Aggregates Manager November 2017

Aggregates outlook PG4

| Dozer maintenance PG20 | Workplace exams PG28

November 2017 | www.AggMan.com

Your guide to profitable production

NEW HARVEY SAND

This operation has customers lining up hours before opening

3 15 Cover_AGRM1117.indd 1

Pruitt talks about regulatory overreach

Dredging in deep water

10/17/17 9:09 AM

A LEGACY OF

MANUFACTURING THE FAMILY-OWNED DEISTER MACHINE COMPANY ALIGNS ITSELF FOR LONG-TERM GROWTH AND BUILDS UPON ITS LEGACY WITH THE NEXT GENERATIONS OF LEADERSHIP. Representing the fourth generation of Deister leadership, Richard (Rich) M. Deister has recently been promoted to Executive Vice President of the company.

Currently marking 30 years of company service, Rich began his career with Deister by learning the business from the ground up. Following his graduation from Purdue University in 1987, he began as an assembler in the company’s machine shop. A few years later, he took to the road as a service technician where he was hands-on in working with producers to install and fine tune each custom-manufactured screen and feeder for use in a variety of applications.

In 1990, Rich became the company’s service manager; and in 2002, he was named Director of Customer Relations, Parts and Service, ascending to vice president of that department in 2007. Also, that same year, he joined the company’s executive board of directors. Rich is a member of the National Stone, Sand and Gravel Association and is the immediate past chair of the Manufacturing and Services Division.

The company is proud to report that its family tradition will continue into the fifth generation of leadership. Max Deister (Rich’s son) has recently joined the company as a full-time member. Like his father, he graduated from Purdue University, and had interned with the company since 2012.

“Our tradition of quality and customer satisfaction began with my great grandfather, Emil Deister, who founded the company in 1912.

Each generation of Deister leadership continues to strengthen our performance history and our dedication to high standards. Our long-term customer relationships, which we have developed over years of support, consultation and service, have resulted in ongoing improvements and innovation in the design, engineering and customization of Deister screening, scalping and feeding equipment,” says Rich Deister

DEISTER MACHINE COMPANY, INC. P.O. Box 1 • Fort Wayne, IN 46801 • 260-426-7495 • Fax: 260-422-1523 email: info@deistermachine.com • www.deistermachine.com

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McCloskey International offers its updated I44Rv3 mobile impact plant with screening and recirculating system.

PAGE 6 On Our Cover: Martin Marietta’s New Harvey Sand plant is investing for the future.

Cover photo by Kerry Clines.

While the crawler undercarriage accounts for only 20 percent of a dozer’s purchase price, it commonly racks up 50 percent of its lifetime repair bill.

PAGE 20

TABLE OF CONTENTS NOVEMBER 2017 |

COLUMNS & DEPARTMENTS

VOLUME 22, NUMBER 11

3 Editorial Pruitt describes changes at the EPA.

FEATURE ARTICLES

10

Mining in the Heartland New Harvey Sand is stacking up safety awards while dredging up profits in the Heartland.

20 Be Proactive with Dozer Maintenance

Taking care of the machine — including the undercarriage — is the key to productivity.

Digitial Exclusive: Portable Processing

Whether you need a small plant for a tight footprint or it’s all about throughput, today’s portable plants can meet your unique production needs.

OPERATIONS ILLUSTRATED

15

Deepwater Dredging

Mining in deep water may increase deposit life, but requires significant planning and testing.

TOC_AGRM1117.indd 1

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

6 RollOuts Caterpillar’s new 988K XE electric drive loader, and other new equipment for the aggregates market.

28 Rock Law Once again, MSHA pushes the effective date and proposes additional substantive changes to the Workplace Examination Rule.

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

31 Classified Ads Aggregates industry classifieds.

32 Carved in Stone Used to protect soldiers since the Revolutionary War, the ubiquitous sandbag has found its way to nearly every front.

10/17/17 9:08 AM

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MI34 Agg Manager.indd 1 Untitled-5 1

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November 2017

EDITORIAL

Vol. 22, No. 11

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

aggman.com /AggregatesManager

Pruitt describes changes at EPA

/AggManEditor

Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Senior Editor: Kerry Clines Online Editor: Wayne Grayson editorial@aggman.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_AGRM1117.indd 3

D

uring the National Stone, Sand & Gravel Association’s 2017 Legislative & Policy Forum, held Sept. 24-28 in Washington, D.C., EPA Administrator Scott Pruitt discussed changes he’s making at the Environmental Protection Agency and what those changes may mean to the aggregates industry.

“Our agency has been seen as the poster child for federal overreach,” he told attendees. “When you look at the past administration, truly there was an abuse of power.”

One of the first issues the EPA took on is one near and dear to many producers: Waters of the United States (WOTUS). Pruitt said he signed paperwork to withdraw the WOTUS rule within minutes of President Trump’s executive order directing the EPA to consider its withdrawal. The agency is working on a replacement definition that “stays within the intent of the statute and within the intent of Congress when the Clean Water Act was adopted,” Pruitt said. “That’s coming no later than the first quarter of 2018. You will know, with clarity, where federal jurisdiction begins and ends.”

Next, Pruitt said he would tackle former President Obama’s Clean Power Plan. On Oct. 10, he signed a proposed rule that would repeal that regulation, aimed at curbing carbon emissions to the detriment of the coal industry. “We’re committed to righting the wrongs of the Obama administration by cleaning the regulatory slate,” he said in a statement. “Any replacement rule will be done carefully, properly, and with humility, by listening to all those affected by the rule.”

A third initiative is to end the EPA’s track record on the practice of sue and settle.

In the past, this has allowed the agency to regulate outside the rulemaking process by encouraging third parties, such as NGOs or environmental groups, to file a lawsuit in a friendly court. The EPA would then enter into a consent decree and change the substantive requirements of the statute, Pruitt said, adding that “it violates what’s important in rulemaking — public participation.”

Common sense rulemaking and regulatory oversight is not only important to achieving regulatory goals, but to economic growth as well. To that end, he said the EPA will undergo restructuring, focusing on a clear mission and getting back to the basics.

“Folks across this country need to know what’s expected of them so they can allocate resources and personnel to achieve the ends regulations are intended to achieve.

Regulatory pancaking — when an agency introduces a rule then changes it or the rules of engagement over and over again — creates uncertainty in the marketplace and affects the economy in negative ways,” Pruitt said. “Fiscal policy affects our GDP. Tax policy does as well, but I will tell you: Over the last several years, the greatest impediment to economic growth has been regulatory uncertainty.”

AGGREGATES MANAGER / November 2017

3

10/17/17 9:10 AM

mining U.S.

On-Highway

Diesel Fuel

Prices 10/2/17

United States $2.792 One Week +0.004 p One Year +0.403 p

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

New England $2.767 One Week +0.005 p One Year +0.353 p

Central Atlantic $2.934 One Week +0.009 p One Year +0.448 p

Lower Atlantic $2.748 One Week +0.008 p One Year +0.421 p

Midwest $2.747 One Week +0.006 p One Year +0.391 p

Gulf Coast $2.615 One Week - 0.009 q One Year +0.365 p

Rocky Mountain $2.860 One Week +0.028 p One Year +0.393 p

West Coast $3.109 One Week +0.006 p One Year +0.451 p

West Coast less California $3.018 One Week +0.010 p One Year +0.494 p

California $3.182 One Week +0.002 p One Year +0.416 p Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).

DataMining_AGRM1117.indd 4

CX

Current Value

52-Week Low

52-Week High

$8.94 q

$6.91

$10.37

CRH plc

CRG

$36.34 p

$33.17

$40.98

Eagle Materials Inc.

EXP

$107.83 p

$73.83

$110.64

Granite Construction Inc.

GVA

$59.96 p

$42.59

$62.18

Heidelberg Cement AG

HEI

$100.56 p

$90.44

$111.19

LafargeHolcim Ltd. ADR

HCMLY

$11.45 q

$9.89

$12.35

Martin Marietta Materials, Inc.

MLM

$205.95 q

$167.06

$244.32

MDU Resources Group, Inc.

MDU

$26.60 q

$24.51

$29.92

Summit Materials

SUM

$31.29 p

$17.84

$32.69

United States Lime & Minerals, Inc.

USLM

$87.53 p

$63.60

$89.15

U.S. Concrete

USCR

$77.40 q

$45.05

$83.85

Vulcan Materials Co.

VMC

$120.25 p

$105.71

$138.18

Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 10/06/17.

COMPANY SPOTLIGHT

East Coast $2.819 One Week +0.008 p One Year +0.421 p

Ticker

M

artin Marietta (MLM) is on a roll. In recent months, it reported second quarter earnings of $2.25 per share (an 18-percent increase), announced the acquisition of Bluegrass Materials, and reported that it will continue to increase production capabilities.

During the second quarter, consolidated net sales grew 8.8 percent to $996.3 million, with Building Materials also growing 8.8 percent to $931.7 million.

“Our record second-quarter results reflect improved sales, gross profits, and earnings from operations in each reportable group, underscoring the breadth of our business and our ability to capitalize on the ongoing recovery in construction activity,” Ward Nye, chairman, president, and CEO, said in a press release.

Gains in the Business Materials segment were attributed to pricing and volume gains. Aggregates prices rose an average of 3.8 percent, with a 10.6-percent increase in the Southeast Group. The West Group and the Mid-America Group reported price increases of 3.4 percent and 2.4 percent, Martin Marietta (MLM) respectively. Aggregates shipments rose by 2.0 percent compared to the second quarter of 2016, with an increase of 3.6 percent in the West Group, followed by a 2.0-percent increase in the Mid-American Group.

In late June, the company announced it would acquire Bluegrass Materials Co., which has 23 active sites and more than 2 billion tons of reserves in Georgia, South Carolina, Tennessee, Maryland, and Kentucky. The deal, made for $1.625 billion in cash, is expected to close by the end of 2017. “As the leading aggregates producer in Maryland, Bluegrass will provide Martin Marietta with a strategic new growth platform within the southern portion of the Northeast Megaregion, serving the Baltimore, Frederick, Hagerstown, and Maryland Eastern Shore metropolitan areas, as well as Delaware,” Nye said. “With aggregates shipments currently 20 to 30 percent below peak levels, all of these markets are expected to benefit from the accelerating economic recovery in the eastern United States.”

To prepare for anticipated strong demand in 2017 and 2018, Nye said Martin Marietta is “continuing key operational initiatives, including increasing production capabilities, investing in personnel, and undertaking grading and equipment maintenance.”

Source: Market Watch

Data

STOCK REPORT

10/12/17 8:59 AM

ek

37

98

64

18

19

35

32

92

69

15

85

18

AGGREGATES INDUSTRY OUTLOOK The October Aggregates Industry Index dipped slightly to an overall score of 128.38, a 0.76-percent decrease from September. Respondents reported mixed opinions on the impact of recent hurricanes on both production and demand, with some noting the short-term decrease in demand, while others anticipate the gains of a long-term recovery. Minimal changes were reported for most business sentiment indicators, including industry and company outlooks, as well as sales, for the quarter and half. Monthly sales experienced a slightly more significant decrease with a 7.5-percent decline, compared to September. More optimistic results were reported for annual sales, with a 7.3-percent increase over September results.

Aggregates Industry Outlook 150

139.35

145

139.94

140

134.60

132.37

135

128.38

124.24 122.43

130

140.38

135.06

125 120

133.61

111.00

115

129.36 108.08

110 105 100 Oct. 2016

Nov. 2016

Dec. 2016

Sand and gravel reserves are depleted in the Denver metro area. All demand is being pushed on the crushed stone operation. Rail (is) soon to enter the market.

— Al Frei, Jr., President, Albert Frei and Sons

Jan. 2017

Feb. 2017

March 2017

April 2017

May 2017

June 2017

July 2017

Aug. 2017

Sept.

2017

Oct. 2017

In our state of Mississippi, our road funding is down almost 30-35 percent. The budget is still shrinking and our lawmakers turn a blind eye to our road system’s decay.

— Tim C. Rakestraw, Area Aggregates Manager, APAC, Inc., an Oldcastle Company

Houston, along with the Gulf Coast Region, is still in recovery mode from Hurricane Harvey. I think it will be another three to six months before we can get an accurate read on the direction of the market.

Despite early year impacts due to weather, 2017 is shaping up to be as good as 2016. Anticipation is high that the economy will maintain on its course in 2018.

— Rob Van Til, Managing Partner, River Aggregates, LLC

— Daryl Zeiner, Sales Manager, The H&K Group

Given the aftermath of two destructive hurricanes and their relative impact on the Southern United States, I see a spike in aggregate demand and production. Coupled with available funding, I believe producers are in a position to increase inventory that will remain very liquid.

In the Southeast, exploration related to potential greenfield sites, along with quarry expansions, is brisk. This being the case, 2017 continues as one of our busiest in the last 40 years.

— O.F. “Russ” Patterson, III, Chief Geologist, Patterson Exploration Services

—Jill Shackelford, President, Jill Shackelford ConsultingExploration Services

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

VALUE OF CONSTRUCTION PUT IN PLACE, SEASONALLY ADJUSTED ANNUAL RATE 8/1/2017

7/1/2017

% change May 2017- April 2017

% change May 2017- May 2016

Residential

526,543

524,159

0.5

11.3

Non-residential

Type of Construction

691,769

688,118

0.5

-3.4

Office

71,221

69,837

2.0

0.6

Commercial

85,432

85,517

-0.1

9.8

Health Care

40,378

39,041

3.4

3.0

Educational

86,496

83,608

3.5

-2.9

Transportation

41,774

40,949

2.0

5.2

Power

101,073

100,551

0.5

-8.0

Highway and Street

82,218

83,257

-1.2

-5.9

Sewage and Waste Disposal

18,241

18,481

-1.3

-17.2

Manufacturing

61,390

64,075

-4.2

-20.8

Seasonally adjusted annual rate. (Millions of dollars. Not all sub-categories of non-residential construction are included.)

DataMining_AGRM1117.indd 5

Source: U.S. Census Bureau

10/12/17 8:59 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

Newly designed for higher production McCloskey International introduces a new version of its I44R mobile impact crusher, the I44Rv3. The updated unit combines a 44-inch impactor with a screening and recirculating system to allow operators to produce a crushed and screened final product with one machine. Changes include direct drive, enhanced material flow path, larger pre-screen, and a more open chassis. In addition, its radial return conveyor features full-length dust suppression control, allowing operators to recirculate oversize material from the screen box to the feed hopper or radial 90 degrees while running.

McCloskey International www.mccloskeyinternational.com

Large-scale dozer features PAT blade John Deere says its 950 PAT Crawler Dozer is the largest dozer equipped with a power-angle-tilt (PAT) blade in North America. The machine incorporates a Tier 4 Final John Deere 9.0-liter engine with 280 horsepower. The hydrostatic powertrain is said to provide 15 percent more power to ground versus a conventional torque-converter powertrain. The 8.6-cubic yard, sixway PAT blade offers flexibility at the site. Equipped with standard electro-hydraulic controls, the dozer is grade-control ready. Like other dozers in the K-Series, it features Eco mode.

John Deere | www.johndeere.com

Excavator offers machine control enabled joysticks Komatsu America Corp. releases its PC210LCi-11 hydraulic excavator. The second-generation unit adds machine-control-joystick functionality and is said to offer up to a 63-percent improvement in excavating efficiency over a PC210LC-11 and traditional stakeplus-grade-checker methods. Key features of intelligent machine control technology include: machine-control-function enabled joysticks, full 3D GNSS capabilities, work equipment automation, stroke sensing hydraulic cylinders, and intelligent guidance. The excavator is covered by the Komatsu Care program for the first three years or 2,000 hours, whichever comes first.

Komatsu America | www.komatsuamerica.com

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AGGREGATES MANAGER / November 2017

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Electric drive loader boosts efficiency, productivity Caterpillar’s new 988K XE is its first wheel loader offered with a high-efficiency electric drive system. It features switched reluctance (SR) technology and has undergone four years of field testing. The C18 Acert engine, mechanical dropbox, driveline, and axles from the standard 988K are carried over in the electric drive loader. The electric drive unit is said to increase efficiency by 25 percent overall and up to 49 percent in face-loading applications, compared to the 988K. At the same time, Cat production studies report it delivers up to 10-percent higher productivity in load-and-carry applications.

A range of buckets, from 6.2- to 17-cubic yards, is available.

Rated standard payload is 12.5 tons when working with face material and 16 tons with loose material. The loader is a three-pass match with the 42.6-ton Cat 770G and a four-pass match with the 51-ton Cat 772.

Caterpillar | www.cat.com

Customizable pedestal boom system Okada America, Inc.’s Pedestal Breaker Boom Systems are designed for stationary primary crushing plants, as well as portable plants. Each system includes positioning pedestal boom, ORV Series hydraulic impact breaker, electric power unit, operator controls, first use start-up, and commissioning — including operator and maintenance training. Options consist of premium and radio remote controls, pan-zoom camera system, and integrated package with rock breaker boom system, power unit, and operator’s cab mounted collectively on an upper carriage platform. Operators can select size options for the boom’s horizontal reach, impact energy class of breaker, and power unit.

Okada America, Inc. | www.okadaamerica.com

Impact cradle protects transition points Superior Industries Inc. expands its conveyor components accessories line with the release of its Impact Cradle. The curved design of the Impact Cradle is said to eliminate the space between the belt and the bed, adding extra protection. Designed to fit into an existing idler mounting footprint, the Impact Cradle is built to receive the blunt force of material flow at transition points in conveying systems to lessen belt wear. Fitted for CEMA C, D, and E idlers, the cradle is available in 20- and 30-degree trough angles for 5-, 6-, or 7-inch diameter roll heights.

Superior Industries Inc. | www.superior-ind.com

AGGREGATES MANAGER / November 2017

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ROLLOUTS Side dump bucket has removable dump plate Rockland’s SDB Side Dump Bucket features a patent-pending removable dump plate that allows operators to quickly transform the side-dump bucket into a general-purpose bucket. The option to unload material either conventionally or laterally at a 45-degree angle offers flexibility for the operator. The dump plate can be removed anywhere without cutting or welding, and functions as an easy-to-replace wear part. All side-dump buckets are powered by a heavy-duty, dual cushioned cylinder that provides safe and quiet operation. The bucket body and dump plate are made from highstrength alloy plate.

Rockland Manufacturing Co. | www.rocklandmfg.com

Software, app aid safety incident management Convergence Training rolls out Convergence IMS (incident management system), its newest safety incident reporting software.

The software and its companion mobile app are designed to centralize documentation, investigation, and compliance reporting for MSHA and OSHA incident recordkeeping. The software can be integrated within the Convergence LMS (learning management system) or licensed as a stand-alone software tool. The software can be configured with company-specific details. Built-in incident categories, injuries and illnesses, root causes, and corrective actions can be customized. Incident scene photos and videos can be attached to any incident, and witnesses can electronically sign statements in the field via the app.

Convergence Training | www.convergencetraining.com

Tramp metal detector offers levels of sensitivity Thermo Fisher Scientific introduces the Thermo Scientific Ramsey Oretronic IV tramp metal detector, which is designed to work with belt conveyors to better detect scrap metal such as bucket teeth, manganese steel mantles, bore crowns, bar scrap, chains, and tools. Its increased sensitivity is said to allow it to identify tramp metal in wet conductive materials quickly and accurately. The metal detector is available in two versions with two levels of sensitivity. It includes a microprocessor-based control unit, receiver coil, transmitter coil, and support frame.

Thermo Fisher Scientific | www.thermofisher.com

Expanded line of high-capacity pumps Atlas Copco Construction Equipment North America expands its dewatering market offerings with more than 30 new heavy-duty, high-capacity pumps.

This includes the addition of three high-flow models to its PAS range of centrifugal dry prime pumps. The new pumps can accommodate flows of up to 6,164 gallons per minute. The new pump range is Atlas Copco branded, but retains the Varisco name as part of the VAR range of centrifugal wet prime pumps. All ranges can be supplied with a diesel or an electric motor, and up to six modular configurations are possible per range.

Atlas Copco Construction Equipment | www.atlascopco.com

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AGGREGATES MANAGER / November 2017

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Dozer boasts durability improvements

Impact crusher line scaled down for small footprint McCloskey International offers a new line of compact impact crushers built to the same standards as its full-size crushers.

The I24 and I34R are designed for projects with small footprints, but big production requirements. Like other McCloskey crushers, the units offer direct drive for fuel efficiency, include integrated hydraulic folding conveyors, and can be switched to recirculating in a few hours. A full-color TEDD control panel screen offers ease of operation while four blow bars and an apron adjustment can be configured for either primary or secondary crushing.

McCloskey International www.mccloskeyinternational.com

Komatsu America Corp. introduces the D375A-8 crawler dozer. The unit features a Tier 4 Final SAA6D170E-7 engine with a net horsepower of 609 horsepower in the forward direction and 748 horsepower in the reverse direction. The additional horsepower yields faster cycle times and a productivity increase of up to 18 percent. It also features an improved suspended undercarriage, larger viscous cab mounts, and a new air-suspension heated and ventilated seat for overall operator comfort.

Komatsu America Corp. www.komatsuamerica.com

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10/18/17 8:49 AM

PLANT PROFILE

by Kerry Clines | Senior Editor

Mining

in the

Heartland

New Harvey Sand is stacking up safety awards while dredging up profits in the Heartland.

O

ff the beaten path in southern Iowa, Martin Marietta’s New Harvey Sand plant is dredging up sand and gravel in the middle of farming country southeast of Des Moines. In fact, the land being mined is the property of a farmer who is leasing it to the company. After mining is complete, the top soil will be backfilled into the mined-out areasto become farmland again, but there will be a nice, big lake to boot.

Martin Marietta purchased the dredging operation from Kaiser Corp. in 1997. The property consists of 350 acres bordered by the Des Moines River to the north and east and Highway 92 to the south. A new scale house/office building was just constructed in 2017.

“We started construction of a new building in January/February this year,”

10

says Tim Chambers, plant manager for New Harvey Sand and four other operations in and around the Des Moines area.

“They ran into problems with frost, so they couldn’t put in the footings. Then we had the spring rains that delayed construction. It has been a challenge,” he explains, adding that they worked out of a small job trailer until the new building was finished.

Dredging up profits The sand and gravel in the area was deposited by the Des Moines River over a long period of time. Before any mining can begin, the area must be cleared of overburden. A stripping crew comes in and strips off the overburden, which varies in depth depending on location.

“Our core drills let them know how much to take off in each area,” Chambers

explains. “Where they’re working now, one end has 2 feet of overburden and the other has 8 feet. Some pits have 18 to 20 feet of overburden.”

Once the sand is exposed, water begins seeping in from the river and forms a pond. The dredge is then moved into the pond and mining can begin.

“We have a chain dredge that looks like a chain saw with a vacuum cleaner hooked to it,” Chambers says. “The big blade rotates and knocks the material loose so it’s not packed tight. Then, the big nozzle sucks it up, and sends it through a 12-inch poly pipeline. A booster pump pushes it the rest of the way through the pipeline to the processing plant.”

When the material reaches the processing plant, it goes up 40 feet to the top of the plant and is fed through a

AGGREGATES MANAGER / November 2017

PlantProfile_AGRM1117.indd 10

10/18/17 9:03 AM

Martin Marietta Materials’ New Harvey Sand is a sand and gravel dredging operation located near the Des Moines River in southern Iowa.

screen that pulls out all the sand and sends it to a classifying tank. The rock drops into a log washer that breaks up the clay balls and takes out the mud.

The classifying tank separates out the concrete sand; everything else is considered fill sand. The concrete sand drops into a dewatering screw, and then goes to the radial stacker and on to a stockpile. In the meantime, the rock passes through the log washer and goes to a vibrating screen that divides it into three different sizes — 2-inch septic gravel, 3/4-inch gravel, and pea gravel — which are then stockpiled for sale.

“We have to keep our asphalt and concrete gradation in spec for roadwork,” says Mark Nicoson, area production manager, adding that they use one product for both because they

are so similar.

Everything is shipped out of the plant by truck. A loader fills all the customer trucks that come in and is also responsible for moving the material around within the plant itself.

“Sand is our main product. We sell it for asphalt and concrete sand. It goes out faster than we can make it,” Nicoson says. “The septic gravel, we can’t make enough of. The size is hard to get. They use it in their leach fields.”

“The customer trucks are here at 3:30 in the morning, waiting for us to open the gate at 7 a.m.,” Chambers adds. “It’s that way all over Iowa.

Gravel is a really scarce commodity.

The bigger it is, the bigger the cavities, and the more water that can drain through it.”

During the summer months, the

operation runs 24 hours a day to try to keep up with customer demand for both sand and gravel, but the current plant is barely abot to do that, so there are plans to put in a new portable plant in 2018.

“They didn’t have this kind of demand for sand 30 years ago, so this plant is running at 110 percent of its capacity,” Chambers says. “The new portable plant will be capable of doing in four months what this plant does pretty much all year, while eliminating the need to run two shifts as well.”

“And we can put the portable plant closer to where we’re dredging and increase our efficiency,” Nicoson adds.

“It’ll save on fuel.”

Caring for the environment When the area around the processing AGGREGATES MANAGER / November 2017

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PLANT PROFILE the extra distance from the dredge to the plant is high efficiency with very low emissions. And once the new portable plant is installed, the booster pump will no longer be necessary.

Safety first

The classifying tank separates out the concrete/asphalt sand for further processing.

Everything else is considered fill sand.

The concrete/asphalt sand passes through a washing screen. The same sand is used for both concrete and asphalt because the spec is so similar.

plant was mined out, the dredge was moved to an another parcel of farmland on the other side of a wooded wetland that can’t be mined for environmental reasons. Bald eagles nest in the area, so if the miners see a nest, they must watch it closely. If the eagles lay eggs and are raising young, they can’t mine within 500-600 feet of the nest. Fortunately, the eagles usually raise their young during

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the operation’s winter break, when the plant shuts down between Thanksgiving and April. Dredging can’t be done during that time anyway, because the pond freezes over.

The operation also helps the environment by recycling all the used oils and fluids that come out of the machinery and mobile equipment. The diesel booster pump that is needed to move the material

Safety comes first at New Harvey Sand… always. “Our main goal for the day is everybody goes home at the end of the day the way they came,” Chambers says.

“Our safety culture is next to none. These guys think safety every day to make sure everybody is doing what they’re supposed to be doing. By working safe, production comes in line with it. We can still be productive and be safe at the same time. It’s a proven fact.”

The operation runs two shifts in the summer. The night shift consists of a dredge operator and a plant operator.

The day shift consists of a dredge operator, a plant operator, and a yard loader operator, along with an office/ scale house person.

Every Monday morning begins with a safety meeting. They read over any MSHA alerts that might have come out and talk about how it could be prevented and what they would do if they had anything like that happen at their plant.

They also discuss visitors to the plant, including customers, and safety regarding the traffic through the site.

On the door in the new building is a poster of the Guardian Angel Creed that the crew reads each day before they begin work. “We live by the Guardian Angel Creed,” Nicoson notes. “It tells the employees they can shut anything down that they want to, if they don’t think it’s safe.”

“They’ll shut it off, fix it, and get back to running the plant,” Chambers adds.

“That’s the key. They know they can turn anything off. If we’re swamped or out of sand, they can still turn things off if they even think something might be a safety hazard. They just shut it off and fix it, which is key to everybody going home.

I can trust them to get it done, make the right decisions, and do it safely.”

There’s another little twist that has been added to the morning safety routine.

After the morning tailgate talk, everyone gets up and stretches before they start

AGGREGATES MANAGER / November 2017

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Safety awards New Harvey Sand has acquired quite a collection of safety awards over the years and aims to continue adding to that collection by striving for continuous improvement.

“We have a Martin Marietta Diamond Achievement Award,” says Mark Nicoson, area production manager, explaining that they must meet certain financial and safety criteria to get the award. Last year, 162 Martin Marietta operations worldwide received the Diamond Achievement Award. From those, 10 operations received the Diamond Honor Award, and one was chosen to receive the Diamond Elite Award, the highest award given by the company. “Next year, we’ll try again,” Nicoson notes.

In 2016, the operation received the Sentinels of Safety Award from the National Mining Association (NMA) in recognition of its outstanding safety achievement of working 10,688 hours without an injury. The award was presented during MinExpo 2016.

“We normally have four employees here, but last year, when we got the Sentinels of Safety Award, we actually worked a lot with only three,” says Tim Chambers, plant manager, adding that people come from other locations when they have high demand and need to run two shifts.

“I don’t remember the last time we had a lost-time injury,” work. “It must be working,” Chambers notes, “because since we started implementing stretches, we haven’t had anyone report a strain or pulled muscle.”

Every day after the stretches, the employees walk through their area and do a workplace exam to make sure everything is good before they start.

“We might burn up a good hour in the morning before we even start production, just to make sure the work areas are safe and clean,” Chambers explains.

“It’s one of MSHA’s new objectives, but we’ve been doing it for years. If there are any safety items, they fix them right away before they start up.”

They also do weekly walks through the plant. A leadman and one employee or safety captain will travel to several sites to get different eyes on them. It helps to have someone look at a plant that doesn’t see it every day.

“One big change we’ve implemented recently is radios for each individual, so they can communicate with each other,” Nicoson notes. “That made a huge difference. It allows for constant communication, and that’s what I think safety’s all about.”

Chambers says it takes a lot of dedication from the crew to stay safe. With only four crew members most of the time, it’s extremely important that they all show up every day. Losing just one to injury takes away 25 percent of the workforce. By working safely and going home safe every night, they’re able to come to work every day. AM

New Harvey Sand personnel (from left: Lead man Jeff Holmes, Tim Chambers, Mark Nicoson) receive the Sentinels of Safety Award from NMA President and CEO Hal Quinn (right).

he continues. “These guys do a really good job. They’re always looking out for each other, which is the main thing.

They work well together to make sure the new employees coming in are trained and know what they’re doing before we just turn them loose.”

After the concrete/ asphalt sand passes through the washing screen, it goes through a dewatering screw and is placed in a stockpile by a radial stacker.

Equipment List • • • • • • • • • • •

Caterpillar 980H loader Caterpillar D6 dozer Dodge half-ton pickup maintenance truck Twinkle chain dredge J40 booster pump Telsmith 4x12 triple-deck scalping screen Eagle Iron Works log washer Rex/Simplicity 4x12 triple-deck rinse screen Eagle Iron Works classifier tank Eagle Iron Works 54-inch single concrete sand screw Superior 36-inch single fill sand screw

• Vari-Vibe 6x12 screen

AGGREGATES MANAGER / November 2017

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OPERATIONS ILLUSTRATED

By Tina Grady Barbaccia, Contributing Editor

Deepwater Dredging

Ensure the dredge and other equipment are designed for the depth.

Conduct site analysis and geological testing.

OUR EXPERTS

Pay attention to details when configuring a deepwater dredge.

J. (Jos) Clement works out of Edmonton, AB, Canada as director of technical services for Calgary-based CEDA Dredging & Fluid Management.

The company has operations throughout Canada and the United States and was involved in the world’s first reclamation of an oil sands tailings pond near Fort McMurray, AB. Clement has more than 37 years of experience in various types of dredging from reclamation work, lake restoration, and environmental cleanup to dredging for minerals, tailings, and marina maintenance.

Bob Wetta is president and chief executive officer of family-owned DSC Dredge, LLC (DSC), based in Reserve, La. He is past president and chairman of the Western Dredging Association’s Board of Directors and a member of the Young Presidents Organization and the Louisiana District Export Council (and a past chairman). Wetta received the Western Dredging Association’s “2014 Dredger of the Year Award.”

Develop a well-thought out mine plan.

Continually sample the material when starting production.

Bob Woodington is owner and manager Phoenix Pinelands Corp., a family-owned and operated sand and gravel producer based in Warren Grove, N.J. Phoenix Pinelands is a recipient of the Green Apple Award for Fine Aggregate Sand, awarded by the New Jersey Chapter of the American Concrete Institute and the New Jersey Concrete and Aggregate Association.

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Mining in deep water may increase deposit life, but requires significant planning and testing.

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s it becomes more difficult to permit additional land to open up greenfield projects, sand and gravel and aggregates operations are increasingly making the decision to dredge deeper. In the last 10 years, companies have discovered they have deeper reserves in areas they have already mined, explains Bob Wetta, president and CEO of Reserve, La.-based DSC Dredge.

CalPortland now has a dredge designed for a depth of 155 feet and Vulcan Materials has a dredge in Florida that was designed to and has achieved 200 feet, although this is atypical. So how does a producer determine whether to abandon an existing site and move to a new location or dig deeper? There are obvious costs to starting up a new operation such as stripping overburden, bringing in utilities, and moving or purchasing new equipment, Wetta says.

“If you can stay at the same site, there are several costs that have already happened that you won’t have to take on again,” he says.

One cost, though, is critical when deciding whether to dredge deeper or find a new location – geological testing, such as boring analysis and compaction testing. “Think long term, educate yourself, and develop a mine plan,” Wetta advises. “Don’t be afraid of testing. It could be the cheapest information you ever pay for so you don’t spend money on something that won’t work.

“You could have a great-looking dredge that can produce material, but you’ll have a really expensive water pump, if you can’t dig it,” Wetta says. “If you can double the life of the deposit, you don’t have to look for new land, but

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you want to make sure you don’t put the dredge in a spot where it has to be moved several times and end up mining around the material instead of mining the material.”

J. (Jos) Clement, director of technical services for CEDA Dredging & Fluid Management in the Edmonton, AB, Canada office, notes that producers/dredging contractors need to carefully examine all physical conditions and process requirements to ensure they have the correct equipment configurations for a deep excavation application. “You can potentially undersize and/or oversize sections that may effectively destroy the viability of the dredge,” Clement says.

“The deeper you go, the more complicated it becomes. You can’t afford to overlook the details.”

Seals on an underwater pump are one example. If the bearing housing seals are not correct and proper lube pressure is not applied, the seals will be destroyed in short order, Clement says. “Then lubricant is lost, putting the bearings at risk,” he says. “All of a sudden, you are contaminating the water because you are losing oil. Little things like this must be taken into account.”

Bob Woodington, owner and manager of Phoenix Pinelands Corp., says, if a producer is going to buy a new dredge and take it to depths such as 125 feet, it’s absolutely critical that it’s being purchased from a manufacturer who establishes a relationship beyond selling the equipment.

“Good manufacturers have real experience in the field – someone who has actually been out there and dredged,” he says, “not just someone who just sits behind a desk and designs things.”

Analyze the site and test reserves

Before taking the plunge to dredge deeper, conduct a boring analysis and compaction test to see if there are additional reserves available and the size and type of material that would be mined. Even if material is available, it’s possible that it is too compact to dig up. A mine plan should also be developed prior to starting production for maximum efficiency. This will help ensure a dredge doesn’t need to be moved several times and is actually mining the material instead of mining around it.

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Repeatedly sample after startup

Producers should continually sample material as it is being produced when dredging material in a new area of an existing location or a new site. It will help obtain adequate information to characterize the quality of the material in the project area. If the product remains consistent in the first few days of continuous sampling, the material no longer needs to be sampled every few hours. Initially, consistent sampling initially is extremely important because material can vary the deeper a dredge mines.

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Design the dredge for the job

In deepwater dredging applications, the equipment is not one size fits all. A dredge needs to be designed to accommodate specific depths. Components such as underwater pumps and ladders must be configured to accommodate outside pressure to which they will be subjected. Improper pump selection could cause its bearing houses to fail, which could potentially allow oil to leak into the water and pollute it. Process conditions, such as how far the dredged material will be pumped, also must be taken into account when determining the right equipment for the job.

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Train employees at all levels

Dredging deeper requires a completely different knowledge base and skills than at traditional depths.

Dredge operators, from seasoned employees to those newer to the job, need to be trained specifically on how the dredge and its components work in a different environment and to understand safety protocol.

Producers should work with the dredge manufacturer or distributor for this training before starting production. A follow-up from the manufacturer/distributor a month or two after should also be done to ensure employees understand how to check and operate the equipment and do not develop bad habits.

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Voices of Experience J. (Jos) Clement

W

hen it comes to successful deepwater dredging, the devil is in the details. The cost and size of vessels have grown exponentially, making it imperative to work out the process conditions and requirements – such as how far material will be pumped – before proceeding, says Jos Clement, director of technical services for CEDA Dredging & Fluid Management.

Just about 15 years ago, dredging 25 to 30 feet deep was sufficient, Clement explains. Gradually, the dredging depth requirement grew to 50 to 60 feet. Now, dredging at the 70- to 100-foot deep mark isn’t extraordinary.

“With the increase in water caps in tailings ponds, we are having to build equipment to get down below 100 feet,” Clement says, adding that his operation began dredging at deeper depths about a year and a half ago. “Some of the tailings are getting very deep. With tailings and reclamation work, you can’t expand the geographic footprint in a horizontal frame anymore, because getting permits to expand is difficult. Deposits are deep so you have to go deep.”

Before digging deeper, Clement says producers need to understand what they are working with and how deep they need to go. A dredge designed for extracting material at 40 feet isn’t adequate for dredging at 60 or 70 feet.

“The deeper you go, the more conditions change,” Clement says. “Once you go beyond 40 feet deep, Mother Nature doesn’t give much assistance into a dredge pump. Below the 50-foot mark, you need to have some form of ‘jet assist’ or a submerged ladder-mounted pump.”

Clement cautions that a jet assist may provide additional material pick up capability, but it will dilute the slurry and actually reduce the overall dredge efficiency. A ladder-mounted submerged pump is more efficient.

“When you have a ladder pump and you are excavating below 40 feet, the primary item of concern will be the actual ability of the cutter and suction arrangement on the dredge to acquire the desired material. “At deeper depths, the ability to get the material into the pump becomes the critical factor for dredge production,” Clement says.

Bob Wetta

D

esigning a dredge to mine material in deepwater is both “challenging and fun” – especially when intended to get to depths of 150 to 200 feet, says Bob Wetta, president and CEO of DSC Dredge.

From a design aspect, safety is very important. This can be challenging, because the dredge needs to accommodate several things without compromising the stability of the dredge.” Achieving this can be difficult, because dredges are designed where the dredge ladder – a.k.a. the boom – experiences a big shift in the center of gravity because the weight is moving the entire time it is going up or down.

“On the long boom, you have deflection in the ladder, so it will sag and bend,” Wetta says. “You have to design around these structural members bending and make sure not to fatigue the beam and jeopardize its useful life. If you start noticing a difference in stability, your flotation tank may have taken on water,” Wetta points out. “You shouldn’t have to watch for that on a properly built dredge.”

Finite element analysis software can be used with the dredge structures to run through worst-case scenarios to tweak as needed during the design process. However, it doesn’t mean the barge can be put in the water and forgotten about.

“There is vibration when mining underwater,” Wetta says. “If you think you’ll run it for years without inspecting bolts, etc., you’ll start seeing things fall off.” Understanding what to inspect on a dredge is all part of the process – a big part – of successful dredging, especially in deep water applications.

“Whether dredge operators are new or pros, mining deeper is different, and dredges are custom pieces of equipment,” Wetta says. “Automation can take a lot out of the hands of operators, but you still need to know how to check and operate the equipment and make sure bad habits aren’t developed.”

Bob Woodington

T

he quality of material being dredged can change as the depth increases, making it essential to conduct test boring and look at the history of an area, explains Bob Woodington, owner and manager of Phoenix Pinelands Corp.

“You want to keep going if you are getting valuable material,” he says. “However, you can go from dredging at 90 feet to 125 feet, but it may not be the material you want, so you have wasted money doing it. Digging deeper takes more horsepower to produce material.”

Although initial testing may have been done, Woodington suggests that producers continually sample the material as it is being produced when beginning to dredge at a new site. “You should be sampling the product all day long as it’s produced,” he says. “If the product is staying consistent in the first couple days, you don’t have to sample the material every three to four hours.”

Plotting at a deeper depth helps determine whether dredging deeper makes sense. Depending on what the producer is looking for, such as gravel or coarse sand, the material has to justify digging that deep.

Woodington also notes that having a computer-generated screen that identifies where and how deep dredging has occurred is very useful to monitoring dredge operations, especially in a deepwater environment. Sometimes, Woodington says he will see something on the monitoring system while in his office that he didn’t notice in the field because he was busy focusing on something else.

“If you’re unsure if you dredged an area, you can look back on the computer,” Woodington says. “You want to go to one area to dredge, be efficient, and be done with it. In this business, sand in the water is revenue. If you leave sand behind, you’re leaving money behind.”

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AGGREGATES MANAGER / November 2017

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EQUIPMENT MANAGEMENT

by Chuck Murawski

A proactive stance toward maintenance is the best way to prevent a small problem from turning into a major maintenance headache. Particular attention should be paid to the undercarriage, which often accounts for half of a dozer’s lifetime repair costs.

Be Proactive with Dozer Maintenance Taking care of the machine — including the undercarriage — is the key to productivity.

D

ozers are workhorses on an aggregate site, so optimizing production while minimizing downtime is a huge priority.

Last year, U.S. domestic production and use of construction aggregates amounted to 2.5 billion short tons of crushed stone, sand, and gravel. That values the industry at $25.1 billion, according to the National Stone, Sand & Gravel Association (NSSGA). Yet, despite its size, by and large, aggregates is a high-volume, low-margin business, so owners need to get the most out of their machines and equipment.

The number one maintenance issue for dozers is damage to the

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undercarriage, because of the large quantity of relatively expensive parts involved and high utilization every time the dozer is travelling. Abrasive sandy soils — the bread and butter of the aggregates industry — accelerate undercarriage wear.

Although a crawler undercarriage typically accounts for 20 percent of a dozer’s purchase price, it commonly racks up 50 percent (or more) of its lifetime repair tab. The undercarriage of a dozer suffers more force, sliding, and abrasion than any other piece of equipment. And that’s a lot of money tied to one component.

With such large potential repair

expenses at stake, keeping the undercarriage in good working condition can significantly minimize repair expenses and lower per-hour operating costs. But, when you figure in 10-hour days, high duty-cycles, and unforgiving terrain, maintaining uptime gets trickier.

Undercarriage management Undercarriage management has been described as part science and part intuition — all refined by experience. It encompasses everything to do with machine operation, routine maintenance, periodic evaluation, and, sometimes, even decisions about how best to handle wearing components.

AGGREGATES MANAGER / November 2017

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EQUIPMENT MANAGEMENT But, ignore undercarriage management at your peril, because the costs quickly escalate.

Good design helps mitigate maintenance

Daily cleaning is important to a dozer’s overall health. Dusty air can plug air filters, and contaminated DEF fluid can plug the injector.

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One way to reduce undercarriage wear is to invest in a premium undercarriage, which is designed to reduce wear, specifically external wear on the bushing. A rotating bushing undercarriage can extend life by a factor of two or more in abrasive soils by eliminating sliding and scuffing between the dry bushing outer surface and sprocket tooth. The rotating bushing stays fixed in place on the sprocket tooth, and all sliding takes place on an oil-filled surface between the bushing inner surface and the track pin. Because a pin and bushing turn is not required, this eliminates a large maintenance expense and costly machine downtime.

Oval shaped undercarriages are designed with fewer components than a high drive, which can lower replacement

cost. With more track wrap at sprocket, the load on each bushing is reduced, because twice the number of bushings transfers the load from the sprocket to the track. Track links and rollers are sized so the entire undercarriage system wears equally. Also, self-adjusting front idlers reduce maintenance cost, since shimming is not required.

Some dozers offer other design features to help minimize maintenance.

Castings at high stress areas of the dozer assembly are stronger and distribute stresses better than fabricated brackets, therefore weld repairs are infrequent.

Well-routed and supported hydraulic hoses and wire harnesses help minimize maintenance by reducing movement and rubbing that can lead to leakage and breakage. Finally, ground-level, ease-of-access for routine maintenance, without the need to remove adjacent components, is important.

Other design features that can reduce maintenance include air

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Ground level access makes for an easier maintenance route and promotes better care of the dozer.

pre-cleaners mounted upstream from the engine and cab filters that extend filter life in dusty environments.

Additionally, there are features on dozers to limit operations that accelerate undercarriage wear. For example, the machine monitor can be programmed to limit reverse travel speed, which is important because undercarriage wear is worse when the machine reverses, and excessive speed accelerates that wear.

Be proactive It cannot be said enough: Be proactive with all maintenance issues. It’s simply the best way to prevent a small problem from turning into an expensive major maintenance headache. Use an oil sampling and wear analysis program regularly to monitor machine component health.

Proactive undercarriage management begins with good operating and maintenance practices. That includes avoiding — as much as is practically possible — high ground speeds, excessive reverse operation, counter-rotation, track spinning, and same-direction turning on large jobs. Good maintenance ranges from shoveling out the tracks daily and frequently checking track tension to periodically measuring wear and making informed decisions based on the results.

The small stuff counts All too often, it’s the small stuff that can trip up an operator. Daily maintenance and upkeep is critical to overall machine health. The undercarriage of a dozer is built on a system of moving components: rollers, idlers, tracks, and other parts.

An ounce of prevention is worth a pound of cure A complete undercarriage inspection should be done daily based on the OEM’s recommendations and guidelines.

Inspect the undercarriage for excessive or uneven wear, as well as damaged or missing components. Any issues should be immediately addressed to minimize further wear or damage.

No excuses: Clean everything On many dozers, a shovel for cleaning the tracks is mounted right to the machine. Make use of it, because a clean undercarriage is a healthy undercarriage!

At the end of the day, mud and debris should be cleaned out and removed from the undercarriage. Built-up dirt accelerates component wear. Cleaning at the end of the day removes any material that could freeze, harden, or dry up overnight.

Secondary maintenance concerns include air filters, fuel filters, diesel exhaust

AGGREGATE SYSTEMS

AGGREGATES MANAGER / November 2016

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EQUIPMENT MANAGEMENT

fluid (DEF) cleanliness, and ground engaging tools. Dusty air can plug air filters, and contaminated DEF fluid can plug the injector. Operators should empty air filter pre-cleaners and keep cab doors closed when dozing. Each time fuel filters are replaced, install them dry and use the fuel priming pump to assure all fuel flowing to the engine is filtered.

Drain any water that has accumulated in the fuel water separator.

Track the tension It’s imperative that operators monitor track tension under actual working conditions. Tracks that are too tight accelerate bushing wear. And tracks that are too loose can create instability or even cause the tracks to derail. Refer to the operator’s manual for specific track inspection and tensioning procedures.

Operate machine correctly The way a dozer is operated also plays a critical role in the health of the undercarriage. To that end, there are some important operating tips that can minimize wear and maximize productivity.

Proper turning contributes significantly to minimizing wear. Operators should be trained to make wide and gradual or Y-turns when possible, because counter-rotation and pivot turns accelerate wear. Alternating turning direction is also important because making continuous turns in the same direction can cause asymmetrical and accelerated wear. Operators should focus on balancing the direction of turns throughout the day. If that’s not possible, then check for wear — and expect it — more often.

It’s also important to limit highspeed and reverse travel. Higher speeds cause more wear, and the same is true for unnecessary travel in reverse.

Unproductive high speeds should be minimized, and excessive travel in reverse should be avoided at all costs.

Telematics are everyone’s friend Telematics systems can be very helpful

with maintenance. Good systems report working time versus idle time, and periodic undercarriage measurement can be scheduled based on actual working hours (not hour-meter readings).

Additionally, if the system also reports forward-travel time and reverse-travel time, it makes it far easier to keep an eye on the excessive wear reverse travel can wreak. For example, if the reverse operation reading seems excessive, then the operation might need to be revamped to ease stress on the undercarriage, or it could mean that the operators require more training.

Good telematics systems keep everyone informed — from owners to fleet managers to operators and distributors (and their technicians) — about the health of the machine and when scheduled maintenance is due. Telematics can be particularly impactful when it comes to preventive maintenance, operator training, and fleet management.

Finally, take advantage of OEM complimentary maintenance programs. Most programs are for a specific amount of time (say, three years) or a number of work hours, whichever comes first.

Specifics will vary based on the OEM, but could include complimentary scheduled engine maintenance and complimentary Diesel Particulate Filter exchanges in the first five years.

The primary benefit of a complimentary maintenance program is that it lowers ownership costs, raises resale value, and improves equipment uptime and availability. And that leads to better productivity on an agg site. AM

Chuck Murawski is Komatsu America Corp.’s product manager, dozers. He can be reached via email at CMurawski@komatsuna.com.

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Complimentary maintenance programs

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AGGREGATES MANAGER / November 2016 11:35 AM 2017-08-10

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PARTNER SOLUTIONS/KESPRY

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3 Reasons Drones Are a Leading Tool for Aggregates From measuring stockpiles in minutes to expediting mine planning to safely capturing data from unsafe areas, here are three of the many reasons why aggregate companies are embracing drone technology.

A fo F W a d t a

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1. Stockpile Measurement in Under a Minute Many aggregates companies use a combination of employees on the ground and third-party surveyors to measure stockpiles. Surveys happen a few times a year, using a variety of surveying equipment, and take anywhere from a few days to a week to complete.

This method is costly, hazardous and time-consuming.

Plus the data isn’t immediately available. Even when the data does become available, it can be hard to share within the company or to audit.

Time for a better way to get that all-important data.

Enter, drones. By using drones, companies can frequently and automatically calculate the perimeter and volume for all their aggregate stockpiles; even the odd-shaped piles against walls. With a drone, they can fly a large site in minutes and have pile measurements that same day. Data captured by drones is being used for everything from daily production measurements and spot checks to end of year audits.

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D c w In t m 2 d v m o

e n

Manual inspection of stockpiles often results in slipping or falling

Captured data is automatically uploaded to the Kespry Cloud

“In my opinion, the drone paid for itself the first time I used it.”

—John P. Davenport, Construction Surveyor, Whitaker Contracting Corporation

A great example of a company that’s using drones for stockpile measurement is Whitaker Contracting.

Founded in 1957 and headquartered in Alabama, Whitaker Contracting, is leading the way in aggregate measurement and tracking. By using drones, Whitaker’s combined yearly cost is 22% less than before. They’re measuring their stockpiles twice as frequently, while spending four times less time.

2. Mine Planning at the Speed of Flight Due to the high cost of manned aerial surveys, many companies may only do an aerial survey once a year, while using ground-based surveyors in between.

In search of a way to collect data on any site at any time, companies are incorporating drones into the mine planning process. They’re finding value in the 2D and 3D models created from data captured by drones. Companies are also using drones to compare volume measurements from stripping, takeoffs and mine reclamation work, as well as to estimate levels of reserves.

APAC-Central (Oldcastle) is a great example of a company embracing the benefits drones can offer.

David Lloyd, Mine Planning Engineer, needed a full topographic survey of a disused pit so his team could do their initial cut and fill and engineering design.

Instead of using a scanner system, having a meeting to plan where they’d drive roads with a dozer, spending a few days driving those roads and spending a full day driving the scanner around - they used their Kespry Automated Drone System and were on-site for just two hours total.

3. Remotely Access Unsafe Areas For staff at aggregate companies, doing inventory means having to climb up and down stockpiles, while carrying heavy equipment. This often results in tripping, falling or sliding. Using drones means that staff no longer need to put themselves in harm’s way and can collect all the data they need from a safe distance.

To learn how the leading aggregate companies are seeing a clear ROI with industrial drone systems, visit www.kespry.com/aggregates

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by K. Brad Oakley and Adam J. Schwendeman

ROCKLAW

Workplace Examination Rule Delayed Yet again, MSHA pushes the effective date of and proposes additional substantive changes to final rule.

I

K. Brad Oakley is a member in Jackson Kelly PLLC’s Lexington, Ky., office, where he practices in the Occupational Safety and Health and Litigation Practice Groups. He can be reached at 859-288-2835 or kboakley@jacksonkelly.com.

Adam J. Schwendeman is an associate in the firm’s Occupational Safety and Health and Litigation Practice Groups. He can be reached at 304-3401077 or aschwendeman@ jacksonkelly.com.

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n the ongoing saga of the Mine Safety and Health Administration’s (MSHA) effort to modify the workplace exam rule, the agency has again published proposed changes to the final rule — and its effective date — that was initially published on Jan. 23, 2017. The most recent proposed rules follow two previous publications by the agency delaying the effective date of the final rule, which was originally set to take effect on May 23, 2017. In March, MSHA published a proposed rule to delay the effective date until July 24, 2017. After receiving comments from stakeholders, the agency published a final rule in May and again pushed back the rule’s effective date, this time to Oct. 2, 2017.

On Sept. 11, 2017, MSHA made available for public viewing two proposed changes to the final rule. The first proposed rule amends the final rule that revised the Workplace Examination standard. The final rule is the subject of a legal challenge in the U.S. Court of Appeals for the Eleventh Circuit.

As has been well documented, the final rule made the following changes to the Workplace Examination standard at 30 C.F.R. §§ 56/57.18002:

• Requires examinations of each working place before miners begin work in that place; • Requires mine operators to notify miners of adverse working conditions in their working places; • Requires the examination record to include: the name of the person conducting the examination, the date of the examination, the location of all areas examined, a description of each condition found that may adversely affect safety or health and, when necessary, be supplemented to include the date of corrective actions taken for adverse conditions; and • Requires operators to make examination records available to miners’ representatives in addition to authorized representatives of the Secretary.

In its most recent changes, MSHA states that it is considering changes to the final rule to address two issues: (1) when working place examinations must begin; and (2) the adverse conditions and related corrective actions that must be included in the examination record.

With respect to the timing of examinations, MSHA is proposing to modify the final rule such that a working place must be examined before

AGGREGATES MANAGER / November 2017

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work begins or as miners begin work. MSHA states that this Operators should take time to think about how the final rule proposed change “would allow miners to enter a working and these proposed modifications will affect their operations place at the same time that the competent person conducts and submit any comments they have to MSHA by the Nov. 13 the examination.” deadline. AM With respect to the record of the examination, MSHA is proposing to amend the recordkeeping requirement so that adverse conditions which are promptly corrected need not be recorded. Similarly, a record of corrective action taken would only be required for those conditions that are not promptly corrected. For purposes of this provision, MSHA interprets “promptly” to mean “before miners are potentially exposed to adverse conditions.”

The second proposed rule unveiled by the agency would extend the effective date of the final rule on workplace examinations from Oct. 2, 2017, to June 2, 2018. MSHA states that the delay in the effective date is designed to allow the agency to consider comments on the proposed amendments to the final rule (discussed above), as well as to conduct Repair Tears, Holes, and Gouges informational sessions and distribute With Devcon® R-Flex®, you can repair tears, compliance assistance material prior holes, or gouges in SBR conveyor belts and get them back in service... in just 90 minutes! to enforcement of the final rule. Recall that MSHA promised to provide such Now Protect Clips compliance assistance prior to the Oct. Devcon® R-Flex® can protect clips, preventing 2, 2017, effective date but, to date, them from catching on a wiper and shutting down a conveyor belt and an entire plant. no such measures have taken place.

MSHA sought comments by Sept. 26, 2017, on the proposed extension of R-Flex® Belt Repair Kit the final rule’s effective date to June Devcon® R-Flex® Kits contain everything 2, 2018. you need to repair damaged SBR conveyor Although the comment deadlibelts or protect exposed clips. And R-Flex’s enhanced formulation offers increased ne concerning the extension of the flexibility, improved crack resistance, and final rule’s effective date has lapsed, longer working times in hot climates.

MSHA is still soliciting comments concerning the changes it is considering with respect to the substance For more information visit: www.devcon.com/RF of the final rule. Those comments or call Devcon Tech Service: are due on Nov. 13, 2017 — 60 days An ITW Polymers Adhesives Brand 1-800-933-8266 after the Sept. 12 publication of the proposed rule in the Federal Register.

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AGGREGATES MANAGER / November 9/29/17 2017 1:56 PM

10/4/17 8:24 AM

10/19/17 9:57 AM

ADINDEX November 2017

Advertiser

Web

Page

BekaWorld LP

www.beka-lube.com

25

BKT Tires

www.bkt-tires.com

22

Deister Machine Co., Inc.

www.deistermachine.com

IFC

Elrus Aggregate Systems

www.elrus.com

21

Elrus Aggregate Systems

www.elrus.com

23

ITW Polymers Adhesive

www.devcon.com/rf

29

Kespry, Inc.

www.kespry.com/aggregates

Martin Sprocket & Gear, Inc.

www.martinsprocket.com

MB America

www.mbamerica.com

Motion Industries

www.MotionIndustries.com

NSSGA Membership

www.nssga.org

Progressive Commercial Insurance

www.progressivecommercial.com

Sandvik

www.construction.sandvik.com

BC

Unified Crushing & Screening

www.electricmotors.com

12

Bill Langer - Research Geologist

www.researchgeologist.com

31

C.L. Dews & Sons Foundry

www.dewsfoundry.com

31

HCEA

www.hcea.net

31

Sweet Manufacturing

www.sweetmfg.com

31

26-27 14 IBC 2 24 9

Classifieds

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

30

AGGREGATES MANAGER / November 2017

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MARKETPLACE

• Technical writing and review • Lecturer

Contact me at:

Bill-Langer@researchgeologist.com www.researchgeologist.com

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Find us: Aggregates Manager Magazine

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/Aggregates Manager

Services Offered: Applied geology and geological research for construction rocks and minerals, with an emphasis on aggregates.

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7/21/16 3:37 PM

• USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present

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Experience: Retired November 2011 following 41 years with the U.S. Geological Survey

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12/14/16 8:54 AM

Join the Historical Construction Equipment Association (a non-profit organization) and receive its quarterly magazine, Equipment Echoes.

Read fascinating articles about all types of old construction equipment, illustrated by beautiful historic photos.

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It’s only $35 US in the USA and Canada, $45 US all others. To join, call us at 419-352-5616, or mail a check or money order to HCEA, 16623 Liberty Hi Road, Bowling Green, Ohio 43402.

Join online and learn more about us at www.hcea.net.

AGGREGATES MANAGER / November 2017

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10/22/15 1:27 PM

10/20/17 9:29 AM

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

A Song of the Sandbags

Used to protect soldiers since as far back as the Revolutionary War, the ubiquitous sandbag has found its way to nearly every front.

A-standin’ up to the sandbags, It’s funny the thoughts wot come; Starin’ into the darkness, ‘Earin’ the bullets ‘um; (ZING! ZIP! PING! RIP! ‘ ARK ‘OW THE BULLETS ‘UM!) A-leanin’ against the sandbags, Wiv me rifle under me ear, Oh, I’ve ‘ad more thoughts on a sentry-go, Than I used to ‘ave in a year.

A Song of the Sandbags, by Robert W. Service, 1916.

I

went to a small K-12 grade school — there were 63 people in my class of 1964. Nearly half of the boys-turned-men in my graduating class served in the military. The U.S. was in the midst of the Vietnam War, and I suspect most of my classmates in the military, myself included, served in Vietnam. My closest friend in college also served in Vietnam, although I never saw him or my high school buddies while “in country.”

One of the first things I noticed after arriving in Vietnam (after the horrible smell) was the prevalence of sandbags. They were placed everywhere to protect people, buildings, and equipment from bullets and shrapnel from mortars and rocket-propelled grenades.

Sandbags were by no means unique to Vietnam. They are known to have been used as long ago as the American Revolutionary War by loyalists defending Fort Ninety-Six (aka Star Fort) in South Carolina. The ubiquitous sandbag has been used in nearly every war since.

However, sandbags are perhaps most famous for the role they played in the trench warfare of World War I. The top two or three feet of the front and rear sides of the trench consisted of a thick line of sandbags to absorb any bullets or shell fragments. Millions of sandbags found their way to the Western Front; 150 million from Scottish factories during just one two-week period in 1915.

Research by the British Army determined that a typical bullet used in World War I would only penetrate a sandbag by 15 inches. So how can sand stop a projectile?

A sandbag works somewhat like a non-Newtonian fluid, which behaves like both a liquid and a solid. Think about Oobleck, non-Newtonian fluid consisting of a mixture of two parts cornstarch and one part water. If you slowly poke your finger into a ball of Oobleck, the cornstarch particles can move out of the way. But if you try to quickly jab your finger into Oobleck, the particles jam up against one another, resisting the penetration. (Caution: If you make Oobleck, don’t wash it down the drain. It can plug up your plumbing.)

Likewise, a sandbag is filled with many small grains of sand that can move out of each other’s way when the sandbag is slowly poked with a stick, but when a bullet strikes a sandbag, the grains of sand can’t get out of each other’s way fast enough.

The impact also results in an extreme frictional force as the sand grains dissipate the pressure while the projectile compacts the sand along its path of penetration. These forces combine to stop the penetration of the bullet.

This is a pretty simple explanation for a pretty simple piece of military equipment. But when you are a-standin’ up to the sandbags, it’s funny the thoughts wot come. AM

Nov. 11 was officially made a legal holiday in 1938 to honor veterans of World War I, but, in 1954, it became a day to honor American veterans of all wars. This article is dedicated to all the men and women who have served in America’s military. Thank you for your service!

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AGGREGATES MANAGER / November 2017

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