance.
For more information on the extensive range of Metso mobile plants, email us today at metso@tuttbryant.com.au!
GRAIN IN THE HOURGLASS
Kayasand founder Andi Lusty looks back at his career and why he believes the future of sand will be engineered.
Creating sand naturally can be a long and drawn-out process. To make it happen, rocks must undergo thousands, if not millions, of years of slow erosion via rivers and glaciers.
While this process is never-ending, most construction companies cannot wait for millennia.
Sand plays a vital role in the creation of concrete, which in turn is necessary for Australia’s infrastructure and houses.
However, as industry stakeholders look to embrace a sustainable outlook, it has become much harder to access natural sands close to urban areas and construction projects.
Kayasand founder Andi Lusty told Quarry that this has been a problem facing the industry for more than 30 years.
“In the early 90s, there was demand for manufactured sand to be used alongside natural sand, as the supply of natural sand was getting harder to access. Companies at the time turned to crusher dust, a waste product in most quarries, and wanted to find a way to use it,” he said.
“They noticed there was an improvement in the strength of concrete when adding crusher dust to the concrete. Too much of it though, and you ended up with a bony concrete that was hard to finish and needed more water.
“The Barmac excelled at supplementing natural sand due to the way it shaped the crusher dust.”
Lusty has been involved in the crushing industry for decades. He moved to New
Zealand in 1981 from the UK to sell Barmac vertical shaft impact (VSI) crushers.
The crushers use ‘rock on rock impact’ to produce a quality cuboid product that could replace up to 60 per cent of the natural sand required in concrete.
JAPANESE INNOVATION
While this manufactured sand was helpful – it still had its limitations. It could not create 1mm particles, had too much ultrafines and required more water in concrete. The availability of sand diminished each year, particularly fine sands that were -1mm that was perfect to blend with Barmac sand. However, limited availability meant the natural sand on the market could only supply so many projects,
Lusty said concrete manufacturers were trying to increase the amount of manufactured sands in their blends.
“Everyone had their own versions of manufactured sand, and because they were all so different, it meant you couldn’t trust it,” he said.
One of the Barmac distributors in Japan, Kemco, saw this firsthand when the government banned dredging. That’s when Kemco chief engineer Takato Kaya saw an opportunity.
Kaya invented a new crusher with a proprietary air screen that uses autogenous crushing in the particle cloud and on the rock bed. When used with a secondary impact zone, the crusher creates sand that is excellent in shape, and the air screen
accurately controls the volume of ultrafine -75 micron particles in the sand. The resulting sand used less water in concrete.
Kemco launched the technology in the early 2000s. Since then, it has been a huge success, with around 60 Kemco V7 plants operating in Japan and more than 100 in China.
Inspired by Kemco’s technology, Lusty retired from selling Barmac VSI crushers, founded a new company to sell the Kemco technology, and named it Kayasand, after the technology’s inventor.
ENGINEERED DIFFERENCES
Kayasand’s plants can precisely control the shape and size of the sand particles, thanks to the grinding impact action that mimics natural erosion. This creates a cuboidal particle that is ideally shaped for strength and workability in concrete.
The material is then fed into a combination of a high-accuracy screen with high throughput air classification to ensure the product meets specifications.
Water and skimmer material are blended into the final product to maximise concrete performance and suppress dust on the stockpile. Ultrafines are extracted and stored dry until needed to dose other quarry products or loaded into trucks and tankers.
This process optimises the shape of the product, removes contamination, and has high levels of product consistency.
Lusty said the company’s product can be used to replace 100 per cent of the
Kayasand put its product to the test in a concrete trial.
used to create even stronger concrete than natural sand.
Last year, Kayasand put its product to the test in a concrete trial. Sand engineered from Greywacke-based crusher dust replaced 100 per cent natural sand in a normal Auckland concrete mix. The resulting concrete proved
to be 24 per cent stronger and used up to 10 per cent less cement. The goal is to reduce cement requirements by 20 per cent.
“Our sand isn’t just any old, manufactured sand – it’s Engineered Sand. We want people to understand the product we are helping create is precision engineered for concrete,” Lusty said.
One of the challenges the company faced with this new technology was an industry that was hesitant to invest in new technologies. However, in recent times, Lusty said there has been an uptick in interest in the technology for three reasons.
“The first is the need for a natural sand replacement. The second is they have been seeing it operate for many years now. The third reason is that from our testing, they have been able to see cement savings that would quickly pay for the plants,” he said.
“They can see the return on investment and clear advantages. There’s also a lot of younger talent that have come to the industry with new ideas.
“They’re now looking at it as an investment that can save them thousands on sand and cement but could also improve their emissions reductions into the double digits. It’s turning heads.”•
For more information, visit kayasand.com
2818VM SCREEN PLANT NEXT GEN SCREENING
Industry-First Design
The 2818VM features a 2.4m wide high frequency screen, making it the widest high frequency screen on the market.
Our externally-mounted vibrators deliver a more aggressive screening action, a unique design feature that allows for easier maintenance and adjustments.
High production capacity, the flexibility of fixed or trailered options, with proven performance in Australian conditions –the 2818VM is the Next Generation in High Frequency Screening.
ON TOP OF THE WORLD
Find out how the Lincom Group won four awards and became Powerscreen’s named global dealer of the year.
Even though Stephen Watterson is the chief executive officer of Lincom Group, he still works on the front lines. In fact, he takes great pride in working alongside the company’s sales team and being part of the customer’s journey.
“The customer is king,” he told Quarry “If someone is willing to spend millions of dollars buying our equipment, we want to make sure they are comfortable and know they won’t be left in the lurch.”
“Providing this service and turning it into an ongoing working relationship and friendship is what sets us apart as a family business, and it’s why we see our repeat business.”
However, to remain competitive, the Lincom Group needed an edge.
Watterson said Lincom Group needed to offer more than just the available machinery.
There are a lot of high-quality crushing and screening equipment suppliers, but the company needed a competitive edge that helped it stand out.
“We wanted to give our customers a reason to come to us because of the services we offer,” he said.
That’s why Lincom Group set out to
NEXT-GEN TRAINING
Lincom’s approach to training is that there needs to be more than just a basic understanding of a machine. That’s why it designed its programs from the ground up to provide a thorough understanding of the equipment’s fundamental systems, coupled with practical tips and techniques for maintenance.
This dual focus helps ensure that each participant can operate their equipment safely, efficiently, and have confidence in their abilities to operate at peak performance.
The facility consists of two parts: a computer-equipped training room and an interactive area that allows participants to get hands-on with mock-ups of the equipment. The idea is to allow those in training to identify faults in a safe, controlled environment.
“There are no trucks moving around, and you’re not putting your bosses’ brand-new machine at risk while learning how to fix it,” Watterson said.
“Importantly, it’s not just a room where you go to suffer death-by-Powerpoint. There’s an interactive area with models that replicate machine functionality. We can simulate anything that occurs in a crusher here to help trainees identify how to fix things when something goes wrong, with no fear of damaging the machine.”
The training service is available to all Lincom customers and has already proven popular. When the facility was officially unveiled last year, the company hosted 20 training sessions, and thanks to expanding awareness, even more are scheduled for 2025.
It also benefits Lincom’s employees, who make use of the facility for internal training.
Watterson said that while Lincom has offered training services in the past, the facility has greatly improved what it can teach.
“That’s important because things are forever changing in the industry. There’s a lot more safety features, electronics, and sensors on machines today – you can’t just turn the key and press a few buttons anymore,” he said.
“Not everyone who operates one of our machines has a trade background, so providing a space for them to get a better understanding of the equipment improves site safety overall.
“We want everyone to go home at the end of the day, whether they’re working at a quarry or in a workshop, and this facility is helping people to do that.”
Following the training, operators can walk away with the knowledge and confidence to try fixing a machine at a quarry. They learn about the most common causes of downtime and how to solve them, and if they can’t fix the issue, they know what to tell Lincom’s support over the phone to help troubleshoot.
“It also gives our customers’ employees a boost. They know the boss is investing in their skills and wants to keep them involved in the business,” Watterson said.
AWARD-WINNING RESULTS
The introduction of the training facility highlighted how important going the extra mile was for Lincom.
It also helped the Australian company stand out among global competition at the 2024 Powerscreen Awards.
Images: Lincom Group
The awards recognise Powerscreen’s dealers who deliver exceptional performance and consistently exceed expectations.
Lincom walked away with four awards: Global Leader in Marketing, Global Leader in Training Engagement, Regional Dealer of the Year (Australia and Asia), and the coveted Global Dealer of the Year.
“These awards are a true testament to the passion and resilience of our entire team,” Watterson said.
“To get all four of these awards was humbling. Being named global dealer of the year was icing on the cake – it was basically the Gold Logie.
“These awards can’t be accredited to just one person – it’s thanks to the hard work of everyone who dons the Lincom shirt.”
LOOKING AHEAD
One of the key lessons from 2024 was the importance of going above and beyond.
Watterson said his goal is to ensure the team doesn’t just do a good job. Instead, he wants the business to continue to do a great job for its customers.
“In 2025, we’re not standing still,” he said. “It’s easy to say you’re an industry leader,
but to actually be one, and to be able to back it up, you need to provide industryleading equipment.”
“We’ve recently taken on a new brand in the Komptech line to support the recycling sector. We’ve also expanded our dedicated sales team and have opened a new facility in Adelaide to better service our customers.
“Our aim is to have a strong business and stick to what we do best – and do it even better.” •
For more information, visit lincom.com.au
L–R: Darren Smith, Mark Crestani, David McDermott, Stephen Watterson, Renata Hjelmstrom, and Joe Cassidy.
THE PINNACLE OF VERSATILITY
From dams to dewatering, Pinnacle Hire has provided a wide range of water management solutions around Australia.
In the quarrying industry, water management has a flow-on effect on production, safety, and overall site management. Because of this, it is important to consult an expert when considering a water management system.
Pinnacle Hire has built a reputation for designing and implementing water management systems across Australia, particularly in the civil, mining and quarry industry. The company was recently engaged to provide water management solutions in Victoria, which involved quite complex planning. The client required an efficient water transfer from a dam to the canal system, as well as a treatment and discharge system that flows into the drainage canal. Additionally, all water management solutions needed to comply with local and environmental regulations.
To resolve the customer’s dilemma, Pinnacle Hire installed a pump system to transfer water from the dam to the canal. The company installed a fuel cell-powered pump that was connected to a clarifier for the initial water treatment. The treated water was the discharged through 40 metres of layflat hose into the drain canal.
Pinnacle Hire went one step further and designed a solution to improve the water quality.
“To enhance water quality, we placed Floc logs containing anionic polyacrylamide co-polymer at the discharge point of the stormwater drain. These logs effectively reduce suspended solids and colloidal clays in the water by causing them to flocculate,” Pinnacle Hire senior dewatering engineer Chris Comito said.
Elsewhere, Pinnacle Hire designed another solution to solve an Australian customer’s groundwater solution.
Pinnacle Hire implemented a precision wellpoint dewatering system, which helped keep the customer’s construction site dry, stable, and excavatable.
“Our dewatering technicians ensure you get the right equipment and support for your specific project needs, allowing you to focus on your core tasks while we manage your water challenges,” Pinnacle Hire said.
Water management requirements can differ depending on the industry and the regulations it must comply with.
That is why Pinnacle Hire employs a team of experts to ensure customers receive the
most up-to-date advice and support tailored to their industry.
The company recently worked alongside a Tier 1 contractor, which approached Pinnacle Hire after struggling to meet the growing demand for its construction water and needing to improve its water treatment system.
Pinnacle Hire took the time to understand the client’s needs within their industry and application. The team of technicians devised a solution using Grindex submersible pumps and upgraded the existing suction lines with 4” camlock fittings.
“It resulted in a more efficient, reliable and sustainable water management system, solving frequent system disruptions and costly downtime for the customer,” Comito said.
Over in the civil construction industry, Pinnacle Hire was engaged by a long-time client to deliver high-flow pump systems. The first system used a BA75 4” pump with two suctions and float switches. The pump was set on auto mode for efficient operation.
The second system featured a BA100 4” pump with two suctions and one 90° fitting. It was equipped with float switches and set to auto mode for easy operation.
“These pumps are designed to handle significant volumes of fluid, ensuring efficient and reliable operations for our client,” Comito said.
“The customer was happy with the outcome and the results our systems produced for them.”
From quarrying to the civil sector, mining and beyond, Pinnacle Hire’s team of expert technicians can help design the ideal system for any application.
“We’ve carefully selected staff who are experienced and dedicated, but also know the value of teamwork,” Pinnacle Hire managing director Jeremy Sailsbury said.
“We’ve also invested in a formidable new fleet of pumps and treatment equipment that is the envy of the industry. This has enabled us to grow from just a single location based in Victoria, to 13 locations across Australia in just the last 24 months.
“No matter where you are around Australia, you can find a Pinnacle Hire specialist to help plan and deliver your next pumping or watering treatment project.” •
For more information, visit pinnaclehire.com.au
Pinnacle Hire supplies solutions to customers around Australia.
Image: Pinnacle Hire
PARTNERS FOR THE LONG HAUL
Astec and Mineral Processing Solutions have expanded their partnership to support customers across Australia.
Australian quarrying customers will benefit from the expanded partnership between Astec Australia and OPS Group subsidiary Mineral Processing Solutions (MPS).
The agreement between the two organisations is a strategic move that enhances the distribution of Astec Australia’s fixed and modular plant equipment across all Australian states and territories through MPS.
MPS has the rights to supply and support all Astec fixed and modular crushing, screening, and washing equipment, as well as material handling and breaker technology products in Australia.
The move builds on a previous agreement announced in mid-2024, which gave MPS the distribution rights for Astec’s aggregate and mining sector equipment in New South Wales. The initial success of the NSW collaboration impressed Astec enough to accelerate the plans to expand MPS’ distribution rights.
Astec material solutions business line manager Adam Gordon told Quarry customers would be the main beneficiaries of the expanded partnership.
“Over the years, Astec and MPS customers have seen the benefits forged from our strong partnership,” he said.
“The MPS team’s extensive local market knowledge and experience in mineral processing – supported by Astec’s innovative technologies and manufacturing capability –
has made MPS the perfect partner to deliver outstanding products and service.”
When considering extending MPS’ distribution rights, Astec Australia realised that MPS’ experienced sales and service team would best suit its extensive range of products. MPS’ existing facilities on Australia’s east coast were also key factors in Astec Australia’s decision to extend the distribution rights. MPS maintains depots in Goodna, Queensland, Rutherford, NSW, and Laverton, Victoria. The company also has branches in Darwin, Perth and Adelaide, which provide customer support and access to equipment, spare parts and technical support, enabling MPS to support mining and construction materials customers.
“The ability to reduce downtime through fast and efficient parts delivery is a critical advantage for businesses operating in these industries,” Gordon said.
“This new network will enable us to deliver parts more efficiently, reducing downtime and enhancing the operational efficiency of Australian businesses.”
Gordon said the expanded partnership would help Astec Australia achieve operational efficiencies by consolidating supply lines and reducing lead times.
“MPS’s reputation for exceptional aftersales support and technical expertise further strengthens the value proposition for businesses relying on high-performance fixed plant solutions,” Gordon said.
“For customers, the expansion means not only greater convenience and accessibility to Astec’s globally recognised equipment; it will provide access to a knowledgeable team that can assist with installation, maintenance and ongoing operational support. Whether in the construction materials sector or large-scale mining operations, operators will benefit from a seamless procurement process and enhanced support services.”
With the partnership between Astec Australia and MPS well-entrenched within the quarrying industry, the two organisations are set to play a key role in the country’s construction materials industry. Customers will now have a streamlined way to access Astec Australia’s expansive range of solutions alongside MPS’ renowned service and technical support.
“As demand for high-quality processing solutions continues to grow, the strengthened partnership between Astec and MPS represents a proactive approach to meeting industry needs,” Gordon said.
“By leveraging our combined expertise and resources, both companies are wellpositioned to support Australia’s mining and construction sectors into the future.
“This agreement not only enhances service delivery but also reinforces the long-term stability and reliability of supply chains for critical equipment in the industry.”•
For more information, visit astec.com
Astec and MPS have maintained a strong partnership over the years.
Image: Astec
Zaxis-7 YOU’RE IN CONTROL .
Be in control with the 7 Series excavators and wheel loaders.
Hitachi Construction Machinery Aus tral ia
FUTURE FOCUSED
Liebherr is set for a major showcase at bauma 2025, including product debuts and showcases for international attendees.
Liebherr will host a 14,000m² booth featuring more than 70 exhibits and several individual solution concepts as it helps shape the future of heavy industries.
The exhibits will encompass a variety of industries and showcase earthmoving machinery, material handling technology, mining equipment, mobile and crawler cranes, tower cranes, deep foundation machines, concrete technology, and components.
“Liebherr sees itself as a dependable partner in technology that works hand-in-
EXPANDED EARTHMOVING
Liebherr will unveil a series of world premieres at the trade show, including in its popular earthmoving segment, with new wheel loaders, telehandlers, wheeled excavators, new railroad excavator as well as R 930 Tunnel crawler excavator.
Liebherr-Werk Bischofshofen GmbH will showcase two key innovations of the “Liebherr Autonomous Operations” system and the world’s first large wheel loader with the hydrogen engine in the
hydrogen-powered wheel loader is expected to save up to 100 tonnes of CO₂ annually, equivalent to about 37,500 litres of diesel at the quarry.
The Liebherr Autonomous Operations system enables repetitive tasks to be carried out easily and intuitively without an operator. The system is suited for loading hoppers and transporting materials from A to B. Attendees to bauma 2025 can see live demonstrations of the autonomous wheel loader.
The L 566 H will be at bauma 2025.
“Liebherr Autonomous Operations can be used anywhere – from a confined industrial hall to an open quarry.”
Alongside the L 566 H and Autonomous Operations system, Liebherr will offer a range of wheel loaders, from the L 504 Compact to the L 586 XPower and battery-electric wheel loaders L 507 E.
Additionally, Liebherr will debut two wheeled excavators in the A 909 Compact and A 911 Compact at bauma 2025. The A 909 Compact (nine-tonne class) and A 911 (11-tonne class) expand the company’s wheeled excavator portfolio and offer operators highly flexible machines in a compact design.
The A 909 Compact and A 911 Compact have small tail swing radiuses (1.5m and 1.6m, respectively) and front swing radiuses (2m and 2.1m, respectively), and their turning circles are 3.86m, which underscores their compact designs. The wheeled excavators offer operators great stability and enormous
QUARRY PUMPING EXPERTS
digging forces even in challenging applications like hard soil.
Attendees of the major trade show will also be able to see the world premiere of Liebherr’s new sixth-generation Telescopic Handler and the new T 48-8s Telescopic Handler, which expands the company’s offerings.
The T 48-8s marks Liebherr’s entry into the eight-metre class of telescopic handlers, catering to customers in the heavy industrial sector. Its design is based on the Liebherr T 55-7s, but the maximum lifting height of eight metres and dumping height give the T48-8s distinct advantages for industrial applications like loading trucks.
The sixth generation of Liebherr’s telescopic handlers retains the hydrostatic drive, which has been a trademark of Liebherr Telescopic handlers. The drive technology is impressive due to its precise manouverability, minimal susceptibility to wear and tear and excellent power transmission. The perfect all-round visibility typical of Liebherr has been further improved with the external ROPS/FOPS grille and offers the driver an unrestricted overview of the surrounding work area.
The new design of the sixth generation delivers load capacity increases of up to nine per cent for individual models. The electronic pilot control of the operating hydraulics is introduced for generation six while new Assistance Systems, such as the bucket shaking function, auto power and improved
fine control of the operating hydraulics, expand the telehandler’s capabilities.
Furthermore, Liebherr will present its new railroad excavators under a new product name for the first time: the RE 25 M Litronic. The model expands the existing portfolio with a machine in the 25-tonne class with hydrostatic rail wheel drive and a profiled uppercarriage.
Developed at Liebherr-France SAS in Colmar (France), the R 930 Tunnel replaces the R 924 Compact Tunnel and allows highlevel performance in all types of underground applications. Alongside the R 950 Tunnel, the R 930 Tunnel completes the range of crawler excavator dedicated to tunnel applications.
DELIVERING ON DIGITALISATION
Digital technology will be a key theme of Liebherr’s bauma 2025 showcase, including demonstrations and its InnovationLab.
“Digitalisation is one of the most significant areas of activity of our time. Though it may often seem abstract and technology-oriented, it is always centred around people and real added value,” Liebherr’s head of digital business and strategy Marcel Flir said.
“Our goal is to establish practical benefits that extend beyond value chains. That’s why we design machines and solutions in ways that best fulfil the needs of our customers and partners.”
For more information, visit liebherr.com.au
Liebherr will showcase its Autonomous Operations system with daily demonstrations at bauma 2025.
AGILE PRIMED FOR SCREEN SUCCESS
A new screening media supplier has entered the Australian market. Quarry finds what it plans to offer local quarries.
The origins of Agile Screening can be traced back to Warrington, England, where Thomas Locker first began weaving wire for the coalfields.
sector due to its market understanding and drive to reduce complications for customers.
Initially operating under the Locker Group banner, the business expanded to include operations throughout Australia and New Zealand.
In 2024, former chief executive officer Ed Sill & his Capital and Advisory firm, Trinity Capital acquired the ANZ business screening media business of Locker.
Agile Screening marketing director Carli Barnes said Sill saw the value in the screening business, given its long track record of success.
“The business is made up of people that have extensive experience and understanding of the Australian quarrying and mining industry,” she told Quarry
“Our team has hundreds of years of collective experience in the screening media industry. We understand history is important, but we are keen to set our own course.”
NIMBLE AND AGILE
Agile Screening is named after its focus – agility.
The company aims to have its products customised to unique site-specific requirements and available for fast delivery to customers.Supply chain management is a vital part of the business to deliver this reliably.
Barnes said Agile Screening’s supply chain optimisation was among the best in the
“Particularly in the quarrying industry, there is a need for fast and responsive delivery,” she said.
“Our focus on screening media means we can deliver this. Unlike others who have multiple markets they serve, we specialise in screens and getting those screens to site as required.
“Agile has developed a global supply chain to ensure its commitment to quality and service are unparalleled.”
Knowing what screen media will work best in the Australian market is a matter of experience for Agile. Its team thoroughly understands the products available on the market and, importantly, knows which screens are suited to particular site or machinery applications.
It also prides itself on keeping up with customer trends to ensure its customers can access the latest innovations in screening.
One such trend is a rise in polyurethane screening media, such as Tufflex and PolyRipple. Tufflex is made with polyurethane-coated wire and synthetic rope, either fully or partially welded. It provides extra flexibility to prevent pegging issues while remaining light and easy to manoeuvre, reducing the safety risks associated with lifting and installing traditional wire screens.
PolyRipple cross-tension screens are ideal for wet and sticky applications and offer high abrasion resistance. Wires can move within
the screen, allowing particles to pass through rather than blocking the aperture. The addition of polyurethane to the ripple screen improves its wear life.
Barnes said Agile Screening takes a customer-centric approach, working closely with clients to find the right solution instead of just selling products.
“Understanding a customer’s objectives and their pain points is important for us –whether that means holding specific screens for them at a location close to their site or if they need to change their screen media in summer due to weather,” she said.
“It’s about supporting them with the tools they need to achieve screening success.
“Even though we’re a new business, we have an experienced team and want to make sure we are delivering for our customers.” • For
Agile Screening works closely with clients to find the right solution
Polyurethane-coated wire and synthetic rope provides extra flexibility to prevent pegging issues.
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Agile Screening
MEET YOUR AMBASSADORS
Quarry talks to Greg Dressler about his time in the industry and the benefits of being an IQA member.
The Institute of Quarrying Australia (IQA) Ambassador program is well underway, and its members are helping to progress the IQA’s goal of enhancing member engagement by 2025.
The latest IQA Ambassador to share their story is Greg Dressler (FIQ). Dressler is the quarry manager for Heidelberg Materials Australia’s Kulnura Quarry, which is located off the New South Wales Central Coast near Gosford. He also serves as the chairperson for the IQA’s Hunter region sub-branch.
Quarry spoke to Dressler about his time in the quarrying industry and why he has remained an IQA member for more than two decades.
HOW LONG HAVE YOU BEEN AN IQA MEMBER, AND WHY DID YOU JOIN?
I joined the IQA around 21 years ago and was recently upgraded to Fellow, which was very satisfying to be recognised as a senior leader in the industry. I joined as I had started my first quarry manager role a couple of years prior. My quarry operations manager at the time suggested I join the IQA to continue expanding my knowledge base.
WHY DID YOU JOIN THE IQA AMBASSADOR PROGRAM?
I am very passionate about quarrying and the essential construction materials industry. This industry has allowed me to grow professionally and personally, and I want to give back to it.
Becoming an IQA Ambassador will provide a platform, alongside the various other roles I do within the IQA, to assist with steering the industry in a direction that is essential to make the sector more appealing to people who want to come into the industry and to help the community understand how essential it is to have the quarrying and construction materials industry. It will also provide a platform to showcase why it is a respected industry through the eyes of people currently employed in the industry,
WHAT DO YOU HOPE TO ACHIEVE AS AN IQA AMBASSADOR?
I want to help by continuing to grow the IQA’s member base. The industry is essential and a major contributor to the community through employment and infrastructure development. It has a significant economic impact and is the foundation for supporting the construction industry. The IQA is the only industry association that can connect people in the industry as it offers great networking opportunities with other quarries and associated industry people. The ambassador role assists with engaging with people and spruiking the IQA’s benefits. The more members, the more the IQA can assist, and the more opinions and ideas that others bring to the table, the better for the whole Industry.
WHY DO YOU RECOMMEND BECOMING AN IQA MEMBER?
The IQA offers everything required to assist people in the industry. Its ever-improving educational offerings are essential for industry professionals. The range of education on offer is ever-expanding and covers all industry roles, including safety, technical, environmental, operational, and quality. Whether you are an operator, a quarry supervisor, or a quarry manager, the range of training and how the training is delivered are high quality, whether face-to-face or online. A saying I heard many years ago was, “You train your people and risk losing them, or you
don’t train your people, and you risk keeping them”. We need competent, well-trained people in our industry, and the IQA is the only organisation that offers the required industryspecific training.
Another benefit of becoming an IQA Member is the networking opportunities. Being able to talk to others in the industry about wide and varied subjects like quarrying expertise from other quarry professionals to suppliers, contractors and consultants to the industry.
We have many very supportive suppliers, contractors, and consultants who support IQA. Networking dinner meetings, face-toface training, webinars, and conferences open up many opportunities to meet other passionate people in the industry. Many people say that people within the quarrying industry are the “salt of the earth, “ which is so true. They have great integrity, are reliable and humble and contribute positively to the industry.
The IQA is currently working on updating its website and is also developing an app. It is also becoming increasingly more active on social media platforms such as LinkedIn, Instagram and Facebook; this can only benefit the industry. The IQA is also investigating options to deliver an improved perception of the industry to the broader community, so watch this space.•
For more information, visit quarry.com.au
Greg Dressler is an IQA Ambassador for 2025.
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TAKEN BY VICTORIA
Liam Neeson’s love of Victoria has continued after the Hollywood star took to the regional areas for his latest film, The Mongoose.
For a man with a very particular set of skills, Liam Neeson has a real affinity for Victoria as the backdrop for his Hollywood blockbusters.
The renowned actor, known for his performances in the Taken series and Schindler’s List, has returned to film his third movie in the state within four years. Previously, Neeson filmed scenes for Blacklight (2020) and Ice Road 2: Road to the Sky (2023) in Victoria, with segments of the latter shot at a Victorian quarry.
In his latest film, The Mongoose, Neeson plays Ryan “Fang” Flanagan, who attempts to clear his name of a crime he didn’t commit while evading police during a televised crosscountry car chase, aided by members of his former Special Forces Army battalion.
“I’m honoured to be back in Victoria working on my latest film The Mongoose with one of the best crews, again, that I have ever worked with in over 100 movies,” Neeson said.
Parts of The Mongoose were filmed in Bacchus Marsh, Castlemaine, Bangholme, the Melbourne CBD, North Melbourne, Kensington, and Moorabbin. Neeson is working with Code Entertainment’s Al Corley, Bart Rosenblatt, and Eugene Musso, who also produced Ice Road 2: Road to the Sky.
In that film, the crew transformed Walhalla’s historic gold mining town to resemble a Nepalese village.
“It’s fantastic to see Bacchus Marsh once again in the spotlight, with this major Liam Neeson production bringing jobs, excitement, and a boost to our local businesses,” Eureka MP Michaela Settle said.
Like Neeson’s earlier film set in Victoria, The Mongoose has utilised a local Victorian quarry as its backdrop, despite the challenging weather conditions noted by Rosenblatt.
“Last week, we had a set-up in the quarry, and out of the blue with no warning, the night before, a flash flood and storm came through
and 50-kilometre winds, and it blew the entire set away,” he told the ABC.
“So we keep adapting … if you don’t like the weather here [in Victoria] just wait five minutes.”
According to the Victorian Government, the latest Hollywood production in Victoria will reportedly create more than 450 jobs for Victorian screen workers and engage 150 local businesses. Neeson’s previous works, Blacklight (2020) and Ice Road 2: Road to the Sky (2023), created more than 1300 jobs.
“The strengths of Victoria’s screen industry are no secret to Liam Neeson, Al Corley and Bart Rosenblatt. They love Victoria,” VicScreen chief executive officer Caroline Pitcher said.
“They have embraced our exceptional film-making talents and our spirit of innovation, which is benefiting Victorian small businesses and screen workers across the state.”
Image:
Liam Neeson’s latest film has been shot in Victoria.
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