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14 21 26 Cover_AGRM0117.indd 1
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January 2017 | www.AggMan.com
Exclusive forecast calls for industry growth Tips for remote control and autonomous operations Electric Site: Volvo’s futuristic quarry operation
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In Volvo’s test site, large haul trucks are replaced with a series of unmanned 15-ton battery-electric haulers. On Our Cover: With technology developing at a breakneck rate, future aggregate operations may look very different. Cover illustration by Sandy Turner, Jr.
PAGE 26
Heavily concentrated loads and high traffic volumes make aggregate applications some of the most demanding in the weighing industry.
PAGE 32
TABLE OF CONTENTS JANUARY 2017 |
VOLUME 22, NUMBER 1
FEATURE ARTICLES
14
Forward Facing After a year of mixed business ratings, operators are optimistic about their odds in 2017.
26 Energy Efficient Quarrying
Volvo’s ambitious Electric Site takes aim at lowering carbon emissions and energy costs.
COLUMNS & DEPARTMENTS 3 Editorial A brave new world. 4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook.
32 Scaling Back on Down Time
6 State and Province News A roundup of the latest news in North America.
36
8 RollOuts Kolberg-Pioneer’s 3365 Pioneer Jaw Crusher, and other new equipment for the aggregates market.
Maximize the life of your scale with upfront design considerations and ongoing maintenance.
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Excavator Enhancements Eye Bottom Line
Greater productivity and fuel efficiency are common features in the latest generation of excavators.
OPERATIONS ILLUSTRATED Remote control and autonomous operations
21
Rapid development and implementation of technology on today’s operating equipment can translate to greater productivity and safer workers.
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40 Rock Law Will the Trump Administration make MSHA great again? 42 Advertiser Index See who’s who and where to find their products. 43 Classified Ads Aggregate industry classifieds. 44 Carved in Stone Aggregates and the environment: highlighting some of the environmentally beneficial uses of aggregates.
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12/14/16 8:42 AM 12/2/2016 9:14:57 AM
January 2017
EDITORIAL
Vol. 22, No.1
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
aggman.com /AggregatesManager @AggMan_editor
A Brave New World
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Contributing Editor: Kerry Clines editorial@aggman.com
Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Linda Hapner production@aggman.com
Construction Media Vice President, Construction Media: Joe Donald sales@randallreillyconstruction.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.
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A
s we turn the page on 2016, it’s time to reflect on all the new year has to offer. By all accounts, 2017 should be a banner year for the aggregate industry. President-elect Donald J. Trump has made infrastructure a priority for his burgeoning administration. Operators who responded to the Aggregates Manager 2016-2017 Forecast Survey predicted the best business conditions in 13 years of forecasts (see page 14). And, technology and automation are moving at a rapid-fire pace. The future truly is now. Throughout this issue, you’ll get a glimpse at some of these innovations and learn how they are being used. For example, remote control technology and autonomous machines are featured in this month’s Operations Illustrated (page 21). For an even more futuristic look, check out this month’s Technology feature (page 26). We were the only aggregate magazine to have an editor attend Volvo’s Xploration Forum in Eskilstuna, Sweden, last fall to view prototypes of hybrid loaders and autonomous haulers. Editorial Director Marcia Gruver Doyle highlights the company’s work on a $30 million project to create an electrified quarry. The result could be an operation that not only cuts carbon emissions, but also operating costs. At a recent press event, I had the chance to see how some equipment innovations are being developed so quickly. Caterpillar gave industry editors a taste of its virtual reality (VR) demonstrator with a walkthrough of a D6 dozer. Using a VR headset and a handheld wand, a user can cut through the machine to get a tech-based look under the hood. The demonstrator made for a buzzworthy press event, but it has much more utility for the equipment development team. Before the use of virtual reality, engineering teams may have multiple ideas on how to approach an equipment design, but would have to vote on one and build it as a prototype. “It cost a lot of time and money,” says Dave Cooper, a design visualization steward with Cat’s Immersive Visualization Department. “Now, we can build all of them — virtually — and put the expert operators in the seat to make sure it meets an operator’s needs, not an engineer’s.” While the demonstrator is new, Cooper explains that Cat has been using VR for more than 20 years. It allows the engineering team to not only test multiple design ideas, but also enables mechanics to look at a machine’s serviceability and customers to provide feedback before a physical prototype is built. “The design process is similar, but evaluating it is new because we don’t have to build a physical prototype (as soon), and we can make minute changes as we go. It allows you to tune and refine continuously,” he says, noting the result is a better design with a shorter lead time. As I wore the headset and worked my way through the D6’s engine and inner workings, I was reminded of an Aldous Huxley line in his novel, Brave New World: “Words can be like X-rays. If you use them properly, they’ll go through anything.” I hope our words help give you insight into what is indeed a brave new world.
AGGREGATES MANAGER / January 2017
3
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Data
STOCK REPORT Company
mining
Cemex, S.A.B. de C.V.
U.S.
On-Highway
Diesel Fuel
Prices 12/5/16
United States $2.480
Central Atlantic $2.602 One Week +0.053 p One Year +0.060 p
Lower Atlantic $2.415 One Week +0.054 p One Year +0.120 p
Midwest $2.431 One Week +0.075 p One Year +0.083 p
Gulf Coast $2.361 One Week +0.071 p One Year +0.129 p
Rocky Mountain $2.457 One Week +0.007 p One Year +0.047 p
West Coast $2.770 One Week +0.043 p One Year +0.167 p
West Coast less California $2.679 One Week +0.044 p One Year +0.202 p
California $2.843 One Week +0.043 p One Year +0.139 p Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
DataMining_AGRM0117.indd 4
52-Week High
CX
$8.21 q
$3.50
$9.35
CRH plc
CRG
$34.42 p
$22.42
$36.66
Eagle Materials Inc.
EXP
$100.97 p
$45.03
$101.76
Granite Construction Inc.
GVA
$59.41 p
$35.69
$62.18
Heidelberg Cement AG
HEI
$90.33 q
$64.53
$101.68
LafargeHolcim Ltd. ADR
HCMLY
$10.60 q
$6.92
$11.66
Martin Marietta Materials, Inc.
MLM
$225.33 p
$108.31
$236.41
MDU Resources Group, Inc.
MDU
$28.85 p
$15.58
$29.38
Summit Materials
SUM
$23.78 p
$13.12
$24.81
United States Lime & Minerals, Inc.
USLM
$76.00 p
$48.41
$76.25
U.S. Concrete
USCR
$60.95 p
$40.42
$69.66
Vulcan Materials Co.
VMC
$128.43 p
$78.83
$138.18
I
n the third quarter, ending Sept. 30, 2016, Granite Construction reported net income of $37.1 million, compared to a net income of $30.8 million in the third quarter of 2015. Earnings per diluted share were $0.92, compared to $0.77 in the prior-year period. “We continue to benefit across the business with a steady demand from private and public markets, pushing total backlog to an all-time high of $3.8 billion,” said James H. Roberts, president and CEO, in the company’s quarterly report. “The Construction Materials segment continues to perform well, reflected in continued, improved margin performance,” he added. “Total production volume in the quarter an d year-todate remained in line with last year, though materials demand shifted to increased internal consumption. As a result, much of the revenue and profit benefit of vertical integration has been captured by our Construction segment.” During the third quarter, consolidated revenue increased 7.0 percent to $803.9 million, compared with $751.4 million during the third quarter of 2015. For the first nine months of 2016, consolidated revenue increased 6.2 percent from 2015 to $1.8 billion. Gross profit for the quarter increased 12.1 percent to $107.7 million, compared with $98.1 million in 2015. For the first nine months of 2016, gross profit increased 10.5 percent to $220.1 million. In the Construction Materials segment, revenue in the third quarter decreased 16.2 percent to $89.9 million, compared with $107.3 million in 2015. Granite Construction says the decrease was driven primarily by a shift to greater internal consumption of materials. Correspondingly, third quarter gross profit declined 9.6 percent to $12.5 million, compared to $14.0 million in 2015. “We continue to anticipate increased infrastructure investment in 2017 and beyond, including tangible benefits from the five-year Fixing America’s Surface Transportation (FAST) Act… as well as increased state and local spending,” Roberts noted. “We remain in an excellent position to close the year safely and strongly, and to prepare efficiently for growth in 2017 and beyond.” Source: Google Finance
One Week +0.054 p One Year +0.011 p
52-Week Low
COMPANY SPOTLIGHT
East Coast $2.499
New England $2.526
Current Value
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 12/7/16.
One Week +0.060 p One Year +0.101 p One Week +0.053 p One Year +0.086 p
Ticker
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k
5
6
6
8
8
6
1
8
1
5
6
8
AGGREGATES INDUSTRY OUTLOOK After months of decline, the Aggregates Industry Outlook surged ahead 13.28 percent in December, to an overall score of 122.43. Responses to outlook questions for all time periods showed gains, with the outlook for tons sold duringthe month gaining the most ground. That score increased from a slightly negative score of 2.91 in November to a healthy 3.80 in December. Predictions for tons of aggregates sold in the next six months also moved up, from 3.09 to 3.67, a gain of 0.58. Expectations for tons sold for the next year increased from 3.45 in November to 3.93, a 0.48-point gain.
Aggregates Industry Outlook 140 132
131.68
127.51
136
126.03
125.60
122.43
128
119.44
124 120
128.99
128.15
128.61
109.80 111.42
108.08
116 112 108
111.00
104 100
Dec. 2015
Jan. 2016
Feb. 2016
With the Trump Administration taking control, there is a perceived business-friendly atmosphere and positive infrastructure outlook that has not been present for many, many years.
Mar. 2016
Apr. 2016
May 2016
Jun. 2016
Jul. 2016
Aug. 2016
Sept. 2016
Oct. 2016
Dec. 2016
Jan. 2017
I am encouraged with the prospect of an infrastructure program proposed by President-elect Trump. This, combined with the FAST Act, should help to get infrastructure spending where it belongs. — Bill Schmitz, Vice President, Quality Control and Sales, Gernatt Asphalt Product, Inc.
— Daryl Zeiner, Sales Manager, The H&K Group
Business has been good and is expected to continue. Waiting to see how the Trump Administration proceeds. — Larry Kessler, Project Manager, Pennsy Supply, Inc.
I believe that our regional markets remain in the early stages of a multi-year recovery in public infrastructure, residential, and non-residential construction spending, as supported by favorable long-term demographic trends. Comments from President-elect Trump are also very positive. — Damian Murphy, Regional President, Summit Materials
Dry weather (except Hurricane Matthew) allowed construction work during most of October and November. If the new administration in Washington delivers on its promises, 2017 should be a good year for infrastructure projects. — O.F. “Russ” Patterson, III, Chief Geologist, Patterson Exploration Services
Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.
QUARTERLY CRUSHED STONE REPORT Region/Division Northeast: Midwest:
South:
West:
New England Middle Atlantic East North Central West North Central South Atlantic East South Central West South Central Mountain Pacific TOTAL
Quantity 2nd qtr. 2016 12,400
Percent change 9.1
Quantity 3rd qtr. 2016 14,500
Percent change -2.7
42,600
-0.6
46,700
-7.8
66,300
11.4
74,200
-1.8
36,600
-2.5
39,300
-19.9
80,900
10
81,700
-2.7
37,900
-1.6
38,600
-7.8
58,200
2.4
60,800
0.4
19,300
12.6
23,400
-2.7
19,000
5.8
21,500
-7.8
377,000
5.5
397,000
5.5
Source: U.S. Geological Survey
DataMining_AGRM0117.indd 5
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STATE & PROVINCE
NEWS
To keep up to date with news from the United States and Canada, visit www.AggMan.com for daily updates.
by Therese Dunphy | Editor-in-Chief tdunphy@randallreilly.com
CALIFORNIA In mid-November, firefighters responded to a blaze at Black Mountain Quarry in Apple Valley. The Daily Press reports that Apple Valley Fire Protection personnel responded to the fire at around 9:45 p.m. on Nov. 15. Multiple units responded to the call and were told that multiple explosions were occurring. The first engine on the scene found a trailer engulfed in flames. The trailer contained flammable liquids, solvents, and grease. Additional engines arrived and were able to control the fire quickly. The cause of the fire is under investigation.
ILLINOIS The Illinois Association of Aggregate Producers (IAAP) will hold its Annual Convention and Aggregate Miner Safety Conference on Feb. 21-23 at the Crowne Plaza Hotel in Springfield. Topics for the conference include risk tolerance, MSHA’s priority issues and safety concerns, rigging safety, blasting safety, supervisor responsibilities, fall protection, and more. A sustainability reception and expo featuring associate members’ product and services will also be part of the convention. For more information, visit www.iaap-aggregates.org.
MAINE Harold MacQuinn Inc. withdrew its appeal of an order to stop work at its quarry in the village of Hall Quarry. The Mount Desert Islander reports that a code enforcement officer issued the order after the company that leases the property resumed quarrying there this summer. There are differing opinions among the parties as to whether the operation is grandfathered into use. The newspaper reports that a 2013 ordinance that bans quarrying allows it for existing operations, if they obtain a license from the town. MacQuinn applied for a license two years ago. Its request is still pending. MacQuinn’s attorney said that the owner will address the withdrawal order following a decision on the pending application. No date has been set for the planning board to consider the application.
MAINE The U.S. Department of Labor (DOL) obtained a permanent injunction against Sullivan Granite Co. and its owner, Conrad J. Smith, according to the Bangor Daily News. The injunction “bars Smith and his company from refusing entry to the Mine Safety and Health Administration inspectors and otherwise hindering or delaying the department in carrying out its duties under the Federal Mine Safety and Health Act of 1977.” As part of its settlement with the DOL, the company also agreed to correct safety violations from 2015 and 2016. The two parties have been at odds for years, but the matter came to a head after DOL officials say Smith hindered inspections in August 2015 and September 2015 and again refused access in December 2015 after they received a temporary restraining order.
6
NEW JERSEY Despite some backlash from voters, two Bloomingdale incumbents who supported the expansion of the Tilcon Quarry there were re-elected. NorthJersey.com reports that council representatives Dawn Hudson and Anthony Costa were both re-elected despite the quarry issue being center to their opponents’ campaigns. Costa told the news agency that the operation’s deeding of 32 acres to the borough for construction of 360 housing units will generate “substantial revenues.” He also said that voters were more concerned with controlling taxes than the quarry issue.
OKLAHOMA In November, 40/29 News reported that a 21-year-old Sallisaw man drowned while swimming in a Le Flore County quarry. The Oklahoma Highway Patrol say the body of Jacob Lewis was recovered in 19 feet of water a day after he disappeared. Other swimmers tried to grab him when he struggled in the water, but were unable to hold him.
SOUTH CAROLINA Approximately 3.7 million tons of crushed stone are being barged in for construction of the Leatherman Terminal. According to The Post & Courier, a series of five barges are transporting shipments of aggregates from a quarry in Newfoundland to the North Charleston site. The stone is being placed within a containment wall that extends into the Cooper River. That area will be paved and used to store cargo boxes moving to and from ships when the terminal opens in 2019. The States Ports Authority (SPA) opted for the stone shipments to work around truck limits that prohibited its typical use of sand and dirt base. The stone is 50 percent heavier and meets construction quality specs, so leftover stone can be sold to help recoup costs. The $762 million project is the SPA’s most expensive capital improvement project as it prepares to better accommodate container ships.
TENNESSEE Sixteen people spoke about Aggregates USA’s proposed expansion of its quarry in Blountville. The Bristol Herald Courier reports that most spoke in favor of the expansion, which would extend the life of the quarry by five years. The company’s request to rezone two parcels of land it owns adjacent to the quarry were approved by a 14-to-9 vote of the Sullivan County Commission. While some said they were concerned about the impacts of blasting, noise and air pollution, and property values, others said the quarry was an essential business partner. Previously, the rezoning request had been approved by the Sullivan County Planning Commission, but not approved by the Kingsport County Planning Commission. The operator will now present details on plans for the parcels to the county’s Board of Zoning Appeals.
AGGREGATES MANAGER / January 2017
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WISCONSIN
VERMONT
After it withdrew an application for a zoning variance with the Village of Rockton, Northern Illinois Service Co. filed another application with the Winnebago County Zoning Board of Appeals for a special-use permit to allow for the construction of an asphalt plant on its 42-acre Rockton Rock Quarry. The Beloit Daily News reports that a village trustee who is opposed to the asphalt plant, Dave Winters, has directed the village attorney to draft a resolution in opposition to the plant and present it to the county.
The owners of Georgia’s Rainville Quarry have applied to the District Environmental Commission to expand their quarry by just under 5 acres. According to the Milton Independent, the application would not extend the time allowed for operations, just the footprint. The application states that the operation would maintain its existing setbacks.
VERMONT Police were searching for the driver of a car that steered into a fully loaded dump truck which was hauling crushed stone at the time of the accident. The Burlington Free Press reports that the truck driver, Bernard Savard, Jr., was hospitalized for multiple injuries. Investigators say a small silver or gray sedan struck the dump truck, sending it into a guardrail where it remained perched precariously above an embankment. A crew stabilized the truck, which was a total loss, by using a specialized wrecker.
PROVINCE NEWS
VIRGINIA Luck Stone announced plans to open a new quarry in Prince Edward County. According to the Richmond Times-Dispatch, the quarry is expected to open for business this summer. Luck is partnering with Mellott Co. to produce aggregates at the site, which will be its first greenfield site in a decade. “This is natural growth opportunity for us, as the 460 corridor is continuing to grow,” Jim Van Ness, regional vice president for Luck Stone’s central region, told the newspaper.
In November, Atlantic Minerals Ltd. announced that it had locked out 130 unionized employees from its Newfoundland’s Port au Port Peninsula. According to CBC News, the company said that it had “no choice” but to lock out employees after the union remained in legal strike position for nearly a week and it began to lose business from cargo ships that did not want to dock with the company due to the risk of a strike. The company and union had been in negotiations since spring time and had brought in a mediator, but had a “huge gap” on wages. The company said it had offered a “reasonable increase to (its) employees,” but the union wanted a raise that would be higher than comparable contracts in the province.
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AGGREGATES MANAGER / January 2017
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ROLLOUTS
Your complete guide to new and updated equipment and supplies in the aggregates industry.
by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Jaw crusher offers increased capacity Kolberg-Pioneer, Inc. expands its jaw crusher line with the 3365 Pioneer Jaw Crusher. The unit features a unique shaft and bearing assembly to increase serviceability and reduce maintenance and rebuild costs, for lower total cost of ownership throughout the lifetime of the machine. 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
Excavator offers 360-degree operator view Hyundai launches the HX430 crawler excavator with a bucket capacity of 2.49 cubic yards. The unit is powered by a 316-horsepower Cummins QSL9 four-cycled turbocharged air-cooled diesel engine and offers easy access to the DEF/AdBlue Supply System. The HX range is fitted with an ECO Gauge, which can offer up to an 8-percent fuel reduction, depending on type of operation. The gauge level and color displays the engine torque and fuel efficiency level on a touch-screen monitor. The Advanced Around View Monitoring System offers a 360-degree operating view, which displays on the 8-inch cluster monitor. An Intelligent Movement Object Detection system warns operators when objects come within working distance of the machine.
Hyundai Heavy Industries Europe | www.hyundai.eu
Underground loader tire reduces downtime Yokohama Tire Corp.’s R69 L5-S off-the-road radial for loaders in underground mine applications is now available in size 18.00R25. Designed to reduce downtime and increase efficiency, the tire is engineered for endurance and operations that want to increase speed and load in long-haul operations. Advanced compounds resist heat build-up and fight chips and cuts for improved durability. A durable belt package creates a cut-resistant tread while a high-angle sidewall increases thickness and decreases sidewall stress.
Yokohama Tire Corp. | www.yokohamatire.com
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AGGREGATES MANAGER / January 2017
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Improves safety during tire inflation Ken-Tool introduces its largest tire inflation safety cage, the Model T112 12-bar Earthmover Inflation Cage. The single-piece cage is specifically designed for the inflation of large earthmoving and mining tires. The cage is said to increase technician safety, while also protecting equipment and facilities, when inflating very large tires — up to 87 inches tall by 48 inches wide. The cage is made using precision mandrel bent 12 gauge 2.25-inch structural steel tubes. It is 80 inches long, 60 inches wide, 99.5 inches tall, and weighs 1,200 pounds.
Ken-Tool | www.kentool.com
Safe solution for haul road maintenance Philippi-Hagenbuch debuts the Material Spreader Body, which 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. The heart of the system is the Phil Rear-Eject Body, coupled with the new material spreader attachment. 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. An optional top-loading grizzly screen controls the maximum size of the material being spread. The ejector blade moves material to the rear of the body and into a cross auger channel. The auger gathers material to the center of the spreader and discharges it onto a set of material spinners for spreading.
Philippi-Hagenbuch Inc. | www.philsystems.com
New engine oil, lubricant line extends drain intervals
Tablet interface provides operator insights
Leveraging its ISOSYN Advanced Technology, Chevron’s new Delo 400 product line is said to offer optimized performance and better engine protection than any previous Delo product. This, in turn, is expected to extend the life of any vehicle — on- and off-highway — and minimize the cost of ownership. The ISOSYN technology is said to increase durability through better oxidation control, anti-wear protection, and piston control, while extending drain intervals compared to API CJ-4 oils. The new product line will be available in a variety of viscosities and will support both API CK-4 and FA-4 HDMO categories.
Volvo introduces Co-Pilot, a 10-inch tablet computer that acts as an interface to its machine-specific Assist applications to provide real-time intelligence to the operator. The first Assist program for aggregates operators is Load Assist for wheel loaders. Built on an Android operation system, the platform is said to be easily scalable as future software updates, additional functionality, and new applications are developed. The system is 3G-compatible when equipped with a SIM Card.
Chevron | www.chevronlubricants.com
Volvo Construction Equipment www.volvoce.com
AGGREGATES MANAGER / January 2017
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ROLLOUTS Feeder works in flat or low-angle applications Superior Industries Inc. launches its Freedom Vibrating Grizzly Feeder, which is manufactured in widths to feed up to 1,400 tons per hour. It says the feeder features a robust pan section. Grizzly cartridges are designed to bolt into the feeder’s frame. Bottle jack lifting points are incorporated into the spring section of the feeder to simplify spring replacement and enhance safety during maintenance. The feeder is available in pan widths ranging from 36 to 60 inches. The same machine can be used in flat or 5-degree applications. Options include customization to the feeder’s width, grizzly sections, punch plate, and finger deck..
Superior Industries, Inc. | www.superior-ind.com
Tire tread designed for cut protection Goodyear Tire & Rubber Co. debuts its haulage mining tire, the RM-4B+. The tire features a high net-to-gross tread pattern for increased cut and impact protection in hard rock applications, an extra deep tread pattern for longer wear, and an enhanced, coolrunning compound that makes it suitable for high heat applications.
Goodyear Tire & Rubber Co. | www.goodyearotr.com
Plant simulation software optimizes operations Haver & Boecker introduces NIAflow plant simulation software, which is designed to help producers optimize quarry operations by diagramming plant flow, machine placement, product precalculations, 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. It also uses scientific-based methods to monitor the operation’s input, output, and waste piles.
Haver & Boecker Canada | www.havercanada.com
Larger dozers get tech upgrade John Deere is integrating SmartGrade machine controls on its 750K and 850K crawler dozers. It says that adding SmartGrade availability on these machines will improve accuracy and quality of work through the complete integration of the Topcon 3D-MC Grade Control System. With SmartGrade integrated into the machines, it removes the need to install blade-mounted sensors and components daily, reducing setup time. External cables are eliminated, which reduces breakage, while removal of the masts from the blade eliminates vulnerability to damage and theft. 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 before returning the blade to grade.
John Deere | www.johndeere.com
10
AGGREGATES MANAGER / January 2017
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ROLLOUTS Belt cleaner handles high-speed, high-volume belts Asgco says its Super–Skalper HD belt cleaner helps operators address challenging carry-back applications. The one-piece mounting tube and E-Z Torque Tensioner apply consistent pressure to create constant cleaning contact through the life of the blade. A wear indicator allows operators to monitor wear without having to shut down the system for inspection.
Asgco | www.asgco.com
Optional GPS-guided steering Vermeer now offers the option of adding GPS-guided steering to its T1255 direct drive Terrain Leveler surface excavation machine. When equipped with this option, machine steering is controlled by an onboard GPS device that can detect deviations from the designed line to provide to provide greater accuracy on each cutting pass. The optional system provides a cutting overlap of 6 inches.
Vermeer Corp. | www.vermeer.com
A Leader in Mining Construction Since 1924
Slopes & Tunnels Access & Ventilation Shafts
Monitoring system provides 360-degree view Continental’s ProViu ASL360 Camera is designed to help operators improve safety and security. The monitoring system allows the operator to view the entire piece of equipment and its surroundings at a single glance, maximizing the field of view and eliminating blind spots. Four, wideangle micro-cameras monitor the front, rear, and sides of the equipment and display the video feeds as a single panoramic stream on a 7-inch or 10-inch display. The system, which can be built into an existing display, also offers a choice of angles: top-down bird’s eye, raw 180-degree, specific focus single views, and multiple split screens. An automotive grade DVR provides GPS functionality and can record up to 32 GB of footage on a standard SD card.
Continental | www.continental-corporation.com
12
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AGGREGATES MANAGER / January 2017
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Untitled-37 1
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FORECAST by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
After a year of mixed business ratings, operators are optimistic about their odds in 2017.
A
fter a year that showed positive, but mixed results, the arrows are overwhelmingly pointing up for 2017, according to the results of the Aggregates Manager 2016-2017 Forecast Survey. The survey assesses production trends for the current year and asks producers their expectations for the coming year. Respondents to the 2016-17 survey reported the most optimistic future business conditions since the survey began tracking industry sentiment in 2004; nearly one in two respondents predicted either excellent (13.3 percent) or very good (34.8 percent) business conditions in 2017. At the same time, negative predictions were among the lowest ever given with fewer than 12 percent calling for a fair year, and less than 1 percent anticipating a poor year.
Looking back For more than three in four respondents, 2016 was a good year; 11.1 percent described it as an excellent year, 28.9 percent said it was very good, and another 36.3 percent said it was good. There were weak segments as well, however, with nearly one in four respondents saying business conditions for the year were either fair (20.0 percent) or poor (3.7 percent). Those at large operations (3 million tons per year or more) reported strong results. Nearly six in 10 (59.2 percent) of respondents at operations that produce more than 5 million tons per year described business conditions as either excellent or very good, while slightly less (57.1 percent) of respondents at operations that produce between 3 million and 5 million tons per year reported the same results. At the other end of the size spectrum, smaller operations (those under 1 million tons per year) were much more likely to report poor business conditions. More than one-third of respondents in operations that produced less than 500,000 tons per year reported either fair (28.6 percent) or poor (7.2 percent) business conditions. By commodity, respondents from companies that produce
14
both crushed stone and sand and gravel were the most likely to characterize 2016 business conditions as either excellent (18.4 percent) or very good (32.7 percent). Sand and gravel producers were the next most optimistic, with 11.8 percent reporting excellent business conditions and 35.3 percent describing them as very good. Crushed stone producers were the most reserved, with 5.7 percent scoring 2016 as excellent and 31.4 percent opting for a rating of very good. By region, operators in the South were the most likely to report strong business conditions, with 15.7 percent describing it as excellent and an additional 29.4 percent saying it was very good. Operators in the Northeast and West followed closely, with 43.8 percent of those in the Northeast reporting excellent or very good conditions and 38.8 percent of operators in the West opting for the top two business condition ratings. This was particularly good news for those in the Northeast, where the percentage of operators with strong results increased by 7.4 percent. Operators in the North Central region were the least likely to report strong business results, with 31.4 percent falling into the excellent and very good categories. That number, however, is still up 5.5 percent over 2015.
Looking ahead Overall business expectations for 2017 are quite strong, but the degree of optimism shifts among the various subgroups. Differences were most notable based on the size of the operation. Respondents in the largest size group (more than 5 million tons) were the most upbeat, with more than one in four (25.9 percent) anticipating an excellent year. Those at the smallest operations (less than 500,000 tons per year) were the most restrained with 1.8 percent calling for a poor year, and an additional 17.9 percent expecting a fair year. By commodity, nearly six out of 10 sand and gravel producers expect either an excellent year (17.6 percent) or a very good one (41.2 percent). Crushed stone and sand and gravel produc-
AGGREGATES MANAGER / January 2017
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2016 Business Rating Trends Excellent
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 (Forecast)
Very Good
Good
Fair
Poor
10.40%
32.40%
41.70%
11.60%
3.90%
12.40%
29.70%
36.60%
17.40%
3.90%
12.90%
32.20%
35.90%
15.10%
3.90%
6.60%
18.60%
35.70%
28.50%
10.50%
2.30%
9.80%
30.30%
35.80%
21.80%
2.90%
7.20%
23.90%
38.80%
27.30%
1.60%
11.20%
22.40%
38.40%
26.40%
5.70%
13.20%
24.50%
34.90%
21.70%
6.90%
10.90%
32.70%
37.60%
11.90%
3.80%
21.90%
37.10%
30.50%
6.70%
8.90%
26.60%
40.30%
20.20%
4.00%
12.00%
23.20%
45.40%
15.70%
3.70%
11.10%
28.90%
36.30%
20.00%
3.70%
13.3%
34.80%
39.30%
11.90%
0.70%
Due to rounding, all numbers may not equal 100 percent of respondents.
Source: Aggregates Manager Forecast Studies
Aggregate Production Volumes Increase:
2016 v. 2015
35.5%
48.1%
46.7%
17.8%
4.5%
Source: Aggregates Manager Forecast Studies
48.1% 2017 the average production Stay the same: % was increase in 2016 Forecast 13.7 v. 46.7% 47.4% of respondents in the South Nearly 2016 said 2016 production increased half Decrease: 17.8% 4.5% Less expect poor business than 1 % conditions in 2017
After 2015, when more than half of survey respondents said they had increased production volumes, growth in volumes was more modest. A total of 35.5 percent of respondents said they grew production volumes in 2016, compared to 17.8 percent who said volumes shrank. The number of respondents who reported lower volumes in 2016 is more than double the size of those who reported lower volumes in 2015. The average production increase was 13.7 percent — 8.5 percent lower than 2015 — while the average decrease was 25.1 percent — 11.6 percent lower than 2015. Once again, large producers in reported the best of respondents the West production results. One in two respondents expect higher production at sites producing 3 million to in 5 million levels 2017 tons said production volumes increased in 2016. They were followed by respondents at sites with 1 million to 3 million tons is the predicted average (42.1 percent), more than 5 million tons (40.7 perproduction increase in 2017 cent), 500,001 to 1 million tons (31.6 percent), and up to 500,000 tons (28.6 percent). Those smallest three saylikely theirtocapital sites were alsointhe most report decreased
47.4%
Decrease:
35.5%
ers were the next most optimistic with more than 50 percent calling for either an excellent or very good year. Crushed stone producers were slightly less optimistic with 40 percent anticipating either an excellent or very good year.
Production reports
Stay the same:
Increase:
While business conditions in 2016 came in slightly below last year’s expectations, they were still quite strong from a historical point. The percentage of operators reporting excellent business conditions in 2016 dropped slightly from 2015, while the percentage of operators reporting fair conditions grew by nearly 5 percent. This bears out responses from the monthly Aggregates Industry Outlook surveys, which have indicated spotty demand throughout the U.S. Looking forward, respondents have predicted what would be the strongest business conditions since Aggregates Manager began tracking them in 2004.
More than half
14.5%
Nearly one
expenditures will increase this year
AGGREGATES MANAGER / January 2017
%
was the average production 15 increaseForecast_AGRM0117.indd in 2016
More than half
of respondents in the West expect higher production
15
12/19/16 1:17 PM
FORECAST 2017 Regional Production Results: Northeastern Region
2012 2013 2014 2015 2016 2017* Increased
Increased
Increased
Increased
Increased
12.4%
31.2%
Stayed about the same
Stayed about the same
Stayed about the same
Stayed about the same
Stayed about the same
Stay about the same
Decreased
Decreased
Decreased
Decreased
Decreased
Decrease
28.6%
31.6%
35.7%
35.7%
42.1%
26.3%
78.9%
21.1% 0.0%
54.5%
36.4% 9.1%
68.8%
18.8%
Increase
62.5% 6.3%
Regional Production Results: North Central Region
2012 2013 2014 2015 2016 2017* Increased
Increased
Increased
Increased
Increased
25.7%
52.9%
Stayed about the same
Stayed about the same
Stayed about the same
30.8%
Stayed about the same
44.4%
Stayed about the same
Stay about the same
Decreased
Decreased
Decreased
Decreased
Decreased
Decrease
20.0%
50.0%
52.0%
28.0%
25.0%
25.0%
56.4%
12.8%
48.2%
7.4%
54.3% 20.0%
Increase
48.6% 8.5%
Regional Production Results: Southern Region
2012 2013 2014 2015 2016 2017* Increased
Increased
Increased
Increased
Increased
Increase
30.0%
48.6%
69.8%
46.3%
49.0%
54.9%
Stayed about the same
40.0%
Stayed about the same
40.0%
Stayed about the same
Stayed about the same
Stayed about the same
Stay about the same
Decreased
Decreased
Decreased
Decreased
Decreased
Decrease
30.0%
11.4%
4.6%
7.4%
15.7%
2.0%
25.6%
46.3%
35.3%
43.1%
Regional Production Results: Western Region
2012 2013 2014 2015 2016 2017* Increased
Increased
Increased
Increased
Increased
Increase
59.7%
47.6%
27.3%
62.1%
35.5%
51.6%
Stayed about the same
Stayed about the same
Stayed about the same
Stayed about the same
Stayed about the same
Stay about the same
Decreased
Decreased
Decreased
Decreased
Decreased
Decrease
9.1%
14.3%
13.6%
10.3%
19.3%
3.2%
31.8%
38.1%
59.1%
*Forecast figures
16
27.6%
45.2%
45.2%
volumes with one in four respondents saying 2016 production volumes were lower in 2016 than 2015. Operations producing crushed stone and sand and gravel were the most likely to report increased production volumes (44.9 percent), with an approximate 10-percent margin over sand and gravel producers (35.3 percent) and crushed stone producers (34.3 percent). By region, respondents in the South, by far, were the most likely to enjoy gains in production volumes. Nearly one in two (49.0 percent) reported increased production in 2016. They were followed by the West (35.5 percent), North Central (25.7 percent), and Northeast (12.4 percent). The Northeast was the only region to have a greater proportion of respondents note a decrease in production (18.8 percent) than an increase. Those who reported an increase there noted gains of 1 to 9 percent. By comparison, more than half of respondents in the South benefited from 10- to 14-percent gains, while an additional 12 percent noted an increase of 30 percent or more.
Production forecasts Looking at 2017, respondents anticipate a strong year for production; 48.1 percent said volumes will be up, 47.4 said they would be stable, and just 4.5 percent said they would fall. Optimism crossed size ranges and commodities, with only a few notable concerns raised. Just over one in five (21.4 percent) respondents at sites producing 3 million to 5 million tons anticipate a decrease in production, but more than double that amount (42.9 percent) call for an increase. Among crushed stone and sand and gravel respondents, 12.2 percent said production would decline, but 49.0 percent of that group said it would increase. By region, the South looks to extend its strong record, with 54.9 percent of respondents who predict higher volumes. They are followed by the West (51.6 percent), North Central (42.9 percent), and Northeast (31.2 percent). Respondents who predicted an increase estimated an average increase of 14.5 percent — 2 percent lower than
Source: Aggregates Manager Forecast Studies
AGGREGATES MANAGER / January 2017
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FORECAST
2016 Work Force Trends
17.0%
Decreased:
17.0%
Increased:
31.1%
The percentage of respondents who increased their workforce in 2016 shrunk by more than 9 percent compared to 2015 when more than four in 10 respondents said they grew their staffing. Employment among hourly labor was the most volatile category, with 23.7 percent of respondents saying they increased staffing and 14.1 percent saying they decreased the number of employees.
31.1%
51.9%
51.9%
Stayed the same:
Source: Aggregates Manager Forecast Studies
2013
Competition for Sales
32.7%
Aggregates Availability /Permitting
22.8%
2015
2014
Aggregates Availability /Permitting
17.7%
20.4%
Retaining Workers
Retaining Workers
2013 17.7%
16.7% Competition for Sales
Regulatory Compliance
20.8%
32.7%
Regulatory Compliance
8.9%
15.7%
5.9%
Water Availability
5.9%
22.8%
Regulatory Fines
9.7%
Safety
Community Relations
8.9%
4.8%
–
17.0% 17.7%
10.2%
4.6%
Safety Retaining Workers
1.6%
5.9%
2.8% Safety
2.8%
Aggregates Availability /Permitting
20.4%
17.7% 7.4%
Environmental issues *
Retaining Workers
16.7%
Competition for Sales
5.9% 15.3%
15.7%
Competition5.2% for Sales
Regulatory Compliance
6.5%
Community Relations
Water Availability
2015
Regulatory Compliance
Retaining14.1% Workers
Environmental issues *
6.5% Regulatory Fines
Environmental issues *
Aggregates Availability Aggregates Availability /Permitting /Permitting
15.7%
8.9% 20.8%
Water Availability
1.0%
Competition for Sales
Regulatory Regulatory FinesRegulatory Regulatory Fines Environmental issuesCompliance * Compliance
Community Relations
2.0%
2014 17.0%
Regulatory Compliance Competition for SalesAvailability Aggregates
/Permitting 13.7%
Retaining Workers
Retaining Workers
Competition for Sales
15.3%
Regulatory Fines
2016
Major Challenges19.3% Facing Aggregates Managers
Aggregates Availability /Permitting
2016
Retaining Workers
19.3%
Competition for Sales
17.0%
Aggregates Availability /Permitting
17.0%
Water Availability
13.7% 4.4%
15.7%
RegulatorySafety Fines
Environmental issues *
Community Relations
3.0%
9.7%
Regulatory Compliance
14.1%
10.2%
Environmental issues *
7.4%
Water Availability
Environmental issues *
Regulatory Fines
5.9%
8.9%
Regulatory Fines
Community Relations
Water Availability
Community Relations
6.5%
4.6%
Water Availability
Safety
Community Relations
Water Availability
Community Relations
Environmental issues *
Safety
Safety
Safety
2.0% 1.0% –
*Category added in 2014.
4.8% 1.6%
6.5%
2.8%
2.8%
5.9%
5.2%
4.4% 3.0%
Source: Aggregates Manager Forecast Studies
Worker retention was the most commonly cited major concern for survey respondents. In both the Northeast (37.5%) and West (25.8%), retaining workers was the most significant challenge. In the South, however, competition for sales (23.5%) was the highest rated concern, and in the North Central region, aggregates availability and permitting (17.1%) was the most frequently cited challenge.
18
AGGREGATES MANAGER / January 2017
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last year’s forecast. Those who called for a decrease suggested an average decrease of 13.3 percent — 17.5 percent lower than last year’s estimate.
Investing in equipment With a strong year expected, many respondents anticipated an increase in capital expenditures for 2017; 31.9 percent said they will spend more, with an average increase of 19.2 percent. In contrast, just 7.4 percent indicated they expect to invest less, with an average decrease of 26.9 percent. Top categories for increased equipment investment include: loading and hauling (33.3 percent), crushing and screening (31.9 percent), conveying and material handling (28.9 percent), equipment and truck maintenance (28.1 percent), and automation (25.2 percent). By region, respondents in the West and South were most likely to invest in loading and hauling, while those in the North Central were most likely to purchase crushing and screening equipment. Northeast respondents were split among loading
and hauling equipment and equipment and truck maintenance, a likely reflection on the tougher season they had in 2016.
What’s next? After a year marked by uneven progress, 2017 could be a breakthrough year. While some operators, such as those in the South, said they are running full tilt, this may be the year their counterparts in the Northeast gain some much-needed ground. Expectations of a strong year were reflected not only in reports of business conditions and production volumes, but also in the area that has been the respondents’ greatest challenge — retaining workers. Nearly one in five described worker retention as a major problem, marking it as a greater concern than competition for sales or aggregates availability and permitting. Last year, 31.1 percent of respondents reported an increase in their total workforce, with the most likely hires being hourly labor or female personnel. If predictions for 2017 bear out, start looking to expand your workforce now. By the summer, you may very well need those extra boots on the ground. AM
Methodology, Objectives, and Sources
The objective of the 2016-2017 Aggregates Manager Forecast Survey was to determine business, production volume, spending, and workforce trends. In November 2016, Aggregates Manager emailed questionnaires to a random selection of readers in the crushed stone and sand and gravel, crushed stone-only, and crushed gravel-only industries. Surveys were sent out just after November elections. A total of 135 useable surveys were completed.
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PULL-OUT GUIDE By Tina Grady Barbaccia, Contributing Editor
January 2017
Remote control technology allows producers to increase reserves and access those that are otherwise inaccessible.
Remote control and autonomous operations
Autonomous hauling is appealing to producers because it offers efficiency, consistency, and productivity gains.
Equipment that can be run without an operator allows operations to shift resources. Autonomous fleets may be the norm in aggregates operations in the next 10 to 20 years. Keep employees safe by using alternatives to operating equipment in the cab or directly on site.
OpsIllustrated_AGRM0117.indd 21
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OPERATIO
Remote contro
1
Prepare for future operations
2
Increase safety and productivity through technology
U
nderstanding and implementing remote control (RC) and autonomous equipment and processes into your aggregates facility can be likened to the famous quote from hockey great Wayne Gretzky — “I skate to where the puck is going to be, not where it has been.” That’s how Richmond, Va.-based Luck Stone Corp. views RC and autonomous operations. It’s not a matter of “if” but “when,” and the when may come faster than anticipated. “Remote control is a proven technology and another tool,” says Travis Chewning, P.E., senior director of engineering and operational support for Luck Stone Corp. “It’s there to give the operator options to access more reserves and not worry about safety. Remote control for us is here and now, and we see a tremendous opportunity to increase our reserves and get into small, narrow reserves that we can get to safely.” Autonomous fleets are the next step. Chewning says it’s hard to imagine that it doesn’t become the norm in the next 20 to 25 years. “It won’t just be ‘a flip of a switch,’” he points out, “but it will come up faster than we think. Autonomy will be part of our future, and we’d like to be prepared for that.” Chewning also sees “tremendous opportunity” for remote-control drilling and the ability to remotely load explosives or operate an excavator in a remote situation. Mike Wentworth, product manager of Atlas Copco Surface Drilling Equipment for Mining, Rock Excavation and Construction LLC, speaks to this. “The
most obvious [advantage] is operator environment,” Wentworth says. “The operator is back from the bench wall with a better viewing point and solid footing while tramming over rough terrain or around obstacles. But even operating on solid, level ground, remote control removes the driller from the noise and dust of the drilling operation, which are contributors to operator fatigue during a work shift.” Although not yet in use in the United States, Komatsu has fully adopted the concept of autonomous operation with its Innovative Haulage Vehicle (AHV). This autonomous vehicle — still in development — was unveiled at MINExpo 2016 in September. Dump trucks equipped with its Autonomous Haulage System have hauled more than 1 billion tons of overburden and minerals at large-scale mines since 2008. The haulage system doesn’t even have a cabin or room for a driver. Instead, the unmanned vehicle eliminates the cabin and is being designed to optimize load distribution. The autonomous haul truck integrates controls, wireless networking, and obstacle detection to facilitate the unmanned operation. Despite the dump bed only being able to articulate in one direction, the AHV can maneuver and operate at the same speed regardless of the direction it is headed without a true front or rear. Komatsu expects that this new vehicle will considerably improve the productivity at mines where existing unmanned haulage vehicles face challenging conditions, such as slippery ground due to frequent rain/snow fall, as well as confined spaces for loading.
Luck Stone Corp. has two big pushes for future operations: remote control technology for reserves that are not easily and safely accessible and the vision of autonomy. With the pace autonomy has moved forward in the auto industry in the last three to five years, the speed of change is starting to accelerate quickly. Luck Stone’s Travis Chewning says that he envisions one or two of its operations beginning to implement autonomous haulage in pit operations in the next five to 10 years. This is feasible, he says, especially because off-highway trucks don’t face the same legal barriers as on-highway autonomous trucks.
4
Improve operator environment
Use of remote control (RC) equipment removes the operator from being in direct contact with and, in some cases, in direct sight of the machines. In the instance of a driller, use of remote control may help reduce operator fatigue. “Decades of study have proven that reducing operator fatigue keeps the operator at peak performance longer and maximizes overall productivity,” notes Mike Wentworth, product manager, Atlas Copco Surface Drilling Equipment for Mining, Rock Excavation and Construction LLC. “RC operations are just another component of what all aggregate facilities need to do to keep productivity at its highest.”
AGGREGATES MANAGER
. OpsIllustrated_AGRM0117.indd 22
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5
RATIONS ILLUSTRATED
ote control and autonomous operations
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Secure the workforce of the future
Use of remote control and autonomous equipment and operations gives Luck Stone employees the opportunity to grow and develop in different areas from their typical job. Current associates don’t view autonomous fleets/ operations as a threat because they realize aggregate operations will not be human-free systems. Securing the workforce of the future continues to be a challenge, particularly finding people who want a career as a haul truck driver. Autonomous haul trucks can help alleviate driver shortages.
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Put operator safety first
If an area is hard to access, conditions are dangerous, or even just make for an uncomfortable ride in a machine’s cab — such as over extremely rocky terrain — consider using remote control and autonomous equipment and equipment with automated features. Integrated machine control uses telematics to track working hours, location, and maintenance alerts to be sent through a secure website allowing remote diagnosis of problems and later analysis of performance data. Automated features on drills can help operators drill benches with uncertain ground conditions.
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Shift and develop resources
Remote control and autonomous/semi-autonomous equipment and functions give producers the flexibility to shift resources where they are needed. This makes interchangeability on equipment fairly seamless. “It does a lot when you can shift resources around to other sites, especially if a big project is going on and one site is getting hammered,” says Craig McGinnis, product marketing manager, wheel loaders, Komatsu America Corp. “You can do more with less. You are going to be out there producing day in and day out. You need to do what you can to do more with less and make it easier for the equipment operators.”
6
OUR
EXPERTS
Increase productivity and save money
In areas that may have not been easily or safely accessible, remote-control equipment operation makes it possible. This increases reserves, and, in turn, an operation’s production. Embracing remote control and autonomous technologies and encouraging OEMs to continue their development of technology provides value and an alternative to traditional methods of mining the previously inaccessible reserves. “We are excited to see some other OEM manufacturers heading in the direction of potentially making RC equipment part of their offering,” says Travis Chewning, P.E., senior director of engineering and operational support for Luck Stone Corp.
Travis Chewning, P.E., is senior director of engineering & operational support for Richmond, Va.-based Luck Stone Corp. Chewning joined Luck Stone in 1999 and has enjoyed a career in engineering supporting the operations team. He is passionate about the company’s innovation and the aggregate industry.
Mike Wentworth is product manager of Atlas Copco Surface Drilling Equipment for Mining, Rock Excavation and Construction LLC. Wentworth is a product expert and works directly with many Atlas Copco customers.
Craig McGinnis is product marketing manager, wheel loaders, at Komatsu America Corp. He is responsible for the WA380 through WA600 size wheel loaders. McGinnis has been with Komatsu for six years, starting in marketing engineering, and spending the last four years working with loaders in the rubber tire group. He has a bachelor’s degree in materials science and engineering from Illinois Institute of Technology. January 2017
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Voices of Experience Travis Chewning
I
t was not uncommon at Luck Stone to pass on stone reserves that would put its loader operators at risk. Embracing the company motto of “Ignite Innovation,” Luck Stone realized it could find a way to access these valuable reserves and keep loader operators safe. Enter remote-control (RC) loaders. The Richmond, Va.-based producer currently runs two remote-control (RC) loaders at its Bull Run operation. “We see the most value in keeping an operator safe when we have need to dig in an area, but want to remove the operator from the hazard,” says Travis Chewning, P.E., senior director of engineering and operational support for Luck Stone Corp. “Now, we have an alternative tool to keep our people safe.” As Luck Stone was developing the Bull Run operation and installing the gyratory primary crusher, there was a slot that had to be shot in muck. “We used an RC loader to muck the slot because we couldn’t put a person in there. We had to work from the top down,” Chewning says. “We used the RC loader and then scaled the highwall. This project saved us $30,000 to $50,000.” Autonomous equipment for safety and efficiency is also on Luck Stone’s radar. It experimented with an autonomous haul truck, but it’s no longer in operation. It had been in development for two years, running in a safeguarded, prototype way. However, the company it had been working with went out of business, halting the program. “Autonomous hauling is attractive because it offers efficiency and productivity gains,” Chewning says. “The performance of drivers is variable, but autonomous trucks perform the same way. There are periods throughout the day where you need more or fewer trucks. “Autonomously adding or taking away a truck to meet needs gives the ability to right-size the fleet when needed instead of finding a driver.”
Craig McGinnis
A
dvances in automation brings myriad advantages to the aggregate industry, helping producers with reliability and predictability, says Craig McGinnis, product marketing manager, wheel loaders, Komatsu America Corp. The heavy equipment manufacturer headquartered in Rolling Meadows, Ill., offers autonomous functions on some of its equipment and remote-control and semi-autonomous machines “to maintain efficiency and productivity while keeping operators out of high-risk applications — and to make their lives easier.” An autonomous function such as auto-dig enables an operator “to just drive into the pile without any other operator input,” McGinnis points out. “It makes digging easier and provides repeatability and predictability.” Ultimately, he says, it doesn’t matter to many jobsite managers if a person or a computer is running the loader. “They just plan on producing so many tons per hour,” McGinnis says. “Autonomous functions help with this predictability. Anything that can make the equipment faster and more productive so you can load the hopper and truck quicker and get it out of the gate quicker makes a difference.” Using remote-control technology can help contribute to this efficiency, as well as keeping equipment operators safe in challenging conditions. Running the OEM’s D155i-8 radio-controlled dozer equipped with “intelligent Machine Control” is done with a joystick without an operator actually being in the cab. This may seem nerve-wracking without a true sense or feel of the surface area, but the intelligent technology enables the dozer to operate in automatic mode, from heavy dozing to fine grading. “Getting a good dozer operator or motor grader operator is worth its weight in gold,” McGinnis says. “Using technology, the operator learning curve is nearly cut in half. You don’t need to find operators with 20 to 25 years of experience. This makes it very easy to switch operators between machines. The key is faster, more productive machines.”
Mike Wentworth
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ncorporating “intelligent” equipment is a smart move for aggregates operations. “This is the way the industry is going — it’s where it’s at now, actually,” notes Mike Wentworth, product manager, Atlas Copco Surface Drilling Equipment for Mining, Rock Excavation and Construction LLC. With advances in equipment technology, come concerns about upkeep and related expense. Wentworth dispels those concerns: “Computerized control has been around long enough to dispel any initial market concerns that computerized rigs would be a maintenance concern.” Adding to that, he notes that “reliability, increased productivity, and enhanced safety are really never drawbacks. Remote-control drills aren’t replacing existing technology, but adding to it.” Automated features that are now available can be remotely controlled to minimize opportunities for human error and add precision not humanly possible, Wentworth explains. For example, features such as a hole navigation system and auto positioning help producers with improving fragmentation characteristics by precisely locating holes, accurately collaring and drilling them to the required depth and inclination, and drilling holes precisely to plan, regardless of the terrain above the hole and how it affects rig attitude, he says, adding “This precision means blast designers can open up their patterns, reducing the amount of explosive required to get the blast characteristics being sought.” A computerized rig control platform and automated features also mean the driller does not need to remain at the rig. “Operation from a remote-control console is exactly the same as controlling it from the driller’s console at the rig,” Wentworth says. “You can now confidently drill benches with uncertain ground conditions. Rig performance and fleet maintenance data can be monitored and logged real-time from anywhere. Comparing performance of a rig or tooling in one part of the quarry to another allows maximum control over productivity and profitability.”
AGGREGATES MANAGER
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TECHNOLOGY by Marcia Gruver Doyle, Editorial Director
When the contractor poured the concrete for the primary, he stamped the quarry’s name and the date the structure was built into the side of the structure.
Energy Efficient
Quarrying Volvo’s Electric Site takes aim at lowering carbon emissions and energy costs.
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olvo Construction Equipment, the Swedish Energy Agency, Skanska Sweden construction firm, and two universities have been working on what the group is calling the Electric Site project. The $30 million project is ambitious, aimed at creating an electrified quarry
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where not only are carbon emissions reduced by up to 95 percent, but also the total cost of quarry ownership can possibly be reduced by 25 percent. While examining how to electrify typical quarry machines, researchers soon realized that this project was an opportunity to address inefficiencies
throughout a quarry, particularly in the ways aggregate is handled. “It actually gets more interesting as we zoom out to broaden the perspective to the whole site,” says Andreas Sunesson, fleet and technology manager for contractor Skanska Sweden. “A lot of what goes into produc-
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Because of their high maneuverability, wheel loaders used in the Electric Site would be hybrid units.
tion is the movement of the rock,” adds Johan Sjoberg, technical specialist in site automation. “Currently, there are a lot of yellow machines that move rock around and stockpile it.” One particular problem is the use of large rigid-frame or articulated dump trucks to move aggregates from Point A to Point B for processing. Sometimes, the processing path is not straightforward, involving intermediate staging areas (and cost) to the overall operation. Then there’s the human element. If production is foremost, truck operators may feel encouraged to speed back to the loading point, only to end up back in a queue behind other trucks, a situation that results in both additional idling and tire wear. Using today’s machines to address these problems presents limited solutions, says Sunesson. Examining the entire site instead gave the research participants the opportunity to identify which activities add value, and which could be eliminated. “The aggregates business is a local business,” Sunesson adds. “Our products
are not competing on a global market, and it’s very comfortable for us as quarry owners to use the haulers because we don’t need any detailed planning to use them.” Since the large haulers usually have capacities above 50 tons, it makes it harder for quarry operators to incrementally increase or decrease their capacity, Sunesson says. “Often, you just want an additional 20 percent capacity, but when you add a new haul truck, you almost double your costs, which makes us sensitive to unplanned downtime,” he says.
which creates additional challenges to automation. In the morning, crushed rock is typically loaded by an excavator into rigid-frame dump trucks. In the afternoon shift, the morning operation continues, but additional rock is stockpiled, ensuring that aggregates are both ready to be loaded the next day and that there is a buffer against unplanned stops. “But this means that we’re letting the material down twice and stockpiling it with a wheel loader,” Sunesson says. “From a site perspective, that’s a lot of waste.”
So, how to electrify a quarry? Changing work place Electrifying a quarry could create a big leap in this industry, Sunesson says. “One challenge is that, in a quarry, the work place changes all the time. “Every time we blast, we move the face further away, and we create more space,” he says. The resulting rock can be approached one of two ways: either it can be moved to the crusher, or a mobile crusher can be moved to the rock. The Skanska quarry runs two shifts,
Flexibility had to remain key in whatever solution was devised, Volvo’s Sjoberg says. Quarries change not only from day to day, but from shift to shift, which is one reason why diesel-powered machines remain popular, since operators don’t have to plan their daily path. One possibility was to have electric-powered machines mimic diesel powered units. This strategy works fine for machines that don’t move around much, such as the mobile crusher and AGGREGATES MANAGER / January 2017
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TECHNOLOGY
This overview highlights how equipment is used during various shifts at the Electric Site.
excavator — just connect them by cable to the electric grid. Because of their high maneuverability, wheel loaders used in the Electric
Site would be hybrid units. But for highly mobile units such as wheel loaders and haulers, attaching a cable was not a possibility. Volvo met the wheel loader
challenge with a hybrid prototype, which it says will increase fuel efficiency by 50 percent over conventional wheel loaders. But the hauler was another story. The logistics of using an electrified larger hauler were impossible: In order to power a 50-ton hauler, you would need roughly 15 tons of batteries. If you used smaller batteries, the trade-off would be more in-between cycle charges and a decrease in productivity. That solution would also require high charging powers, putting too much demand on the power grid. “We realized we had to go down in machine size,” Sjoberg says, but for manned machines that also meant additional operators and labor costs. All this pushed the researchers toward a battery-electric,
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AGGREGATES MANAGER / January 2017
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autonomous vehicle, what Volvo is calling the HX1 load carrier. The autonomous, battery-electric HX1 would weigh 6 tons and carry 15 tons. As seen currently, a fleet of the 15-ton capacity machines, managed by a fleet control system, would replace the diesel-powered haulers on site. Functional at both ends, which eliminates the need to back up and reposition the carrier as is needed on machines with operator cabs, the HX1 can be loaded directly from the crusher, thereby reducing one time the rock is placed on the ground. Quarry capacity can be quickly adjusted by adding or subtracting one of the HX1s. “And if one of the machines goes down, it won’t influence production much,” Sjoberg says. There are trade-offs, however. “Even though the HX1 is good at stockpiling, it’s not versatile,” Sjoberg says. “It can only do this and nothing else, so we have traded efficiency for versatility.” And investments will need to be made in
The autonomous, battery-electric HX1 would weigh 6 tons and carry 15 tons.
fleet system infrastructure to direct each HX1’s logistics.
Transforming the aggregate industry? “This project is a step towards transforming quarries and the aggregate industry,” Sjoberg says. “By using electricity instead of diesel to power construction
equipment in a quarry, we have the potential to deliver significant reductions in fuel consumption, carbon dioxide emissions, environmental impact, and cost per ton.” The Electric Site project will be finalized in 2018 with a 10-week demonstration at a Skanska Sweden quarry in western Sweden. AM
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3 Ways Drones Can Save You Time and Money While Increasing Safety
A fo F W c p d le s t
Drones are quickly becoming a leading tool for Aggregate companies. Here are three examples of how drones can help you lower costs, improve efficiency and increase safety.
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1) Stockpile Measurement 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, time-consuming and 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.
Companies seeking a more efficient way to do stockpile measurement are using drones. By using drones, companies can frequently and automatically calculate the perimeter and volume for all their aggregate stockpiles; even odd-shaped piles against walls. Drones enable them to 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 third-party audits.
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D c w s c p 3
PARTNER SOLUTIONS
3D Models provide a unique perspective for mine planning
Manual inspection of stockpiles often results in slipping or falling
Using drones saved Whitaker 22% on yearly stockpile measurement costs
Companies can view and download contours
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, a leading aggregates company, previously used employees and thirdparty surveyors, to measure their stockpiles. By using drones, Whitaker’s combined yearly cost is 22% less than before and they’re able to measure their stockpiles twice as frequently, while spending four times less time.
The aerial maps provide them with a greater perspective on large quarries. Companies are also using drones to compare volume measurements from stripping, takeoffs and mine reclamation work, as well as to estimate levels of reserves. For example, SullyMiller (part of Colas USA) uses the data from Kespry drones to overlay known information such as borehole data, mine limits, property boundaries and setbacks, which ensures that mining is following the prescribed plan and eliminating unforeseen surprises.
2) Mine Planning
3) Safety
Due to the 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.
For staff at aggregate companies, doing inventory at quarries means having to climb up and down stockpiles, while carrying heavy equipment, which often results in tripping, falling or sliding down. By using drones, staff no longer need to access unsafe environments, with data being collected remotely and safely.
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To learn how the Kespry Automated Drone System can save you time and money, while increasing safety, visit www.kespry.com/aggregates
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EQUIPMENT MANAGEMENT
Scaling Back on Down Time Maximize the life of your scale with upfront design considerations and ongoing maintenance.
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T
ruck scales are a vital tool for aggregate operations, and the performance of the scale can have an enormous impact on profitability. The truck scale is often the “cash register” of an operation through which materials are bought and sold and where profit and loss is measured. A challenge facing many truck scale owners today is determining how to maximize the life of that cash register with the routine wear and tear of aggregate operations. Today, the average cost of a truck scale service call can run anywhere from a few hundred dollars to several thousand dollars depending on the age, condition, type of problem, and design of the equipment being used. Chances are, if maintenance costs are already significant, they will increase in the future. Heavily concentrated loads and high-traffic volumes make rock and gravel applications some of the most demanding in the weighing industry. With that in mind, a well-designed truck scale and proper maintenance plan are the two most important elements in ensuring the sustained profitability of your aggregate facility. Maintenance frequency is directly related to the daily truck volume and axle loads of the vehicle being weighed. A thorough inspection is recommended, at a minimum, every six months. However, number of weighments, climate, and the value of the product being weighed could change that frequency. Aside from the actual calibration, most of the inspection will consist of you or your scale technician conducting a visual inspection of the scale, foundation, and surrounding area.
Weighbridge Proper weighbridge inspection is essential to ensure accuracy and consistent performance of a truck scale. Visual inspection of the top-deck surface, including welds, should be performed on each maintenance visit. Areas beneath the bridge should be inspected for potential mechanical bindings as a result of debris accumulation, loose bolts, and misalignment of the suspension system. Debris or ice buildup between the approach bulkhead and the end of the scale, as well as between the scale modules, should also be checked and removed. Paint coating conditions on the scale should be examined and
noted yearly. Depending on weighbridge design, geographical location, load material, and environmental factors, removing the weighbridge from the foundation for sandblasting and paint may be required. Excessive corrosion could indicate complete replacement of the weighbridge.
Foundation A truck scale is only as good as the foundation on which it rests. Keeping the foundation clean and well drained will provide more accurate and dependable vehicle weighing. A quick visual check of sump pumps and drains should be done at least once a month. The condition of the concrete piers or slab and concrete approaches are very important for maximum equipment performance. Approaches to and from the scale should be level to ensure a smooth transition from the approach to the scale. The steel coping or trim on the approach head walls and/or pit walls should be checked for proper anchoring or wear. Areas around the load cells should be inspected for binding due to debris build-up. A minimum clearance of 0.75 inches should be provided between the weighbridge and the headwall and side walls when applicable. Any cracks in the concrete or evidence of heaving due to frost or poor soil conditions should be recorded and resolved immediately. Foundation issues are common causes for inaccurate scale performance.
Load cells Examine load cells and the area surrounding them. The load cell area may contain dirt and debris that has built up since the scale’s last check. Load cells must have clearance to deflect through their capacity range. The same debris that can bind the scale deck can also keep the load cells and suspension components from moving freely. Inspect load cell cables for damage. If damage is present, the seal is probably degraded as well. To combat this problem, some manufacturers offer rigid or flexible metal conduit to run the cable through, providing a layer of protection that’s nearly impervious to damage from rodents. Even though steel over braid cable provides more protection from damage than cable sheathed with polyurethane or plastic, they still need to be checked as well. When exposed to moisture, cables can become AGGREGATES MANAGER / January 2017
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EQUIPMENT MANAGEMENT
Keep the scale foundation clean and well drained. Approaches to and from the scale should be level.
wall during scale movement. Bumper bolts need to be fastened in place and maintain clearance whether the scale is empty or loaded. Bolts should be adjusted with approximately 1/4-inch to 3/8-inch clearance from the end wall plates. Seasonal weather changes can cause thermal expansion and contraction of steel and concrete in the bridge, resulting in potential binds. Bumper bolts that are too tight against the stops can result in errors that may go unnoticed for extended periods. Bumper bolts that are too loose can result in potentially damaging side loads to the load cells, or even, in some cases, a sudden collapse of the bridge structure. A bridge that does not swing freely or is noisy as vehicles enter and exit may require immediate attention from your scale service provider.
Junction box
Remove any debris around load cells and the surrounding area. Be sure to check cables for signs of damage.
wicks. Water can be sucked through the cable’s length by capillary action until it enters the load cell or junction box. Once inside, it can damage components and seep into the inner layer of the cable. Wet cables may not cause signal distortion immediately, but they may slowly corrode the copper wires or shield beneath the insulation, causing big trouble sooner or later. Corrosion of the shield limits the cable’s effectiveness in blocking electromagnetic interference (EMI) and radio frequency interference (RFI). Corrosion of individual wires will degrade the signal. If you discover a wet home run cable or load cell, replace it. To help prevent moisture
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from entering the cell from the cable, bend the cable or flexible conduit downward to create a drip loop at the location just before it enters the cell.
Bumper bolts Although there are truck scale designs that eliminate the need for bumper bolts, many manufacturers still require them. Frequent inspection is required on these models. Bumper bolts minimize the momentum of the weighbridge as vehicles move on and off the scale. They are normally positioned at the ends of the weighbridge and are designed to bump the plates embedded in the end
Moisture caused from internal condensation is the most common problem for junction boxes. This occurs from normal air exchanges from heating and cooling cycles, and over-aggressive washing that damages sealing components that haven’t been properly maintained. If left unchecked, wiring terminals and other components in the enclosure will corrode. Due to its material properties, a stainless steel j-box is more vulnerable to internal condensation. If stainless steel is not required, install a junction box with a fiberglass-reinforced polyester (FRP) enclosure. A desiccant bag in the enclosure will help control moisture.
Grounding Scale manufacturers suggest a variety of grounding procedures including single-point grounding, AC transient protection, DC transient protection, determining AC ground, and transient bypass cables. To avoid multiple zero references, which can create havoc with data lines and attract lightning damage, single-point grounding is recommended. Checking a single-point ground involves several steps. 1. Verify the ground system of the AC power supply. Using a multi-meter, check the resistance of the AC outlet ground to the actual AC power ground
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rod coming into the building. The multi-meter should read less than 1 ohm. Measure the AC voltage across the ground and neutral of the AC outlet. The result should be 0 volts AC, not to exceed 0.5 volts AC. Following both of these procedures is recommended; however, completing one of the steps above should allow you to evaluate the quality of the ground. If you discover grounding issues with the AC power supply, notify the building owner and/or the power company. 2. Check the scale’s grounding. a. Make sure the scale and all peripherals are connected to a transient protection device such as an uninterruptible power supply to deter voltage distortions. b. Use a bare, 10-gauge copper wire connected to the frame of the scale platform and the grounding lug on the junction box board, and run the copper wire back to the ground rod provided by the power company. The copper wire can be buried underground from the scale to the AC ground. c. If your scale uses transient protection such as an uninterruptible power supply, the device needs to be grounded to this wire as well. d. Make sure a braided transient bypass cable is positioned across each load cell mount to ensure electrical transients pass through the bypass cable instead of the load. e. Measure the resistance between the scale sections and the AC ground. The reading should be less than 1 ohm. Higher readings are typically caused by corroded connections. f. Check the AC power supplied to peripherals such as remote displays, printers, and computers. A remote device may not have the same AC power source as the indicator; therefore, each device may not be grounded to the same point. Transient protection
Truck scales should be calibrated and tested by a state-licensed service agency using at least 12.5 percent of the scale’s nominal capacity.
Keep your scale clean and dry. Be sure to remove all debris.
devices should be grounded to the same wire as the peripherals they are protecting. g. Measure the resistance between the AC power ground-points. The multi-meter should read less than 1 ohm.
Calibration and testing Truck scales should be calibrated and tested by a state-licensed service agency using no less than 12.5 percent of the scale’s nominal capacity, or 25,000 pounds of certified test weights. The scale’s calibration interval is determined by the frequency of use, individual application requirements, and federal, state,
and local guidelines. Each section of the scale should be tested and detailed test reports should be provided to the customer and government authorities. Truck scales are traditionally longterm investments that should provide decades of reliable and dependable service. Saving a few hundred dollars on the front end may cost thousands in unexpected maintenance costs later. With proper maintenance and grounding, aggregate producers can extend the life of their truck scales and keep their “cash register” fully operational. AM Article courtesy of Rice Lake Weighing Systems. AGGREGATES MANAGER / January 2017
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CONEXPO-CON/AGG PREVIEW Staff report
Place Your Bet on
Las Vegas
Before the early bird rates go up and hotel rooms are gone, make plans to attend ConExpo-Con/Agg 2017.
F
or the last several months, we’ve highlighted some of the exciting opportunities available at ConExpoCon/Agg 2017, to be held March 7-11 at the Las Vegas Convention Center. Designed for producers, contractors, dealers, distributors, engineers, and service providers, the triennial show is the biggest event in the construction industry. But, if you want to attend, it’s time to make your hotel reservations while rooms are still available and purchase attendee badges before prices go up. Show hotels can be found on its website at www.conexpoconagg.com. Experient is the official housing provider and is the only company that can sell rooms within the official show hotel blocks.
The big picture ConExpo-Con/Agg features more than 2,500 exhibitors with over 2.5 million square feet of exhibition space. Among those numbers are nearly 700 new exhibitors and the 75,000 square foot Tech Experience that provides a glimpse into the future of the construction industry. The show opens on Tuesday, March 7, and is open from 9 a.m. to 5 p.m. each weekday through Friday. Saturday hours are from 9 a.m. to 3 p.m. Check out the hall map to see which halls feature aggregates equipment, and keep your step count for the day manageable.
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The badge-pack A new Badge-Pack includes a free multi-day pass for the Las Vegas Monorail, a free deluxe coach bus to and from most of the show hotels, access to seven different halls and lots for both ConExpo-Con/Agg and IFPE each day of the show, discounts to various area restaurants, and entry into the Tech Experience, which we highlighted in the November issue. Until Jan. 13, the early bird price for the Badge-Pack is $149. On Jan. 14, the price increases to $195. On the opening day of the show, the price jumps to $249, so be sure to get your badge in advance.
The education sessions ConExpo-Con/Agg’s educational seminars offer insights for a variety of audiences, including aggregate industry rookies and veterans. The aggregates track is one of 10 tracks available. See our October issue for a full listing of aggregates educational seminars, as well as other general sessions relevant to the aggregate industry. A full session pass, which is included in the show’s Supreme pack, is available for $395. For those who plan shorter visits to the show, a session day pass, which is included in the Deluxe pack, may be purchased for $195. Passes to a single session are available for $69.
AGGREGATES MANAGER / January 2017
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The NASCAR celebration Show attendees can also sign up for a NASCAR celebration, which will be held on Friday night at the Las Vegas Motor Speedway. The event includes live music, beverages, buffet, and ‘unique’ concessions. Registration includes roundtrip transportation to and from the Las Vegas Convention Center. With NASCAR in town, packages are also available for Saturday and Sunday. They include race tickets, Neon Garage/Pre-Race Pit Road passes, and race day transportation. The weekend package is $325. A Sunday-only package costs $219.
The news coverage ConExpo-Con/Agg radio is a new service provided by the American Equipment Manufacturers. Hosted by
Peggy Smedley, the program will debut Tuesday at 10 a.m. Smedley’s podcasts will focus on how manufacturers are developing technology that is enhancing efficiency and reducing operating and maintenance costs while maximizing performance levels. For coverage of new product introductions, interviews with equipment
product segment experts, and news from the National Stone, Sand & Gravel Association’s annual meeting — which takes place March 3-7, be sure to visit www.aggman.com regularly throughout the show. We’ll post even more coverage on Facebook (AggregatesManager) and Twitter (AggregatesMgr and AggManEditor). AM
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SUPPLYLINES by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Excavator Enhancements Eye Bottom Line Greater productivity and fuel efficiency are common features in the latest generation of excavators.
Performance with operator-focused comfort The Doosan DX530LC-5 crawler excavator is said to offer performance, operator-focused comfort, improved fuel efficiency, reliability, and durability. It has an operating weight of 116,576 pounds and a maximum digging depth of 24 feet. Operators can choose from four work modes to maximize efficiency and fuel economy. Helping improve productivity is an intelligent floating boom. Options include a straight travel pedal, two-way auxiliary hydraulic pedal, and diesel-powered coolant heater for cold starts. To meet Tier 4 emission standards, the 373-net-horsepower excavator includes a mass airflow sensor and exhaust brake to the engine. To help save fuel, an added auto-shutdown, with an idler time from 3 to 60 minutes, was added to help owners save fuel during nonworking conditions. Doosan Construction Equipment | www.doosanequipment.com
Production-class machine is Tier 4 Final The updated John Deere 870G LC excavator offers a fuel-efficient Tier 4 Final diesel engine that boasts 512 horsepower. The productionclass machine features cooled exhaust gas recirculation (EGR), a diesel oxidation catalyst (DOC), and selective catalytic reduction (SCR). With an improved piston design, the excavator burns particulate matter in the cylinder, so operators can save on service time and lower operating costs without the need for a diesel particulate filter. The 87-ton machine also has a battery disconnect switch, spin-on fuel filters, and two additional water separators to maintain long fuel filter life. Engine and hydraulic oil sample ports streamline maintenance. An improved step position on the track frame and handrails provide multiple points of contact when accessing the engine compartment. John Deere | www.johndeere.com
Hydraulic regen system boosts digging force Kobelco’s SK300LC is part of its Generation 10 lineup, which was developed with a focus on value, productivity, and durability. The 68,100-pound model is powered by a 252-horsepower Tier 4 Final HINO engine. The engine incorporates a selective catalytic reduction system with diesel particulate filters, which converts NOx into nitrogen and water emisions. The dual system minimizes diesel exhaust fluid and decreases NOx emissions by 88 percent. The excavator delivers a bucket digging force of 37,300 foot pounds. Much of the boost comes from a new hydraulic regeneration system that aids the arm by reusing force generated by the boom to minimize energy loss. A higher boom foot cross-section, thicker arm-foot base plate, and stronger foot bases are provided for additional reinforcement, while a redesigned boss shape and boom foot improve stability. Kobelco | www.kobelco-usa.com
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e
Telematics track multiple users Komatsu just introduced the PC650LC-11 hydraulic excavator. With an operating weight between 140,456 and 145,284 pounds, it maintains the productivity and transportability of its predecessor, but improves fuel efficiency, cab design, and serviceability to maximize production while lowering operating costs. Equipped with the latest Komtrax technology, it collects data such as fuel levels, diesel exhaust fluid levels, operating hours, location, cautions, and maintenance alerts, which are relayed to the web application for analysis. A new Operator Identification System reports key operating information for multiple operators, and a new Auto Idle Shutdown feature helps reduce idle time. The excavator is powered by a 436-net-horsepower Komatsu SAA6D140E-7 Tier 4 Final engine. Komatsu America Corp. | www.komatsuamerica.com
Six work modes optimize fuel consumption LiuGong North America’s Tier 4 Final excavators, the new E-Series, include the 915E, 922E, 925E, 930E, and 936E. The machines are said to feature best-in-class fuel consumption and a ROPS cab that meets ISO 12117-2 safety standards and is larger than previous model cabs. The cab boasts a nine-position suspension with a joystick module that moves independently for increased comfort and controllability. A standard rearview camera improves operator visibility when traveling. The line is powered by Tier 4 Final turbocharged Cummins engines. Six selectable working modes optimize hydraulic performance and fuel consumption for specific working conditions. Auto-idle speed function reduces fuel consumption and engine noise when pilot controls are placed in neutral. LiuGong North America | www.liugongna.com
Heavy-duty lifting combines with fuel efficiency Volvo’s largest excavator for the North American market is the new EC750E. Designed to offer heavy lifting power and high productivity without sacrificing fuel efficiency, the machine can deliver up to 15 percent higher productivity and 5 percent greater fuel efficiency than its predecessor, the EC700OCL. Productivity gains are due, in part, to a more powerful 516-horsepower Tier 4 Final engine. When combined with the larger diameter boom cylinders and increased working pressure, the EC750E delivers a 7-percent increase in digging force and a 4-percent increase in hydraulic flow. A new range of buckets, including general purpose, heavy duty, and extreme duty, further increase productivity. The new excavator weighs 3 tons more than its predecessor, but achieves a 5-percent gain in fuel efficiency. Volvo Construction Equipment | www.volvoce.com
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by Ross J. Watzman
ROCKLAW MSHA: Under New Managment Will the Trump Administration make MSHA great again?
O
Ross J. Watzman is counsel in Jackson Kelly PLLC’s Denver office, practicing in the firm’s Occupational Safety and Health Practice Group. He can be reached at 303390-0189 or ross.watzman@ jacksonkelly.com
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n Jan. 20, 2017, President-elect Donald Trump will take the oath of office to formally become the 45th president of the United States. But what happens after the inauguration, and how will it affect the mining industry? While the answer to this question is largely unknown, we can expect a significant departure from the Obama Administration’s aggressive regulatory and enforcement agenda. Throughout his campaign, Trump indicated that economic growth and job creation are top priorities of his administration. Specifically, he plans to create 25 million new jobs and grow the economy at 3.5 percent annually. Although the devil is in the details, Trump will attempt to accomplish this goal by reducing the federal government’s influence in the workplace. His administration will likely take a hard look at current regulations and any regulations that the Mine Safety and Health Administration (MSHA) may try to promulgate prior to the transition of administration to determine which regulations create the greatest burden for companies. In the waning hours of the Obama Administration, it is likely that the industry will see a significant increase in the number of issued regulations. This phenomenon, known as “midnight rulemaking, is well established in history and typically used by the outgoing administration to achieve certain policy goals
before the end of its term. For example, one week after the election, on Nov. 15, 2016, the Obama Administration published 527 pages of new regulations in the Federal Register. This included a Methane and Waste Prevention Rule published as part of the Interior Department’s agenda to create a cleaner and more sustainable energy future. Moreover, on Nov. 18, 2016, the Occupational Safety and Health Administration (OSHA) issued a Final Rule to update the general industry Walking-Working Surfaces and Fall Protection Standards. Among other things, the new OSHA rule updates general industry standards addressing slip, trip, and fall hazards (subpart D) and adds requirements for personal fall protection systems (subpart I). To this end, we expect MSHA will have tried to finalize two rules prior to the end of the Obama Administration, namely: (1) the Examination of Working Places in Metal and Non-metal Mines rule, and (2) the Respirable Crystalline Silica rule. Both rules have drawn significant criticism from a number of industry and business groups, which claim that key components of the rules are burdensome and compliance is nearly impossible. The Respirable Crystalline Silica rule would likely be modeled after the OSHA rule, which is currently being litigated. As such, the Trump Administration could re-open the rulemaking process to revise and nullify these rules.
AGGREGATES MANAGER / January 2017
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claims by heightening the threshold for a claimant to estabWhile the 527 pages published in the Federal Register lish a prima facie claim. This increase in the burden of proof shortly after the presidential election on Nov. 8, 2016, likely would signify a significant shift towards protecting employsignify the start of an onslaught of new regulations by the ers from false discrimination claims. Obama Administration, current Republican leaders have exFinally, the Trump Administration will likely overhaul the pressed their disapproval of these actions. On Nov. 15, 2016, Federal Mine Safety and Health Review Commission (FMRepublican leaders, including House Majority Leader Kevin SHRC). The FMSHRC is an independent adjudicative agency McCarthy, sent a letter to the current heads of all regulatory that provides administrative trial and appellate review of agencies cautioning them against “midnight rulemaking.” legal disputes arising under the Mine Act. It currently has a They stated: vacancy, and while operating with quorum, the administra“We write to caution you against finalizing pending tion could move to name a Republican to fill that vacancy. rules or regulations in the Administration’s last days. Additionally, the terms of two additional members of the By refraining from acting with undue haste, you will FMSHRC will expire on Aug. 30, 2018, opening up the ensure that agency staff may fully assess the costs chance for a Republican majority on the Commission. and benefits of rules, making it less likely that unAll in all, it is impossible to know exactly how much intended consequences will harm consumers and emphasis the Trump Administration will place on MSHA businesses. Moreover, such forbearance is necessary considering his campaign only targeted the coal industry. to afford the recently elected Administration and However, based on Trump’s views of labor and employCongress the opportunity to review and give direcment and government involvement in business, it is likely tion concerning pending rulemakings. Should you that the mining industry could see some significant changes ignore this counsel, please be aware that we will starting in 2017. AM work with our colleagues to ensure that Congress scrutinizes your actions and, if appropriate, overturns them pursuant to the Congressional SEE US AT Review Act.” This letter clearly outlines the Booth # mentality of the Republican-conG72213 trolled Legislature, a view that is expectedly shared by the Trump Adabout cold weather ministration. performance by In addition to reviewing regulaBEKA! tions, the new administration may For winter weather and high altitudes, you need mark the start of differing policy a BEKA auto-lube system to keep your equipment objectives, ranging from changing running smooth. enforcement to changing the burden • Cast aluminum base resists hot/cold temperature swings and witstands impacts without leaks of proof for discrimination claims. • No springs! Eccentric drive gear ensures From an enforcement standpoint, we reliable service in all climates and conditions may potentially see an MSHA that • Engineered to pump grease down to -13°F/-25°C stresses compliance assistance and Find out why industries are choosing BEKA for fosters cooperative programs, rather today’s best-built auto-lube systems. than focusing strictly on enforceCall 1.888.862.7461 or email us ment. This could potentially affect at info@beka-lube.com. the way MSHA utilizes its pattern of violations (POV) authority under the 1.888.862.7461 Federal Mine Safety and Health Act of www. beka-lube.com 1977 (Mine Act). Moreover, the Trump Administration may attempt to scale BEKA - LUBRICATION SPECIALISTS SINCE 1927 back whistleblower programs and
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AGGREGATES MANAGER / January 2017 2:42 PM 2016-12-01 12/12/16 9:28 AM
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ADINDEX January 2017
Advertiser
Web
Page
Aggregates Manager Atlas Data/CD Products
www.aggmanatlas.com
20
AZFAB, LLC
www.azfab.com
19
BekaWorld (formerly Beka-Max of America)
www.beka-lube.com
41
Bill Langer - Research Geologist
www.researchgeologist.com
43
C.L. Dews & Sons Foundry
www.dewsfoundry.com
43
ConExpo-Con/Agg 2017
www.conexpoconagg.com
11
Cowin & Company, Inc.
www.cowin-co.com
Crisp Industries, Inc.
www.crispindustries.com
Elrus Aggregate System
www.elrus.com
Excel Machinery
www.excelmach.com
7
Kespry, Inc.
www.kespry.com/aggregates
2
Kespry Partner Solutions
www.kespry.com/aggregates
30-31
KPI-JCI and Astec Mobile Screens
www.kpijci.com
25
Kruse Integration
www.kruseintegration.com
43
Martin Sprocket & Gear, Inc.
www.martinsprocket.com
17
NSSGA Annual Convention Registration
www.nssga.org
insert
NSSGA Membership
www.nssga.org
7
Progressive Commercial Insurance
www.progressivecommercial.com
28
Pugmill Systems, Inc.
www.pugmillsystems.com
43
Rice Lake Weighing Systems
www.ricelake.com/truckscales
BC
Sweet Manufacturing
www.sweetmfg.com
43
United Employment Assoc.
www.unitedemployment.com
43
7 29 IBC
This index is provided as a service. The publisher does not assume any liability for errors or omissions.
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AGGREGATES MANAGER / January 2017
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• 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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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
Aggregates and the Environment In 2017, this column will highlight some of the environmentally beneficial uses of aggregates.
B
reakfast table talk with my wife, Pam, recently included the discussion of topics for future Carved in Stone articles. Pam had just finished reading an article about permeable pavement when she suggested, “How about writing some articles on uses of aggregate for environmental purposes?” I am NOT making this up! Why was she reading that? Would that topic work? I cast about on the internet using the search string “aggregate environment,” and Google came up with about 89,100,000 hits in 0.31 seconds. I was pleased to see that my publication Aggregate and the Environment was near the top of the list. It can be downloaded for free from the American Geosciences Institute at www.americangeosciences.org/ sites/default/files/aggregate.pdf. Unfortunately, it didn’t take long for me to become somewhat alarmed. Clicking on most of the hits took me to sites describing the terrible things that aggregate mining does to the environment. I tried other search strings like “environmental applications for aggregate,” and “environmental uses gravel;” all with no better results. That did it! I know there are many situations where the use of aggregates actually benefits the environment. I need to vent, so, this year, Carved in Stone will contain a number of articles on the environmentally beneficial uses of aggregate. I will begin with the one Pam read about — permeable pavement. Does the idea of permeable pavement hold water? Let’s see. In the simplest of terms, permeable pavement is a hard surface used in applications such as parking lots or roads, with a base and subbase that allow the movement of storm water through the surface. The permeable pavement Pam was reading about was made from aggregate, crumb rubber, and asphalt. Permeable pavement can also be made with no crumb rubber; just aggregate bound with asphalt or concrete. Some low-traffic permeable pavement can be made from unbound aggregate or grass with, or without, geotextiles and interlocking pavers. The drawing shows the general design of a permeable pavement. Don’t be fooled by the simplicity of the drawing; each individual system has its own specific requirements. Here is the problem. During a storm, the first 1 1/2 inches of rainfall mobilizes about 90 percent of surface pollutants. Instead of going into treatment facilities, runoff typically is channeled directly into storm sewers and then into local water bodies. The pollutants can cause an increase in algae content, harm aquatic life, and require expensive treatments to make the water potable. If that initial runoff can somehow be retained, some of the ill effects of storm water runoff can be reduced. Conventional pavement causes increased runoff by preventing water from infiltrating into the soil. By contrast, pervious pavement captures rainwater in a network of voids, thus reducing runoff. In addition, the captured water can slowly percolate into the underlying soil and filter out pollutants carried by the runoff. In some geologic settings, that water recharges local aquifers. If pervious concrete or asphalt roadways and parking lots cover enough area, they can double as water retention structures. That may reduce or eliminate the need for traditional storm water retention ponds, thus lowering overall project cost. In addition to storm water control, pervious pavements aid in reducing the urban heat-island effect. The open-cell structure of the pervious pavement allows free air circulation, allowing more rapid cooling of the pavement. So, it looks like permeable pavement really does hold water. Thanks for the idea, Pam.
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