February 2014
www.AggMan.com
17
NSSGAʼs Mike Johnson talks about putting aggregates first
23 42
Six steps to matching machines MSHA expands its use of Section 103(k) orders
Meet Innovation. Discover Diversity. t Visit us a
nexpo 2014 Co Show Con /Agg
55 a, USA s, Nevad Booth 21 Las Vega Gold Lot, 4 1 0 2 , 8 -0 4 0 m h o Marc xpo.c herr-cone www.lieb
The Liebherr Group is proud to present an extensive selection of its most innovative Earthmoving, Material Handling and Construction Equipment at Conexpo Con/Agg 2014. More than 20 pieces of equipment for multiple industries and job applications will be part of this incredible selection.
Mobile and Crawler Cranes Tower Cranes Hydraulic Excavators Material Handlers Crawler Tractor and Loaders Wheel Loaders Liebherr High-Performance Components Innovative Equipment Simulators
We welcome you to experience our company.
Text INFO to 205-289-3782 or visit www.aggman.com/info
The Group
36
When oversized rock is fed into the jaw, but is too large for the chamber, it interrupts crushing and stalls production. On Our Cover: CalPortland tackles underwater mining. Cover photo by Kerry Clines.
12
Powerscreen’s new Premiertrak 300 jaw crusher can produce up to 308 tons per hour.
CONTENTS FEBRUARY 2014
FEATURE ARTICLES
17 Speaking with One Voice
NSSGA’s new CEO, Mike Johnson, focuses advocacy efforts by putting aggregates first.
28
Success in the Pacific Northwest
CalPortland’s Santosh Aggregates Plant continues to scoop up profits in Oregon, one dragline bucket at a time.
36
Focus on Your Primary Goals
Proper care — and application — will keep your primary jaw crusher properly feeding the production cycle.
WEB EXCLUSIVES Visit www.aggman.com for expanded editorial coverage. Get ready for the big show with our expansive coverage of equipment on display, listings of aggregates-specific educational seminars, and news from the show floor.
VOLUME 19, NUMBER 2
COLUMNS & DEPARTMENTS
3 5 9 11
EDITORIAL A taxing situation. STATE AND PROVINCE NEWS A roundup of the latest news in North America.
DATA MINING The latest financial analysis of
42
issues impacting in the industry. ROLLOUTS Rice Lake Weighing System’s newest digital weight indicator, and other new equipment for the aggregate market. ROCK LAW MSHA expands its use of Section 103(k) orders as the Federal Mine Safety and Health Review Commission broadens the definition of ‘accident.’
OPERATIONS ILLUSTRATED
23
Mobile Equipment Matchups
Matching the size of the loading machine to the truck is critical to hitting your plant’s production target.
44 47 48
CLASSIFIED ADS Aggregate industry classifieds. ADVERTISER INDEX See who’s who and where to find their products. CARVED IN STONE From the land of Lincoln to the Gateway Arch, Route 66 highlights interesting insights into history.
Booth #83830
Text INFO to 205-289-3782 or visit www.aggman.com/info
RAPID SUPPORT TO THE MOST REMOTE JOBSITES.
SMART. PROVEN. POWER. With hundreds of locations, Volvo Penta service is available wherever, whenever. Learn more at volvopenta.com/industrial.
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
February 2014
A Taxing
Vol. 19, No. 2
SITUATION
aggman.com /AggregatesManager @AggMan_editor
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Online Managing Editor: Amanda Bayhi editorial@aggman.com
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Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly Publishing Company copyright 2014. 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 707.4.12.5); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.
C
onventional wisdom dictates that most onerous local regulations are born in the West and migrate East. It was a bit of a surprise, therefore, when I read about a dispute involving taxes levied on aggregates. This particular gem cropped up in Johnston County, Okla. In mid-January, the Johnston County Commissioners endorsed Oklahoma Citizens for Aggregate Benefits. The Oklahoman reports that the organization is “designed to lobby for a tax on the production of silica, sand, gravel, and other aggregates.” The group is encouraging local elected officials to support H.B. 1876, authored by Rep. Charles McCall (R-Atoka), which would allow counties to set up tax rates of up to 7 percent on the production of aggregates. A Senate version of the bill, sponsored by Frank Simpson (R-Springer), didn’t make it out of committee last year. Jim Rodriguez, executive director for the Oklahoma Aggregates Association, quickly pointed out some of the bill’s numerous flaws, including the fact that the tax rate could be set at different rates in different counties, creating a logistics nightmare for operators. He also noted that the only state that currently has a severance tax is Arkansas. Its tax is 4 cents per ton. The proposed tax, Rodriguez said could add up to 42 cents per ton. Let’s reflect on average construction materials prices in Oklahoma. According to the U.S. Geological Survey’s most recent quarterly production reports, the average price of sand and gravel there is $6.22 per metric ton, while crushed stone rates a slightly higher price of $7.58. These tax rates could reflect the difference between profit and loss for many operators. McCall claims that trucks hauling aggregate are damaging roads and infrastructure. That lever is being used to encourage support among county commissioners, but it fails to address two points: First, most operations have some sort of agreement with the local communities to upgrade the roads into and out of their operations; and second, most operations are in close proximity to highways (which are built to handle these loads) so they can efficiently transport their product to market. On the upside, new taxes in Oklahoma require a 75-percent vote from the state legislature. If the tax is passed, however, homeowners, business owners, and the state DOT may find that the cost of purchasing Oklahoma aggregates may increase… perhaps by as much as 42 cents per ton.
3
things I learned from this issue:
1
Manufacturer software can help calculate whether it’s more efficient to rebuild or replace equipment, page 23.
2
Jaw dies should be flipped or replaced when corrugations get to about 20 percent of beginning dimensions (or irregular wear is detected), page 36.
3
While the definition of ‘accident’ has a more narrow scope in 30 C.F.R. Part 50, § 50.2(h), the FMSHRC allows a broader definition under § 103(k), page 42.
AGGREGATES MANAGER February 2014
3
DEISTER
Second Century of Continuing Excellence
Innovative screening, scalping and feeding solutions
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State & Province
NEWS by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
Alabama
APAC Mid-South, Inc. is considering shutting down its operation on Highway 169 in Opelika after experiencing continued problems with sinkholes near the operation. According to WTVM.com, the company has spent millions of dollars repairing sinkholes and trying to prevent new ones from developing by restructuring large portions of several roads and building a new water discharge system. When new sinkholes continued to develop, a lawyer for the company told the television station that the company was considering scaling back the size of the operation or moving it to another location. The quarry has been in operation since the Civil War.
Connecticut
A public hearing on an East Granby quarry was continued from Jan. 15 to Feb. 5. The operator, Galasso, is seeking a third phase of expansion, including clearing of 22.9 acres and mining on 17.6 of those acres. Galasso has been working on its application for two years, the Granby-East Granby Patch reports. The hearing was continued at the applicant’s request so it has more time to revise plans according to commission and staff comments.
Georgia
Contract hauler Lewis Pippin, who owns Junior Pippin Trucking Co. and hauls aggregates for Vulcan Materials Co.’s Conyers and Grayson quarries, is sharing a unique message with his most recent truck purchases. NewtonCitizen.com reports that his two new dump trucks are painted black and pink and sport pink lettering and breast cancer ribbons. “I want to raise money and awareness because breast cancer is a hideous disease — any cancer is,” Pippin told the newspaper. His wife, Lisa, was diagnosed with cancer in 2012 and is now in remission.
Illinois
Winter storms dropped continuous snow on Elmhurst at the beginning of the year. As road crews worked nonstop to clear the streets, snow was deposited in the Elmhurst Quarry. According to the Chicago Tribune, the quarry not only serves as a flood protection reservoir, but also doubles as a snow depository in the winter.
To keep up to date with this breakdown of news in the United States and Canada, visit www.AggMan.com for daily updates.
Indiana
Lehigh Hanson closed its Salem quarry, but officials say it could reopen if the market improves. According to the Salem Leader, the operation employed 12 individuals; most of whom were transferred to another Hanson operation. Customers are now being served by the company’s operation in Scott County.
Maryland
Lafarge announced the sale of five aggregates operations, as well as related assets, to Blueglass Materials for a total enterprise value of $320 million. With these divestments, the company reports, it has largely completed its strategy of refocusing on its core U.S. markets, including cement plants, cement terminals, and aggregate sites along the Great Lakes and Mississippi River.
Missouri
J.W. Strack, owner of Strack Stone Co., announced a $1,000 reward for information leading to the arrest and conviction of whoever stole approximately $20,000 worth of copper wire. The Southeast Missourian reports that more than 6,000 pounds of scrap copper were stolen from the quarry. Cape Girardeau police have reported at least 19 cases of copper theft during the last year. A lieutenant with the police department told the newspaper that thefts tend to rise and fall with copper prices. Strack said the current theft is his second in 12 months.
New Jersey
Kinnelon police alerted residents to blasting at the Riverdale Quarry after receiving calls from residents about the event. According to the Tri-Boro Patch, the police alert notified residents that Picatinny Arsenal, which provides arms and munitions to the U.S. Armed Forces, and Tilcon were conducting blasting at Tilcon’s Riverdale Quarry.
New York
The Lockport Planning Board granted a two-year extraction permit and recommended to the Common Council a one-year special-use permit be granted to Lafarge North America’s Lockport Quarry. The Lockport Union-Sun & Journal reports that the operation needs to expand its quarry in order to stay in business. The operation is seeking approval for mining on a 15-acre city parcel, with mining to take place on 9.1 of those acres. The recommendation was made conditional on a report from the city director of engineering and public works as to whether blasting will affect the city’s water supply line.
AGGREGATES MANAGER February 2014
5
Here on time. Here for you.
Metso Quarry Supply Solutions
Screen Media
Lining Solutions
Conveyor Accessories
Conveyor Components
Crusher Wears & Spares
Efficient, accurate delivery: One more way we deliver service Your profits depend on getting the right parts – on time, every time. And when you partner with your local Metso distributor for all your quarry supply needs, you can always count on efficiency, accuracy and the industry’s best service. For more information about Metso Quarry Supply Solutions and distributors near you, email us at quarrysupplies@metso.com Text INFO to 205-289-3782 or visit www.aggman.com/info
BOOTH 50979
New York
On Jan. 1, Donald E. Fane took over as president of Callanan Industries, Inc., following the retirement of Jonas E. Havens. According to the Albany Business Review, Fane joined the company in 1995 and rose up to become executive vice president before being tapped as president. One of his goals, the newspaper reports, is to continue diversifying the company beyond a traditional contractor and into a strategic consultant for customers. Callanan operates six quarries, 11 asphalt production facilities, and 14 ready-mix concrete plants. It is an Oldcastle Materials Inc. subsidiary.
MAXIMIZE PAYLOAD, MAXIMUM PROFIT L2180 Wheel loader scales
Ohio
The future health of Bolivar is at question, after residents passed an initiative to rezone property from sand and gravel to agricultural. According to the Times Reporter, the land belongs to Howard Wenger. Approximately 181 acres were purchased from Lawrence Township nearly a decade ago, while an additional 65 acres were purchased in 2012. The second purchase totaled $1.1 million and was welcomed by the Bolivar Village Council because it allowed the village to become debt free, as well as provide a surplus of revenue of approximately $400,000. Last November, some residents, joined by opponents from Lawrence Township, capped a year of arguing with Bolivar Village Council by getting the zoning initiative on the ballot and passing it by a 238-158 vote. Wenger, who owns Massillon Materials, had provided a revenue stream that would have allowed the village to invest in beautification projects to boost tourism and gradually replace old water lines. Now, the mayor says those plans are on hold.
X2350 Excavator scales
C1850 Conveyor belt scales
South Carolina
Neither the St. Cloud City Council nor the mayor appealed the Zoning Board of Appeals’ decision to grant a conditional permit for Coldspring by the Jan. 3 deadline. SCTimes.com reports that the conditional use permit allows the operator to expand its quarry by 14.4 acres and allows quarrying operations to move in a different direction from the area defined in its former permit. The permit does include conditions regarding hours of operation, truck traffic, and groundwater monitoring.
Texas
Owners of Dallas-based TXI are reportedly exploring a sale of the company and are working with Citigroup to find a buyer. According to Bloomberg, the company has a market valuation of $1.67 billion and may draw interest from Vulcan Materials Co. and Holcim Ltd. Reuters reports that the company’s largest shareholders, Southeastern Asset Management and NNS Holding, have been looking to exit their stakes in the company for some time. During the last month, TXI stock has jumped to a Jan. 9 close of $68.19 per share.
Use LOADRITE scales on wheel loaders, excavators and conveyor belts for maximum operational efficiency. For proven cost savings & increased profits, supported by our expert technical team across the US and the world, choose LOADRITE.
See us at booth 50119
For more info phone 1 800 528 5623, email info@loadritescales.com, or visit our website for your local distributor.
A frac sand operation was assessed an $80,000 fine for discharging sediment into Burnett County wetlands, a creek, and the St. Croix River, the Wisconsin State Journal reports. A civil judgment against Interstate Energy Partners, which owns the operation, and Tiller Corp., which operates it, was announced on Jan. 5. The civil complaint, which states the company failed to maintain dikes and berms in April 2012, stems from a citizen report to the Wisconsin Department of Natural Resources.
LR AGM 01.14
Wisconsin
www.loadritescales.com Text INFO to 205-289-3782 or visit www.aggman.com/info
Your trusted advisor since 1953. Everett Quarries
Handwerk Materials Division and Lebanon Materials Division of
* Represented by FMI Capital Advisors, Inc. Text INFO to 205-289-3782 or visit www.aggman.com/info
FMI’s dedicated focus on construction and engineering has led to more than 600 closed industry transactions. Serving a broad range of sub-sectors, we have extensive industry-focused knowledge, expertise and relationships that have led us to be one of the industry’s most trusted advisors for 60 years. Knowledge
•
Expertise
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Will Hill | 303.398.7237 | whill@fminet.com • George Reddin | 919.785.9286 | greddin@fminet.com www.fminet.com/CA Investment banking services provided by FMI Capital Advisors, Inc., a registered broker-dealer and wholly owned subsidiary of FMI.
Data Stock Report Company
U.S. On-Highway Diesel Fuel Prices Ticker
Current Value
52-Week 52-Week High Low
1/6/2014
One Week
One Year
United States
$3.910
+0.007 p
-0.001 q
East Coast
$3.950
+0.007 p
-0.056 q
New England
$4.115
+0.004 p
-0.038 q
Central Atlantic
$4.046
+0.030 p
-0.055 q
$3.847
-0.009 q
-0.055 q +0.018 p
Cemex, S.A.B. de C.V.
CX
$12.16 p
$12.57
$9.13
CRH plc
CRG
$26.67 p
$27.17
$19.83
Eagle Materials Inc.
EXP
$76.93 p
$79.91
$59.08
Granite Construction Inc.
GVA
$34.83 p
$37.74
$26.07
Heidelberg Cement AG
HEI
$76.14 q
$82.72
$60.85
Holcim Ltd.
HOLN
$73.59 q
$87.08
$69.02
Lower Atlantic
Martin Marietta Materials, Inc.
MLM
$105.01 p
$113.65
$93.03
MDU Resources Group, Inc.
MDU
$30.47 p
$30.97
$21.72
Texas Industries Inc.
TXI
$68.19 p
$75.30
$53.23
United States Lime & Minerals, Inc. USLM
$57.28 p
$62.50
$45.00
U.S. Concrete
$22.40 p
$23.60
$9.15
Vulcan Materials Co.
USCR VMC
$59.36 p
$60.14
$45.42
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 1/9/14.
Midwest
$3.888
+0.001 p
Gulf Coast
$3.802
+0.013 p
-0.035 q
Rocky Mountain
$3.901
+0.012 p
+0.213 p
West Coast
$4.034
+0.009 p
+0.046 p
West Coast less California
$3.934
+0.004 p
+0.016 p
California
$4.119
+0.015 p
+0.071 p
Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
If you’d like to get better performance and longer wear life out of your top deck bolt-down scalping media, it’s time you tried ArmadexTM. Using a custom natural gum rubber compound, high strength/low alloy steel and Polydeck’s unique binary injection molding (BIM) technology, ArmadexTM has been proven to outwear competitive bolt-down solutions by as much as 2 to 1. Can your synthetic screen media producer offer that?
See Armadex and several more screening innovations at
Call us at 1-864-579-4594 or visit polydeckscreen.com/aggregate to find the Polydeck sales representative in your area.
Central Hall • Booth 51610
Text INFO to 205-289-3782 or visit www.aggman.com/info AGGREGATES MANAGER February 2014
9
See us in
Las Vegas Booth #4264 Silver Lot
Purpose-built
from the ground up Material handlers from SENNEBOGEN from 44,000 lbs. to 375,000 lbs. Simple design‌ Lift more. Move faster. Save fuel. Run longer.
www.sennebogen-na.com Tel: +1-704-347-4910 Text INFO to 205-289-3782 or visit www.aggman.com/info
For
FREE Product Information Text INFO to
205-289-3782,
by Therese Dunphy, Editor-in-Chief
Your complete guide to new and updated equipment and supplies in the aggregates industry.
tdunphy@randallreilly.com
or visit
aggman.com/info.
For coverage of the products that will be on display at ConExpo-Con/Agg, visit www.aggman.com
Tier 4 Final medium wheel loaders Caterpillar introduces its new 980M and 982M wheel loaders. Equipped with Tier 4 Final ACERT engines, the units boast a combination of electronic, fuel, air, and after-treatment components. The 982M is a new all-purpose machine that will load on-highway trucks in two passes; however, design changes to the frames, linkage, horsepower, and powertrain extend its application to sand and gravel and earth bank excavation, as well as face loading in shot rock applications. It also has longer standard lift arms than the 980M, making it suitable for rail car loading. Like other M series loaders, powertrain updates have improved both performance and fuel efficiency. The hydraulic service center is virtually identical across the M series, with a consistent layout simplifying maintenance for service technicians. For operator ease, a switch has been added to the electronic service center to unlatch the door remotely, while the angle of the steps has been increased to 15 degrees, which enables operators to walk up as if they were using stairs. New roll-formed ROPS posts, larger convex mirrors, and integrated spot mirrors all improve safety. A new multipurpose touch screen simplifies operator interface with machine controls, rearview camera, and a fully integrated Cat Production Measurement system.
Specifications Engine Net power Operating weight Bucket capacity Bucket pin height (std/high lift)
980M Cat C13 386 65,698-75,663 pounds 5.5-15.7 cubic yards 178/186 inches
982M Cat C13 392 75,398-79,829 pounds 6-18.3 cubic yards 186 inches
Caterpillar | www.cat.com
Elevator pulleys Baldor Electric Co. offers a complete line of Dodge elevator pulleys, available in drum or single-disc design with HE, XT, QD, or Taper-Lock hubs and bushings. The heavy-duty elevator pulleys not only meet CEMA standards, but are also available with Mine Duty Extra construction for increased strength and durability. The pulleys are available in diameters from 6 inches through 72 inches, with face widths up to 120 inches. Four lagging options are available. Baldor | www.baldor.com
Text INFO to 205-289-3782, or visit aggman.com/info.
AGGREGATES MANAGER February 2014
11
Mobile jaw crusher Powerscreen’s new Premiertrak 300 jaw crusher is said to excel at higher fuel efficiency and lower transportation costs. The unit uses a 40-inch by 24-inch jaw chamber and is capable of producing up to 308 tons per hour of crushed material. Options include a vibrating grizzly feeder or a large fully independent hydraulically driven pre-screen. Both options are proportionally controlled by engine load to maintain optimal throughput. An optional hydraulically folding extended side conveyor, with a stockpile height of 10 feet, 2 inches, is available with the prescreen feature. A new bypass chute design incorporates a flap gate to allow operators to switch between using the side conveyor or sending material to the main belt without the need to fit a blanking mat on the bottom screen deck. A hydraulically adjustable closed-side setting can be adjusted in a matter of minutes without requiring tools, while the new hopper design incorporates a complete hydraulic fold-andlock system to eliminate the need for manual wedges. The crusher is powered by a 275-horsepower Tier 3-compliant Cat C9 ACERT engine or a 272-horsepower Tier 4 Final compliant Scania DC9 engine. Powerscreen | www.powerscreen.com
Digital weight indicator Rice Lake Weighing Systems announces its newest weight indicator, the 880 Performance Series, a compact digital weight system and controller for mounting within larger control panels and DIN-rail applications. A smaller, removable indicator face and overall depth of just 4 inches make it one of the most compact full-size controllers on the market. The unit also adapts to a spectrum of technologies, whether they require USB, RS-232, or standard Ethernet connection. It can operate as a standalone controller, but also connects with a range of industrial networking protocols for PLCs. Rice Lake | www.ricelake.com
Fuel efficient generator Atlas Copco introduces the QAC 1200 1MW generator, featuring a Cummins QST30G5 diesel engine that is Tier 2-certified and provides 1140 kVA/912 kW prime power rating. With a fuel efficient, electronically governed engine, the integrated fuel tank provides a minimum run time of eight hours. The unit was engineered with 500-hour service intervals to lower owning and operating costs. Low noise levels (85 dBA at 1 meter) make it suitable for sound-sensitive applications. An available option is a controller that allows a user to create a Power Management System. This allows a simple method to parallel two or more generators beyond 1MW. Atlas Copco | www.atlascopco.us
Utility class loader Built from the ground up, Kawasaki’s new 70Z7 uses the IntelliTech Operation System, which captures every aspect of working conditions and operating demands and adjusts the powertrain and hydraulics for the most efficient use. Unlike its larger-sized classmates, this unit’s intelligence is automated to take guesswork out of the operator’s hands. It has a high-intensity LCD monitor, straightforward dash arrangement, and intuitive systems, making it easy for operators of varying skill levels to run. The unit sports a 173-horsepower Cummins engine, a ZF five-speed transmission, work mode selector, 50-degree bucket tilt-back for carrying, and a full turn tipping load of 22,800 pounds. Kawasaki | www.kawasakiloaders.com
12
AGGREGATES MANAGER February 2014
HOW CAN YOU MAXIMIZE YOUR CONVEYOR’S PRODUCTIVITY? Find out with a free conveyor assessment — Booth 7710
At Flexco, your business is our business. That’s why we’re offering you an opportunity to sign up for a free conveyor assessment at CONEXPO-CON/AGG 2014. With this service, our experts will come on-site, thoroughly examine your conveyor, and identify ways we can optimize productivity — together. Stop by Booth 7710 to take advantage of this unique consultation, meet our expert engineers, and see our newest products.
flexco.com
Text INFO to 205-289-3782 or visit www.aggman.com/info
Aluminum rollers Aluminum conveyor rollers, from Horizon Conveyor Equipment, are said to offer robust strength at nearly half the weight of their standard steel counterparts. Designed using a 6-mm-thick aluminum tube, the rollers contain a steel shaft and sealed bearings, with the bearing housings manufactured from electrically conductive, glass-reinforced nylon. A large stationary integral stone guard forms the outer primary labyrinth seal, which prevents spillage buildup between the roller and the frame. Dust, debris, and smaller contaminants are kept out by a greased inner cupped lip seal, together with a sealed bearing. Horizon Conveyor Equipment | www.horizonconveyors.co.uk
More powerful artics The new Cat C-Series articulated dump trucks, 725C, 730C, and 730C EJ ejector, feature new engines with more power, advanced transmission control, enhanced operator amenities, new serviceability features, and — for the 730C and 730C EJ models — automatic traction control. The design centers on customer requests for increased productivity, lower operating costs, superior availability, long-term durability, added rimpull/retarding capability, ease of operation, and high resale value. The 725C has a rated payload capacity of 26 tons and is powered by a Cat C9.3 ACERT engine rated at 314 horsepower. The 730C and 730C EJ are rated at 31 tons and are powered by a Cat 13 ACERT engine rated at 367 horsepower. All three models are available in Tier 2, Tier 3, or Tier 4 Final configurations. A diesel particulate filter and selective-catalytic-reduction system provide exhaust after treatment for Tier 4 Final models. Compared to prior models, the 725C has a 4-percent gain in gross power and a 20-percent boost in gross torque; the 730C and 730C EJ models have nearly 16 percent more power and more than a 30-percent gross torque improvement. To control speeds on downhill grades, 730C models employ a new engine-compression brake that provides 60 percent more retarding power than predecessor models. The 725C uses a fluid retarder with four operating modes. Caterpillar | www.cat.com
Vocational truck The all-new Kenworth T880 is designed for heavy-duty use, including hauling applications. It comes standard with a PAACAR MX-13 engine rated at up to 500 horsepower and 1,850 foot-pounds of torque. The engine provides lightweight, fuel-efficient power for vocational applications. The unit can be ordered with a 116.5-inch BBC hood optimized for the PACCAR engine or with the 122.5-inch BBC hood. The truck features a panoramic windshield for better visibility, quiet cab with triple-sealed doors, a five-piece Metton hood for easier and faster repairs, air-assisted hydraulic clutch, and lightweight, factory-installed lift axles. Kenworth Truck Co. | www.kenworth.com
Electric-driven air compressor Doosan Portable Power’s new electric-driven VP900e portable air compressor operates between 400 and 900 cfm, without wasted energy. Replacing the typical diesel engine on the air compressor are three onboard electric motors that are controlled by a variable frequency drive system (VFD) — one air end motor and two cooling fan motors. The design creates operational efficiencies, using less power than is required of a typical, one-motor-fits-all design. The VFD monitors the needs of the compressor by changing performance of the motors to meet precise power requirements, preventing the use of unnecessary power. A low power start further enhances energy efficiency as it requires only a fraction of the power typically needed for motor start-up. Doosan Portable Power | www.doosanportablepower.com
14
AGGREGATES MANAGER February 2014
EXPERIENCE THE POWER OF
HYUNDAI
Text INFO to 205-289-3782 or visit www.aggman.com/info
Looking for power? Hyundai machines come standard with the industry’s best warranty. That’s the power of reliability, the key to your long-term success. Experience the power of Hyundai at Booth #10052
www.hceamericas.com
THE INDUSTRIAL
REVOLUTION
SM
Join the revolution. To learn more about waterless dust-control sweeping, contact us today for a demo
847.741.5370 www.elginsweeper.com ©Elgin Sweeper Company 2013.
NO DUST. NO MUD. JUST CLEAN. Your operation needs a heavy-duty sweeper to minimize dust and debris, control storm water runoff and create a cleaner environment for your people and the surrounding community. The leader in environmentally efficient waterless dust-control sweeping, Elgin Sweeper builds industrial-strength machines that deliver unmatched sweeping performance in the harshest outdoor applications. These powerful sweepers tackle coal dust, cement, fly ash and other dirt and debris found in industrial settings—without the use of spray water. That’s a revolution worth joining. Text INFO to 205-289-3782 or visit www.aggman.com/info
by Therese Dunphy, Editor-in-Chief
TakeFIVE NSSGA’s new CEO, Mike Johnson, focuses advocacy efforts by putting aggregates first.
Speaking
WITH ONE VOICE Q.
When it comes to association management, what are the key commonalities and differences between the beer and aggregate industries? First, thank you for the opportunity to respond to your questions and communicate with your readers. While there is no question that beer and rocks are quite different, the reason that companies in the beer distribution industry and the aggregates industry came together many years ago to form national trade associations is largely the same. The participants in both industries recognized a need to have a unified voice in Washington to advocate for their collective interests before the administration, Congress, and the specific regulatory agencies engaged with each industry. So, while the products are quite different, for both NBWA and NSSGA, advocacy was, and still is, job one. Both industries have a vested interest in policy that facilitates a strong national economy, federal laws that promote business growth, and a regulatory environment that is fair and balanced. At NBWA, we built an advocacy organization that was routinely cited as one of the most effective in Washington. That was possible because the members of NBWA understood the importance of being involved and were committed to and willing to invest in building a strong, united voice. It also happened because those of us who they hired to represent them were devoted, disciplined, and strategic. At NBWA, the goal was to maximize our members’ ROI by
A.
On Aug. 1, 2013, Michael W. Johnson joined the National Stone, Sand and Gravel Association (NSSGA) as president and CEO. He previously served as the executive vice president and chief advocacy officer for the National Beer Wholesalers Association (NBWA). As his first national convention approaches, he addresses strategic planning and what’s next for the association.
focusing on those things that mattered most to the success of their businesses and the industry, and, that if we did not raise, nobody else would. In short, the guiding association management principle was “putting distributors first.” I am excited because I see that same level of understanding about the importance of being involved and willingness to invest among the members of NSSGA. My commitment, and the commitment of our entire staff team, is to maximize our members’ ROI by building a stronger, more effective advocacy organization that is laser focused on “aggregates first.”
Q.
The association surveyed its membership at the beginning of your tenure. What surprised or excited you about the feedback? Any concerns? As was hopefully evident in my previous response, I believe that trade associations have to be member driven. When I learned that NSSGA had not fielded a benchmark membership survey in some time, doing so became an obvious priority. The results showed that the membership agreed. The first surprise, a pleasant one, was the response rate. Around a 20-percent response rate is about average for association membership surveys. Our response rate was more than 35 percent! I was also pleasantly surprised and very excited by what the respondents told us about the value of NSSGA membership to their businesses. There are many associations active in the construction and construction materials industries that our members could, and
A.
AGGREGATES MANAGER February 2014
17
Take Five
in many cases do, belong to, in addition to NSSGA. However, they overwhelmingly see NSSGA as the most valuable trade association for their business interests. As for concerns, nothing in particular jumped out as alarming. The survey asked about priorities and, not surprisingly, reauthorization of a long-term highway bill, the solvency of the Highway Trust Fund, and fighting for more effective, balanced regulation in the areas of safety, health, and the environment topped the list. Respondents were also asked to assess the effectiveness of NSSGA on these issues and a number of other core activities of the association. The responses were instructive. While the association is focused on the right things and generally doing a good job, there is room for improvement. Bottom line: NSSGA membership is of high value, and we have an opportunity to, borrowing a line from Jim Collins, move from “Good to Great” in delivering on that value proposition. The really good news is that the new three-year strategic plan we are developing right now will position us to do exactly that.
Q.
Now that you’ve had a little time to get your steeltoed boots broken in, what top priorities have you identified for the National Stone, Sand & Gravel Association (NSSGA)? You know, steel toes are one of the things that my professional past and my future have in common. While rocks may be harder and heavier, a pallet of cases or a keg can do pretty good damage to a foot, too. My boots were already broken in pretty well on day one. As for priorities, I made reference to the new three-year strategic plan that we are working on right now. I am a big believer in the need to plan your work…and work your plan. Putting us in a position to do both, based upon what we learned in the membership survey, is where I am focusing first. The process we are engaged in, with Harrison Coerver — a well-known and highly respected planning consultant who has been part of developing more than 1,200 association strategic plans — will produce a member-focused, priority-driven plan that will chart an aggressive course from good to great for NSSGA. I am excited about sharing the plan with the membership at our upcoming Annual Convention, March 3-6, in Las Vegas. However, we know that there are some ongoing priorities that we must continue to address while we work on the new plan. With the expiration of MAP-21 in September of this year and dependence upon a funding mechanism that will be insolvent in 2015, the stakes are high. We are continuing to aggressively
A.
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AggregAtes MAnAger February 2014
advocate for a new long-term highway bill and a solution to the solvency issues surrounding the Highway Trust Fund. At the same time, we will continue to push back against unreasonable actions and unwise proposals by federal regulatory agencies. We will keep working to facilitate a better dialogue with our regulators. However, when that is not enough, we will also push for greater congressional oversight and not be afraid to engage in litigation when we have to protect our members’ ability to do business responsibly.
Q.
Getting anything done in Washington, D.C., is a challenge these days. How will NSSGA, under your leadership, navigate the partisan political atmosphere? No doubt about it...the situation in Washington is challenging, to put it politely. Frankly, the past few years have been the worst that I have experienced in more than 20-plus years of working in this town. The President and Congress have lurched from man-made crisis to man-made crisis — the debt ceiling, the fiscal cliff, to the sequester, and ultimately a government shutdown; and the brink of a debt ceiling default all over again. Absolute disaster has been avoided only by last-minute “deals” that are crafted to prevent the worst case and kick the can down the road rather than any concern for sound policy and real solutions. Unfortunately, it is too simplistic to blame pure partisanship, while it is about as bad as it has ever been, as the underlying cause is actually even more complicated and harder to address. Whether it was Reagan and the House Democrats or Clinton and the House Republicans, pure partisan differences have historically been overcome by cooler heads prevailing and moderates coming together to make progress on matters of national importance. The current situation is even worse because current electoral politics have resulted in fewer moderates on either side of the aisle, and the parties have moved more toward their respective bases, making the incentive to find compromise even less. This has especially been a problem for Republicans who are literally in the midst of a civil war of sorts for control of their party. All that said, and it’s plenty, there have been some bright spots recently, including one directly related to infrastructure investment, that give us reason for some optimism. The recent passage of the NSSGA-supported water resources (WRRDA) legislation followed by approval of the end of the year budget deal by broad bipartisan margins and, maybe more importantly, broad margins within each party in each chamber shows that there still is a path forward on issues deemed to be of high national importance.
A.
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TAke Five
message about the importance of transportation infrastructure to their success will be impossible for those in Washington to ignore. There is a path forward, and, working together, NSSGA will put aggregates first and be that one voice, powerful and effective, for the industry. AM
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The goal for NSSGA, working with our allies in the construction materials industry and broader infrastructure coalition partners, is to foster an environment in which reauthorization of the surface transportation law and a long-term, stable funding solution are viewed universally as matters of high national importance. To accomplish that, we will need to work with non-traditional allies to deliver a message from the grassroots up that transportation infrastructure in not only the backbone of our national economy, but also the Main Street economy. You cannot have the number one economy in the world with the 23rd rated infrastructure, and you cannot run a successful business and create jobs on Main Street if it takes too long and costs too much for your customers to get to you.
Q.
How can individual aggregate operators help spur transportation reauthorization? There are a couple of ways for individual aggregate producers to really make a difference. The first is to support NSSGA with both membership dues and contributions to ROCKPAC. Doing so will help the association be well positioned and equipped to be the most effective advocate for the aggregates industry. For our current members, renew for 2014 and grow your support for ROCKPAC. For those companies who are not current members, join us so that we can fight more effectively for you. The second thing that individual companies can do is to make the most of an invaluable and irreplaceable strength they already have. There are aggregates companies doing business in every congressional district across this country. Aggregates producers and the manufacturers and service providers who support them are strongly rooted, respected members of the communities in which they are based. The jobs they provide are key to local economies from coast to coast. Leveraging that and engaging other businesses in delivering a
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PULL-OUT GUIDE by Mary Foster, Contributing Editor
OPERATIONS ILLUSTRATED M o b il e E q u i p m e n t M at c h u p s
Technology has taken out much of the footwork and guesswork.
Loaders and trucks must match material, mine layout, production, and each other.
Properly trained operators have skills and understand goals.
It all starts with plant production rates.
OPERAT 1
Matchup starts at the processing plant
Balancing Production and Equipment Utilization
T
he machine-to-machine matchup of haul trucks to loading units — whether the latter machines are wheel loaders, excavators, or even shovels — is important from the standpoint of using the correct loader or the correct truck bed size, for instance, to allow for proper spotting and load distribution. But why does it really matter if the capacities of these vehicles match? The starting point and reason for mobile machine matchups should ultimately be the production rate of the processing plant. If a loader is undersized for the haul truck fleet, too many loading passes will cause subsequent trucks to line up, waiting for their loads. Similarly, if the trucks are undersized or there are too few trucks, the loader must wait between vehicles. Idling equipment wastes fuel, and bottlenecks at the face, slowing production right from the start. “We generally start with the feed rate for the processing plant and work backward from there to make sure our haul trucks and loadout are properly matched,” says Dennis Hunter, regional equipment manager for the Pacific region of Knife River Corp. “We also look at the site plan, looking at how far away the equipment is loading from the plant. If we’ve enhanced production flow one year, we may see the support equipment can’t keep up. If the support is causing bottlenecks, we might add a truck, or we might upsize.” AGGREGATES MANAGER
Working back from the plant feed rate, Don Gengelbach, equipment manager for Mulzer Crushed Stone, says haul distance from the face to the primary is another major factor when determining truck size and numbers for the fleet. Site studies are a great help in determining mobile equipment needs, he says. “At one time, there was a lot of footwork involved in calculating distances. Now, almost all suppliers have software that will map out your site and calculate distances. It makes it all a lot easier.” Hunter says equipment managers rely on the “boots on the ground” personnel at each site to help them assess whether existing mobile equipment is meeting the plant’s production needs. Since inexperienced operators can hurt loadout and haulage from a skills standpoint — as well as have a lack of understanding about the operation’s overall production goals — Knife River has invested in operator training. “Loader and truck operators can have as much as a 15 percent to 30 percent impact on production. In fact, I’ve seen as much as a 40 percent impact,” says Tim Noon, senior marketing training consultant for Caterpillar, Inc. “It’s better to train, train, train your operators, and know they will make sure the equipment produces what it’s capable of producing. There’s no such thing as a spare truck anymore. You have to be able to produce what you need when you need it.”
The process of matching mobile equipment is a balancing act that begins with production capability and feed rate for the primary, working backwards from that point. Undersized loaders and trucks slow production as the plant waits on material. Oversized mobile equipment will drive up capital and operating costs, due to idling equipment.
4
Estimation for utilization
Producers must take into account the number of hours each unit will work, as well as what the availability and utilization will be, setting aside time for scheduled maintenance. Other considerations include the machine’s estimated longevity from any given point. Also, will material characteristic or mine layout changes require a new unit or modifications (attachments, beds, etc.) to existing units?
TIONS ILLUSTRATED Mobile Equipment Matchups 2
A sum of all parts
3
OUR EXPERTS
Mine plan plays a role
Don Gengelbach is equipment manager for Mulzer Crushed Stone. He started his career with Mulzer in 1982 as a welder. He has worked for Mulzer in the positions of mechanic for the truck repair shop, quarry mechanic, and quarry supervisor, prior to becoming equipment manager. Gengelbach has been a certified AEMP construction equipment manager since 2011.
The loading unit and truck must match the type of material being produced, i.e., material weight, density, and shape can affect equipment and attachment choices. The truck must match the loading unit type or tool. Is the producer loading with a wheel loader, an excavator, or a shovel? The loading unit will also help dictate the size and number of trucks required.
The type and size of mobile equipment in the pit are dependent on the mine plan. How far away is the face from the processing plant? If the primary is closer to the face, smaller equipment units may navigate potentially tight turning loops better than larger equipment. The opposite is true for equipment that must haul material over greater distances, where bigger may be better.
5
6
Replace or rebuild?
Production increases and mine layout changes may ultimately result in upsizing or increasing fleets. Manufacturer software can help producers determine if a like replacement or an upsized machine is in order. Manufacturers also have embraced the option to rebuild machines, which extends lifecycles with less capital outlay. Scheduled rebuilds can help to prevent unexpected downtime.
Operator ability
Perfectly matched loading and hauling equipment — matched to production, to the mine, and to each other — can still be adversely affected up to 30 percent or more by the operator’s ability. Proper training will improve this; however, effective mobile equipment operation lies not just in skill, but also in the understanding of what the producer is ultimately trying to accomplish.
As senior marketing training consultant for Caterpillar, Inc., Tim Noon has been with Caterpillar since 2008. He spent more than three years as a Cat Global Mining continuous improvement application consultant. Most recently, Noon worked on developing the Cat Fleet Production and Cost program. He has a degree from the Pennsylvania College of Technology.
Dennis Hunter began his construction career in 1986 as a heavy equipment mechanic and began working for DSS Co. in 1990. DSS was acquired by Knife River Corp., a subsidiary of MDU Resources Group, in 1999. Hunter took on the role of regional equipment manager for Knife River in 2008. His territory includes California, Alaska, and Hawaii. February 2014
OPERATIONS ILLUSTRATED Voices of Experience Don Gengelbach
I
t
ndustry consolidation allows producers to leverage buying power. According to Don Gengelbach, equipment manager for Tell City, Ind.-based Mulzer Crushed Stone, the company looks at equipment needs across all of its sites annually. Mulzer takes a teamwork approach to equipment decisions, with input from the owner, production supervisor, and Gengelbach. “By using a combination of proprietary and purchased software as a planning resource, and grouping pieces of equipment for quotes, the process is easier than it once was,” he says. Software helps producers make such decisions as whether to upsize or rebuild equipment. “We might have a site that is using three smaller haul trucks, but determine that, for improved efficiency, the site would be better served with two larger haul trucks,” Gengelbach says. He adds that a plant improvement that increases tonnage could dictate the need for upsized or greater numbers of equipment. “Beyond that, for most locations, maximum tonnage is a set number. If you need to produce more or less, you set up single or double shifts of personnel,” he says. According to Gengelbach, the company evaluates each piece of equipment when deciding to repower, rebuild, or replace, to look for the most cost-effective option. But how does this process align with the new Tier 4 engine emission regulations? “We have purchased some new and used equipment in recent years that have Tierclass engines, and in the coming years, we will be buying some new equipment that have Tier 4,” he says. “You have to look at utilization, the cost-effective options, and how strict or lenient your state regulations are. For Mulzer, we still have a large mixed fleet of equipment that is pre-Tier. If we determine it’s more cost-effective to repower or to rebuild the equipment, we’ll do that. If those options don’t make sense, we’ll buy new — which may ultimately be Tier 4.” AggregAtes MAnAger
Tim Noon
“W
t
hen you’re sizing your mobile fleet, you should always start with your production goal,” says Tim Noon, senior marketing training consultant for Caterpillar, Inc. “Is it an hourly production rate? A yearly target? Are you working five or seven days a week? Begin sizing your fleet based on the amount of material you’re producing in the timeframe.” Noon says variables include the type of loading unit, which dictates flexibility in size and number of trucks required. Proximity of the primary plant to the working face certainly affects fleet choices. But producers also should be thinking about the direction the mine will take, and whether land has been acquired and reserves permitted. “There was a time when you could plan for a 10- or 20-year lifecycle on a machine,” Noon says. “But I’ve seen huge changes in the industry over the last 20 years.” Changes such as emission regulations and the tiered engines ushered in to meet increasingly stringent emission levels have made it more difficult for producers to look ahead 10 to 15 years for their fleet requirements. Noon says that engine rebuild capabilities on the manufacturers’ parts have allowed many producers to meet regulations while extending machine lifecycles. “You can generally rebuild a machine for 50 percent to 70 percent the cost of new,” he says. Tier 4 emission regulations are now in effect, but most states have “grandfathered” permission to use lower-tier engines. In fact, until manufacturer inventories of Tier 3 engines are depleted, producers in most states can continue to use them for rebuilds. “Producers need to know that Tier 4 engines have strict fuel quality and maintenance requirements,” says Noon. “There is a level of care that must stay on track so the engine will do what it’s designed to do.”
Dennis Hunter
W
t
hile correct equipment capacities and matches are critical to meeting the feed rate needs for the plant, operator ability is another factor that greatly affects the material flow efficiency, says Dennis Hunter, regional equipment manager for the Pacific region of Knife River Corp. “As a corporation, we started looking at the skill levels of our operators,” he says. “We decided there was a need for training, and we went and had our own operators trained as certified trainers.” What Knife River discovered was that the company began to save money in maintenance costs, equipment availability, machine life, and rebuild opportunities. “When the operators began to work the machines correctly, the equipment didn’t have to work as hard,” Hunter says. “The operation wasn’t jerky and inconsistent. Uptime increased.” The company now completely supports extensive training. The company also went through a proactive and thorough preparation for Tier 4 engine emission regulations. With facilities in California, Hunter says preparing for Tier 4 regulations has been an ongoing battle. “We moved ahead with equipment purchases and rebuilds with higher Tier engines, starting when the regulation was written,” he says. “We didn’t want to get caught in a situation where we were trying to comply late in the game.” While the goal has been to rebuild machines where possible, the company’s push in California has been to purchase new equipment to ensure long-term compliance with the new emissions regulations. “You can rebuild an old unit for 50 percent to 60 percent of the cost to replace. But there’s still a date where that machine won’t be operable,” he says. “With the stricter compliance need in California, we’ve had to look at that date more seriously, and we’ve found that often replacement is the better choice.”
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CalPortland’s Santosh Aggregate Plant continues to scoop up profits in Oregon, one dragline bucket at a time.
by Kerry Clines, Contributing Editor
N
orthwest of Portland, Ore., in the small town of Scappoose, is an area along the Columbia River that is situated adjacent to the Multnomah Channel. This area is rich with deposits of sand and gravel ideal for construction use. It is also the location of CalPortland’s Santosh Aggregate Plant, a sand and gravel operation that has managed to stay very busy during the last few years while other operations were struggling to stay afloat.
The deposit
There are several theories about where the deposits of material in the area came from, but the predominant
28
AggregAtes MAnAger February 2014
theory is that it was originally deposited by the Missoula Floods, a series of floods that occurred over a period of 50 to 60 years at the end of the last ice age. The theory suggests that the floods were the result of sudden breaks in the ice dam of Lake Missoula, a large prehistoric glacial lake formed when the southernmost edge of the Cordilleran Ice Sheet blocked the flow of the Clark Fork River in Idaho. The lake, which covered much of the western part of Montana and the panhandle of Idaho, was 3,000 square miles in size and contained approximately 500 cubic miles of water, about half the water volume of Lake Michigan. During each flood, it is believed that the peak flow rate of the water was as much as 15
PLANT PROFILE
CalPortland’s Santosh Aggregate Plant in Scappoose, Ore., has managed to stay busy throughout the economic slowdown of the past few years.
cubic miles per hour, and that it traveled at a speed of up to 80 miles per hour. The flood would pick up sediment, loess, and basalt found in Montana and Idaho and deposit them along the Columbia River Gorge in Oregon and Washington and throughout the surrounding valleys as it rushed toward the ocean.
The operation
“This facility has been around since the 1960s,” says Gene Northway, plant manager. The operation originally used a clamshell dredge to mine the area, but it wasn’t very
successful. Other types of mining techniques were also tried — yarders, sourman buckets, and long-hoe excavators — but none were very successful, so the decision was made to use a dragline. “In the ’90s, we purchased a used Marion dragline with a 16-yard bucket,” Northway says. “By dragline standards, it’s kind of midsized. It makes the small ones look tiny and the big ones look huge. The dragline allowed us to complete a lot of the mining out there that we hadn’t been able to do before.” A big part of the machine’s time is spent doing preparation work. The dragline
excavates the overburden, most of which is underwater, down to gravel. Then it excavates the gravel and places it where the overburden came out to create a bench area so that the dragline can move to that spot to dig. The rest of the machine’s time is spent digging production rock. The dragline has a hoist cable and a drag cable. The operator swings the bucket out with the teeth of the bucket facing downward and drops it into the water. Once it hits the bottom, the operator pulls on the bucket to fill it up. When the bucket is full, the operator pulls it in until it is fairly close AGGREGATES MANAGER February 2014
29
In the ’90s, CalPortland purchased a used Marion dragline with a 16-yard bucket. The dragline allowed the plant to complete much of the mining that couldn’t be accomplished with other mining equipment. to the shore. Then he lifts it out of the water and dumps the material into a spoil pile. A front-end loader scoops up the material from the pile and loads it into the
haul trucks, which carry it to a belt feeder. The belt feeder feeds the material onto a 48-inch-wide, 4,500-foot-long overland conveyor, where it dumps the material on-
to another 1,200-foot-long conveyor, and then another 2,200-foot-long conveyor. The conveyor system eventually carries the material to a portable processing plant that has been set up in a permanent location. The processing plant has a 6 x16 vibratory screen and a jaw crusher. Larger material is sized through the screen and moved to a stockpile area. There, it is either stockpiled or sent on to a tunnel where it goes up a series of conveyors to a screening tower. The screening tower has two screens — a 7x20 JCI and a 7x20 Telsmith. At this point, concrete aggregate is pulled out, and sand is filtered through a sump at the bottom of the tower and pumped through a tunnel that goes underneath all of the stockpiles. The sand is pumped through an HDPE sand line that runs out to an underground sand classifier system. At the classifier, the concrete sand can be blended with other products. The
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Plant Profile
Material can be run directly to the barge loadout from the tunnel or the additional hoppers.
have three barges actively in use and one that is only used periodically. Two are sister barges, nearly identical, with just a few features that differ. Depending on water level, each will hold between 2,000 and 2,100 tons of material. The third barge holds 3,000 to 3,100 tons of material.” A program in the computer tells the barge loadout operator which product is required and which feeder to run, so all he has to do is punch a button and make small adjustments. The operator can control the flow of the material if the wind is blowing. A series of cables running along the dock attach to the vents on the barge, allowing the loadout operator to pull the barge back and forth during the loading process. The plant employs three tug boat companies to push its barges. All of the barges are self-unloading hopper barges with a conveyor that swings out to the side. When the barge arrives at its destination, material is dumped from the bottom of the hoppers onto the conveyor and is offloaded onto a series of conveyors onshore.
Unique challenges
The self-unloading hopper barges feature a conveyor that swings out to the side. Upon arrival at its destination, the swing-out conveyor feeds the material onto a series of onshore conveyors. tunnel system is also used for blending. Seventeen feeders allow the operation to blend different materials to produce an assortment of products. “The crushing plant produces four sizes of material — quarter minus, half to quarter, inch and a half to three-quarter, and threequarter to half,” Northway explains. “The crushing plant has the capacity to recirculate loads, so when we’re long on inch and a half,
we can shut it off and recirculate it through the system.” Though the operation ships some of its product by truck, a vast majority of the material leaves by barge. “Material can be run directly to the barge loadout from the tunnel or the addditional hoppers,” Northway says. “We have a barge canal that comes in off the Multnomah Channel, which feeds directly out into the Columbia River system. We
“There are some unique aspects to what we do here,” Northway says. “For one thing, there aren’t many facilities that do the majority of their mining underwater. Mining underwater with a dragline is a whole different type of operation. There’s no delineation between some of the pits because it’s all water.” The dragline is electric, so a sub-station is located right on the property. The electric cable is a certain length, so moving the dragline from one location to another can be a bit of a challenge. During one particular move, the dragline was walked out as far as the cable would reach and was shut down. The substation was then relocated, the dragline was hooked up again, and moved the rest of the distance. Conveying wet material is also challenging. “It’s not like pushing it down the side AggregAtes MAnAger February 2014
33
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of a slope with a dozer or picking up dry material and throwing it in a hopper,” Northway says. “All of the material comes up wet on the conveyors. Plus, it rains nine to 10 months out of the year, so we have to work with wet material all the time. It’s like trying to convey water at times.”
Staying busy
depth, which isn’t as deep as the operation’s permitted depth of 150 feet. But for now, all of the prep work and digging is done with the dragline. AM
Equipment List
“We’ve actually been very fortunate during the economic downturn, particularly over the last three years, to have a fair amount of work out of this facility,” Northway says. “We’re supplying the lion’s share of the concrete aggregate for a large project in Hillsboro.” There has also been quite a bit of work going on at the Portland airport. The Santosh plant specializes in that type of work and has been supplying rock to the airport for both asphalt and concrete paving. Northway says they will eventually go back to using a dredge at the plant, but it will be a cutter-head dredge rather than the clamshell dredge that was originally used at the plant. The dragline can only reach a certain
Cat 992D wheel loader
Telsmith 57 cone crushers (2)
Cat 988F wheel loaders (2)
Universal 3042 jaw crusher
Cat 988G wheel loader
ISC 82 vertical shaft impact crusher
John Deere 450 excavator
JCI 8x20 horizontal screens (4)
Cat D400 haul trucks (2)
JCI 7x20 horizontal screen
John Deere 300D haul truck
Telsmith 7x20 incline screen
Cat 980H wheel loader
Cedarapids 6x20 incline screen
Cat 1T 24F wheel loader
Simplicity 8x20 incline screen
Marion 7450 dragline
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Cat D9T dozer
JCI 6x16 incline screen
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48-inch overland conveyor (8,200 feet)
John Deere 770B motor grader
150-foot radial stackers (3)
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NSSGA Member Text INFO to 205-289-3782 or visit www.aggman.com/info AggregAtes MAnAger February 2014
35
Jaw crushers often serve as the primary crusher in a stationary application, but to ensure maximum production, the feed must be the right size for the application.
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AggregAtes MAnAger February 2014
EquipmEnt managEmEnt
Proper care — and application — will keep your primary jaw crusher properly feeding the production cycle. by Michelle Cwach
W
hen it comes to maintaining a jaw crusher and securing the most uptime possible, the key is to develop a proactive preventive care program and become properly trained on the equipment, according to industry expert Wade Lippert. Lippert, a field service representative for KPI-JCI and Astec Mobile Screens, has been servicing aggregate equipment for 25 years. In his years of experience, Lippert says he often comes across tunnel-visioned producers who are solely focused on one specific part of an operation — like how large material can be and still be fed into a crusher. What they should be concerned about, Lippert says, is how much production can be achieved and the best way to achieve it. That all boils down to maintenance and education. “There has to be investment in a comprehensive maintenance and training program,” Lippert says. “Too often, I am told how much downtime a producer is experiencing and how much that downtime is costing them, and yet I find they are not taking care of the equipment. Investment in maintenance is considered an operating expense that can affect your bottom line, positively or negatively.” But maintenance is far more extensive than just greasing bearings and miscellaneous “housekeeping,” Lippert says.
“If you purchase a piece of equipment, you expect a certain amount of longevity in the equipment,” he says. “This applies to anything you buy. If you purchase a vehicle, you need scheduled maintenance like fluid changes, tire checks, and, yes, housekeeping. If these basic practices are not performed, the vehicle will fail you, as well as affect the resale value dramatically. These fundamentals in vehicle maintenance are understood by most and considered common sense. The same fundamentals can be applied with crushing equipment, but with much more attention to detail.” Because of the violent nature of a jaw crusher, the equipment — regardless of application or manufacturer — will fail at some point without preventive care. But a proper maintenance program can help producers avoid costly breakdowns by repairing problems in their infancy. This could be something as minor as a loose or missing bolt, a broken weld, a loose belt, or a buildup of material that is allowed to remain, Lippert says. When taken care of daily, they remain small issues that can be immediately resolved to avoid downtime, but, over time, they can affect the longevity of the equipment. Factory training and education goes hand-inhand with a preventive care program in extending the lifespan of a piece of equipment. While new technology can greatly enhance the efficiency of an operation, it can also add a challenge to those who have not been exposed to it. AggregAtes MAnAger February 2014
37
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EquipmEnt managEmEnt “There is often a fear associated with new technology, and the fear provides lack of understanding in how the equipment works,” Lippert says. “But if proper training and education is provided, the fear disappears and is replaced with an understanding of how the equipment functions. Technology can either be friend or foe. Become educated, and it will profit you. Cling to ignorance, and technology will eat your lunch.”
Keep fines manageable
Although too large of material can cause problems for the producer, too many fines can also affect crushing performance. An excess of fine material will fill in all of the voids, which are necessary for the material that is being crushed to expand into. This creates an event called compaction. Compaction amplifies the forces in the crush-
Avoid oversized feed
To establish a preventive care program that will extend the lifespan of a jaw crusher, producers must go beyond greasing bearings daily and consider the application of equipment. Although daily greasing is vital to a jaw crusher’s survival, it’s only part of a much bigger picture, Lippert says. “The way the jaw crusher is applied is as important to maintaining the jaw as a good grease interval,” he says. “The jaw crusher is most often the primary crusher in a quarry or recycling operation. It is asked to perform the first stage of crushing, which can be the most difficult stage of product reduction. However, it is too often misapplied by feeding too large of material. This creates loss of production and the potential to damage the crusher.” Every producer seeks high production in order to achieve the best bottom line, but when oversize material is fed into the crusher, the opposite can occur, Lippert says. “Oversize material can cause what we call ‘black belt,’ which is essentially caused when an oversized rock is introduced into the jaw, but is too large to fit into the chamber,” he says. “This causes an interruption in crushing, which equals no production. It also imposes stress to the crusher as the rock is pounded against the area of the pitman known as the pitman barrel, which is where the shaft and bearings are located. Pre-sizing material is vital to providing the proper feed and achieving high production. A general rule of thumb is to keep the maximum feed size under 80 percent of the jaw opening or gap as measured from the top of the stationary die to the top of the moving die.”
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AggregAtes MAnAger February 2014
39
When oversized rock is introduced into the jaw, but is too large to fit into the chamber, it creates an interruption in crushing, which equals no production. Presizing material is vital to providing the proper feed and achieving high production.
ing chamber, up to five times the normal crushing forces. As with any force that is generated, the energy must find a point of release, which is usually in the jaw base structure or in the shaft and bearings. Over time, this can cause damage, Lippert says. Excessive amounts of fine material also limit production because these fines are taking the place of otherwise crushable larger rock. Compaction can also be caused by improper use of the jaw die or plates. The corrugations of the jaw dies are crucial to the jaw performance, as the corrugations provide the expansion room needed as well as the leverage required to break the rock. Jaw dies should be flipped or replaced once the remaining corrugations get to about 20 percent of their beginning dimensions or irregular wear is detected. The wear of a jaw die should be gauged by the
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Pictured is a brandnew jaw die. Jaw dies should be flipped or replaced once the remaining corrugations get to about 20 percent of their beginning dimensions or irregular wear is detected.
remaining corrugations at the bottom, not the overall weight of the jaw die itself.
Aim for attrition crushing
If the proper feed size is introduced into the jaw and the jaw die maintenance is performed as recommended, the result will be a higher output, and true attrition crushing will take place. Attrition crushing, or rock-on-rock crushing, helps with output gradations and improves wear cost for the producer, as more of the wear takes place on the rock rather than the jaw dies. As with all crushers, the maintenance of a crusher depends on how it is applied and taking a proactive approach to maintenance items like wear parts. Replacing wear parts before they
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EQUIPMENT MANAGEMENT Minor maintenance issues such as loose bolts can affect the longevity of equipment when not resolved immediately.
are worn out costs less and improves the crusher’s performance, ultimately saving money, increasing uptime, and providing crusher longevity, Lippert says. Although the fundamentals of jaw crusher maintenance apply to all jaw crushers, it is important to consider each scenario according to each specific producer when it comes to preventive care, he adds. “Every producer needs to consider what he can do to improve his situation by adding to or developing a program that will work for his specific needs,” Lippert says. “Every customer is unique in that there are no two identical applications, both in material and in people themselves. But there are similarities that can be the foundation for building a good maintenance
A proper maintenance program can help producers avoid costly breakdowns by repairing problems in their infancy, such as material buildup. This photo, which was taken after buildup was removed, shows the effects of material buildup.
program, so it is important to remain flexible. Keeping an open mind to suggestions may save you money and make you more profitable. It also serves as a morale booster to the employees asked to operate and maintain the equipment, and maintaining good employees will help in assuring that proper maintenance is being performed. “In short, investment in maintenance is both a financial and a personal commitment to man and machine, which translates to a positive work environment and a profitable bottom line.” AM Michelle Cwach manages the communications and media relations for KPI-JCI and Astec Mobile Screens. She can be reached at 605-6682606 or michellecwach@kpijci.com.
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Rock Agency expands its use of Section 103(k) orders as the Commission broadens the definition of accident. by Kristin R.B. White
MSHA
TAKES CONTROL S
ection 103(k) of the Federal Mine Safety & Health Act of 1977, 30 U.S.C. § 801 et seq., (the Mine Act), provides the Mine Safety and Health Administration (MSHA) with a broad grant of authority to assert control over mine sites in critical accident situations. The Federal Mine Safety and Health Review Commission, which adjudicates contests of orders and citations under the Mine Act, has recognized that orders issued under § 103(k) of the Mine Act are “the means by which the Secretary may assume initial control of a mine in the event of an accident, in order to protect lives, initiate rescue and recovery operations, and preserve evidence.”
Kristin R.B. White is a member in Jackson Kelly PLLC’s Denver office, where she practices with the Occupational Safety and Health Practice Group. She can be reached at 303-390-0006 or via email at kwhite@jacksonkelly.com.
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AGGREGATES MANAGER February 2014
Section 103(k) states as follows: In the event of any accident occurring in a coal or other mine, an authorized representative of the Secretary, when present, may issue such orders as he deems appropriate to insure the safety of any person in the coal or other mine, and the operator of such mine shall obtain the approval of such representative, in consultation with appropriate State representatives, when feasible, of any plan to recover any person in such mine or to recover the coal or other mine or return affected areas of such mine to normal. Based on the statutory definition, the Sec-
retary’s authority to issue a § 103(k) order is predicated upon the occurrence of an “accident” at a mine. However, defining what constitutes an “accident” for purposes of § 103(k) has proven elusive. There must be a limit to the Secretary’s authority to issue a § 103(k) order to an operator, but that limit has not been clearly defined. The Mine Act includes a general definition of “accident” in § 3(k), which states that “‘accident’ includes a mine explosion, mine ignition, mine fire, or mine inundation, or injury to, or death of, any person.” This definition, however, is exceedingly broad and, by its nature, open-ended. And as a result, a trend has developed in which MSHA routinely asserts its authority under § 103(k) into situations that do not involve what most operators would consider an accident. In furthering this trend, the Commission recently affirmed MSHA’s authority to act under § 103(k) regarding “events that are similar to, or have a similar potential for injury or death” as the events specifically listed in § 103(k) in Revelation Energy, LLC, Docket No. KENT 2011-71-R (Nov. 20, 2013). Revelation Energy involved an instance where a large rock travelled off a mine site after a blast and landed in a residential yard, with no injuries resulting. MSHA issued a § 103(k) order, which stated that it was intended “to
ROCKLAW
protect the safety of all persons on mine site and off mine site.” The operator contested the order, arguing that the event at issue did not constitute an “accident” for purposes of § 103(k). The operator argued that the event fit neither the definition of “accident” in the reporting regulations at 30 C.F.R. Part 50 nor the Program Policy Manual. The operator further argued that by not limiting the Secretary to the definitions of “accident” in her regulations and Program Policy Manual, the Secretary could justify a 103(k) order with an “ad hoc definition of ‘accident.’” The Commission affirmed the ALJ’s decision upholding MSHA’s order issued under § 103(k). The Commission held that the plain meaning of “accident” in § 3(k) includes more than the specific events enumerated in § 3(k) and that the scope of § 3(k) is ambiguous. As a result, the Commission accorded deference to the Secretary’s interpretation of “accident” as events that are similar in nature to or have a similar potential for injury or death as a mine explosion, ignition, fire, or inundation. Here, the launching of the rock took place inside of the mine and, based on the Secretary’s
definition, amounted to an accident occurring in a mine because the blast that unexpectedly caused a large rock to enter a nearby residential yard had the potential to cause injury or death. The Commission also distinguished the definition of accident in § 50.2(h) and § 3(k) of the Mine Act by holding that the definition of accident in § 50.2(h) was narrower in scope and limited to the terms used in Part 50 of MSHA’s regulations. However, the term “accident” was not similarly limited in § 3(k) of the Act. The Commission’s decision upholding the issuance of the § 103(k) order has served to expand MSHA’s authority under that provision. The use of such orders in instances that may not qualify as accidents has enlarged the types of incidents that may give rise to such an order. As a result, this broad scope allows MSHA to control areas that may have had nothing to do with the incident at hand. If MSHA issues a § 103(k) order, operators must evaluate whether the incident resulted in an “accident” as that term is being defined by both MSHA and the Commission. AM
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AZFAB LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.azfab.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Beka-Max of America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.beka-lube.com. . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Bill Langer - Research Geologist . . . . . . . . . . . . . . . . . . . . . . . . . . .www.researchgeologist.com . . . . . . . . . . . . . . . . . . . . . 46 Breaker Technology, Inc., an Astec Industries Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.rockbreaker.com . . . . . . . . . . . . . . . . . . . . . . . . . 43 C.L. Dews & Sons Foundry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.dewsfoundry.com . . . . . . . . . . . . . . . . . . . . . . . . . 46 Caterpillar, Inc... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.cat.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Columbia Steel Casting Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.columbiasteel.com . . . . . . . . . . . . . . . . . . . . . . . . .BC Deister Machine Co., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.deistermachine.com . . . . . . . . . . . . . . . . . . . . . . . . 4 Elgin Sweeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.elginsweeper.com. . . . . . . . . . . . . . . . . . . . . . . . . 16 Flexco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.flexco.com. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FMI Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.fminet.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hillhead 2014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.hillhead.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Hyundai Construction Equipment . . . . . . . . . . . . . . . . . . . . . . . . . .www.hceamericas.com . . . . . . . . . . . . . . . . . . . . . . . . . 15 Kleemann, A Wirtgen Group Co. .. . . . . . . . . . . . . . . . . . . . . . . . . .www.wirtgenamerica.com. . . . . . . . . . . . . . . . . . . . . . . 27 KPI-JCI, Astec Mobile Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.kpijci.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Kruse Controls, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.krusecontrols.com . . . . . . . . . . . . . . . . . . . . . . . . 46 Laser Technology Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.lasertech.com/aggman. . . . . . . . . . . . . . . . . . . . . 41 Liebherr-America, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.liebherr-conexpo.com. . . . . . . . . . . . . . . . . . . . . . IFC Loadrite North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.loadritescales.com . . . . . . . . . . . . . . . . . . . . . . . . . 7 Loup Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.loupelectronics.com . . . . . . . . . . . . . . . . . . . . . . . 40 Major Wire Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.majorwire.cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP Martin Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.martin-eng.com . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Martin Sprocket & Gear Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.martinsprocket.com . . . . . . . . . . . . . . . . . . . . . . . 32 McLanahan Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.mclanahan.com . . . . . . . . . . . . . . . . . . . . . . . . . . IBC McLanahan Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.mclanahan.com . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Met Pro Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.metprosupply.com . . . . . . . . . . . . . . . . . . . . . . . . 34 Metso Minerals Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.metso.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Midwestern Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.midwesternind.com . . . . . . . . . . . . . . . . . . . . . . . 39 Natural Resource Partners LP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.nrplp.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 NSSGA 2014 Convention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.nssga.org. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Phoenix Process Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.dewater.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Polydeck Screen Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.polydeckscreen.com . . . . . . . . . . . . . . . . . . . . . . . . 9 Pugmill Systems, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.pugmillsystems.com . . . . . . . . . . . . . . . . . . . . . . . 46 Resource Erectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.resource-erectors.com . . . . . . . . . . . . . . . . . . . . . 47 Sennebogen LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.sennebogen.com . . . . . . . . . . . . . . . . . . . . . . . . . 10 Sweet Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.sweetmfg.com . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Telsmith . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.telsmith.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Terex Minerals Processing Systems. . . . . . . . . . . . . . . . . . . . . . . . .www.terexmps.com . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Terrasource Global. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.terrasource.com . . . . . . . . . . . . . . . . . . . . . . . . . . 47 United Employment Assoc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.unitedemployment.com . . . . . . . . . . . . . . . . . . . . 46 Volvo Penta. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.volvopenta.com/industrial . . . . . . . . . . . . . . . . . . . 2
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Experience: Retired November 2011 following 41 years with the U.S. Geological Survey • 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 Services Offered: Applied geology and geological research for construction rocks and minerals, with an emphasis on aggregates. • Resource evaluation • Non-technical writing • Expert testimony • Conflict assessment • Technical writing and review • Lecturer Contact me at:
Bill_Langer@hotmail.com www.researchgeologist.com
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Jeffrey Rader®, a brand of TerraSource™ Global, is a leading manufacturer of crushers, feeders, conveyors, and other equipment for the aggregates, coal, and mining industries. Our line of electromagnetic, electromechanical, and brute force vibratory feeders are unsurpassed in quality, durability, and output. With unit capacities of up to 2,500 TPH and one of the quickest delivery schedules in the industry, we can build and ship your equipment when you need it and guarantee it to work. Contact us today for more information. We also offer market-leading equipment and systems for ... Screening & Processing Size Reduction Material Handling Storage & Reclaim Pneumatic Feeding
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Handling a World of Materials
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by Bill Langer
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
In Stone
MEET ME IN St. Louis
From the land of Lincoln to the Gateway Arch, Route 66 highlights interesting insights into history.
A
s we continue our trip along old Route 66 from Chicago, Ill., to St. Louis, Mo., we pass through Springfield, Ill., home of Abraham Lincoln. A side trip to see the associated historical sites is certainly in order. Further down the road, we can hop off the interstate at Litchfield and experience the nostalgia of three miles of original Route 66 ‘Mother Road’ highway; then off down the road to St. Louis, Mo. — our destination for today. About 15 minutes east of St. Louis, we come to the Cahokia Mounds State Historical Site. A great civilization of Mississippian people lived here during ancient times. In A.D. 1150, the population of Cahokia was about 15,000 making it one of the greatest cities of the world — comparable to the populations of London or Paris at the time. Cahokia began to decline after A.D. 1200 and was abandoned more than a century before Europeans arrived in North America. Maintaining the houses, stockade, and residential and ritual fires of the community would have required the annual harvesting of thousands of logs, and some scholars believe that deforestation and over-hunting were causes for its decline. I’ll drive as we travel along I-55 so you can gaze around as we cross over the Mississippi River into Missouri. The Gateway Arch is about half a mile upriver, but don’t be distracted. If you look over the rails, you can see dozens of barges moving up and down the river. Barge tows operating above St. Louis on the upper Mississippi, and on the Ohio and Illinois Rivers, must pass through locks so they are restricted in size to 15 barges; three across and five long. Barge tows headed downstream from St. Louis can be much larger because they have no locks to navigate. A typical tow consisting of 40 barges lashed together, eight wide by five long, can carry a whopping 60,000 tons of cargo, the equivalent of six 100-car unit trains, or 2,400 large semi-trucks. The Mississippi has been used to move goods long before the towboats and barges we see today. For example, the inhabitants at Cahokia, the place we visited on the way here, maintained trade along the Mississippi with communities as far away as the Great Lakes to the north and the Gulf Coast to the south. A wide range of bulk commercial commodities travel up and down the Mississippi River. Fertilizer from Florida goes upriver to grow the grain that comes down river. Salt from Louisiana is used on northern winter roads. Cement goes downstream for construction in Gulf Coast states. Other bulk commodities include ammonia, caustic soda, coal, molasses, pipe, slag, steel, twine...the list goes on and on. My favorite commodity — the 60 to 70 million tons of sand, gravel, crushed stone, and building stone that are shipped on the Mississippi Waterway every year. Most of the aggregate comes from aggregate operations located along the Mississippi and its tributaries. Let’s take a side trip a few miles downstream to visit one of those quarries that started in 1882 to make crushed stone for the Corps of Engineers river levee program. The limestone from this quarry comes from underground mines engineered for the final after-mining use of climate-controlled warehouses. The constant year-round temperature within the finished underground space is between 65 and 72 degrees, providing tenants with utility savings of up to 70 percent. Pretty cool! I hate to leave, but we’ve got lots more This artwork, by Michael Hampshire, depicts community life in Cahokia and is used with permission from the Cahokia Mounts State Historic Site. to see along old Route 66. AM
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AGGREGATES MANAGER February 2014
PROCESSING SOLUTIONS To make a buck in today’s challenging marketplace, you need to be more efficient and productive on every ton you process. At McLanahan, we’ve built our reputation on helping customers do more by custom engineering safer, simpler and smarter processing solutions – all with your bottom line in mind. Family-owned since 1835, McLanahan has experienced engineers on staff ready to solve your dry or wet processing needs. Our team is committed to helping you do more.
Joe Adams
Director of Safety McLanahan
Rob McGee
Director of Continuous Innovation McLanahan
Scott O’Brien
Director of Process Engineering McLanahan
Visit us at Booth 51756
mclanahan.com Text INFO to 205-289-3782 or visit www.aggman.com/info
Text INFO to 205-289-3782 or visit www.aggman.com/info