Aggregates Manager December 2017

Aggregates outlook PG4

| Tier 4 primer PG16 | Judicial stalemate PG28

December 2017 | www.AggMan.com

Your guide to profitable production

AggMan of the

Year 2017 Houston aggregate producers and volunteers

11

Material science advances and screening efficiency

20

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

Among this year’s Top 25 RollOuts is Sandvik’s UI310+ wheeled impact crusher.

PAGE 20 On Our Cover: Aggregates producers come to the rescue in Houston.

Cover photo by James Tre’ Oquin.

To meet Tier 4 requirements, a combination of technologies may be used.

PAGE 16

TABLE OF CONTENTS DECEMBER 2017 |

VOLUME 22, NUMBER 12

FEATURE ARTICLES

6 16

AggMan of the Year 2017 When Hurricane Harvey hit Houston, these aggregates producers went above and beyond for their community.

Taking on Tier 4 Engines

While the transition may seem overwhelming, Tier 4 is simply the next step in engine evolution. Here’s how to approach it.

20 Top 25 RollOuts of 2017

Capacity, efficiency, and technology are common themes among this year’s new equipment introductions.

OPERATIONS ILLUSTRATED

11

Best Practices in Screening

COLUMNS & DEPARTMENTS 3 Editorial Pushback from the public.

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

28 Rock Law A split Review Commission thwarts the expeditious, fair, and legally sound adjudication of mine safety cases.

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

31 Classified Ads Aggregates industry classifieds.

32 Carved in Stone Water storage is an environmental concern that may transform neighbors from saying ‘NIMBY’ to “In My Back Yard, Please!’

Material science advances are enabling screen customization for maximum throughput.

TOC_AGRM1217.indd 1

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December 2017

EDITORIAL

Vol. 22, No. 12

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

aggman.com /AggregatesManager

Pushback

/AggManEditor

Editorial

from the Public

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Editorial_AGRM1217.indd 3

O

ver the years, I’ve often talked about the importance of having a social license to operate. Essentially, operators need to obtain and maintain goodwill from the communities in which they operate to ensure their ability to get greenfield permits and expand operations as needed.

For much of the last decade, an operator’s ability to get this permission seemed to be a little easier. Why? During the great recession, many local bodies looked more favorably at businesses that added jobs as well as tax dollars to their bottom line.

While permits were by no means easy to obtain, it seemed like timelines had shortened a bit, and community opposition was a little less fierce. No more.

As local economies have rebounded, communities are once again providing fierce opposition to some aggregate operations — even as a stronger economy fuels a greater need for construction materials.

Consider these examples from just the last couple of weeks.

In Indiana, the Tippecanoe County Board of Zoning Appeals voted 4-2 against Rogers Group’s request for a proposed 524-acre operation there. According to the Journal & Courier, approximately 70 people wrote letters in support or against the project. A community group, the Americus Area Community Coalition, gathered signatures of more than 1,400 people on a petition in opposition of the project. Rogers Group has been working on this project for about seven years, and has been given a mere 30 days to appeal.

In Greensboro, N.C., Gilford County commissioners voted 8-0 against Lehigh Hanson’s request to rezone 352 acres of land and facilitate its intended $30 million investment there. The News & Record reports that the community opposition centered on traffic, well water, and “quality of life for nearby residents.” The operator had proposed nearly two dozen new conditions ranging from groundwater monitoring to road upgrades to ease the concerns of community members, but the project was still unanimously rejected.

In Maine, despite a 2013 local ordinance that “was understood to have been written specifically to allow (Harold MacQuinn Inc.) to continue,” the Appeals Board upheld the local Planning Board’s decision that the operator could not obtain a permit to operate in the village of Hall Quarry. According to the Mount Desert Islander, the operator applied for a license after the village passed the 2013 ordinance. To be grandfathered, it had to have been in continuous operation without a break of more than 12 months since 2009. Although originally believed to have been grandfathered, the planning board determined that it had been dormant for too long since the ordinance was passed.

As local planning bodies return to emotion-based decision making, operators must pull their focus back to facts and rational thought if they are to obtain that all-important social license.

AGGREGATES MANAGER / December 2017

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Company

mining

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

U.S.

On-Highway

Diesel Fuel

Prices 11/6/17

United States $2.882

One Week +0.042 p One Year +0.310 p

Central Atlantic $2.975 One Week +0.037 p One Year +0.391 p

Lower Atlantic $2.764 One Week +0.035 p One Year +0.380 p

Midwest $2.861 One Week +0.051 p One Year +0.436 p

Gulf Coast $2.668 One Week +0.029 p One Year +0.328 p

Rocky Mountain $2.965 One Week +0.022 p One Year +0.433 p

West Coast $3.332 One Week +0.221 p One Year +0.566 p

West Coast less California $3.075 One Week +0.055 p One Year +0.402 p

California $3.541 One Week +0.356 p One Year +0.702 p Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).

DataMining_AGRM1217.indd 4

52-Week Low

52-Week High

CX

$8.08 q

$6.91

$10.37

CRH plc

CRG

$36.18 q

$32.71

$40.41

Eagle Materials Inc.

EXP

$103.49 q

$86.51

$110.98

Granite Construction Inc.

GVA

$66.66 p

$45.14

$67.20

Heidelberg Cement AG

HEI

$100.56 p

$89.18

$109.64

LafargeHolcim Ltd. ADR

HCMLY

$11.16 q

$10.01

$12.35

Martin Marietta Materials, Inc.

MLM

$213.20 p

$191.09

$244.32

MDU Resources Group, Inc.

MDU

$26.80 p

$25.14

$29.92

Summit Materials

SUM

$30.43 q

$22.19

$32.69

United States Lime & Minerals, Inc.

USLM

$88.08 p

$63.60

$101.40

U.S. Concrete

USCR

$79.20 p

$54.90

$83.85

Vulcan Materials Co.

VMC

$123.90 p

$108.95

$138.18

COMPANY SPOTLIGHT

East Coast $2.848

New England $2.812

Current Value

Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 11/07/17.

One Week +0.063 p One Year +0.412 p One Week +0.037 p One Year +0.374 p

Ticker

I

n its third quarter earnings statement, Summit Materials (SUM) reported diluted net income of $79.1 million compared to $44.8 million in the prior year period.

“We delivered double-digit year-over-year growth in net revenue, operating income, and net income during the third quarter, driven by a combination of increased organic sales volumes in our materials businesses, together with contributions from recently completed acquisitions,” CEO Tom Hill said in a press release.

“Demand fundamentals remain strong in our core regional markets,” he added. “Organic sales volumes of cement and aggregates increased 10.0 percent and 2.6 percent, respectively, in the third quarter 2017, when Summit Materials (SUM) compared to the prior year period. Organic sales volumes of cement in our northern Mississippi River markets increased significantly on a year-over-year basis in the third quarter, while organic aggregates sales volumes in both the East and West Segments increased versus the prior year period.”

Hill noted that organic sales prices on aggregates declined less than 1 percent, due mainly to sales mix-related factors in the West segment. Excluding this, estimated aggregate prices increased nearly 3 percent in the third quarter compared to the same period in the prior year. Net revenues for its aggregates business increased by 15.7 percent to $90.6 million in the third quarter 2017, when compared with the prior year period.

Since its August update, Summit Materials has closed on four materials-based acquisitions including Georgia Stone/McLanahan, which provides an entry point into the Georgia market; Alan Ritchey Materials, which offers an entry point into the Dallas market; and Columbia Silica and Stockman, which are bolt-on purchases to existing footprints in South Carolina and Missouri, respectively.

“As before, we remain disciplined acquirers, transacting on quality aggregates reserves with high synergy potential,” Hill said.

Adverse weather did impact the company during the quarter. “In the aftermath of Hurricanes Harvey and Irma, sales volumes in our Texas and southeastern U.S. markets temporarily declined below historical levels in September and, to a lesser degree, in October, the combined impact of which has led us to reduce our full-year Adjusted EBITDA guidance,” he noted.

Source: Market Watch

Data

STOCK REPORT

11/15/17 1:31 PM

ek

37

41

98

20

64

35

32

92

69

40

85

18

AGGREGATES INDUSTRY OUTLOOK The November Aggregates Industry Index fell to an overall score of 121.69, a 5.21Aggregates Industry Outlook percent decrease from October. The monthly 150 variation marks the most significant month139.35 139.94 145 over-month decline since late summer 134.60 132.37 140 2016. While reports for commercial sales 128.38 124.24 135 were consistently strong, lack of infrastruc122.43 ture investment, as well as the impact of 130 140.38 135.06 133.61 proposed federal tax changes on residential 125 construction, were key concerns. Ratings 120 129.36 for the industry’s outlook in the next year 115 108.08 fell 9.1 percent from October reports. The 110 outlook for quarterly sales experienced the 105 most significant decline — 9.5 percent — in 100 month-over-month ratings. The only cateDec. Jan. Feb. March April May June July Aug. Sept.

Oct. Nov. 2016 2017 2017 2017 2017 2017 2017 2017 2017 2017 2017 2016 gory to mark an increase in November was the outlook for monthly sales, which rose 5.2 percent over October ratings. October ratings, however, were unusually low due to a post-hurricane sales slump.

121.69

Nov. 2017

The lack of sufficient federal appropriations to fulfill the Fast Act programs is having a trickle-down effect in New York.

This, combined with our governor’s focus on social issues instead of infrastructure, is shrinking the transportation budget dramatically. Commercial volumes remain steady.

— Bill Schmitz, Vice President, Quality Control and Sales, Gernatt Asphalt Products, Inc.

The housing market has been steady with interest rates remaining low, however, the new tax plan could slow down growth, particularly on higher end homes. The commercial and government markets remain strong, and I see a continuation into 2018.

Architects are busy, and the pipeline is full.

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

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)

155

Excavator (160-520 horsepower)

102

Wheel loaders Cat 980M

Top Cat 982M models Cat 980K financed

Number financed 17

Cat 966M

7

Cat 336FL

10

6 6

Deere 350 G LC

5

Komatsu PC360LC-10

5

9

7

11

Texas

15

Excavators Massachusetts New York 7

5

10 7

Pennsylvania

Missouri

California

Number financed

Deere 470 G LC

DataMining_AGRM1217.indd 5

Wisconsin

8 8

Top Cat 349FL models financed Cat 336EL

Wheel Loader

11

Cat 988K

Excavators

TOP STATES

07/01/201709/30/17

California

6

Tennessee

5

Texas

10

Florida

5

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AGGMAN OF THE YEAR

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

AggMan of the Year 2017

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

When Hurricane Harvey hit Houston, these aggregates producers went above and beyond for their community.

Darryn Lindsey, Jacob McCurry, and Sean Steagall were among Hanson volunteers during Hurricane Harvey evacuation efforts.

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AGGREGATES MANAGER / December 2017

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S

ince the AggMan of the Year award was launched in 1999, we have always recognized a single individual for his or her industry leadership each year. When Hurricane Harvey struck the Houston area in late August, however, numerous aggregates professionals stepped forward to help their community — and rightly so; many hands were needed. Rather than recognize just one person, we’ve opted to recognize a handful of those who volunteered with rescue and recovery efforts. This year’s recipients include Josh Leftwich, regional environmental and business development manager, Knife River Corp.; Darryn Lindsey, area operations manager, Hanson Aggregates; James Tre’ Oquin, central Texas market manager, Alamo Cement; and Rob Van Til, managing partner, River Aggregates, LLC. These gentlemen, and others who came to the aid of their communities during the trio of fall hurricanes, truly represent the industry at its best.

Rescue efforts According to The Weather Channel, more than 60 inches of total rainfall was recorded as the result of Hurricane Harvey. In fact, it set a record for the continental United States.

As flooding began, Oquin talked with his wife and employer about traveling from his San Antonio home into Houston to help with rescue efforts. He towed his airboat to the city outskirts and slept in his truck as his wife contacted local rescue efforts to offer his assistance. The first day, he worked with the Fulshear Police Department evacuating people from the city of Weston Lake.

The next day, he met with state troopers and traveled to the Sugarland area where more than a dozen people were ferried from their homes. On the final two days of his volunteer stint, he spent time in the communities along the Colorado River, which had crested at around 59 feet. Over the course of four days, he transported about 60 people, including a family of seven and a very pregnant woman and her husband.

Leftwich teamed up with his brotherin-law and some friends to help with rescue efforts. As duck hunters and fishermen, the six men had three fishing boats. They relied on social media reports, including Facebook

posts, to see where help was needed. Cajun Navy, a Louisiana grassroots group formed by private citizens during Hurricane Katrina, also provided guidance.

“The Cajun Navy dispatcher organized rescue workers,” Leftwich says. “They were very well organized and would announce areas where people needed to be evacuated.

“The neat part about it was citizens just came together without anyone telling us what to do,” he adds. “Everybody worked together to get it done.”

At Hanson Aggregates, Lindsey had gone to the company’s Brazos plant to pick up the boat the operation uses to shuttle back and forth to its dredge so he would be able to get back into the plant and assess damage after the hurricane passed. As the storm worsened, he realized there was a more immediate need. “We knew the neighborhoods in the surrounding area were going to get flooded, just based off the weather forecasts,” he says. “We thought there might be an opportunity to help. The need was so great that there just weren’t enough emergency responders to evacuate everybody that needed to be evacuated.”

Working with the site’s outgoing plant manager, Sean Steagall, and incoming plant manager, Jake McCurry, the Hanson contingent took the boat into the Weston Lakes area, a neighborhood cut off by water.

Lindsey stayed on the shore to allow more passengers to be evacuated. Steagall and McCurry evacuated about 25 people over the course of the day.

“I was surprised at how calm everyone was — even those who had lost more or less everything,” Lindsey says, “maybe it was because they were still trying to soak in what had just happened.”

Oquin spotted Lindsey’s bright personal protective gear that day. “He noticed my rain jacket said Hanson Aggregates,” Lindsey recalls. “We got to talking and knew a lot of the same people.”

“He road with me for a couple hours and asked if I had a place to stay,” Oquin says. When Oquin mentioned sleeping in his truck, Lindsey and his wife had him spend the night at their home and fed him.

“He called me every day to see if I needed help or a place to stay,” he adds.

Another construction materials company, Sprint Services (owner of Sprint Sand & Clay, LLC) also provided housing for Oquin and some state troopers for the remainder of his stay in the Houston area. “Sprint went above and beyond what they needed to do,” he says. “They had shower facilities there. Every day, I would get back and they would fill my truck with diesel. They would feed us at night and again in the morning. They were great to work with.”

AGGREGATES MANAGER / December 2017

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AGGMAN OF THE YEAR

James Tre’ Oquin (back row, green shirt) worked with Texas State Troopers from West Texas during his four-day volunteer effort.

Josh Leftwich; his brother-in-law, James Garner (shown at left); and friends used their fishing boats to help transport Houston residents out of water-filled neighborhoods.

When flooding began in his neighborhood, Van Til was at home with his family. “We were sitting in our house, and the water was moving up about one inch every 10 minutes,” he says. “It never got to our house. We were very lucky.”

In the following days, Van Til volunteered with clean-up efforts. Area churches, relief organizations, and the city itself sponsored volunteer efforts to clean up the thousands and thousands of homes damaged by water. One home belonged to a young family who quickly understood that everything, including the furniture, had to go. That project was a pretty straightforward job of tearing the house down to the studs. The second home proved to be a more difficult project.

8

“There was still 6 inches of water in the house,” Van Til says. “It was a retired couple, and they still had the power on. They didn’t know where to begin, and this was four days later.”

Helping others return to everyday life was the focus of Van Til’s family, which pitched in to help by transporting those who needed it, making meals for others, and working with the demolition crews. The biggest challenge, he says, was dealing with the “intricacies of life.”

For example, dozens of local high schools were damaged as well. For these schools, simple matters such as locating jerseys for the football team became another hurdle in a return to normalcy.

Rob Van Til and his son, Jack, helped gut water damaged homes in the aftermath of the hurricane.

Getting back to business With $150 billion to $180 billion in damage estimated by Texas Governor Greg Abbott, Hurricane Harvey didn’t just impact the city of Houston. It also affected many aggregates operations and, more importantly, their employees. “Our Beaumont operation was hit pretty hard,” Leftwich says. “We had roughly 15 of our employees’ homes ruined.” Van Til adds that a number of River Aggregates employees’ homes had water damage, but only one was displaced from his home.

While many of the operations themselves were flooded, planning efforts minimized damage as much as possible. “We’re pretty good at anticipating floods,” Lindsey says. “We’ve learned

AGGREGATES MANAGER / December 2017

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a lot of lessons over the years, mining along these rivers.” Three of Hanson’s Houston operations are dredging sites.

They prepare for high water by ensuring that there is plenty of slack in the swing lines and spuds don’t have a pin at the top to allow the dredge to float higher, if necessary. “It’s better to lose a spud than an entire dredge,” Lindsey explains. The plants are built to ensure their boosters are either on high ground and well out of the flood plain or on pontoons so they can float if the river swells. “We did have some components that got a little water in them, but we should be okay,” he adds, noting that electricians assessed the plant after they could regain access.

“Most of our sites are used to water getting high,” Leftwich says. “We got all of our equipment to high ground, but one of our sites does sit on a bayou, so it had some damage to pumps and motors.”

River Aggregates had a similar scenario. Mobile equipment was moved to high ground, Van Til says, but his

control rooms were under water, creating a number of electrical projects with issues such as load cells on the scale, motors on conveyor belts, and cards for classifying tanks.

Beyond equipment recovery, labor is another challenge facing many operators. “One of the big problems now is that all the work we had is delayed because contractors are delayed and a lot of subcontractors have left and are not coming back,” Leftwich explains. A portion of the subcontractor labor force was comprised of migrant workers who either relocated or found that they can earn more money with cleanup efforts than construction projects.

While recovery — both personally and professionally — is a slow process, the people of Houston are working together to make it happen. “What I’m most proud of is the community’s response. It’s not about cars or buildings or equipment. It’s about people,” Van Til says. “Houston is nothing if not resilient.” AM

Cemex steps up to help employees Cemex, S.A.B. de C.V. made a $500,000 donation for employee and community relief efforts following Hurricane Harvey. The company, whose Cemex USA subsidiary is based in Houston, also set up a fund for voluntary donations from its personnel worldwide and pledged to match those contributions.

“Our top priority is the safety of our employees. We will continue to assist our colleagues and their families affected by this devastating storm,” Fernando Gonzalez, Cemex CEO, said in a press release. “We trust their resilience and solidarity will help them overcome this tragedy.”

Our name is behind every product.

For more than 140 years, our family-owned company has been helping customers solve problems and meet demand. We are proud to be working alongside customers on some of the hardest jobs around. Rock is hard work, and we are up to the challenge.

Unified’s Board of Directors Anne Marie Peltier Bob Kleason Debbie Lentsch Tom Lentsch Andrew Lentsch info@unifiedscreening.com www.unifiedscreening.com 866.968.3697 1221-BG-UnifiedScreeningAd-Dec2017-AggManager-7x4.5.indd 1 Untitled-26 1

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AGGREGATES MANAGER / December 2017 11/14/17 2:37 PM

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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

Best Practices in Screening

OUR EXPERTS Wet material before it reaches the screen.

Craig Burke currently serves as director of engineering and sales support at Polydeck Screen Corp. He joined the company 11 years ago, beginning his tenure as an applications engineer.

Prior to joining Polydeck, he spent 10 years in engineering and operations management for a large national aggregate producer. He received his bachelor’s degree in mining engineering at the University of Kentucky and is a licensed professional engineer.

Take advantage of modular and flexible design options.

Conduct a gradation analysis of material coming off the deck.

Check for damaged equipment.

Michael Vacchi is quarry manager of PJ Keating’s Cranston, R.I., operation.

He began in the precast concrete industry, operating heavy equipment in sand pits. Vacchi then worked as an equipment operator for an international company’s soils recycling division. He took on a supervisory role in that field prior to becoming a quarry supervisor.

Vacchi has worked in aggregates operations for about eight years.

Make sure material is being properly fed down the conveyor.

Sam Durnavich is a regional sales manager for Polydeck Screen Corp.

He worked in operations in Colorado as a plant manager for a large aggregates producer prior to joining Polydeck. Durnavich graduated from Virginia Tech’s College of Engineering with a degree in mining and minerals engineering.

AGGREGATES MANAGER / December 2017

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Material science advances are enabling screen customization for maximum throughput.

W

hen trying to maximize the efficiency and throughput of your operation’s screen media system, it begins with a “holistic view of crushing and screening,” says Craig Burke, P.E., director of engineering for Polydeck Screen Corp. and a former plant manager for a large aggregates producer.

“Everything you tweak in a processing system affects all the other parts,” Burke says. “To make screening more efficient, you have to understand what is going on in front and behind the screen.”

The processes that feed the screen and the processes the screen itself feeds all interact to play a role in desired throughput, Burke points out. “In some cases, increasing throughput at one point can overload another point,” he explains. “Once you establish a holistic view, you can anticipate problems that may arise and plan for them.”

For example, if a producer is trying to maximize throughput on a particular product, it is important to examine the entire crushing and processing system. Burke suggests reviewing the system from finished product all the way back as far as the initial phase of processing. “Good blasting technique is just as important as proper crusher operation to produce more of a desired product,” Burke says. “People want good screen efficiency, but the product may not be there to be recovered. Regardless of how well a screen is set up, if the product you want is not in the feed coming to the screen, it can’t be produced.”

1

Another consideration is the combination and type of screen being used for the various decks. Open area is “king” for more throughput, but sometimes must be sacrificed for longevity and limited footprint. “You need to optimize the screen system design,” explains Sam Durnavich, regional sales manager for Polydeck and a former plant manager for another top producer.

A “mixed approach” — such as heavy-duty panels on the hot spots of the screen and high open area and lower-duty panels on non-heavy-duty screens — may be used to maximize throughput and achieve producer goals.

Even if the screen system is meeting throughput goals, producers need to make sure this doesn’t become all for naught in the finished product piles coming off the screens.

“If you have a dedicated finished stockpile, try to load out of it so new production falls to one side,” says Michael Vacchi, quarry manager of PJ Keating’s Cranston (Rhode Island) Quarry. “If you have large stockpiles, it can contaminate the finished product. You want to manage potential contamination.”

Vacchi suggests digging out a half-moon finished stockpile so material always falls down instead of covering the entire cone. “That way you are only contaminating one side instead of the whole stockpile,” Vacchi says. “A lot of plants have dedicated stacking conveyors, but it may put you at risk of contaminating the entire stockpile. A radial stacker can help.”

Set up screen deck properly

To ensure the screen deck has been properly set up, check the acceleration, displacement, and all technical aspects of the screen when it is running.

If one side moves differently than the other or the G-Force is set too high or too low, it can affect the performance of the screen media. If improper set up causes these problems, a screen performance evaluation should be conducted. Multiple readings of several places on the machine should be taken to determine if it needs to be tweaked and if it is running as efficiently as possible.

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AGGREGATES MANAGER / December 2017

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Customize screen systems

New material science enables producers to customize their screen systems to better match their production goals while fitting various budgets. Wire mesh has been the traditional screen media and is known for having the most open area, crucial to getting the most throughput. However, alternate materials such as rubber and urethane — and now rubber with a metal panel in the center — are being used to create more robust and modular screen system designs.

Lower durometer screen materials help to keep the screens from plugging up while creating a consistent product.

3

Take a holistic view toward processing

Understand what occurs in front of and behind the screen and how interaction between these various facets affects material throughput and efficiency. In a moderate feed, the speed and stroke play a role in efficiency. If material is only being fed down one side of the conveyor to the screen, it will affect production and could cause unnecessary wear on the equipment. Also, the closer in size the material is to the aperture, the harder it is to get through the screen. A larger aperture may be necessary to sort near-size product.

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Focus on quality control and maintenance

Before or during each shift, the operation’s maintenance team should check screen panels. With a heavy feed rate, it’s also important to use the entire top deck of a screen system to achieve the greatest efficiency from all the decks. As part of quality control measures, check for consistency of the crusher feed.

If a crusher goes empty, material will not be screened properly because a finished product is not being sent, and the material will continue to recirculate. Take note if crushing is being done efficiently by monitoring what is coming off of the top screen and what is going back to the crusher.

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Voices of Experience Craig Burke, P.E.

Michael Vacchi

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O

ll too often, total plant throughput is used as a measure of efficient operation, says Craig Burke, P.E., director of engineering and sales support at Polydeck Screen Corp.

Efficiency is more accurately thought of as how easily you are getting product into the pile the first time you try. “That’s when you have to look at the whole picture,” he says. “Screen operating parameters, mechancial conditions of the screen, and feed distribution are just a few critical factors that can have a big effect on efficiency.”

Missing the first, or subsequent, opportunities to get product into the pile can lead to recirculating loads that bog your plant down. “One key is understanding the physical characteristics of the equipment and setting up operating parameters correctly,” Burke says.

Without understanding the effect of speed and stroke on the screen media, producers may have a screen set at a speed or stroke better suited to fine material, but have coarse material feed.

“In a case like that, you can’t get coarse material to stratify as it should so that the right sizes find the apertures,” he explains. “Alternatively, some people may have a screen set at a high-energy level for coarse material, and when fine material is fed to it, the material bounces too high and can’t find its way through.”

Inspecting the feed arrangement and physical condition of the screen is also important. “Is the feed stream segregated? Is the feed all to one side of the screen? Are there broken cross members or springs? Is the chute clear under the screen? Sometimes the screen is smacking up and down on packed material in the chute and shaking itself apart,” he says. When troubleshooting feed arrangements, check to see if you are feeding to the center of the screen or to one side or the other. And remember, feeding from two different conveyors isn’t a ‘no-no’ as long as you properly mix at the feed box.

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ne of biggest issues with screen throughput is managing dust suppression and emissions coming from transfer points, says Michael Vacchi, quarry manager for PJ Keating’s Cranston Quarry in Cranston, R.I. “We manage this in production daily,” he says. “No matter what material you are feeding through, you are trying to manage the right amount of water to control dust and allow the material to screen out — both of which are very important.”

Ensure that you’re not trying to put water over the top of the screen, but wetting the material prior to hitting the screen so it has the best chance of being properly screened.

Regardless of the type of screen media being used, producers often see the most success when they fabricate either a feed shoot or a diverter on the feed plate of a screen to spread out the material on the top deck. “A lot of people don’t use the whole top deck, so it hurts screening ability through the rest of the screening,” Vacchi says. “If all of the top deck is used, you’ll get the greatest efficiency out of all the decks.”

This also makes the finished product much more consistent. If only the middle of the top deck is utilized, it’s difficult to efficiently screen material without it being spread out. It also contributes to improper wear.

“If I have a box or diverter gate dumping onto the feed plate, sometimes the metal on it will begin to wear,” Vacchi notes. “Instead of taking impact on the feed plate of the screen, the first row of screen panels will take the impact. It’s only a matter of time before it will go through and cause contamination.”

Although it may not seem directly related, equipment maintenance plays a vital role in maximizing throughput. “As soon as you go out of spec, things can go awry very quickly,” Vacchi cautions.

Sam Durnavich

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raditionally, wire cloth has been the predominate technology because it is relatively inexpensive, fairly easy to procure, and has high open area. However, it comes in large 4- by 8-foot sections, has a high bed depth, and tends to wear out quickly.

Polyurethane and rubber media tends to be a much higher cost at the outset and may not have as much open area, but it may only need to be changed every six months instead of every 10 days, Sam Durnavich, regional sales manager for Polydeck Screen Corp., says of conventional screen media options.

Now, a combination of wire and synthetic screen media is being used to give producers a screen with higher open area combined with the advantage of lower maintenance. A section of welded wire inside a polyurethane border in a modular format is being used to customize screen system designs.

“Using this type of modular approach allows producers to choose row by row to fine-tune the screen to their needs and hit their production targets,” Durnavich says. However, he stresses that even with the flexibility of a modular design, it’s critical for producers to work with an applications engineer and provide accurate information on production goals, current system setup, and gradation analysis.

“If one side of the screen machine is moving differently than the other side of the machine or the G Force is set too high or too low, it can affect the performance of the screen media,” he says.

Older panels had a tendency to plug and blind. By experimenting with the material science behind the rubber and urethane used in newer modular design screens, more robust — and lighter — designs are being developed.

“Screens are being designed with lower-durometer rubbers to allow the panels to self-clean so they don’t plug badly,” Durnavich says. “It has a trampoline-like action — a secondary motion for self-cleaning.”

AGGREGATES MANAGER / December 2017

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EQUIPMENT MANAGEMENT Three primary maintenance practices for Tier 4 Final engines include keeping the system clean, properly storing and handling DEF, and using the correct materials.

Taking on Tier 4 Engines While the transition may seem overwhelming, Tier 4 is simply the next step in engine evolution. Here’s how to approach it.

A

s emissions requirements continue to evolve and the off-highway industry reaches the final stage of current emissions standards, equipment operators will soon make the switch to working with Final Tier 4 engines — if they haven’t already.

With additional emissions control technology, making the jump to Tier 4 engines may seem like an overwhelming transition at first. However, transitioning to Tier 4 is simply another step in the history of diesel technology advancement. For example, when electronics were first introduced during the Tier 2 emissions stage, end-users were

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initially concerned about the addition.

Today, it has become the standard, as almost every engine features electronics.

It is also important to note the on-highway market has been involved with Final Tier 4 technology longer than off-highway, and manufacturers have learned from the insights gleaned from its implementation.

There are three main reasons why users may find Final Tier 4 equipment intimidating: 1. Lack of familiarity with new emissions technologies; 2. Fear of complexity impacting equipment performance; and

3. Conflicting information about how new technologies impact long-term engine care.

With the perceived intricacy of emissions systems, paired with varied approaches between manufacturers, general education is key in easing the transition to Tier 4. Experts at John Deere Power Systems weighed in on how emissions technologies work together in a Final Tier 4 engine, as well as outlined simple maintenance practices to help ensure you’re prepared.

The road to Tier 4 “John Deere engines are built on a legacy of heavy-duty off-road

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engines,” says Ryan Cawelti, manager of Worldwide Engine Market Planning at John Deere Power Systems. “John Deere has been on a journey to deliver engines that meet Final Tier 4 emissions over the last 20 years. We have used a building block approach that has allowed us to add scalable technology to meet each subsequent emissions regulation.”

The industry introduced a combination of technologies and aftertreatment systems to meet Tier 4 regulations.

To achieve the needed Nitrogen Oxide (NOx) and particulate matter (PM) reductions, different combinations of the following technologies are used: High-pressure common rail (HPCR) fuel system: The HPCR fuel system was introduced during the Tier 2 emissions phase and provides constant control over fuel injection variables such as pressure, timing, duration, and multiple injections. The HPCR fuel system provides higher injection pressures, resulting in more efficient combustion, which, in turn, leads to a reduction in particulate matter.

Cooled-exhaust gas recirculation (EGR): Cooled-EGR was introduced with the start of the Tier 3 engines. The system mixes measured amounts of cooled exhaust gas with incoming fresh air back into the intake manifold to lower the engine’s exhaust temperature, thereby reducing NOx emissions to an acceptable level. The use of cooled-EGR enables smaller SCR systems when used to meet Tier 4 emissions regulations.

Diesel oxidation catalyst (DOC) and diesel particulate filter (DPF): Many Tier 4 engines feature an exhaust filter that contains a diesel oxidation catalyst and a diesel particulate filter.

The DOC reacts with exhaust gases to reduce carbon monoxide, hydrocarbons, and some particulate matter. DPFs operate in conjunction with a diesel oxidation catalyst that is located upstream of the particulate filter. The downstream DPF forces exhaust gases to flow through porous channel walls, trapping and holding particulate matter. Trapped particles are eventually oxidized within the DPF through a continuous cleaning

process called passive regeneration, using exhaust heat created under normal operating conditions.

Selective catalytic reduction (SCR) system: The SCR system uses a urea-based additive, often referred to as diesel exhaust fluid (DEF). DEF is injected into the exhaust stream prior to the SCR catalyst, which then converts NOx in the exhaust stream into nitrogen and water, helping to further reduce NOx emissions.

Each of these systems dynamically interact with each other to adapt to various operating conditions and ensure Tier 4 emissions compliance.

Three practices for a well-performing system There are three primary maintenance practices operators should keep in mind with Tier 4 engines: system cleanliness, proper storage and handling, and using the correct materials.

1. System cleanliness: Cleanliness is essential when using diesel exhaust fluid (DEF) to ensure reliability of the SCR system. This includes making sure storage tanks and any equipment used to handle or transport DEF are clean and free of debris. “Treat the DEF circuit like a hydraulic circuit. Taking precautions to preserve the cleanliness of the fluid will help ensure a trouble-free system in the long run,” says Bryan Wood, manager of OEM Applications at John Deere Power Systems.

Ensuring a clean system also includes setting aside containers to use only for DEF. Operators can benefit from using specialized DEF equipment, such as totes, stainless steel pumps, and fuel lines, as DEF can be corrosive to certain materials such as steel, iron, zinc, nickel, copper, aluminum, and magnesium.

DEF contamination, even with trace amounts of metals, can damage the catalyst in the SCR system.

2. Proper storage and handling: Proper storage and handling of DEF are critical, as they can directly impact the fluid’s quality. “Users should

be aware that there is a shelf life for DEF, and it will start to degrade depending on how well it’s preserved during storage,” Wood says.

DEF freezes around 12 degrees Fahrenheit, and it cannot be directly exposed to sunlight. However, DEF can still be used, even if it freezes solid. On the engine or equipment, the DEF tank is equipped with a heating element that uses engine coolant to thaw DEF in temperatures below 12 degrees Fahrenheit. Do not use antifreeze fluid products to winterize pumps, nozzles, and hoses, as the residual antifreeze fluid can damage the SCR system.

3. Using the correct materials: The last maintenance practice users should observe is using the correct materials, including fuel and engine oil that is specified for off-highway applications. Through the various off-highway emissions stages, engine oil has been specifically formulated to reduce the buildup of ash in the diesel particulate filter, which differs from engine oils used for on-highway vehicles.

Using the correct fuel, although routine, is crucial in keeping the exhaust system running smoothly on a Tier 4 engine. “Fuel filtration needs have increased as we’ve moved to high-pressure common rail fuel systems. Using diesel fuel that meets operator manual specifications is essential to assure adequate filter life and keep the fuel system operating efficiently,” Wood says. “In addition, excess sulfur content in the fuel will reduce efficiency of the SCR system and lead to diagnostic trouble codes and unscheduled machine downtime.

It is critical to use fuels with sulfur contents that meet ultra-low sulfur diesel (ULSD) specifications.”

Other than taking extra precautions to ensure system cleanliness and proper storage, other basic maintenance practices, such as abiding by proper service intervals and using the correct fluids, remain the same from Tier 3.

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EQUIPMENT MANAGEMENT

To meet Tier 4 regulatory requirements, a combination of technologies may be used, with each system dynamically interacting with the other to adapt to operating conditions.

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Maintaining diesel particulate filters Diesel particulate filters trap particulate matter that exists in the exhaust stream, much of which is cleaned during regular operating conditions through passive regeneration. However, over time, the filter reaches a point where it needs to be cleaned by raising exhaust temperatures, otherwise known as active regeneration.

An active regeneration cycle will happen automatically without operator action. It shouldn’t affect normal operation and will only be noticeable by an indicator light on the dashboard when it is in process. It is also important to note that users should not override an active regeneration cycle when it is already in process.

“One of the main takeaways for operators is to let the system work, which includes letting it run through necessary regeneration cycles” Cawelti adds. “When left to operate under

normal conditions, the system will run as it should.”

Leverage existing experience As always, one of the biggest things operators can do to ensure a smooth engine operating experience is to keep lines of communications open. “Talk to your OEM and to the engine manufacturer representatives. Learn about what’s there and what you can and cannot do,” Wood says.

Becoming informed about the new technology, whether through conversations with engine manufacturers or product research, will generally ease the transition into Tier 4. In fact, many of these technologies have been implemented in the on-highway market for some time, so users may already have experience with Tier 4 technology from driving their truck, for example.

“It is also important for operators to understand that our application engineering team works hand-in-hand

with OEM equipment manufacturers to ensure that Tier 4 installations are as seamless as possible for end-users,” Cawelti explains. “We are here to make sure everything under the hood operates as it should for you.”

When it comes to operating a Tier 4 piece of equipment, capitalize on your experience. “Work your machine like it wants to be worked. Maintain it by keeping proper service intervals, which are defined for the different systems on the engine, and use the right fluids,” Wood said. “If you do that, we are confident you will have a positive experience.” AM

Article courtesy of John Deere Power Systems, which has more than 425 million hours in the field working with DPF technology as an off-road only condition and more than 100 million hours with SCR. For more information, visit JohnDeere.com.

Is Open Area The Key...

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Top25Rollouts of 2017

by Therese Dunphy, Editor-in-Chief

Capacity, efficiency & technology are common traits among introductions.

HOW WE MADE OUR CHOICES

When we ask readers how we can best help them keep track of changes in the products and services they use to produce aggregates, almost everyone wants an annual short list of the really important stuff.

No wonder. The sheer volume of introductions is overwhelming. Aggregates Manager covers numerous products each year in RollOuts and Supply Lines, and offers even more product coverage through newsletters and online products of the week.

So each year, our staff reviews all the product introductions we’ve covered for the past year to pick out 25 that we believe are worth further review. Our priorities are new concept products, which are rare; new series/new generation products in categories that relate to the aggregates industry; and other rollouts which serve our readers’ interests by increasing competition in a product category. We also consider reader engagement through website and social media traffic.

Inevitably, we omit deserving products, either because we just didn’t understand the significance of the product or because the announcing company didn’t communicate what was special about the product, or both. In either case, we apologize in advance for these omissions.

Drilling and Blasting ATLAS COPCO

UNDERGROUND DRILLING AUTOMATION SOFTWARE

Atlas Copco’s Dynamic tunneling package is an automation software for face drilling rigs. Previously, an operator imported a 3D model into software used for planning and reporting of drill rig data and information and would then complete drill plans manually. With the automation software, the 3D model is imported and a set of rules is established in the planning and reporting software. The rules and model are then sent to the drill rig via USB or WiFi connection, and the drill rig will make its own drill plans based on location and the model, allowing drill plans to be adapted precisely to the size and section to be excavated.

Atlas Copco | www.atlascopcogroup.com

SANDVIK

DRILL RIG OFFERS ENHANCED EFFICIENCY, TECHNOLOGY

Sandvik’s Pantera DP11000i top hammer drill rig is an intelligent, self-propelled, crawler based surface rig designed for hole sizes of 3.5 to 5.5 inches. Engine options include Tier 3 and Tier 4 Final engines. It is available with a high-frequency RD1635CF rock drill, which is designed to ensure hole straightness, and the Circulating Shank Lubrication System, which is said to reduce shank lubrication oil consumption by up to 70 percent compared to the old system. Both Driller’s Office and Driller’s Notes software come with the rig, with an option for one-hole automatics.

Sandvik | www.construction.sandvik.com

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ns.

Processing ASTEC MOBILE SCREENS

HYBRID MULTI-FREQUENCY SCREEN INCREASES CAPACITY

Astec Mobile Screens’ GT205 Mobile Multi-Frequency Screen features patent-pending hybrid technology. The multi-frequency screen can run on either line power or diesel power.

It features a 5-foot by 20-foot screen. The manufacturer says operators can expect up to 50 percent higher screening capacity on the bottom deck. The unit offers on-site flexibility and simple controls.

Astec Mobile Screens | www.kpijci.com

DEISTER

CONE CRUSHER FEEDER

Deister Machine Co., Inc.’s EMCO 360 Crusher Optimizer Feeder is specifically engineered to optimize cone crusher performance. It features a 360-degree discharge opening and distributes a homogeneous feed to cone crushers to keep them choke-fed for improved efficiency, product consistency, and higher production rates.

Deister Machine Co., Inc. | www.deistermachine.com

HAVER & BOECKER

PLANT SIMULATION SOFTWARE OPTIMIZES OPERATIONS

Haver & Boecker’s NIAflow plant simulation software is designed to help producers optimize quarry operations by diagramming plant flow, machine placement, product pre-calculations, and more. The software is said to instantly analyze existing or proposed processes, record plant statuses, and recognize potential for plant optimization. It is available for download on Windows-based systems. The software allows users to analyze more than 90 pieces of equipment.

Haver & Boecker Canada | www.havercanada.com

KLEEMANN

MOBILE CRUSHER IS BUILT FOR QUARRY APPLICATIONS

Kleemann’s Mobicone MCO 11i PRO mobile cone crusher is designed for demanding quarry applications. The high-performance cone is powered by a diesel-electric drive and achieves an output of up to 518 tons per hour. The plant can also be equipped with an external power supply. By installing the hydraulics in the lower part of the plant, the unit achieves a lower center of gravity, which improves stability while reducing noise and vibration. All plant components can be accessed from ground level or work platforms. Kleemann’s control concept, Spective, is available on the crusher.

Kleemann | www.wirtgen-group.com AGGREGATES MANAGER / December 2017

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ROLLOUTS KOLBERG-PIONEER

JAW CRUSHER OFFERS INCREASED CAPACITY

Kolberg-Pioneer, Inc.’s 3365 Pioneer Jaw Crusher features a unique shaft and bearing assembly to increase serviceability, reduce maintenance, and rebuild costs for lower total cost of ownership. The electric motor mount, v-belt drive, and guarding are all integrated on the machine, simplifying installation for mobile or stationary applications. The crusher is said to offer up to 20 percent more capacity than the next machine in its width class in hard rock and recycled applications. It features an automatic adjust for both the wedge style and tramp iron release systems, as well as replaceable jaw die seats and barrel protector plate.

Kolberg-Pioneer, Inc. | www.kpijci.com

MCCLOSKEY WASHING SYSTEMS

MCLANAHAN

MODULAR WASH PLANT BUILT ON A SINGLE CHASSIS

TROMMEL FEATURES FAST SET UP

McCloskey Washing Systems’ Sandstorm is a modular wash plant that includes feeding, screening, and washing, along with stockpiling of products, on a single compact chassis. The range, including the 516, 620, and 824, can process feeds up to 550 tons per hour with up to four grades of aggregate and two grades of classified sand. Easy access around the plant allows for simple operation and safe maintenance. The S-Line range combines the modular plant with sand screws as another option for sand producers..

McCloskey Washing Systems | www.mccloskeywashing.com

McLanahan Corp.’s MMS Track Trommel is a mobile unit that can be containerized when nearly fully assembled. It can be set up and running within 15 minutes. Capable of handling up to 165 tons per hour of material, it features a self-cleaning drum to minimize downtime. The drum — which measures 16 foot, 9 inches, by 4 foot, 7 inches — features four lifter bars and three wraparound screen mesh sections. All mesh sections are bolted to the outside for quick media change outs. The trommel has variable speed drives on all conveyors and can be hydraulically driven with forward and reverse capabilities.

McLanahan | www.mclanahan.com

METSO

CONE COMBINES PISTON AND ROTATING BOWL METHODS

Metso’s MX crusher is based on patented multi-action crushing technology that combines the piston and rotating in a single crusher. It is said to cut operational costs by 10 percent and enable 10-percent higher uptime than traditional cone crushers. Key benefits include an easy under-load setting adjustment and wear compensation without having to stop the crusher. The cavity design, stroke direction, and distributed crushing action enhance rockon-rock crushing for extended maintenance intervals.

Metso | www.metso.com

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SANDVIK

EXPANDED MOBILE OPTIONS WITH WHEELED CRUSHER

Sandvik’s UI310+ Prisec impact crusher features the patented CI512 Prisec impactor and a triple-deck vibrating pre-screen on a single trailer frame. It was designed to be configured into either a primary or secondary configuration. Operator friendly features include safety guards around the crusher and screen and a self-contained switchgear cabinet on board for power distribution.

Sandvik | www.construction.sandvik.com

SUPERIOR INDUSTRIES

NEW OPTION IN WASHING CRUSHER FINES

Superior Industries, Inc.’s Alliance Low Water Washers offers a new solution for processing crusher fines right next to the crushing circuit. The unit accepts a dry feed directly from the crushing circuit and processes material into a higher value manufactured sand. It is said to use up to 80 percent less water than the traditional screw/screen combination. An agitator section is positioned at the front end of the screen where water is added to the dry feed and mixed, producing a thick slurry. The slurry is then dumped onto a dewatering screen with a series of spray bars to help clean and wash out the fines. The end result is a saleable manufactured sand with approximately 8 percent moisture content.

The unit processes up to 300 tons per hour.

Superior Industries | www.superior-ind.com

TEREX FINLAY

WIDER COMPONENTS ENHANCE MATERIAL FLOW

Terex Finlay’s I-140 direct drive 50- by 48-inch horizontal impact crusher features enhanced material flow achieved by increasing the width of components. The machine features an electronic control system that manages the speed of the rotor and regulates the heavy-duty vibrating feeder with integrated pre-screen to maintain a consistent feed of material to the impact chamber. Material from the integrated pre-screen can be diverted to a stockpile via an optional by-pass conveyor, or it can join the crushed product on the main belt. The hopper capacity is 7.5 cubic yards.

Terex Finlay | www.terexfinlay.com

Conveying ASGCO

BELT VULCANIZING PRESS

Asgco’s Vul-Con Vulcanizing Press is said to be lightweight and easy to set up and maintain. Made of high grade aluminum platens and beams to provide maximum tensile and bending strength with minimum weight, the press provides uniform temperature and pressure required to vulcanize a wide variety of conveyor belts.

Asgco | www.asgco.com

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ROLLOUTS CONTINENTAL

CONVEYOR BELTING FOR STEEP INCLINES

Continental’s Select ContiCleat is a conveyor belt for steep inclines and challenging conveyor applications. In 17 different profile options, the cleated belts are said to be ideal for conveying materials such as stone, sand, and gravel. They are available in both U and V shapes. In a 1-inch cleat design, the belts can convey products at up to a 45-degree incline.

Continental | www.contitech.us

MARTIN ENGINEERING

BELT TRACKER PREVENTS DRIFT

Building on a standard crowned roller, the Martin Roller Tracker, from Martin Engineering, uses a unique ribbed lagging made of polyurethane to keep return belts on track. The roller does not come in contact with the belt edge, which means no fraying, as well as consistent tracking for single-direction or reversing belts. The tracker’s 7.5-inch diameter allows it to react quickly to fluctuations in the belt path. As the belt drifts, the roller constantly tilts and turns, reacting to the direction of the belt’s drift.

Martin Engineering Co. | www.martin-eng.com

Mobile Equipment CASE

EXCAVATOR OFFERS GREATER DIGGING FORCE, LIFTING CAPACITY

Case Construction Equipment’s CX750D is its largest excavator. The Tier 4 Final 512-horsepower unit is available in standard and mass excavation configurations.

An electronically controlled hydraulic pump and larger control and solenoid valves boost breakout forces, increase lifting strength, and improve responsiveness. A larger cab offers a fully adjustable workstation with a new high-back seat for comfort and support. Standard rear- and side-view cameras feed a 7-inch monitor that provides access to performance parameters such as fuel consumption, operating hours, and machine information.

Case Construction Equipment | www.casece.com

CATERPILLAR

ELECTRIC DRIVE LOADER BOOSTS EFFICIENCY, PRODUCTIVITY

Caterpillar’s 988K XE is its first wheel loader offered with a high-efficiency electric drive system. It features switched reluctance (SR) technology. 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 faceloading applications, compared to the 988K. At the same time, Cat production studies report it delivers up to 10-percent higher productivity in load-andcarry applications.

Caterpillar | www.cat.com

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JOHN DEERE

DOZER GETS TECH UPGRADE

John Deere integrated SmartGrade machine controls on its 850K crawler dozer, which is said to improve accuracy and quality of work through the complete integration of the Topcon 3D-MC Grade Control System. A key feature of the integrated machine control is Auto SmartGrade, which allows the operator to easily adjust the system when moving the machine from one soil type to another. It also automatically lifts the blade over heavy loads before track slippage occurs when returning the blade to grade.

John Deere | www.johndeere.com

JOHN DEERE

AGGREGATE HANDLER LOADS IN TWO PASSES

John Deere’s 844K Series-III Aggregate Handler features a 401-horsepower, 13.5-liter John Deere PowerTech Tier 4 Final diesel engine. It is equipped with standard five-speed transmission with torque-converter lockup in gears two through five. This increases acceleration, speeds, and cycles, and optimizes power and fuel efficiency during transport, roading, and ramp climbing. It is built for two-pass loading with increased power, large tilt cylinders, higher hydraulic pressure, and increased counterweighing to handle bigger material-handling buckets. The result is a 30-percent decrease in loading time, eliminating the third pass.

John Deere | www.johndeere.com Untitled-29 1

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ROLLOUTS KOMATSU

EXCAVATOR OFFERS MACHINE CONTROL ENABLED JOYSTICKS

Komatsu America Corp.’s PC210LCi-11 hydraulic excavator is a second-generation unit that adds machine-control joystick functionality and up to a 63-percent improvement in excavating efficiency over a PC210LC-11 and traditional stake-plus-grade-checker methods. Key features include: machine-control-function enabled joysticks, full 3D GNSS capabilities, work equipment automation, stroke-sensing hydraulic cylinders, and intelligent guidance.

Komatsu America | www.komatsuamerica.com

KOMATSU

OFF-HIGHWAY TRUCKS REDUCE FUEL CONSUMPTION

Komatsu America Corp.’s HD605-8 off-highway truck is equipped with a 724-horsepower Tier 4 Final SAA6D170E-7 engine and reduces fuel consumption by up to 12 percent when compared to its predecessor. It has a payload capacity of 69 tons. Standard features include a 7-inch LCD monitor, dedicated rearview monitor, fast-fill system, engine compartment light, and premium heated and ventilated operator’s seat with air suspension.

Komatsu America Corp. | www.komatsuna.com

PHILIPPI-HAGENBUCH

SAFE HAUL ROAD MAINTENANCE SOLUTION

Philippi-Hagenbuch’s Material Spreader Body is designed to provide a safe and efficient solution for haul road maintenance.

In winter weather, it can apply road grit to icy roads. In the spring, it can spread repair material and build up areas on deteriorating roads. It couples the new material spreader attachment with the Phil Rear-Eject Body. The attachment can spread material ranging in size from very fine to more than 2 inches. The haul truck operator controls the material spreading rate and width from the truck’s cab.

Philippi-Hagenbuch Inc. | www.philsystems.com

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ROLLOUTS VOLVO CONSTRUCTION EQUIPMENT

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by Patrick W. Dennison

ROCKLAW Judicial Stalemate How the split Commission thwarts the expeditious, fair, and legally sound adjudication of mine safety cases.

I

Patrick W. Dennison is an attorney in Jackson Kelly PLLC’s Pittsburgh, office, where he practices in the Occupational Safety and Health and Coal and Oil and Gas Industry Groups.

He can be reached at 412434-8815 or pwdennison@ jacksonkelly.com.

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n the May 2017 edition of Aggregates Manager, Jackson Kelly attorney Arthur Wolfson discussed the Trump Administration’s need to appoint a fifth commissioner to the Federal Mine Safety and Health Review Commission (Review Commission) who “will restore a sense of independence to the Review Commission so that it may fulfill its responsibility to the regulated community.” The Review Commission’s vacancy, which began on Sept. 1, 2016, at the end of former-Commissioner Patrick K. Nakamura’s term, has resulted in a judicial stalemate duly reflected

by Commission decisions since May 2017.

The Review Commission is an independent adjudicative agency that provides administrative trial and appellate review of legal disputes arising under the Federal Mine Safety and Health Act of 1977 (Mine Act). The Review Commission consists of its administrative law judges (ALJs), who hear and decide cases, and the Commission itself, which consists of five presidential appointees who hear appeals of the ALJs’ decisions. Three of the five Commissioners are selected by the Administration of the party in power with two selected by the party out of power. Because of the vacancy, however, only four Commissioners have decided cases since August 2016, many of which have resulted in 2-2 decisions.

Despite the fact that half of the Commissioners may disagree with an ALJ’s decision, the effect of an even split is to allow the ALJ’s decision to

stand as if affirmed. Moreover, even more importantly, such split decisions are non-precedential.

See Pennsylvania Elec. Co., 12 FMSHRC 1562, 1563-65 (August 1990), aff’d on other grounds, 969 F.2d 1501 (3d Cir. 1992).

For instance, in Bussen Quarries, Inc., 39 FMSHRC 970 (Review Commission May 2017), the Commissioners evenly divided on the issue of whether to affirm the ALJ’s decision in its entirety, which was in favor of MSHA, or to reverse the finding of a violation. The split decision resulted in the affirmance of the ALJ. Two Commissioners in Peabody Twentymile Mining, 39 FMSHRC 1323 (Review Commission July 2017), voted to affirm the ALJ’s decision, which found in favor of MSHA, and two voted to reverse the decision. The two Commissioners voting to reverse the ALJ joined in one opinion and found that MSHA did not offer any convincing argument for reversal of a longstanding interpretation for a method of construction of ventilation stoppings in underground coal mines. The same two Commissioners also found that the litigation prompted sacrifice of MSHA’s integrity as “unwarranted” and “shameful.”

Meanwhile, the two Commissioners who voted to affirm the ALJ wrote separate opinions, each affirming the ALJ’s decision on separate grounds.

As a result, the ALJ’s decision stands as issued.

In Canyon Fuel Co., LLC, 39 FMSHRC 1578 (Review Commission August 2017), the Commission unanimously upheld the ALJ’s decision

AGGREGATES MANAGER / December 2017

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concerning one citation, but evenly split on another. In so doing, An appeal to the Commission is a lengthy process which two Commissioners voted to affirm the ALJ’s decision, which may persist for years, and a split Commission fails to achieve found in favor of MSHA, and two voted to reverse the decision. the number one strategic goal of the Commission itself — that The two Commissioners who voted to reverse the ALJ again is — “to ensure expeditious, fair, and legally sound adjudication joined in one opinion and found that MSHA’s actions were the of [mine safety] cases.” See Federal Mine Safety and Health product of arbitrary and capricious decision making. Despite Review Commission Strategic Plan, 2014-2018. The next two such findings, the result was the affirmance of the ALJ. Two Commission vacancies occur at the end of August 2018, and Commissioners in Consolidation Coal Co., __ FMSHRC __ (Rethis Administration must not allow the Commission to languish view Commission September 2017), voted to affirm the ALJ and without appropriate and fair appointees. After all, as my colleconcluded that the ALJ’s decision, which found the violations ague, citing to the legislative history of the Mine Act, so aptly to be non-S&S, was supported by substantial evidence. In pointed out in May, “[A]n independent Commission is essential contrast, two Commissioners concluded that the evidence deto provide administrative adjudication, which preserves due monstrated that the violation was S&S and, accordingly, would process and instills much more confidence in the [Mine Safety] reverse the ALJ. program.” Human Resources Committee, S. Rep. No. 95 181, The Commissioners evenly split in Arnold Stone, Inc., __ Mine Safety & Health Act of 1977, at 47 (May 16, 1977). That FMSHRC ___ (Review Commission September 2017), on the statement, which Congress asserted over 40 years ago, rings issue of whether to affirm the ALJ’s penalty assessment or to truer now more than ever. AM vacate and remand it. Hence, because there was no majority, the ALJ’s assessment of penalty stands as if affirmed despite the reversal of the ALJ’s substantive findings. In Consol Pennsylvania Coal Co., __ FMSHRC __ (Review Commission October 2017), the Commission reversed the ALJ (3-1) as to her unwarrantable BEKA auto-lube is built to take the failure, high negligence, highly likely, and bumps and grinds of a hard-working fatal findings for a § 104(d) citation and life on the road or off. Give your fleet reversed the ALJ (3-1) as to unwarrantabthe solution that keeps them on the job. le failure, highly likely, and fatal findings • Cast aluminum base withstands for a § 104(d) order. The Commission also impacts and hot/cold cycles unanimously affirmed the S&S designawithout leaking • No springs! Eccentric gear drive tion for the citation and affirmed, by a resists wear, fatigue and cold 2-2 split, the S&S and high negligence • Consistently precise grease dosing designations for the order. In Nally & Find out why industries are choosing Hamilton Enterprises, Inc., ___ FMSHRC today’s best-built auto-lube systems. ___ (Review Commission October 2017), Call 1.888.862.7461 or email us two Commissioners decided to affirm the at info@beka-lube.com.

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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

Not In My Back Yard During the past year, this column has discussed some environmental friendly uses of aggregate. This article describes an environmentally friendly use for the hole left behind after the gravel is mined.

B

ack in the early 1990s, I was studying the gravels of Clear Creek near Golden, Colo. One beautiful fall day, I was looking at a residential lake development near Clear Creek that was built surrounding a water-filled reclaimed gravel pit. I was on the public sidewalk being mindful to not trespass or disturb the residents. I was deeply engrossed in “framing” my camera for a picturesque photograph between the houses when I was startled (putting it mildly) by a loud voice from behind.

“Who are you, and what are you doing?”

“I am a geologist with the U.S. Geological Survey, and I am studying residential lakes,” I replied.

That temporarily calmed down my accuser. I went on to say what a beautiful lake it was and how lucky they were to live there. That was met with a big smile, but the smile turned upside down when I went on to say that it was a marvelous use for a reclaimed gravel pit.

“There is NOT a gravel pit! It is a natural lake!”

To make a long story short, I finally diffused the situation when I said that the natural floodplain lakes around Golden often are created by floods and come and go at the whim of Mother Nature. Their lake, on the other hand, was well designed and would outlast what Mother Nature had in store for her own lakes.

Time-travel backward a decade. Water law is a serious issue in the arid to semi-arid west. Colorado and Nebraska have an agreement that Colorado will allow no less than a specified amount of water to flow along the South Platte River from Colorado to Nebraska. The problem is that most of the flow of the South Platte comes in the spring from the melting of the snowpack.

Millions of gallons of water flow into Nebraska, far exceeding the amount required under the Colorado-Nebraska compact.

To remedy this, the Two Forks Dam was proposed to be built on the South Platte River, near Deckers, Colo. However, the permit to build the dam, which would have held enough to meet the annual needs of 400,000 people, was denied.

Now, fast forward to the start of the 21st century. Just about the time Two Forks was dying, state mining engineers decided that mined-out gravel pits could be used as storage reservoirs. That decision changed the way aggregate companies and local municipalities looked at the pits. Not only could aggregate companies get the economic benefit from the gravel, but they could turn the mined-out land into a water storage facility for the nearby communities.

Municipalities along the South Platte scrambled to permit new gravel operations, as long as they could purchase the hole. Gravel operators were happy to oblige because, frequently, the holes in the ground were worth more than the gravel that came out of them.

Some rock quarries also became suitable storage places for municipal water supplies. Pictured at the right is one of those quarries, just starting to be filled.

With the decline in the construction of new dams, this phenomenon has spread across the country. In some places, “Not in My Back Yard” has become “In MY Back Yard, PLEASE.” AM

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