Aggregates Manager October 2017

Aggregates outlook PG4

| Wheel loader roundup PG24 | Part 50 reporting PG28

Your guide to profitable production

8 13 Cover_AGRM1017.indd 1

October 2017 | www.AggMan.com

Estimate the costs of an injury

Streamline your ticketing

9/22/17 9:50 AM

How the top 5 aggregate companies gather aerial intelligence

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PQ_Kespry_Ad_Jan2016.indd 1 Untitled-22 1

2/8/2017 10:35:06 AM 6/14/17 3:13 PM

Kolberg-Pioneer’s filter kits for mobile equipment are designed to improve engine performance in dusty environments.

On Our Cover: Six fundamental rules can lead to better results with your drilling operation.

PAGE 6

Cover photo courtesy of Sandvik Mining and Rock Technology.

New app helps operators estimate the cost of common injuries and better understand the impact of health and safety interventions at their sites.

PAGE 8

TABLE OF CONTENTS OCTOBER 2017 |

VOLUME 22, NUMBER 10

FEATURE ARTICLES

8

What’s the Cost of an Injury?

A new app from NIOSH, Safety Pays in Mining, estimates costs of common mining injuries.

18 A Drilling Cheat Sheet

Six expert tips can help drillers punch the perfect hole.

24 Carrying a Heavy Load

New and updated wheel loaders offer higher efficiency, greater safety, and ease of operation.

OPERATIONS ILLUSTRATED

13

Best Practices for Loading and Ticketing

For efficiency and safety, keep drivers in the truck and out of the scale house.

TOC_AGRM1017.indd 1

COLUMNS & DEPARTMENTS 3 Editorial Standing tall in rising waters.

4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook.

6 RollOuts Komatsu’s new HD325-8 and HD405-8 off-highway trucks, and other new equipment for the aggregates market.

28 Rock Law Look to Commission decisions for guidance on Part 50 reporting requirements, particularly its definition of ‘entrapment.’

30 Advertiser Index See who’s who and where to find their products.

31 Classified Ads Aggregate industry classifieds.

32 Carved in Stone Rock dusting, another beneficial use of aggregates, makes coal mining safer.

9/20/17 11:00 AM

VISIT US #3422 INDOOR 3 - 5 OCT 2017

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8/21/17 9:53 AM

October 2017

EDITORIAL

Vol. 22, No. 10

by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com

aggman.com /AggregatesManager /AggManEditor

Standing Tall in Rising Waters

Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Senior Editor: Kerry Clines Online Editor: Wayne Grayson editorial@aggman.com

Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Kim Knight production@aggman.com

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3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com

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For change of address and other subscription inquiries, please contact: aggregatesmanager@halldata.com.

Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2017. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them.

Publisher reserves the right to refuse non-qualified subscriptions.

Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

Editorial_AGRM1017.indd 3

I

n late August, Hurricane Harvey dropped nearly 52 inches of rain on Houston.

According to the Federal Emergency Management Agency, nearly 600,000 structures were damaged, with one in four of those structures sustaining major damage or destruction, and almost 35,000 people sought shelter away from their homes.

While many of us watched coverage of the storm and donated funds, members of the local aggregates industry did much, much more. They got in their trucks or their boats and helped with rescue and cleanup efforts.

Rob Van Til, a managing partner of River Aggregates, LLC, and his family worked with local teams to help people whose homes were damaged. “What I’m proudest of is the community’s response,” he said. “It’s not about cars or buildings or equipment.

It’s about people.” Rob and his son volunteered with a crew helping to gut homes that needed to be torn back to the studs. His wife and daughter made food and transported those who had lost their homes as needed.

Although he’d joined Alamo Cement as its central Texas market manager less than a month before, James Oquin quickly volunteered to help with rescue efforts. With the full support of his company, James hauled his airboat to Houston, where he spent a night sleeping in his truck before getting a call from the Fulshear Police Department for help with an emergency medical evacuation. He transported a woman who was 36 weeks pregnant, along with her husband and two dogs, to the hospital. Over four days, he helped rescue 60 people from their homes. “It was amazing,” Oquin says.

On his second day in Houston, James spotted the bright yellow safety gear sported by a crew from Hanson Aggregates, including its Houston area operations manager, Darryn Lindsey. When Darryn learned that James didn’t have a place to stay, he offered him one at his house and made sure he had shelter until returning to San Antonio. “I was really just pleased to run into a fellow industry guy out there doing the same thing; sacrificing his time and using his own boat to come down and help out. I thought that was pretty awesome,” Darryn says.

Darryn was assisting rescue efforts with his incoming and outgoing Brazos Plant managers Jake McCurry and Sean Steagull. They took a boat used to access the plant’s dredging operation and shuttled residents out of the Weston Lakes area. Over the course of the day, they ferried between 25 and 30 people to high-water vehicles that could transport them out of the neighborhood. “Everybody was pretty grateful. They knew we were all there as volunteers, just trying to help them,” Darryn says.

When disaster struck, these are just a few of the members of the aggregate industry who quietly went to work helping neighbors and strangers alike. So, walk a little taller, hold your head a little higher, and know that your industry friends and peers truly served as good neighbors to the greater Houston community.

AGGREGATES MANAGER / October 2017

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9/18/17 8:21 AM

mining

U.S.

On-Highway

Diesel Fuel

Prices 8/7/17

Company Cemex, S.A.B. de C.V.

New England $2.384 One Week +0.027 p One Year +0.259 p

Central Atlantic $2.470 One Week +0.053 p One Year +0.326 p

Lower Atlantic $2.221 One Week +0.014 p One Year +0.230 p

Midwest $2.284 One Week +0.008 p One Year +0.169 p

Gulf Coast $2.154 One Week +0.071 p One Year +0.226 p

Rocky Mountain $2.390 One Week +0.047 p One Year +0.164 p

West Coast $2.842 One Week +0.009 p One Year +0.269 p

West Coast less California $2.588 One Week +0.009 p One Year +0.201 p Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).

DataMining_AGRM0917.indd 4

52-Week Low

52-Week High

$9.65 q

$6.91

$10.37

CRG

$34.74 q

$31.42

$38.04

Eagle Materials Inc.

EXP

$91.47 q

$73.27

$110.64

Granite Construction Inc.

GVA

$53.54 p

$42.59

$62.18

Heidelberg Cement AG

HEI

$95.87 q

$90.43

$111.09

LafargeHolcim Ltd. ADR

HCMLY

$12.17 p

$9.89

$12.23

Martin Marietta Materials, Inc.

MLM

$209.87 q

$167.06

$244.32

MDU Resources Group, Inc.

MDU

$26.10 p

$22.94

$29.92

Summit Materials

SUM

$29.51 q

$17.27

$29.72

United States Lime & Minerals, Inc.

USLM

$81.77 p

$60.24

$83.00

U.S. Concrete

USCR

$78.50 q

$42.82

$80.45

Vulcan Materials Co.

VMC

$118.39 q

$105.71

$138.18

Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 8/08/17.

COMPANY SPOTLIGHT

One Week +0.026 p One Year +0.228 p

East Coast $2.336

CX

Current Value

CRH plc

United States $2.378

One Week +0.030 p One Year +0.270 p

Ticker

E

agle Materials (EXP) started off strong during the first quarter of its fiscal 2018 year, which ended June 30. It posted record revenues of $336.1 million, an increase of 23 percent against its first quarter 2017 results. Net earnings per diluted share of $1.13 were up 22 percent. First quarter earnings before interest and income taxes also increased by 22 percent. Higher sales volumes and net sales prices across most of its businesses, as well as its acquisition of a Fairborn, Ohio, cement plant from Cemex, fostered these results.

Cement revenues for the first quarter totaled $182.9 million — 26 percent higher than the same quarter in 2017. The average cement net sales price for the quarter was $106.95 per ton, a 6-percent increase over the first quarter of 2017. Like-for-like average net cement sales prices and sales volumes increased 4 percent and 7 percent, respectively, compared to the same quarter a year earlier.

Concrete and Aggregates revenues Eagle Materials (EXP) for the first quarter were $43.5 million, an increase of 26 percent from first quarter 2017. First quarter operating earnings were $6.0 million for the first quarter, a 63-percent improvement for the same quarter in the prior year.

This reflects improved concrete and aggregates pricing and concrete sales volumes.

“The opportunity to sell products across all of our businesses — cement, wallboard, proppants, and concrete and aggregates — continues to improve, and we’re taking advantage of these trends,” said President and CEO Dave Powers during the company’s quarterly conference call. “The underlying drivers of our businesses are almost universally toggled in the up position, and longer-term risk currently skew to the upside.

“Single-family housing starts, for example, continue to improve and have substantial room for growth. Household formation trends, combined with an economic environment of low unemployment, healthy job growth, and low interest rates, are a powerful combination,” he added. “Most areas of the U.S. are doing well, especially in the markets that we operate. Infrastructure investment is growing and could grow even more in the years to come.”

Source: Market Watch

Data

STOCK REPORT

9/18/17 10:55 AM

ek

37

04

64

18

09

23

32

92

72

00

45

AGGREGATES INDUSTRY OUTLOOK The August Aggregates Industry Index increased for the second consecutive month to an overall score of 134.60, a 0.74-percent increase from July. While wet weather seemed to hamper some operators earlier this year, monthly sales reports increased 6.3 percent from last month’s results, the survey’s most dramatic monthly increase.

Looking back to August 2016 results, all categories have reported significant increases. Annual increases range from a low of a 13.6-percent increase in expectations for tons of aggregates sold for the next year to a high of a 26.8-percent jump in the outlook for tons of aggregate sold in the current month, compared to a year prior.

Aggregates Industry Outlook 150

139.35

145

139.94

140 135

124.24 122.43

130 125 120

134.60

132.37

140.38

135.06

133.61

109.80 111.42

111.00

115

108.08

110 105 100 Sept.

2016

Oct. 2016

Nov. 2016

Dec. 2016

Jan. 2017

Feb. 2017

March 2017

April 2017

May 2017

June 2017

July 2017

Aug. 2017

Sept.

2017

18 The demand for construction related products remains strong.

New projects are continually popping up in each market that we manufacture and service in. The outlook is very positive, and expectations remain high.

I believe that Trump has got it going again. Our family is involved in a number of business sectors, and all seem to be on the upswing.

— Jon Thompson, President, Letart Corp.

— Van Stockstill, President, Consolidated Aggregates

I believe another positive influx is the recent addition of eight states that have enacted legislation to increase the gas tax. I think a direct correlation will be seen in the aggregates industry as a result of the increase and the need to support deteriorating infrastructure across the United States.

— Jill Shackelford, President, Shackelford Consulting

Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.

MOBILE EQUIPMENT FINANCED Type of Equipment Wheel loader (250-1,000 horsepower)

198

Excavator (160-520 horsepower)

102

Wheel loaders Cat 980M

Top Cat 982M models Cat 980G financed

14 13

Cat 988K

7

Top Cat 349FL models financed Komatsu PC360LC-11

Wheel Loader Wisconsin

18

Pennsylvania Ohio 10

11

California

8

28

8

Cat 336FL

DataMining_AGRM0917.indd 5

Number financed

Komatsu WA500-8

Excavators

TOP STATES

04/01/201706/30/17

Alabama

8

Texas

18

Excavators Wisconsin

Number financed

6

19

Pennsylvania Ohio 6

5

10 8

Deere 470 G LC

8

Volvo EC480EL

5

Texas

9

Florida

5

9/18/17 10:56 AM

ROLLOUTS

Your complete guide to new and updated equipment and supplies in the aggregates industry.

by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com

Tier 4 Final rigid frame trucks offer better fuel efficiency Komatsu America Corp. introduces the HD325-8 and HD405-8 offhighway trucks. Equipped with a Tier 4 Final engine, these rigid frame trucks feature increased horsepower and a new Komatsu Traction Control System for improved productivity. The models have payload capacities of 40.3 and 44.1 short tons, respectively, and replace the HD325-7 and HD405-7 models. The Komatsu SAA6D140E-7 engines have a net 514 horsepower. Fuel consumption is up to 9 percent lower in the HD325-8 and up to 6 percent lower in the HD405-8, compared to their predecessors. The Komatsu Traction Control System, which is standard on these models, automatically applies independent brake assemblies to optimize traction in varying ground conditions. Other new features include a 78-decibel cab, 7-inch LCD color monitor, dedicated rearview monitor, fast-fill fuel system, and a premium heated and ventilated operator’s seat with air suspension.

Komatsu America Corp. | www.komatsuamerica.com

New bucket options for wheel loaders John Deere rolls out its enhanced series buckets for the 744K-II, 824K-II, and 844K-III wheel loaders. The buckets offer several new features, including an improved bucket profile, integrated narrow spill guards, bushed static bucket pin joints, and optional wear plating. Curved profile side cutters are said to improve material retention and allow for better bucket fill of loose material. Integrated narrow spill guards provide better visibility to the load so the operator can see when the bucket is full to help reduce loading time, fuel consumption, and number of loads on the machine, while protecting wheel loader linkage. Bushed static bucket pin joints reduce the need for welding and enable repair in the field.

John Deere | www.johndeere.com

Filter kits protect engines from dust Kolberg-Pioneer, Inc. offers new filter kits for all mobile equipment.

Designed to improve engine performance in dusty environments, the filter kits cover all access doors and openings. They can be retrofitted to any model and serial number. The filter media is easily replaceable using a simple retention system with positive locking pins and clips.

Kolberg-Pioneer | www.kpijci.com

Railcar vibrators promote free flow of bulk materials Martin Engineering introduces the Martin IMP3 Impacting Railcar Vibrator, a portable vibrator that activates the free flow of materials from closed-top hopper railcars. Said to offer one of the highest force-to-weight ratios available, the vibrator can evacuate bulk commodities such as Portland cement. The vibrator produces 3,000 vibrations per minute and 3,400 pounds of force, which is comparable to 50 sledgehammer blows per second. The rapid impacts generate a vibratory wave through the metal hopper of the railcar, loosening adhered material to promote fast and even flow.

Martin Engineering | www.martin-eng.com

6

AGGREGATES MANAGER / October 2017

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Redesigned screening plant adds rinser Irock Crusher’s TS-522 TDR track portable screening plant has been redesigned to include a rinser. The portable unit gives quarries the ability to screen and wash materials simultaneously for end-use applications. The machine sorts and washes as many as three sized and one oversized products at once. Capable of processing 200 to 300 tons per hour, the unit features three decks with nine spray bars along the top deck and eight each on the middle and bottom decks. The spray bars deliver 25 pounds per square inch of water pressure to remove dirt and debris from material, while a rinse box at the top of the unit features two more spray bars that pre-soak material. A 14-foot-wide hopper holds up to 12 cubic yards of material.

Irock Crushers | www.irockcrushers.com

Off-the-road radial tire line Bridgestone Americas, Inc. showcases its Firestone VersaBuilt tire line, its first full line of off-the-road radial tires. Designed to balance reliability and affordability, the line is suitable for loaders, graders, and earthmovers working in a range of conditions from muddy to rocky surfaces. The tires feature a steel casing and SideArmor sidewalls to protect against cuts and punctures; a nondirectional, self-cleaning tread for added traction; three different tread patterns; and 11 size offerings.

Bridgestone Americas, Inc. | www.bridgestoneamericas.com

Compact jaw fits in a container Terex Materials Processing’s EvoQuip, a compact crushing and screening line designed to provide ease of operation and transportation, debuts its Bison 120 Jaw Crusher.

The Bison 120 was designed for operators who need versatility, maneuverability, and transportability. Small enough to fit inside a container for transport, the crusher features a 26.77- by 15.75-inch single toggle jaw crusher that can be adjusted hydraulically using the remote control that comes standard with the machine. The jaw is driven hydraulically, allowing operators to reverse the crusher to clear a blockage.

The ability to adjust the jaw setting and operate the plant fully from the remote control allows for quick set up.

EvoQuip | www.terex.com

Diesel and DEF transfer tank Thunder Creek Equipment introduces a combination diesel and diesel exhaust fluid transfer tank for pickup trucks. The combo tank provides 100 gallons of diesel and 18 gallons of DEF capacity that fits into the bed of pickup trucks that are half-ton or larger. Both pumping systems are concealed within its structure, with no elements protruding from the tank. Both fill nozzles are located on the driver side and extend 10 feet from the tank. An optional thermostatically controlled DEF heating system is available for use in northern climates to ensure the temperature of the tank, pumps, and hoses doesn’t dip below 25 degrees. The entire transfer tank and all components are concealed in a lockable-weather-sealed enclosure.

Thunder Creek Equipment | www.thundercreek.com

AGGREGATES MANAGER / October 2017

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SPECIAL REPORT

by John R. Heberger

What’s the Cost of an Injury?

A new app from NIOSH, Safety Pays in Mining, estimates costs of common mining injuries.

D

o you have any idea how much a lacerated finger or back sprain can cost your company? Safety Pays in Mining — a new, free web app from the National Institute for Occupational Safety and Health (NIOSH) — can help you find out.

Safety Pays in Mining not only gives you the cost of injury claims, but also reports the most common injuries and work activities by commodity, shows how selected injuries can impact profits, and offers suggestions on how that same money might be spent if injury was prevented. The web app is available on the NIOSH Mining webpage at https://go.usa.gov/xNk8U. Injuries on the job cause pain and suffering. They can also

8

profoundly affect profits and daily operations. In addition to paying direct costs or increased premiums for workers’ comp insurance, you might need to pay for overtime for other workers to fill an injured worker’s role, cover training costs for a replacement, or divert administrative resources in the wake of an injury. This web app estimates the unknown distribution of these injury costs.

The costs of specific types of occupational injuries in mining are not readily available because mining and insurance companies don’t usually share this information. As a consequence, companies only have cost information based on previous experience with their own employees. Therefore, if a mine never experienced a finger amputation for one of its miners, it

AGGREGATES MANAGER / October 2017

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Discover the ELRUS Advantage. www.elrus.com

Untitled-21 1

AGGREGATE SYSTEMS

9/5/17 8:31 AM

SPECIAL REPORT Figure 1

Safety Pays in Mining displays the most common injuries and work activities at the time of injury for 2015 by commodity.

Figure 2

Using real cost data Safety Pays in Mining has accurate cost estimates because it uses real workers’ comp costs. The web app uses direct costs, which include medical expenses and indemnity payments that were calculated from cost data for specific mining injuries obtained from the Ohio Bureau of Workers’ Compensation.

Identifying information was removed from claims data and only injury types with more than 10 claims were included. Workers’ compensation claims for miners from 2001 to 2011 were used for the cost estimates.

Companies who self-insure pay direct costs out of pocket.

Companies who purchase workers’ comp insurance would have these direct costs paid by the insurance company. However, the cost impact for mines with insurance would largely be through increased premiums and eligibility to participate in group policies.

Indirect cost estimates were also calculated in order to provide a realistic injury cost estimate. These are costs to the employer that are generally not covered by insurance. Such costs could include reduced productivity due to disruption of work or replacing damaged equipment, and temporary or permanent replacement of injured workers. The total cost of an injury is the sum of the direct and indirect costs. All costs were adjusted to 2015 dollars. Future versions of Safety Pays in Mining will update costs to the most recent calendar years.

Using the app

The “What is the Cost of Occupational Injury?” section demonstrates that the total cost of a single back injury could be over $31,000.

would not be aware of the possible costs. In addition, injury costs are unique in that the cost distribution is so wide — just using an average cost doesn’t provide adequate information.

Some injuries involve immensely high costs, and even though the risk of these injuries is low, mines need to be aware of their potential impact on their financial health.

With Safety Pays in Mining, you can see what specific injuries, such as burns, fractures, dislocations, and sprains, might cost you — from $820 for an ankle sprain, to $22,500 for a fractured hand, to more than $45,000 for a sprained shoulder. You can enter your own figures, or use the default values based on the mining industry to show impact to profit margins.

10

To use the app, you select options from drop-down menus in four sections representing (1) common injuries and activities, (2) cost of injury, (3) impact of injury cost on profits, and (4) how the company could spend the cost savings from injury prevention. Default values are automatically included in most fields to allow you to make general estimates, or in case the desired specifics on your company’s injuries are not known.

In the “Most Common Injuries and Work Activities for 2015” section (Figure 1), choose the commodity of interest, and an injury summary for that commodity is displayed for 2015. This shows what the most common injuries were and what miners were doing when injured. For example, for the commodities of stone, sand, and gravel, the most common types of injuries reported to MSHA were hand and finger lacerations and back sprains/strains. The most common mine worker activities where miners were injured were handling supplies/materials, machine maintenance and repair, and using hand tools.

The section “What is the Cost of Occupational Injury?” is the app’s main feature (see Figure 2). First, select one of two lists of injury types: injury by “nature” (type of damage to the body) or injury by “cause” (manner in which the injury was inflicted). Once selected, the distribution of injury costs for that type is displayed. Then, select the number of injuries of this type that have occurred or may occur. It is important to consider the expected number of injuries, because a higher number of claims results in a higher chance of a very expensive claim. A note in the app suggests percentile cost figures to use based on number of total injury claims. You can select the mean cost or one of the cost percentiles for the specific injury type.

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Figure 3

This screen capture shows the financial impact of an example back sprain injury.

This back sprain cost 1.56 percent of the company’s annual sales, and the mine would need to have more than $567,000 in sales to make up the cost of the back sprain.

After making these selections, the report then shows a summary of the injury, the number of injuries, the direct cost, the indirect cost, and the total cost. You can repeat this process for each injury type and then generate a summary report for all injuries.

Other features of the app The section “What is the Impact of the Cost of Occupational Injury on Your Company?” shows how injury costs can affect profits. Enter your company’s profit margin and annual sales, or accept the default values based on the commodity selected in the “Most Common Injuries and Work Activities for 2015” section. The resulting impact report shows the total injury cost, the total injury cost as a percentage of annual sales, and the additional sales needed to pay for the injury total cost (Figure 3).

The section “How Could Your Company Spend Its Savings from Preventing Injury?” shows different ways a mine operator could use the money otherwise spent on injuries. You can use the default values or input the average amount that your company pays for an annual hearing loss prevention program, a pair of boots, or a hard hat. Based on these values, the app displays how many of each could be purchased if the injuries were prevented.

Benefits from using the app This web app educates users on the wide range of occupational injury costs. For specific injuries, mine management will find it useful to see the distribution of workers’ compensation costs, as well as the indirect costs, which are often overlooked. The web app demonstrates that even a common injury has the potential to be extremely expensive. This app will help you to prioritize health and safety interventions at your mine. AM Disclaimer The findings and conclusions in this article are those of the author and do not necessarily represent the views of the National Institute for Occupational Safety and Health.

AGGREGATE SYSTEMS

John R. Heberger is an epidemiologist with the NIOSH’s Pittsburgh Mining Research Division.

AGGREGATES MANAGER / October 2017

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9/20/17 10:37 AM

Ready whenever and wherever you are.

Aggregates Manager Magazine makes it easy to keep up-to-date while you are on the go. Get the latest news in the aggregates industry, along with insight from our award-winning editorial team, through our mobile version of AggMan.com.

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6/15/17 1:38 PM

OPERATIONS ILLUSTRATED

By Tina Grady Barbaccia, Contributing Editor

OUR EXPERTS

Print directly at the scale for safety and efficiency.

Ron Becker is a business consultant for the Apex line at Command Alkon. Becker previously worked for The Shelley Co., part of Oldcastle Corp., in the IT department. In this position, he handled implementing point-of-sale systems in aggregates operations and working with plants to set up remote scaling and related operations.

Best Practices for Loading and Ticketing

Identify trucks via the web or RFID tags as soon as they enter the operation.

Maintain baghouses and air pads in the plant’s silos.

Jay Wise is a partner at Kruse Integration.

He has a background in electrical and electronics engineering and helps design systems to provide process automation and control, including for loading and ticketing systems.

Glenn Carr is Cemex ‘s regional manager of logistics operations for the West Region. He has 20 years of experience with Cemex. Carr started at Cemex ‘s Victorville facility in 1997, serving in the kiln operations department. He also served two years as operations manager over finish mill operations manufacturing cement.

AGGREGATES MANAGER / October 2017

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9/7/17 8:27 AM

Keep Your Ticketing System Efficient

T

he key to efficient loading and ticketing in an aggregates operation is to keep loadout trucks moving and increase the speed to complete the entire material loading cycle — from scale house to stockpile and back to the exit, says Ron Becker, business consultant with Command Alkon.

Automation technology can help play a role in speeding up this process by automatically identifying a truck as it enters the scale house. This can be done with a radio frequency identification (RFID) tag or reading a license plate.

“Anything that identifies the truck without having to interact with a person helps move things along,” says Becker, who set up point-of-sale and remote scaling systems for Oldcastle Materials’ Shelly Co. in a previous position. “If a truck is coming in and being identified, a conversation is being started with the right truck.”

When a truck initially enters a plant to load material, the haul truck driver can identify himself and indicate the product needed. “If you’re coming in and out several times, you don’t need to check in every single time,” Becker points out. “You can assume the truck is there for the same thing, unless indicated otherwise.”

This allows the loader operator to handle other tasks when trucks are not in line. “If you can ‘talk’ to the loader-operator via the web or wireless check-in,” Becker notes,” you can provide information ahead of time on the

1

product needed and the loader operator knows who is here for what and where to go.”

Efficiency is also important for the equipment being used. Cemex has EnergyStar-rated terminals at some of its operations, which keeps electrical consumption to a minimum by turning on operating equipment only as needed, explains Glenn Carr, Cemex regional manager of logistics operations for the West Region.

“If you keep employees engaged with a common goal of energy conservation, it can keep your equipment running as efficiently as possible,” Carr says. “It gives everyone a chance to succeed.”

Automation is important to making a plant efficient, says Jay Wise, a partner with Kruse Integration, noting that some small operations — i.e. “mom and pop” facilities — may not have much experience with it or think it is important. “Their grandfather may have worked the plant with a shovel, so that’s what they have known,” he says.

“But it’s hard to be efficient this way. Someone may end up eventually buying the operation or it may go out of business because they won’t have data recorded about where improvements are needed.”

However, Kruse notes that automation alone is not enough to make it successful. Education is also essential.

“You need a few guys that understand the entire system and how it works,” Kruse says.

Develop a graphical system

Develop a graphical system that mirrors the physical system to make it simple to understand. All elements of the loading and ticketing system need to be integrated, simplified, and monitored, including equipment load cells, scales, and batching loadout information. Create a variety of batching recipes that can be accessed through a simple drop-down menu so there is no confusion or unnecessary time taken to plug in a recipe. This can be set up so, if different silos, cement bins, and belts drive the loadout system, a different batch can be loaded to each truck.

14

AGGREGATES MANAGER / October 2017

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2

Offer ticketing at the scale

Keep the trucks moving through the plant by offering ticketing at the scale. This eliminates time that would be spent by drivers going into the scale house to get a ticket, as well as the potential for the driver to stop and chat. Although it may only be a few minutes each load, the time adds up throughout the day. Lost time could be equivalent to an entire load.

Eliminating the need for drivers to exit their vehicle also reduces the potential for them to fall, especially during inclement weather.

3

Provide truck ID to loader

Traditional aggregates and sand and gravel operations have used a CB to communicate with the loader.

However, through the use of a web check-in or radio frequency identification (RFID), the loader operator is able to be more efficient by knowing when and where to be at a specific stockpile. It also enables the loader operator to handle other necessary tasks, such as mixing ag-lime and charging the plant, when no trucks are in the yard, instead of waiting at the pile.

Unless the desired material changes, it eliminates the need for the truck to check in every time.

4

Monitor system reports

Review the detailed reports available with your loading and ticketing system. Paying attention to inventory is important, but be sure to pay attention to both uptime and downtime to get a better understanding of where there are efficiencies and bottlenecks or other problems. Look for trends such as a belt repeatedly getting jammed or an overload tripped numerous times to determine what issues need to be addressed. Also ensure that at least a couple plant employees understand all aspects of the system.

AGGREGATES MANAGER / October 2017

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9/7/17 8:27 AM

Voices of Experience Ron Becker

S

howing customer appreciation is important, but it needs to be strategic so it doesn’t slow down cycle time. “It may seem totally harmless to have snacks and coffee at the scale house, but get rid of it if you really want to move trucks along,” says Ron Becker, a business consultant at Command Alkon. “You want trucks coming in and getting rid of material.

If they stop for 10 minutes here and there, that time could add up to a load.”

The ability to print a loadout ticket at the scale also helps keep cycle time and the loading process moving along because it keeps trucks in the line of traffic. “It adds huge efficiencies so things don’t break down at the scale house,” Becker says.

There is also a safety aspect of printing a ticket directly at the scale instead of drivers going inside the scale house and potentially falling, especially in areas that experience inclement weather, such as snow and ice.

“If you are watching your gate-togate times and accurately tracking them, it skews the numbers when someone comes in to get a ticket and then talks for 10 minutes.” Becker adds.

Although it’s good to keep the drivers happy, ultimately, the trucking company is the paying customer.

“When a trucking company calls and asks why a load took so long but you have no explanation, because the ticket time doesn’t reflect how long it took to complete the load cycle, it could be problematic,” Becker says.

Instead, he suggests planning a separate event in spring or summer during good weather. “There is nothing wrong with having a grill near the scale house and handing out a hot dog on the way through to get a ticket,” he says. “This allows you to take care of the customer — the trucking company — and show appreciation for the driver, too.”

16

Jay Wise

Glenn Carr

T

A

o have the most efficient loading and ticketing process, all elements of the system need to be integrated and simplified. This includes pulling together equipment load cells, scales, PLCs, and incorporating information to do a batching load-out and inventory.

“From this information, you can develop a graphical, user-friendly system for operators to be able to easily load-in and load-out,” says Jay Wise, a partner with Kruse Integration.

Graphically depicting a physical system makes it easier to be understood and allows for quick learning, operations, and troubleshooting. Within the system’s PLC and database, a variety of batching recipes can be created so they can quickly be selected via a drop-down menu.

“You might want a different mix of materials for load out into the trucks or rails,” Wise explains. “There may be different silos and cement bins — and even belts — that drive the system when a truck goes under them to load the material. The drop-down menu of formulas allows a different batch to be loaded to each truck.”

A system that tracks and records information such as downtime and inventory allows producers to identify problems, as well as what is keeping the loading and ticketing process moving along. “You can’t fix something or improve it if you aren’t recording data,” Wise says.

Report details highlight specific areas that require improvement. Wise gives an example of the old school way of reporting downtime to a supervisor — a napkin with notes on it about the reasons for downtime. “This isn’t detailed enough,” Wise says. “If not as efficient as possible, you won’t be able to keep costs down. Selling a ton of sand or rock for $6 or $7 is a low margin. If you’re not automated to get reports, you aren’t being as profitable as possible.”

t Cemex’s Victorville, Calif. facility, the largest portion of its trucks are dispatched, making it paramount to keep the loading and ticketing system as efficient as possible.

To expedite the process, white cards are handed out to all drivers at the guard gate and each driver is asked to fill out his/her information.

“This speeds up the process when the information is being put in for ticketing,” explains Glenn Carr, Cemex regional manager of logistics operations for the West Region. “The card is used to confirm any discrepancies with the customer.”

It also allows the loading system in place to operate efficiently, enabling a truck to be loaded in less than seven minutes.

“Keeping the drivers in their equipment as we load their trucks minimizes the potential for slips and other accidents,” Carr adds.

Moving the signature pad and ticket delivery closer to the drivers’ hatch-closing station also further reduces customer exposure and time at the terminal, which reduces the average trip time between loads, he says.

“The utilization of a traffic light system is another effective way to communicate with the drivers on the scale,” Carr adds.

“In our environment, communication is key. Starting with spotting the truck on the scale, a good PA system is important.

This eliminates wasting time trying to get the truck under the spouts.”

Producers should ensure they have a good recovery system in place and keep the operation’s baghouses maintained for top efficiency. Keeping the baghouses and air pad silos in good condition enables trucks to be loaded both cleanly and quickly.

“If you have a good supply of cement, but it overruns your recovery system, your load time will be substantially be reduced,” Carr points out. “Investing in a good baghouse and recovery system can help the process.”

AGGREGATES MANAGER / October 2017

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Mining Mastermind Evolve to meet challenges with the intelligence and strength of the SmartROC family of drill rigs.

• Ideal for mining and quarrying • Planning and control with Hole Navigation • Remote operation options

800-732-6762 www.atlascopco.com

Untitled-79 1

9/13/17 9:10 AM

EQUIPMENT MANAGEMENT Mineralogy and application will determine how quickly a drill bit will dull. Watch the diameter of the flat area of a worn button to determine if it’s time to change the bit.

A Drilling Cheat Sheet Six expert tips can help drillers punch the perfect hole.

“I

n daily drilling production, the mission of the drill is to punch holes. It’s that simple,” says Bill Hissem, a 40-year veteran of the industry and senior mining engineer at Sandvik Mining and Rock Technology. The Colorado School of Mines graduate has consulted and worked in every state, as well as in Canada, and on several other continents, including South America, Western Europe, and Australia.

18

From this broad experience, Hissem has developed fundamental rules to guide drill rig operators in their quest to efficiently punch the perfect hole.

Following is a summary of those rules as contained in six tips — plus a bonus piece of advice for drilling managers.

1) Read the operator’s manual.

“You really don’t want to do stuff with your drill that it shouldn’t do,” Hissem says. “Some try to just operate a new

drill like they did the old one, but that only works if the new one is like the old one.” Chances are, it isn’t, the nature of technology being to evolve and advance. So, read the manual, Hissem says, adding that most of today’s operator’s manuals are clearly written and illustrated. He adds, as an aside, that he has encountered a few drill operators who are unable to read, which might say something about the lack of operator certification in this country as opposed

AGGREGATES MANAGER / October 2017

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Cubee the AggMan helping educate children about the importance of aggregate since 1998 “The Story of Cubee the Aggregate” helps teach children at the youngest ages about the important role aggregate plays in their daily lives. Geared for students in grades K-3, Cubee and his aggregate friends will take children on a magical journey from Cubee’s birthplace in the neighborhood quarry to his new home in the schools, roads and other structures that enrich our communities and our lives.

The “You’re on Rock” Workbook presents basic earth science information while emphasizing the vital role of the industry in our world. An aggregate activity book for junior geologists, mining engineers and earth scientists. Geared for students in grades 4-6.

Cubee the AggMan T-Shirts are available.

To learn more about these great tools for community outreach, adopt-a-school programs, and receive sample copies of the coloring/workbooks,

Call 800-430-4540 e-mail: cubee@aggman.com

Cubee_AGRM0612pg145.indd 1

or visit www.AggMan.com

5/15/12 8:53 AM

EQUIPMENT MANAGEMENT

While smart drills offer onboard intelligence, it’s important that the driller monitor things such as the flushing action, pitch changes in the drill string, and movements that indicate a change in rock pressure.

to Europe. Bottom line: If you can read this, read your manual to be safe and productive.

2) Use sharp bits.

How quickly a bit will dull varies on its application. In hard, abrasive rock, an

20

operator can get as little as 200 feet out of a bit — compared to the experience of a top-hammer drill operator in Oklahoma who told Hissem he once got 50,000 feet out of one. How do you know when to change out a bit? Hissem advises doing so when the diameter of the flat area

of a worn button on a bit exceeds one third of the base diameter of the button.

He compares a flattened button to a pair of flat shoes, which spread the weight of the wearer across the bottom of the shoe. Whereas, a rounded button is like a pair of stiletto high heels, which transfer the weight to the surface in a very small area. The smaller the button area touching the surface, the greater the psi and rock-breaking stress brought to bear upon the rock surface. “You never get 100 percent of the energy applied to the bit into the rock. The best you can get is 95 percent, with 5 percent bouncing back,” he says. The point is, the sharper the bit, the less energy reflection you will get, and the faster the bit will cut the rock.

3) Balance feed, rotation, and percussion.

These forces are the key variables, and optimizing them can be helped by watching for such things as the size of cuttings coming out of the hole. The chips should be as large as possible,

AGGREGATES MANAGER / October 2017

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thumbnail-sized ideally. The goal is to minimize the amount of mechanical kinetic energy and heat bouncing back to the drill, while transferring as much energy as possible into the rock to spall and break it. “The challenge has never been about generating enough power.

Rather, it is about improving the durability, longevity, and efficient energy transfer of the drill string and cutting tools,” says Hissem. He believes metallurgical advances and new drill technologies have together produced “a modern physics miracle.” Effective operators can tap into this miracle by tuning and balancing the forces being applied.

4) Drill smart.

This tip is a collective of several fundamental techniques. First, set up a rig precisely. If it is supposed to be vertical to the surface, the mast dial should read 90 degrees, not 85. “Close enough” isn’t good enough. Second, when the drill bit is lowered to the rock surface, ease into the boring. When collaring in, grind

RR Recruiting_AGRM_half hz.indd 1

EquipmentManagement_AGRM1017.indd 21

Balance quality control and production rather than speed when motivating drillers.

Otherwise, operators may take shortcuts to gain footage, but compromise safety and overall cost.

out a pocket for the bit to seat in before powering up. Otherwise, the drill head is apt to skew off, producing lateral stress on the string, Hissem says. Last, if loose, unstable material is left over from a

prior shooting, proceed carefully, because the unstable rock can easily fall into the hole atop the drill head and become wedged there. If possible, clear away unconsolidated surface material before

AGGREGATES MANAGER / 9/19/17 October 2017 2:50 PM

21

9/19/17 3:01 PM

Trimble connects people with payload and productivity data across the quarry.

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5/01/2017 11:22:30 AM 9/18/17 10:33 AM

EQUIPMENT MANAGEMENT

in the field is to get it done fast, operators will take costly shortcuts to gain footage per hour and please the boss.

But holes will angle off, safety will be compromised, and, ultimately, more expense will be incurred. Hissem recalls the advice of his grandparents to “make

beginning to drill, because if you can’t hold that hole open, you are in trouble.

5) Use a larger-diameter drill string.

Compared to the diameter of the bit, a comparatively large diameter drill string is stiffer and minimizes hole deviation while it maximizes air-flushing capacity. This is especially important when drilling in porous material that bleeds off the air. In using a larger diameter pipe or drill rod, check to ensure adequate clearance is being maintained for cuttings to flow to the surface. With that provision met, the velocity of the flushing airstream is increased or better maintained, which, Hissem observes, helps the operator maintain a hole-tohole cycle time.

haste slowly.” Or, to use another maxim, look before you leap. “Rarely can one rush quality,” he says. AM

Article is courtesy of Sandvik Mining and Rock Technology.

Get your damaged SBR conveyor back in service in just 90 minutes!

6) Develop a sixth sense.

Watching only gauges can be self-defeating, because, by the time they register an anomaly, something significant already has happened in the ground.

Hissem talks of the old days when drill operators were exposed to the heat and cold and dust and noise. “Then we got cabs and old-timers didn’t like it, even though they were more comfortable, because it cut them off from sensory information.” So-called “smart drills” are being developed with onboard intelligence and systems that will separate operators even more from the “feel” of operation. Until such machines dominate drill sites, operators should keep sensing the pulse of their machines. They should actively monitor such things as the flushing action, any pitch changes in the drill string, subtle movements that indicate a change in rock pressure, the size of cuttings, and groundwater. Hissem believes a master driller can fully develop this “sixth sense” in a couple of years.

Bonus tip for management: Be careful how you motivate operators.

Quality control should vie with productivity in determining the success of an operation. If the only directive to those

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23

AGGREGATES MANAGER / October3/21/17 2017 10:31 AM

8/2/17 2:33 PM

9/19/17 4:01 PM

SUPPLYLINES

by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com

Carrying a Heavy Load New and updated wheel loaders offer higher efficiency, greater safety, and ease of operation.

Intuitive and easy to operate Case Construction Equipment’s 1121G wheel loader is the largest model in its G Series, which features Tier 4 Final engines that use Selective Catalytic Reduction Technology. It also features the Case cooling cube, which provides direct access to fresh air for each cooler and features a reversible fan and easy access for cleaning. The 347-horsepower 1121G has bucket capacities of 5.25 to 6.25 cubic yards and breakout force of 56,245 pounds. The unit has an all-new operator environment, controls, and interface, making it intuitive and easy to operate. Linkage options include Z-bar for the best breakout force, XR for extended reach, and XT for use as a tool carrier.

Case Construction Equipment | www.casece.com

Design for fuel-efficient loading Designed to lower fuel costs and increase operating efficiency, the updated Cat 992K Wheel Loader features Caterpillar’s Economy Mode operation. With the On-Demand Throttle arrangement, the 992K automatically manages engine speed, combining the efficiency of a manual throttle with ergonomic throttle lock operation. Performance studies by the manufacturer have shown fuel reductions of up to 21 percent, compared to the previous model series. Production-matched to deliver three-pass loading of the Cat 775 and four-pass loading of the Cat 777 trucks, the loader offers Cat Production Measurement (CPM), a payload weight measuring system.

Caterpillar | www.cat.com

24

AGGREGATES MANAGER / October 2017

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Loader offers variable transmissions - new Doosan Construction Equipment’s DL420-5 CVT (continuously variable transmission) is its first wheel loader to combine the benefits of a traditional automatic transmission and a hydrostatic transmission in one machine. The CVT design automatically transitions from a hydrostatic transmission to an automatic transition to operate at higher speeds. The automatic transmission is a one-to-one-ratio with the engine and is said to improve powertrain efficiency in load-and-carry applications. Doosan says operators will see an increase in machine performance and productivity in digging, loading, and lifting applications. Three power modes — power, standard, and economy — adjust engine rpm, and an auto-shutdown system is available.

Doosan Construction Equipment | www.doosanequipment.com

New cab and bucket improve productivity - new Hyundai recently added the HL965 to its wheel loader lineup. The 44,313-pound loader is powered by a Tier 4 Final Cummins QSL9 electronically controlled diesel engine with a gross power of 272 horsepower. A new ROPS/FOPS cab is 10 percent larger than in prior models and is fully sound-proofed. A 7-inch touchscreen monitor provides easy-to-read access to equipment data. Joystick controls for boom, bucket, and third hydraulic line are standard, while fingertip control is available as an option. A Hyundai branded onboard weighing system that is said to be accurate to +/-1 percent is also standard, while the redesigned bucket features a wider opening, curved side plates, and enhanced spill guards to maximize bucket capacity.

Hyundai Construction Equipment Americas, Inc. | www.hceamericas.com

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AGGREGATES MANAGER / October 2017

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9/19/17 4:07 PM

SUPPLYLINES Aggregate handler loads in two passes - new John Deere added the 844K Series-III and 844K Series-III Aggregate Handler to its loader lineup. The new wheel loaders feature a 13.5-liter John Deere PowerTech Tier 4 Final diesel engine (380 horsepower for the standard unit, 401 horsepower for the aggregate handler). They are equipped with standard five-speed transmission with torqueconverter lockup in gears two through five. This feature increases acceleration speeds and cycles, and optimizes power and fuel efficiency during transport, roading, and ramp climbing, the manufacturer says.

The Aggregate Handler is built for two-pass loading with increased power, large tilt cylinders, higher hydraulic pressure, and increased counterweighing to handle bigger material-handling buckets (9.3 cubic yards/9.8 cubic yards). It is said to cut loading time by 30 percent with reduced fuel consumption by eliminating the third pass.

John Deere | www.johndeere.com

Achieves Tier 4 Final standards without DPF -

new

KCMA Corp. announced the Tier 4 Final version of its 70Z7, which is said to cycle faster, offer more power, and achieve near zero emissions. The loader is equipped with a 3.7-cubicyard general purpose bucket, and produces 173 gross horsepower from the Cummins QSB6.7 diesel engine. The unit achieves Tier 4 Final standards without a diesel particulate filter, meaning no DPF plugging or DPF regen. A five-speed automatic transmission with variable shift points is said to provide faster speeds and fuel savings, while an auto idle shut down feature senses excessive idling and shuts down the engine to increase fuel efficiency. The KCM Global e-Service telematics system is standard.

KCMA Corp. | www.kcmcorp.com

Adaptive lighting options improve safety -

new

Liebherr introduced two new lighting options for its XPower wheel loaders: adaptive working lighting and the Liebherr key with remote control. Both options improve lighting and safety, particularly at twilight, during night operations, and in underground or lowlight conditions. Adaptive working lighting is an intelligent light control system. It reacts intuitively to the lift arm position and articulation angle of the wheel loader using LED light sensors to keep working areas evenly lit. The Liebherr key with remote control opens the driver’s door at the push of a button and activates the cab lighting. This illuminates the entire entry area and improves the operator’s ability to climb into the cab safely.

Liebherr | www.liebherr.com

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AGGREGATES MANAGER / October 2017

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Statement of Ownership, Management, and Circulation (Requester Publications Only)

PS Form 3526 1. Publication Title RANDALL REILLY PUBLISHING/AGGREGATES MANAGER

2. Publication Number 19277

ISSN 15523071

3. Filing Date 09/05/2017

4. Issue Frequency MONTHLY

5. Number of Issues Published Annually 6. Annual Subscription Price 12 $ 24.00

7. Complete Mailing Address of Known Office of Publication 3200 RICE MINE RD NE TUSCALOOSA, TUSCALOOSA AL, AL 35406-1510

Contact Person JULIE PUCKETT Telephone (224) 577-6882

8. Complete Mailing Address of Headquarters or General Business Office of Publisher 3200 RICE MINE RD NE TUSCALOOSA, AL 35406-1510

9. Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor Publisher (Name and complete mailing address) Michael Newman 3200 RICE MINE RD NE TUSCALOOSA, AL 35406-1510

Editor (Name and complete mailing address) Therese Dunphy 2849 LEE RD SILVER LAKE, OH 44224-3715

Managing Editor (Name and complete mailing address) Marcia Gruver Doyle 3200 RICE MINE RD NE TUSCALOOSA, AL 35406-1510

Heat-treated components increase strength Designed for quarry and aggregate applications, the 890H wheel loader from LiuGong North America is powered by a 370-horsepower Cummins QSG12 Tier 4 Final engine and equipped with 6.5- to 9.4-cubic-yard bucket capacity. A special heat treatment process is said to increase the strength of key components such as hinge pins and lift arm mounting plates. The new Z-bar linkage improves distribution of stress. Its redesigned geometry positions the bucket closer to the tires for high bucket breakout forces with maximum rollback. Stable transport of materials and the bucket’s increased fill factor and material retention result in minimal spillage and increased productivity.

Safety features include a ROPS- and FOPS-certified cab and improved allaround operator visibility that is supported by a rear-view camera.

Liugong North America | www.liugong.com

10. Owner (Do not leave blank. If the publication is owned by a corporation, give the name and address of the corporation immediately followed by the names and addresses of all stockholders owning or holding 1 percent or more of the total amount of stock. If not owned by a corporation, give names and addresses of the individual owners. If owned by a partnership or other unincorporated firm, give its name and address as well as those of each individual owner. If the publication is published by a nonprofit organization, give its name and address.)

Full Name

Complete Mailing Address

RANDALL-REILLY HOLDING CO., LL

3200 RICE MINE RD NE, TUSCALOOSA, AL 35406-1510

11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Hoding 1 Percent or More of Total Amount of Bonds. Mortgages, or Other Securities. If none, check box Full Name Complete Mailing Address GE CAPITAL

None

11175 CICERO DRIVE, SUITE 600, ALPHARETTA, GA 30022-1167

PS Form 3526-R, September 2007 (Page 1)

PRIVACY NOTICE: See our privacy policy on www.usps.com

13. Publication Title

14. Issue Date for Circulation Data Below

RANDALL REILLY PUBLISHING/AGGREGATES MANAGER

08/01/2017 Average No. Copies Each Issue No. Copies of Single Issue During Preceding 12 Months Published Nearest to Filing Date

15. Extend and Nature of Circulation a. Total Numbers of Copies (Net press run) Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. (Include direct written request from telemarketing and Internet requests from (1) recipient, recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser's proof copies, and exchange copies.) b. Legitimate In-County Paid/Requested Mail Subscriptions stated on Paid PS Form 3541. (Include direct written request from and/or recipient, telemarketing and Internet requests from Requested (2) recipient, paid subscriptions including nominal rate Distribution subscriptions, employer requests, advertiser's proof (By Mail copies, and exchange copies.) and Sales through Dealers and Carriers, Street Vendors, Outside (3) Counter Sales, and Other Paid or Requested Distribution the Mail) Outside USPS (4) Requested Copies Distributed by Other Mail Classes Through the USPS (e.g. First-Class Mail) c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), (4)) Outside County Nonrequested Copies stated on PS Form 3541 (include Sample copies, Requests Over years old, Requests induced by a Premium, Bulk (1) 3 Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other soruces) d. NonreIn-County Nonrequested Copies stated on PS Form quested 3541 (include Sample copies, Requests Over 3 Distribution old, Requests induced by a Premium, Bulk (2) years (By Mail Sales and Requests including Association Requests, and Names obtained from Business Directories, Lists, Outside the and other soruces) Mail) Nonrequested Copies Distributed Through the USPS (3) by Other Classes of Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Limit Nonrequested Copies Distributed Outside the Mail (4) (include Pickup Stands, Trade Shows, Showrooms and Other Sources) e. Total Nonrequested Distribution (Sum of 15d (1), (2), (3), (4))

Purpose-built, two-pass loader - new

f. Total Distribution (Sum of 15c and 15e) g. Copies not Distributed

Volvo Construction Equipment’s L260H is a purpose-built, two-pass loader that achieves a 10-percent fuel efficiency improvement over its predecessor. The 38-ton loader boasts 5 percent more horsepower and torque, 15 percent more payload, and features two larger bucket sizes designed specifically for the unit: the Volvo Rock bucket and Volvo Rehandling bucket.

Fitted with a 416-horsepower Volvo D13J Tier 4 Final engine, the H-series uses passive regeneration to automatically clean the diesel particulate filter during normal operation, without operator input. Fuel efficiency is enhanced by the patented OptiShift technology, which integrates the Volvo Reverse By Braking function and new torque converter with lock-up. A new load-sensing hydraulic system supplies power to the hydraulic functions only when required. Rather than use hydraulic pumps to lower the boom, the L260H relies on the combined gravitational effect and weight of the boom and bucket.

Volvo Construction Equipment | www.volvoce.com

19612

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0

202

35

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7037

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260

42

7297

6274

19375

18871

237

616

19612

19487

62.34 %

66.75 %

a. Requested and Paid Electronic Copies(Sum of 15c and 15e)

0

0

Total Requested and Paid Print Copies(Line 15c) + Requested/Paid b. Electronic Copies

0

0

Requested Copy Distribution(Line 15f)+ Requested/Paid c. Total Electronic Copies

0

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0.00 %

0.00 %

h. Total (Sum of 15f and 15g) i. Percent Paid and/or Requested Circulation ((15c / 15f) times 100) 16. If total circulation includes electronic copies, report that circulation on lines below.

Paid and/or Requested Circulation (Both print and Electronic d. Percent Copies) I Certify that 50% of all my distributed copies (Electronic & Print) are legitimate requests.

17. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the 10/01/2017 issue of this publication.

18. Signature and Title of Editor, Publisher, Business Manager, or Owner Title JULIE PUCKETT

Date AUD DEV DIR

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I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties).

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AGGREGATES MANAGER / October 2017 Statement of Ownership_AGRM1016pg.indd 1

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by Benjamin J. Ross

ROCKLAW Part 50: A Primer on Reporting Requirements Look to Commission decisions for guidance on the definition of “entrapment” for reporting purposes, but err to the side of safety.

T

Benjamin J. Ross is an associate in Jackson Kelly PLLC’s Denver office, where he practices in the Occupational Safety and Health and Litigation Practice Groups. He can be reached at 303-390-0026 or bross@ jacksonkelly.com.

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he Mine Safety and Health Administration (MSHA) requires under Part 50 that mine operators immediately notify MSHA once an operator knows or should know that an accident has occurred. 30 C.F.R. § 50.10. The regulations list categories of accidents that operators must report, including entrapments that last for longer than 30 minutes or may reasonably cause death. 30 C.F.R. §§ 50.10(c), 50.2(h)(3). For entrapments, there are three elements under § 50.10 that a mine operator must evaluate in determining whether to report: 1) is the miner entrapped; 2) does the entrapment last for more than 30 minutes; and 3) might the entrapment have a reasonable potential to cause death?

As mine operators know, the terms used in MSHA’s regulations often can be vague or ambiguous. Part 50 is no different. The Federal Mine Safety and Health Review Commission (Commission) has considered the meaning of “immediate” under Part 50 and provided interpretative guidance for the industry. The Commission concluded that Part 50 allows a mine operator the opportunity to investigate an event to determine if it is reportable.

Consolidation Coal Co., 11 FMSHRC 1935, 1938 (October 1989). The decision regarding whether an operator reported in a timely fashion is made on a case-by-case basis and takes into consideration the nature of the accident and a number of variables that affect reaction and reporting. Id. Once a

good faith investigation reveals to the operator that an accident occurred, the operator must report that accident immediately (i.e., within 15 minutes). Wolf Run Mining Co., 35 FMSHRC 3512 (December 2013).

For purpose of deciding whether an entrapment has existed long enough to trigger the reporting requirement, case law discussing the reporting of unplanned fires under Part 50 is helpful. According to the Commission, a fire (and, similarly, an entrapment) ends upon the complete cessation of the condition. Phelps Dodge Tyrone, 30 FMSHRC 646, 656 (August 2008). A fire that continues to produce smoke remains a fire, and intermittent flames that recur are not separate fires. For entrapment, an elevator that momentarily moves without the occupants being freed does not end the entrapment and restart the 30-minute period.

The Commission has also considered how operators should determine whether an accident “may reasonably cause death” for the purposes of immediate reporting. Any reasonable doubt as to whether an operator should report an accident should be resolved in favor of notification. Signal Peak Energy, LLC, 37 FMSHRC 470 (March 2015).

Operators should not delay reporting to perform technical or medical evaluations. Cougar Coal Co., 25 FMSHRC 513, 521 (September 2003); Donovan on behalf of Anderson v. Stafford Constr. Co., 732 F.2d 954, 959 (D.C. Cir. 1984). An accident involving either an injury or entrapment should be

AGGREGATES MANAGER / October 2017

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reported if the circumstances are of a nature or type that could means to stop the climber. Id. at 25. Where escape is more reasonably cause death. For example, miners trapped in areas dangerous than remaining in an area, an entrapment exists if with exposure to airborne contaminants or a limited air supply miners remain for more than 30 minutes. Id. at 24. are likely to trigger the immediate reporting requirement.

J.S. Redpath is a reasonable interpretation of § 50.10. When Despite examining numerous terms from Part 50, the Coma reasonable doubt exists, operators should err on the side of mission has given no guidance on what constitutes an entrapreporting. The definition of entrapment allows for the existence ment. The dictionary definition of entrapment is “the condition of possible, yet difficult, escape. However, if it is safer to remain of being entrapped” or caught “as if in a trap.” Merriam-Webster. in an area than to move, then it is reasonable the miner should com. 2017. https://www.merriam-webster.com (17 August 2017). not move. Thus, operators should report an entrapment to MSHA “Trap” means “something by which one is caught or stopped even when a means of escape exists if that escape poses a unawares” or “a position or situation from which it is difficult or hazard to miner safety. impossible to escape.” Merriam-Webster.com. 2017. https://www.

An operator must evaluate each specific situation and decide merriam-webster.com (17 August 2017). It is clear that a miner whether the miner would be safer staying confined than escais entrapped when that miner is unable to exit an enclosure, ping an area. If escaping an area exposes the miner to additional machine, or other area. When an area is possible but difficult to danger, that miner is entrapped. Operators should report that exit, it is less clear whether an entrapment exists. situation to MSHA if the miner remains in that state for more One administrative law judge (ALJ) considered whether than 30 minutes. Identifying specific hazards is key to deciding entrapment existed where a miner could exit an area, albeit whether to report an entrapment. Remember: miner safety is unsafely. In J.S. Redpath, the ALJ analyzed whether a piece of always the most important consideration. AM mining equipment stopped in a 1,600foot raise was “entrapment.” J.S. Redpath Corp., 30 FMSHRC 12, 24-26 (January 2008) (ALJ) (Barbour). Compressed-air powered climbers moved up and down the raise with one or two miners inside.

The conduit supplying compressed air to a climber broke when the climber was some distance up the raise. Id. at 24. WitBEKA auto-lube is built to take the hout compressed air, the primary braking bumps and grinds of a hard-working life on the road or off. Give your fleet system could not function. Id. While the the solution that keeps them on the job. miners in the climber could use foot and • Cast aluminum base withstands hand brakes to affect a controlled descent impacts and hot/cold cycles of the climber, they chose not to move without leaking the climber. Id. at 25. As a result, the • No springs! Eccentric gear drive miners remained in the climber approxiresists wear, fatigue and cold mately 1,400 feet above the ground for • Consistently precise grease dosing more than 30 minutes. The ALJ examined Find out why industries are choosing whether the means to descend and exit today’s best-built auto-lube systems. the climber meant that no entrapment Call 1.888.862.7461 or email us existed. at info@beka-lube.com.

According to the ALJ, an alternate means of escape does not necessarily 1.888.862.7461 preclude an entrapment. The two miners

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11:35 AM AGGREGATES MANAGER / October2017-08-10 2017

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ADINDEX October 2017

Advertiser

Web

Page

Atlas Copco

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BKT Tires

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BekaWorld LP

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29

Elrus Aggregate Systems

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Hazemag US

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BC

ITW Polymeres Adhesive

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23

Kespry, Inc.

www.kespry.com/aggregates

IFC

MB America

www.mbamerica.com

Progressive Commercial Insurance

www.progressivecommercial.com

25

Trimble New Zealand Solutions

www.aggregates.trimble.com

22

C.L. Dews & Sons Foundry

www.dewsfoundry.com

31

Bill Langer - Research Geologist

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Sillica Mine

www.fineandcompany.com

31

HCEA

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31

9, 11

2

Classifieds

This index is provided as a service. The publisher does not assume any liability for errors or omissions.

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AGGREGATES MANAGER / October 2017

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CARVED IN STONE

Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at Bill_Langer@hotmail.com

Rock Dusting

The use of rock dust makes coal mining safer.

M

y maternal grandfather was a mechanic who worked in the coal mines in Pennsylvania. My only memories of him start after he retired, but I heard him complain about how dusty it was in the mines. Coal dust not only presents concerns for the workers’ health, but also is of concern for coal mine explosions.

Grandpa worked in the anthracite region. At the time, the U.S. Bureau of Mines (Coal Dust Explosions, 1911) had already determined that — although anthracite dust may ignite when suspended in the air — “there seems to be little danger of this under ordinary mining conditions.” Why this is so is beyond the scope of this article, but suffice it to say that, by definition, anthracite is not volatile enough to serve as a fuel for an explosion. It is a completely different story in underground bituminous coal mines where the risk of widespread explosion disasters is quite substantial unless proper precautions are taken.

You may recall that there are three necessary elements that must occur simultaneously to cause a fire; fuel, heat, and oxygen (the three sides of the fire triangle). When you remove any one of these elements, a fire cannot occur. For an explosion to occur, two additional elements, suspension and confinement, also must occur simultaneously with the three fire elements. A technique referred to as rock dusting can help disrupt the explosion pentagon.

Rock dust (pulverized aggregate) has been used in the U.S. and many major coal producing countries as a primary means of defense against coal dust explosions in underground coal mines. Rock dust can be a variety of light colored rock types, but commonly is pulverized limestone or dolomite. There are specific limits on the particle size, amount of combustible material, and silica in the rock dust. In addition, when rock dust is wetted and dried, it should not form a cake that cannot be dispersed into separate particles by a light blast of air.

The proper application and maintenance of rock dust that covers specified areas of mines commonly can remove one or more sides of the explosion pentagon. In a low-velocity explosion, the heavier rock dust covering the lighter coal dust serves as an isolator that prevents the coal dust underneath from becoming airborne, thus removing the suspension side of the explosion pentagon.

However, a high-velocity explosion can quickly reach supersonic speed and generate a shock wave that suspends coal and rock dusts in the mine air. The airborne rock dust absorbs the heat from the hot air and lowers its temperature, thus acting as a heat sink, reducing the heat side of the explosion pentagon.

If the temperature of the explosion exceeds 1,472 degrees F, the main component of limestone rock dust, CaCO3, almost instantaneously will be converted into lime (CaO) in an endothermic (heat adsorbing) chemical reaction. The thermal energy consumed in the limestone-to-lime conversion can greatly reduce the heat side of the explosion pentagon and, thus, greatly reduce the intensity of the coal dust explosion.

Mine dust production is only a small portion of the overall crushed stone production. During 2014, about 816,813 short tons of crushed stone, worth about $19,700,000, were produced for mine dusting or acid water treatment. (The two uses are grouped to prevent disclosing proprietary data.) You can bet that not many coal miners complain when they see that kind of dust at their work site. AM

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AGGREGATES MANAGER / October 2017

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