Yo u r
g u i d e
t o
p r o f i t a b l e
p r o d u c t i o n
February 2016 | www.AggMan.com
21 26 40
Achieve better fragmentation
15 tips for a healthy undercarriage Worker endangerment initiative could lead to more criminal prosecutions
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Cleaning the undercarriage is one of the most important daily tasks an operator can perform to ensure the life and longevity of the undercarriage.
PAGE 26
On Our Cover: Guernsey Quarry moves toward modernization. Cover photo by Kerry Clines.
Superior Industries has a new technology to maintain level movement when its Telestackers travel.
PAGE 11
TABLE OF CONTENTS FEBRUARY 2016 |
VOLUME 21, NUMBER 2
FEATURE ARTICLES
COLUMNS & DEPARTMENTS
14
Recognition in the Rockies
3 Editorial EPA oversteps when promotng WOTUS.
26
15 Tips for a Healthy Undercarriage
31
Clean and Classified
36
Since Martin Marietta acquired Guernsey Quarry in 2009, quarry employees have turned it into something to be proud of, blazing the trail for recognition and honors.
The undercarriage represents a significant portion of a machine’s owning and operating costs, so protect your investment.
Washing and classifying equipment can solve myriad problems ranging from product dryness to fines recovery.
A New Approach to Gravel Road Repair A linear crusher rehabs gravel roads using onsite material at a fraction of the cost of traditional methods.
4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook. 7 State and Province News A roundup of the latest news in North America. 11 RollOuts Atlas Copco’s FlexiRoc T20 R drill rig, and other new equipment for the aggregate market. 40 Rock Law DOJ and DOL may increase prosecutions of worker safety-related cases through its “worker endangerment initiative.” 42 Advertiser Index See who’s who and where to find their products.
OPERATIONS ILLUSTRATED Optimizing Drilling and Blasting
21
A good shot should improve production and efficiency throughout the plant. Our expert tips can help you achieve that shot.
43 Classified Ads Aggregate industry classifieds. 44 Carved in Stone The Glasshouse Mountains are a geologic wonder.
Track equipment is just for contractors.
WE DISAGREE.
The GT165DF offers up to 40% more class-leading stockpile capacity. Modular top deck suits wide range of applications. Optional heavy-duty apron or belt feeder offers application diversity.
TOUGHNESS REFINED.
Aggregate
Recycle
Construction
Infrastructure
Mining
Loading/Unloading
Energy
www.kpijci.com
February 2016
EDITORIAL
Vol. 21, No. 2
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
aggman.com /AggregatesManager @AggMan_editor
EPA Oversteps on WOTUS
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Online Managing Editor: Bobby Atkinson editorial@aggman.com
Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Linda Hapner production@aggman.com
Construction Media VP of Sales, Construction Media: Joe Donald sales@randallreillyconstruction.com
3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com
Corporate Chairman: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Russell McEwen Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Vice President of Events: Stacy McCants Vice President, Audience Development: Prescott Shibles Vice President, Digital Services: Nick Reid Vice President, Marketing: Julie Arsenault 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 2016. 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.
T
he Environmental Protection Agency (EPA) went too far in its efforts to promote its Waters of the U.S. rule. While that is likely the opinion of many reading this, it’s also the opinion of the U.S. Government Accountability Office (GAO). Specifically, it notes that EPA is bound by Section 718 of the Financial Services and General Government Appropriations Act — which prohibits use of the EPA’s appropriations for unauthorized publicity or propaganda, Section 715 of the same act — which prohibits the use of EPA appropriations for indirect or grassroots lobbying in support or opposition to pending legislation, and Section 401 of the Department of Interior, Environment, and Related Agencies Appropriation Act, 2015 — which also prohibits the use of EPA appropriations for grassroots lobbying. In a letter to Sen. Jim Inhofe (R-Okla.), chairman of the Senate Committee on Environment and Public Works, Susan A. Poling, general counsel for the GAO, writes, “We conclude that the EPA violated the described provisions through the use of social media in association with its rulemaking efforts to define “Waters of the U.S.” under the Clean Water Act during FYs 2014 and 2015… We also conclude that EPA violated the Antideficiency Act 31, U.S.C. § 341(a)(1)(A), as the agency’s appropriations were not available for these prohibited uses.” Two portions of the EPA’s communication campaign included prohibited behaviors. The first was a Thunderclap campaign, which solicited supporters to share its message across Facebook, Twitter, and Tumblr. Once it achieved its support goal, EPA’s message was simultaneously shared across the various platforms. The problem was that, while supporters knew the EPA was behind the message, the estimated 1.8 million members of their social networks did not. The second violation tied to an EPA blog post that contained links to the Natural Resources Defense Council web page and a Surfrider Foundation blog post. Those groups encouraged their members to contact members of Congress in support of WOTUS. The GAO determined that the links in the EPA’s post constituted grassroots lobbying. “EPA’s illegal attempts to manufacture public support for its Waters of the U.S. rule and sway Congressional opinion regarding legislation to address that rule have undermined the integrity of the rulemaking process and have demonstrated how baseless this unprecedented expansion of EPA regulatory authority really is,” Inhofe said in a statement. Indeed. When a public entity uses public funds and employees to influence other public officials, our tax dollars are being seriously misused. Incidents such as this undermine the public’s trust and, ultimately, erode its faith in the political process.
AGGREGATES MANAGER / February 2016
3
DATAMINING Stock Report Company
Ticker
Cemex, S.A.B. de C.V. CRH plc Eagle Materials Inc. Granite Construction Inc. Heidelberg Cement AG LafargeHolcim Ltd. ADR Martin Marietta Materials, Inc. MDU Resources Group, Inc. Summit Materials United States Lime & Minerals, Inc. U.S. Concrete Vulcan Materials Co.
CX CRG EXP GVA HEI HCMLY MLM MDU SUM USLM USCR VMC
Current Value
$4.31 q $26.61 q $54.98 q $38.26 q $75.61 q $9.26 q $126.13 q $17.50 p $16.51 q $55.01 p $46.45 q $86.25 q
52-Week High
52-Week Low
$10.48 $30.95 $88.81 $44.40 $76.94 $15.49 $178.67 $24.01 $28.57 $76.13 $62.82 $106.84
$4.30 $22.52 $53.59 $28.45 $75.15 $8.95 $104.53 $16.15 $16.19 $45.56 $25.02 $65.37
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 1/8/16.
U.S. On-Highway Diesel Fuel Prices 1/4/16
One Week
United States
$2.211
-0.024 q
-0.926 q
East Coast
$2.260
-0.019 q
-0.944 q
New England
$2.344
-0.021 q
-0.943 q
Central Atlantic
$2.391
-0.021 q
-0.912 q
Lower Atlantic
$2.143
-0.018 q
-0.966 q
Midwest
$2.130
-0.033 q
-0.972 q
Gulf Coast
$2.114
-0.026 q
-0.931 q
Rocky Mountain
$2.191
-0.036 q
-0.948 q
West Coast
$2.464
-0.003 q
-0.756 q
West Coast less California
$2.303
+0.011 p
-0.771 q
California
$2.595
-0.014 q
-0.746 q
Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
4
AGGREGATES MANAGER / February 2016
One Year
Aggregates Industry Outlook 150 140
129.05
130.00
130.99
128.42
125.60
122.49
130
127.51
120 110 100
July 2015
August 2015
September 2015
October 2015
November 2015
December 2015
January 2016
In January, the Aggregates Industry Outlook (AIO) rebounded by more 1.52 percent against December, to an overall score of 127.51. The increase came — with cautious optimism — on the heels of the passage of the Fixing America’s Surface Transportation Act, also known as the FAST Act. Adverse weather, however, is impacting some operators.
Comments: Weather may influence the next quarter vs. last year. 2015 never really had a winter rain season. This year looks to be shaping up as a strong rain event. — Keith Severson, Marketing Communications Manager, Graniterock
The spending bill ratified by Congress and signed by the President has potential to create an influx of capital for much needed infrastructure improvements. We’re watching with great interest what is accomplished regionally. — Robert L. Stone, Manager of Sales and Compliance, Hunter Sand & Gravel, LLC
The transportation budget approval will allow farther range planning by DOTs. This should have a positive impact on the industry (stating the obvious, of course)! — Lewis Graham, President, GeoCue Group
AGGREGATES MANAGER / February 2016
5
MARCH 22-24, 2016 MUSIC CITY CENTER | NASHVILLE, TENNESSEE
MAKING GREAT MUSIC TOGETHER in Nashville
Registration Now Open! This year, aggregate industry professionals will come together in Music City USA for the NSSGA Annual Convention and the AGG1 Academy & Expo. Don’t Miss a Beat At the convention, you’ll be re-connecting with colleagues, building new relationships and developing the strategies necessary to rebuild America’s infrastructure to world-class standards. When you attend the convention, you can be
sure your voice will be heard as the plans for our organization and for the future of the industry are developed. Tune Up for Better Performance AGG1 presents a unique opportunity for aggregates industry professionals to enhance their knowledge and expertise, learn about new innovations in equipment and technology and share ideas with their peers from around the country. This is an event you don’t want to miss!
www.nssga.org
To make sure your operation hits a high note, register for the joint show at www.nssga.org. For registration to AGG1 only, visit www.agg1.org.
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
MAINE
CALIFORNIA Planetary scientists are testing a new type of drill, which is intended to look for signs of life deep below Mars’ surface, at a United States Gypsum Co. operation in California. According to the Arizona Science and Innovation Desk, the operation has a 200-foot-thick gypsum deposit, which is similar in strength to cryogenic ice that has formed over millions of years on the polar caps of Mars. Current rovers have only scratched the surface of the planet, but this prototype has a 15-foot cylinder with a 15-inch tungsten bit. The Planetary Deep Drill hasn’t been assigned to a mission yet.
Rockland City Council is discussing the possibility of using quarries for the disposal of demolition debris. According to the Bangor Daily News, the council decided that a top priority would be to see whether it would have an effect on its efforts to get state reimbursement for closing the current quarry landfill. The city manager told council members that it may be difficult to convince the Maine Department of Environmental Protection to allow it to open another landfill in a quarry. The state’s reimbursement program for closing landfills pays up to 75 percent of those expenses.
NEVADA INDIANA Lake County Surveyor Bill Emerson Jr. issued a stop work order on a portion of the Singleton Quarry project. The Times reports that all activity related to stone removal and processing was to stop until the operation received written notice from Emerson’s office. The official told the newspaper that, while the company had submitted a design revision, it had not been approved by his office. The operator is allowed to continue work on construction of a pond.
IOWA A man who sustained injuries at a quarry near Buffalo died from those injuries. According to KWQC, the victim was a contract worker performing work at the Lafarge operation. He was injured when a boom was being lowered, malfunctioned, and fell. The man was under the boom and became trapped. He suffered significant head, neck, and chest injuries.
NEW JERSEY Two neighbors of a granite quarry leased by Freshwater Stone hired a lawyer and asked the local planning board to schedule another visit to the Hall Quarry operation after being asked to leave during the planning board’s initial visit to the site. The Mount Desert Islander reports that Jeff Gammelin, president of Freshwater Stone, told Laurie and Gerald Shencavitz to leave during the first tour because they had previously trespassed on the property. A security camera captured pictures of the couple walking their dog on the site. Gammelin called the police and had the couple charged with trespassing, but the charges were later dismissed. They then claimed that he interfered with their right to attend a public meeting. Both the couple and Gammelin were on hand for the second site visit. As the operator seeks a new quarrying license, noise and abatement plans are expected to be the focus of public hearings.
A hiker, who fell about 50 feet in the Sandstone Quarry portion of the Red Rock National Recreation Area, was rescued by Metro forces. KSNV reports that the man suffered minor to moderate injuries and was lifted out of the Sandstone Quarry by helicopter and transported to UMC. A week earlier, another man fell to his death in the Oak Canyon Ridge area of Red Rock.
NEW JERSEY The borough of Riverdale reached an agreement with Tilcon to renew its 2015-2020 operating license. According to NorthJersey. com, residents sought a property damage guarantee in case of damage to nearby condos, a limit to blasting hours, notification of when blasting would occur, and a “reduction in intensity of the blasting.” There was also discussion of limiting the size of material stockpiles, increasing the reclamation bond from $2.1 to $15.9 million, and charging an extraction fee to cover any damage from blasting. In the end, Tilcon agreed to limit stockpile size, and neighbors said communication improved.
NEW YORK During a session of the state Department of Environmental Conservation to hear concerns about Lafarge’s draft environmental impact plan, Town of Lockport Supervisor-elect Mark Crocker suggested that the operator be required to establish a trust fund to pay for damage to nearby homes that is caused by blasting. The Buffalo News reports that Crocker also said the 243-acre site — which is located opposite of its current quarry — is not zoned for mining. Employees, customers, and a board member of the local chamber of commerce spoke in favor of the operation.
AGGREGATES MANAGER / February 2016
7
Ready whenever and wherever you are. Aggregates Manager Magazine makes it easy to keep up-to-date while you are on the go. Get the latest news in the aggregates industry, along with insight from our award-winning editorial team, through our mobile version of AggMan.com.
Test it out for yourself and subscribe at AggMan.com.
STATE & PROVINCE NEWS OKLAHOMA
WISCONSIN
The Board of Adjustment denied APAC-Central Inc.’s request for a special exception from city zoning on land where it currently operates a quarry. According to Tulsa World, one member of the board of adjustment said that he was uncomfortable approving the request decades before the company would actually mine that area. A spokesman for APAC said he couldn’t comment on whether it would appeal the decision, but that it would continue operations at the existing quarry. APAC can also return to the board of adjustment with another request for a special exception.
A proposed state law could end a long legal fight over Native American effigy mounds in Blooming Grove. The Wisconsin State Journal reports that the bill would force the Wisconsin Historical Society to allow owners of the Wingra Stone limestone quarry to excavate their property to prove whether human remains are buried there. The operator has been mining around the mounds for more than 20 years, and the company disputes the presence of human remains, which would remove them from the state’s registry of protected burial sites. Approximately $10 million to $15 million in minerals lies beneath the mounds.
TENNESSEE Rogers Group paid $1.83 million to the Habitat for Humanity of Greater Nashville for approximately 183 acres of land that is adjacent to 60 acres of vacant land it already owns near its current Whites Creek Quarry, the Tennessean reports. Rogers Group CEO Jerry Geraghty said the purchased land expands the buffer to the existing quarry, and the company has no immediate plans for expansion. Previously, the company nixed plans to relocate its operation underground and across from its current quarry. Danny Herron, CEO of Habitat for Humanity of Greater Nashville, said that, under the sale agreement with Rogers Group, the 183 acres would remain green space above ground, with any future excavation requiring a minimum of a 100-foot buffer from underneath any home. His organization retains enough property to build 100 homes.
WISCONSIN The Village of Sussex board and planning commission approved land-use plan and zoning changes that could pave the way for the development of a 73-home subdivision on 41 acres of land adjacent to the Halquist Stone quarry. According to Lake Country Now, Halquist Stone sold the land to Johansson Farms — which it formed as an independent company 15 years ago — for $286,000. Blasting at the operation is expected to cease within two years, although processing activities are expected to continue.
VIRGINIA Floyd County’s quarry will reopen under new ownership, according to SWVAtoday.com. The quarry, formerly R&S Stone, was closed in spring 2015 following an investigation by the Mine Safety and Health Administration. It has since been sold to Salem Stone Corp., which operates 14 other quarries in Virginia and North Carolina. “We’re in the people business first and the mining business secondarily,” M.J. O’Brien, Jr., Salem Stone Corp. president and CEO, told the news agency. “Our philosophy drives our culture to include safety, environmental stewardship, and involvement of the surrounding communities.”
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Need to find specific rock types to fill that order? Get the the most current information with the 2015 Aggregates Industry Atlas and the Atlas on CD. While the printed version of the Aggregates Manager 2015 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more. The Atlas on CD contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2015 Aggregates Industry Atlas in pdf format.
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Your guide to aggregates operations, locations & ownership
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7 15 23
Equipment investments pick up steam Meet the USGS’ top 25 crushed stone producers What will MSHA’s crystalline silica rule look like?
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To order, visit AggManAtlas.com or call 1-800-430-4540
ROLLOUTS
Your complete guide to new and updated equipment and supplies in the aggregates industry.
by Bobby Atkinson | Online Managing Editor | BobbyAtkinson@randallreilly.com
An upgraded compact, remote-controlled drill rig Atlas Copco has made upgrades to improve its FlexiROC T20 R drill rig. The compact, remote-controlled equipment is said to be more reliable with a maximized uptime. It has a new rig control system with electrical and hydraulic components and a Radio Remote Control. The T20 R has a new cylinder feed in three lengths, a new front-facing feed holder, and better service access. The new engine has a 30 percent higher impact energy and 30 percent higher rotation torque. The drilling performance is also up 40 percent on the new model.
Atlas Copco | atlascopco.com
Enhanced belt tracking on stacking conveyors
Superior Industries has released new technology for its TeleStacker Conveyors that maintains level movement while in travel mode. The new technology allows the telescopic radial stacking conveyer to keep a balanced conveyor structure at all times, which means mistracking is much less likely. The new auto-level technology is now standard on the FD Axle models of the TeleStacker Conveyors that are equipped with PilePro Automation.
Superior Industries | www.superior-ind.com
AGGREGATES MANAGER / February 2016
11
ROLLOUTS
Severe-duty cooling tower motors
Marathon Motors’ new enclosed air-over cooling tower motors are IP56 rated and were designed for harsh environments. The cooling towers have cast iron construction for reduced vibration, as well as internal and external epoxy paint, sealed bearings, T-drains in both endshields, drive-end bearing isolators with shaft slingers, and fully gasketed conduit boxes. The tower motors were made for 10:1 VT or 20:1 CT operation and have Max Guard Class F insulation with Aegis Bearing Protection Rings. The rings are installed internally to protect them from the extreme temperatures and moisture.
Marathon Electric | www.MarathonElectric.com
Intelligent controllers for dust collector operators
FilterSense’s new B-PAC series of Baghouse Performance Analyzers and Controllers help dust collector operators reduce costs, minimize maintenance rounds, eliminate visual inspections, and be up to Environmental Protection Agency and Occupational Safety and Health Administration standards. The controllers integrate and display the status of the process parameters such as filter condition, DP, temperature, air flow, hopper level fan amps, and solenoids. The display means that operators won’t need to make visual baghouse rounds.
FilterSense | www.filtersense.com
Idler rolls for confined spaces
ASGCO’s new One-Sided Slide-lers allow for quicker roll changes. The new product makes it possible to change idler rolls under the conveyor loading skirt area without having to remove any of the adjacent belt idlers. This means the unit can fit in tighter spaces and makes changing rollers much easier. Modularly designed so that an operator can remove the wing and center roll hangers for replacement, it can hold any manufacturer roll in the industry.
ASGCO | www.ASGCO.com
12
AGGREGATES MANAGER / February 2016
THIS IS HOW DEERE DOES BIG. Your ideas carry lots of weight with us. You’ll see them in our expanded line of heavy equipment. And in the customized support you get that’s so critical to high-production operations. Together, we’re building big things.
For proof, visit JohnDeere.com/Big
PLANT PROFILE by Kerry Clines | Contributing Editor
Recognition in the Rockies Since Martin Marietta acquired Guernsey Quarry in 2009, quarry employees have turned it into something to be proud of, blazing the trail for recognition and honors.
M
artin Marietta’s Guernsey Quarry is nestled in the hills and glacial landscapes of southeastern Wyoming on the outskirts of Guernsey, a small town with a population of just over 1,000. The quarry, quite literally, is rife with aggregate deposits. Five geological rock types are being mined at the quarry — limestone, dolomite, quartzite, basalt, and sandstone — which provide a very colorful array of stockpiles. “The geologists have a theory of how all these different deposits ended up together,” says Tim Kuball, plant manager, “but I just say
14
AGGREGATES MANAGER / February 2016
the good Lord put them here.” With so many different deposits, there are just as many pits being mined. Kuball explains that the limestone is used, primarily, for construction materials in Nebraska, and dolomite, which is mined in what he calls the pink pit because of its color, is used for construction materials in Wyoming. The quartzite is used for chip seals and whenever a high abrasion specification is required. It is also in demand as a landscaping material because of its red color. The black basalt is used to make ballast for the Burlington Northern and Santa Fe Railway, as well
as for asphalt and cover coat chips. Sandstone is buckskin colored and, because it is a somewhat soft rock, is used only for landscape material.
Modernizing the operation Guernsey Quarry has been in operation since 1945, but Martin Marietta didn’t acquire it until June of 2009. “This plant has been here for a long time,” Kuball explains. “It’s a good little plant, but she needs some upgrades. We’re in the process of modernizing it, but it takes a while to get everything updated.” “We didn’t put in any automation
Martin Marietta’s Guernsey Quarry, located in southeastern Wyoming, mines five different geological rock formations.
after we bought the plant in 2009,” says Steve Redenbaugh, area production manager. “But we put in a camera at the jaw crusher, so now, instead of three plant operators, there’s just one in the processing plant. We reduced the workforce from 24 to 16, but we’re doing the same tonnages out the gate. We’ve been running between 450,000 and 500,000 tons a year.” Much of the equipment in use at the quarry today was there when Martin Marietta bought it. “The haul trucks are 35 years old,” Kuball says. “Our pit loader is probably nine years old, and our com-
mercial loader is 10 to 11 years old.” Upgrades and equipment weren’t the only things that needed to be addressed when the operation was acquired; it needed a good cleanup and some organization as well. “We’ve done a lot of housekeeping in appearance and a lot of cleanup at this location,” Redenbaugh notes. “We cleaned up old scraps and weeds, got rid of old trailers, and doubled the size of the crew shack. The main thing we’ve done here is to bring the plant up from the 1950s to modern technology. At that time, they were using hand wrenches to change out screens.
Now, they’re doing it with cordless wrenches.”
Daily operations Production starts with two drills — a large downhole hammer drill and a smaller drill. Though the quarry does its own drilling, it hires Buckley Powder to do all the blasting. A small blast shack provides protection for anyone in the area during a blast. After the blast, haul trucks transfer the material to the primary crusher and then to the primary plant. Average total daily production at the primary plant ranges from 350 to 400 tons per hour. AGGREGATES MANAGER / February 2016
15
PLANT PROFILE materials that aren’t good enough for landscaping or concrete. Even the red quartzite is used in asphalt, as evidenced by the rich red color found on many of the interstates and highways in the area. “The previous owners mined different deposits all the time,” Kuball says. “We try not to do that. We go with demand.” Though most of the finished products are shipped by truck, approximately 20 to 25 percent of the finished products are shipped by rail. The rail line runs right into the processing plant so that a 32-car belt train can pull right in to get loaded with material. A train ships out every two or three days.
Being a good neighbor
In the processing plant, oversize material is sent to a surge pile for more processing. Undersize material is screened to remove the fines, and the remaining material is separated into assorted types and sizes and placed in stockpiles.
Although 20 to 25 percent of the aggregate produced at Guernsey Quarry is shipped by rail, the majority is shipped by truck.
Material is sent through the primary jaw crusher and screened. Oversize material is then sent to a surge pile in the secondary plant for more processing. The undersize material is screened to remove the fines, and the remaining material is separated into assorted sizes and placed in stockpiles for use in asphalt and concrete production.
16
AGGREGATES MANAGER / February 2016
At the secondary plant, average total daily production ranges from 200 to 250 tons per hour, depending on the size of the products being produced. The material is fed from the surge pile into the secondary crusher and then sent through a series of screens to remove additional fines and produce the final products. Asphalt products are made from the
“The National Guard station here has been using our material to pave the roads in the base for a long time,” Kuball notes. “We did a training exercise with them on a Saturday and Sunday last year. We opened up the scale, and military engineers came in here, got their materials, and built roads on another site near town.” The quarry supplies material for many of the projects around town. One of the biggest projects for which it supplied thousands of tons of material was the Guernsey Dam just north of town. The quarry also donated money for the scoreboard at the baseball field, donated material for a walking trail, and supplied the funding to build concrete picnic tables that bear the Martin Marietta name at the city park. In addition, large boulders were donated to the city for use as landscaping for the gardens in front of the park building. The quarry also donates money to the county fair every year. Guernsey Quarry participates in the Fourth of July parade every year and is a voting member on the Guernsey Economic Development Committee. “We recently voted to, hopefully, rehabilitate an old historic hotel in Guernsey,” Kuball adds. The quarry opens its doors to the Fire Department for tours. “We, basically, show them the operation and show them where we can help them,” Kuball notes. “The biggest benefit is that, if they are ever called on site, they are familiar with the operation.”
Quarrying + Construction + Recycling 28 – 30 June 2016 Hillhead Quarry Buxton Derbyshire, UK
Seeing is believing...
Hillhead 2016 @hillheadshow #hillhead2016 Follow us now
www.hillhead.com
PLANT PROFILE Community relations and the environment go hand in hand, and the quarry is doing what it can to lessen its impact on the surrounding areas. New fuel and oil storage tanks were installed just a few years ago. The new tanks are double-walled to ensure that no leaks occur. The quarry’s water source is a pond at the bottom of an old mined-out pit. Water is pulled from there and returns there after passing through the processing plant, so none of the used water goes into the nearby river. When there’s plenty of rainfall, there’s plenty of water, but in 2012, drought caused the pond to dry up. When that happened, the quarry had to buy all of its water from the city. Another water source is now available at the bottom of the sandstone pit.
The safety culture “I’ve been doing this for 28 years, and one thing I’ve seen change for the better is the safety culture,” Kuball says. “We call our safety culture the Guardian Angel, and it’s a great thing. We do observations, report on near misses, and the crew submits safety suggestions.” Every morning, Kuball has a safety meeting with the entire day shift. When the swing shift comes in at about 3 o’clock in the afternoon, he has a safety meeting with them as well. Once a month, he has a cookout in conjunction with a major safety meeting that can last up to two hours. He tries to line up guest speakers such as vendors, EMTs, or the Fire Department to come in and talk to the crew about safety. Kuball and Redenbaugh feel that one of the strongest points, as far as safety goes, is that most of the crew grew up together and went to school together in the small Guernsey community. “They all know each other, so they communicate well and watch out for each other,” Kuball says. “When we have a safety meeting, we push pretty hard to get feedback. For the most part, they’re a vocal crew, and if we have an issue, it’s talked about. Sometimes, what’s supposed to be a 10-minute safety meeting will end up being a 20 to 25 minute safety meeting. It’s all good conversation, which is a necessary thing.” Kuball says cross-training is a big
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AGGREGATES MANAGER / February 2016
priority at the quarry. Every employee can perform almost every job at the quarry, except for the new employees. “It takes a little bit of time to get them cross-trained on everything,” he explains. So, when one of the crew is out sick or on vacation, another crewmember can step up and perform the job safely and effectively. When Martin Marietta took over Guernsey Quarry in 2009, a lot of the catwalks and walkways were very narrow, only 24 inches wide, and made out of wood. Three years ago, the catwalks were upgraded. “We took out all the wooden planks and put in regular corrugated catwalk,” Kuball explains. “The majority of them now are 30 inches wide. Wherever you see yellow handrails, that’s where we replaced the catwalks. It’s a very wonderful upgrade.” An employee building was recently installed at the quarry. It includes a big flat-screen television that is used during safety meetings. “We have anywhere from 5- to 30-minute Martin Marietta University safety presentations that we can put on the TV,” Redenbaugh notes. Three years ago, the Rocky Mountain Aggregate District of Martin Marietta developed a quarterly contest in which the quarries compete against each other to get safety points. The participation of the employees — each observation, each near-miss, each suggestion — is worth a given number of points. If an employee is on the safety committee, it’s worth a certain number of points. “I read every one of the suggestions from the crew,” Kuball notes. “It’s meaningful. We pick a winner and that employee gets a $25 Walmart card. Plus, if we win the quarterly district competition, they get a $75 Visa card. We’ve won all of the district competitions so far. This crew is instrumental in that. Safety is an important thing, and they drive that. I’m very proud of that.” Kuball notes that the quarry hasn’t reported a single incident in its nearly seven years of operation thanks, in part, to the Guardian Angel and Gold Star rewards programs. All of the employees contribute to the safety culture.
Recognition All the hard work the employees have put in at the quarry hasn’t gone unnoticed by Martin Marietta. Guernsey Quarry was an Honor Plant Award recipient for 2015. The companywide award, which includes overseas operations, recognizes outstanding achievement in eight areas including safety, operating costs, maintenance practices, appearances, community relations, productivity improvements, innovation, and financial performance. Only 10 quarries companywide received the award in 2015. The award is a first for Guernsey Quarry, but, hopefully, it won’t be the last. “This is a great honor,” Kuball says. “We’ve come a long way over the past three years, and it’s a pretty neat thing to be looked at by Martin Marietta as an Honor Plant.” AM
Equipment List • Reedrill 400CR drill with 4-inch diameter bit • Atlas Copco DM30 drill • Caterpillar 980H loader • Caterpillar 988F loader • Caterpillar 988H loader • Caterpillar 769C haul trucks (3) • Caterpillar 320 excavator • Surestrike SS25 breaker • Nico 60” x 20’ apron feeder • Cedarapids 42” x 48” jaw crusher • Symons 4 1/4’ standard crusher • Metso HP300 cone crusher • Cedarapids 5’ x 14’ two-deck screens (2) • Cedarapids 4’ x 12’ two-deck screens (3) • Cedarapids 5’ x 16’ two-deck screen • Deister 4’ x 14’ triple-deck screen. • Fairbanks 10’ x 70’ truck scale • Lexmark M-3150 remote printer
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PULL-OUT GUIDE By Mary McCaig-Foster, Contributing Editor
February 2016
Drilling & Blasting: Optimizing for Production The shot can create the best fragmentation for the processing plant.
The shot can also create oversize and fine material that adversely affects the plant. Focus on the variables in a drill and blast design that can be changed.
Experienced personnel are critical for optimization and safety.
Feedback from operators can provide clues to how a shot affects production.
OPERAT Drilling &
1
Effects on processing costs
Get Great Fragmentation
T
he goal of drilling and blasting is more than just putting rock onto the ground for the processing plant. Many mine operators do not make efforts to optimize the drilling and blasting process until they run into problems, such as excessive oversize, which requires additional processing maneuvers such as breaking, or an abundance of fines, which can affect crusher wear parts and also creates waste. “The goal with every shot should be to improve production and efficiency in the plant,” says Billy Zimmerman, senior blasting technician for Luck Stone. “It is a balancing act, through shot design, powder factor, and loading techniques — which are 90 percent of how your shot turns out — and fine tuning with timing, to create uniformity in your shot.” The shot will affect the amount and size of material for the plant, and it should be optimized to achieve the best fragmentation size for loading and hauling, for crushing processes, and for helping to meet product specifications at the lowest cost, according to Andrew Heinemann, manager of geology and mine engineering at Benchmark Resources. “Generally, drilling and blasting has the highest effect on the cost to produce the final product,” he adds. Matthew Boatman, president of General Drilling agrees. “Paying for professional drilling and blasting can reap benefits in the processing plant,” Boatman says. “Better drilling and blasting will result in a more AGGREGATES MANAGER
efficient plant. This will improve the production and quality of your material in the plant, and it will lower your costs overall.” Reduced overall mining and processing cost is influenced by the drill and blast design — specifically the drill-hole diameter, drill-hole spacing, type of blasting agent and initiation, subdrilling, stemming, burden width, and timing. These are the variables in a drill and blast design that can be controlled and adjusted to optimize fragmentation at the lowest cost, effectively lowering the overall cost of mining and processing. Heinemann says an important parameter that often is linked to the distribution of explosive energy in the blast is the drill-hole diameter. It controls the distribution of energy in the blast and, therefore, affects fragmentation. “Large diameters are often associated with expansion of drilling patterns; however, large holes intersect fewer in-situ blocks of rock, resulting in more oversized material, especially in the case of jointed rock,” he says. Typically, the drill-hole diameter changes depending on the geology or the type of drill machine. Similarly, changing the bench height (e.g., for a new loading machine) affects all dependent parameters or the fragmentation size of the blast muck pile. Modifying a drillhole diameter, a bench height, or a product size tends to change all other relevant blast design parameters. Comparative calculations in every case allow the designer to determine the optimum cost parameters.
The cheapest cost in making rock is at the face, through drilling and blasting. The better the drilling and blasting process is in an operation, the lower the costs will be due to efficient loading, hauling, and crushing. Poor drilling and blasting practices, however, can increase expenses, as the material will require additional handling to move it through the plant.
4
Reduction of fines
Fines can affect equipment wear and also create waste. The amount of fines generated by a blast is influenced by the explosive properties, priming methods, rock properties, blast geometry, and delay timing on the occurrence and extent of the fracture process. To reduce fines, the proper explosive type, blast parameters, initiation sequence, and charge distribution must be used.
TIONS ILLUSTRATED Blasting: Optimizing for Production 2
Goals of the shot
Typically the goal is to drill and blast in a way that results in optimal fragmentation size. The drill and blast design can affect cost by achieving the optimal drillhole diameter, drill-hole spacing, type of blasting agent and initiation, subdrilling, stemming, burden width, and timing. These are the variables in a drill and blast design that can be controlled.
3
OUR
EXPERTS
Better production rates
The size of the blasted rock affects crushing and screening processes. If the rock is too big, it cannot be loaded efficiently into the hauling and loading equipment, and it cannot be loaded into the crushing equipment. Oversize rock that cannot be loaded must be broken down using either a hydraulic hammer or secondary, small-scale blasting — ultimately increasing production rates and costs.
Communicate
5
6
Experienced, trained personnel are critical to creating the safest and best blast for production. This includes the drill operator. The drilling process is too important to the overall success of the quarry to allow inexperienced employees to operate the drill. The best drill operators are the ones who enjoy what they do, and who will improve their skills over time.
A log of each drill and blast is important to improving the process, and it should include input not only from the designer, driller, and blaster, but also from the plant superintendent or manager and feedback from the haul truck, loader, and processing plant operators. The latter personnel can provide valuable information about how a shot has affected the final product, for future fine-tuning.
For more than 18 years, Billy Zimmerman has been a senior Bblasting technician for Luck Stone, based in Richmond, Va., where he is responsible for blasting and also training of blasting personnel for the company at 16 different plants. Prior to joining the company, he also worked for blasting, explosives and engineering contractors as a blast designer, blaster, sales rep, and tech rep. Zimmerman began his career in 1978 working for the Virginia Division of Mined Land Reclamation.
Andrew Heinemann, manager of geology and mine engineering at Folsom, Calif.-based Benchmark Resources, is a California-registered geologist and mining engineer with more than 20 years of experience in mine planning; engineering; and plant management, operations, and maintenance. Heinemann earned a bachelor of science degree in geology from the California State University, Sacramento, in 1995 and a master of engineering degree in mining engineering from Missouri University of Science and Technology in 2010.
Matthew Boatman, president of General Drilling Inc., graduated from Purdue University in 1997 with a degree in geological engineering. Boatman has been active in the industry his whole life and has been a presenter at NSSGA’s drilling and blasting workshops and AGG 1 since 2004. He has previously served on the NSSGA Young Leaders Steering Committee and the NSSGA M&S Board of Directors. He has also presented on various safety topics for MSHA at both the local and national level.
February 2016
Voices of Experience Matthew Boatman
“T
he cheapest cost to produce rock is at the face,” says Matthew Boatman, president of General Drilling. “It can also be the most expensive, if it produces oversize (materials) or excessive fines.” The value of a good drilling and blasting program is that, while the program may cost the producer a little more up front, the processing plant will be more efficient, which will increase production and improve product quality and overall cost in the end. In addition to putting product on the ground that will sell, the goal of every operation is throughput, notes Boatman. Producers want quick drilling, an effective shot, and the material to be loaded into the primary and sent through the plant to the stockpile. This starts with a good blast design and proper drilling. In order to drill the prescribed pattern correctly, an experienced driller needs to know geology, and needs to be able to detail what was encountered du ring the drilling for purposes of the log, but also so that the blaster has a better idea of any geological anomalies within the shot location. To optimize drilling rates, the drill operator must be a trained expert. The drill must be maintained at a very high level. If the operator is not able to get the hydraulic pressure correct or if the drill bit is worn, for example, the drill operator cannot achieve optimum drill rates. “My value is in providing a good bore hole or blast hole in a timely manner by trained, qualified personnel,” Boatman says. “There is no one-size-fits-all with drilling. You have to have the right people and equipment for each unique situation.”
Billy Zimmerman
P
roduction can be affected by numerous variables tied to drilling and blasting. But geology’s effect on the shot — and ultimately on material flow through the processing plant — is an element that cannot be altered. “Geology is always a factor with the shot,” says Billy Zimmerman, senior blasting technician for Luck Stone. “From the type of rock, to geological seams that can alter the shot — such as a mica seam that can affect the shape of the rock — you always have to take geology into consideration with the blast.” Zimmerman explains that seams of quartz, or dikes of basalt and diabase will affect the shape of rock, creating more pointy, flat, and elongated stone. “There may not be much that can be done with some of these issues,” he says. “And typically, such geology may only be found in one section of a pit, so the answer will be to blend it with other material during production.” Luck Stone handles its blasting in-house, with a professional plant blaster at each location. “We have an associate at each plant who is familiar with that pit and its unique geology. This helps with determining a blast pattern and powder factor combination that will give you a quality shot each time,” he says. Luck Stone also uses 2D face profiling systems, which help the blast designer to determine a perpendicular cross section of the face at each blasthole location and adjust the hole to the correct distance from the face. “We may decide to vary the angle of the blastholes or move the driller back from the wall — all with the goal of creating more consistent burden.” Another geological factor affecting blasting is the presence of water. Zimmerman says the amount of water in each hole affects blast design. “If the holes are dewatered and a packaged explosive product is used to get above any remaining water, you lose 40 percent of the explosive power at the floor elevation,” he explains. “This is why many blasters will use a waterproof gassed emulsion in wet conditions.”
Andrew Heinemann
O
ne challenge producers often face is the creation of fines with the shot. The amount of fines created by a shot is influenced by the explosive properties, priming methods, rock properties, blast geometry, and delay timing on the occurrence and extent of the fracture process. In order to reduce fines, the blaster must employ the proper explosive type, blast parameters, initiation sequence, and charge distribution. A high level of burden with the blast can actually cause crushing, produced by high gas pressures on the walls of adjacent radial cracks, resulting in more fines. Andrew Heinemann, manager of geology and mine engineering at Benchmark Resources, provides these tips to reduce fines with the shot: Drill-hole spacing: If the drill-hole spacing is increased and the burden is kept the same, the fines generation decreases. An increase in burden and decrease in spacing lead to more fines. Drill-hole diameter: If the powder factor is kept constant, increasing the drill-hole diameter typically increases fines. Subdrilling: If subdrilling is increased too much, explosive energy has more time to fragment the rock and more fines are produced. Stemming: Increased stemming length influences the fines generation in three ways: it provides explosive energy more time to work, which can increase fragmentation; it reduces the length of the explosive column, reducing fines; and it can result in more boulders. Powder factor: A higher powder factor can increase the amount of fines. A powder factor that is too low results in oversized boulders. Design for overall blast size and pattern: Having a length-to-width ratio of at least 3.0, if possible, is good practice because the blast must have space to move forward without sealing the back rows of the blast pattern. If a blast pattern row is not allowed to move forward, the explosion gases are trapped in the material for a longer time and unnecessary fines are generated. The bench should be wide and shallow, not narrow and deep. Delay timing: To minimize fines, the rock in front of a row of the blast pattern must be loosened before the next row behind it starts to move to reduce confinement. The rock needs open space to move into. The amount of fines rises when shorter delay times and a greater number of boreholes are used. AGGREGATES MANAGER
AT HOME ON ANY RANGE Wherever the job takes you, our variety of surface crawlers will fit right in. 800-732-6762 www.atlascopco.us
EQUIPMENT MANAGEMENT by John Bauer
It’s recommended that excavator operators dig over the front idlers, which properly transfers the vertical load that can otherwise cause damage.
15 Tips for a
Healthy Undercarriage The undercarriage represents a significant portion of a machine’s owning and operating costs, so protect your investment.
U
ndercarriage maintenance is critical to the overall productivity of a machine. It is the mechanism that gives tracked machines much of their power and stability. It also represents a high percentage of the total operating cost of the machine over its life. Proper maintenance and operation play a critical role in controlling oper-
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AGGREGATES MANAGER / February 2016
ating costs over the life of any piece of equipment. Here are the top 15 maintenance and operating considerations that will help you maintain the health and productivity of your tracked machine.
Proper undercarriage maintenance practices Undercarriage monitoring and upkeep is critical, and there are several basic
maintenance practices that owners and operators can engage in to extend undercarriage life.
1. Daily inspections. Operators should perform daily inspections of their machine’s undercarriage, looking for excessive or uneven wear and damaged or missing components. Check for proper clearance between the
track chain and idler roller. Also, be sure to check the drive sprockets and track pads for damage and wear. These and other wear issues can be indicative of a larger potential problem, or can lead to further damage, and should be addressed immediately.
2. Track tension. One of the most important things to check regularly is proper track tension, ideally while the machine is in actual working conditions. When steel tracks are too tight, it creates added load on contact areas, which can accelerate component wear. A track that is too tight also robs the machine of its power and fuel efficiency, as it actually takes more effort to turn the track. If a track is too loose, it can create instability and potentially cause the tracks to derail, while also causing wear on other components of the undercarriage. Track tension should be checked daily, with the sag adjusted to the OEM-recommended measurement for each machine. If conditions change throughout the day, it would be wise to check track tension as the machine settles into that new working environment. When working in mud, snow, and sandy conditions, the track tension should be checked more often. Material will pack on the undercarriage parts and increase track tension.
3. Keep it clean. It is important to keep the undercarriage clean. At the end of a workday, operators should clean out any mud or debris from the undercarriage. This is particularly important in northern climates where material can freeze inside the track during the winter months. Optional covers and guards are available to help keep the undercarriage clear of ice and debris.
4. Track alignment. Correct track alignment is necessary in order to prevent wear of the undercarriage components. Misalignment problems will affect more undercarriage components than any other issue. Track
A track that is too tight robs the machine of its power, as it actually takes more effort to turn the track.
links, idler flanges, track and carrier roller flanges, sprockets, and rock guards can all suffer from increased wear when the tracks are not properly aligned.
5. Benchmarks and planned maintenance. Equipment owners can better tackle undercarriage costs and needs if they know where they are in the life of their undercarriage. We recommend setting a benchmark — based on the type of environment the machine is engaged in — to measure the undercarriage. Measure the bushings and rollers and, if these components have been reduced to 85 percent of their original diameter, rotate them 180 degrees. Gauging this pace of wear over time will give the equipment owner insight into the life expectancy and wear patterns of the undercarriage.
6. Follow the schedule. Conduct a complete undercarriage inspection in keeping with the manufacturer’s recommendations. More frequent inspections should be performed if the machine is used in conditions that are more demanding than normal. Adhere to routine maintenance guidelines, including oil changes for final drives and checks on undercarriage bolt torques.
Best operating practices Proper operation is just as critical as maintenance when it comes to preventing and minimizing undercarriage wear. Here are several operating considerations that can extend the life of your undercarriage components.
7. Planning and proper training. Proper operating procedures begin before the machine even gets to the operation. Check the ground conditions and the terrain — consider the need to minimize travel on the site, as well as the use of steel tracks or rubber tracks, and the narrowest shoe width possible to meet the required flotation. Most importantly, discuss these things with your operators. It should go without saying, but a properly trained and informed operator will follow best practices and make decisions at the operation that will minimize wear and tear on the equipment. Always make sure that your operators are properly trained, and have the necessary resources — operating manuals, etc. — made available to them.
8. Selecting the right tracks for the job. Knowing which track width is best for the job is an important consideration when it comes to undercarriage health. AGGREGATES MANAGER / February 2016
27
EQUIPMENT MANAGEMENT Track (CELT) works best in low impact/ highly abrasive ground conditions. It has a hardened bushing placed over a standard type track bushing, which results in almost twice the wear life of a standard lubricated track design.
9. High-speed and reverse operation.
Cleaning the undercarriage is one of the most important daily tasks an operator can perform to ensure the life and longevity of the undercarriage.
For firm ground conditions with minimal slope, long tracks are the best fit. With their narrow track gauge and narrow track shoes, they provide high ground pressure and the best traction. When it comes to firm ground conditions with more varied terrain, wide tracks are the preferred track option. Their wide track gauge and wider track
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shoes provide lateral stability in sloped areas. Low ground pressure tracks are the best suited for soft, swampy ground conditions. The wide track gauge and widest possible track shoes ensure lateral stability and the best flotation. Some manufacturers offer lubricated track designs. The Case Extended Life
High speeds can affect the wear rate on pins, bushings, and sprockets; the faster the speed, the faster the wear rate. It’s important to note that wear rate is a function of speed and distance traveled, not just hours worked. Operators should also avoid excessive use of reverse operation. It’s not only a non-productive use of the machine, but it also accelerates bushing and sprocket wear unnecessarily.
10. Wide turns. Counter-rotation, or pivot turns, can cause accelerated wear on the undercarriage. Operators should try to make wider, more gradual turns whenever possible.
AGGREGATES MANAGER / February 2016 Untitled-16 1
1/8/16 8:45 AM
EQUIPMENT MANAGEMENT 11. Alternate turning direction. Continuous turning on the same side can cause accelerated asymmetrical wear. Make every effort to balance the direction of turns throughout the day. If that is not possible, be sure to check for wear more often.
12. Control track spinning. Unnecessary spinning can increase wear and decrease productivity. This can be avoided by decreasing the blade or bucket load.
13. Try to stay on flat surfaces. Another important practice for operators to follow is working up and down on slopes. Constant operation on hills in one direction can accelerate wear to idlers, rollers, and guide lugs by placing greater force on one side. Minimizing time spent on the slope will pay off in reduced wear and load to the undercarriage. Try to stay on relatively flat surfaces. Operating the machine with the outside/ inside edge of the track turned up can cause damage to the edges and lugs of
the rubber track. Avoid traveling with the tracks on uneven ground, or surfaces with obstructions.
14. Digging over the front idlers. It’s recommended that excavator operators dig over the front idlers, which properly transfers the vertical load that can otherwise cause damage. Avoid digging over the sprocket because it can cause bushings to crack or break. It’s also important to avoid digging over the sides of the machine given the additional stress it places on track shoes and the track link assembly.
15. Telematics. At this point in time, most manufacturers offer some type of telematics solution. The critical maintenance and operating data made available through the use of telematics can have a significant impact on undercarriage life, even though no sensors specifically report on undercarriage health. In its most simple form, the reporting hours provided by telematics can be
used to accurately keep up on undercarriage maintenance activities, and also create benchmarks for each specific machine and application based on the conditions they are working in. Fleet managers can also dive down deeper and examine the difference between actual working time and idle time to get a better idea of how much load is placed on the undercarriage everyday. Some telematics systems provide details on ground speed, so owners can monitor track speed, which increases wear and decreases the life of the undercarriage. Following these key considerations will optimize the life of the undercarriage of your tracked machine. Remember, your productivity is on the line, so it’s critical to regularly monitor track appearance, wear, and performance — and never hesitate to contact your local dealer/equipment service partner with questions or concerns. AM John Bauer is the brand marketing manager for Case Construction Equipment.
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Need to navigate your way around the industry? Get the the most current information with the Atlas on CD While the printed version of the Aggregates Manager 2015 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more. The Atlas on CD contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2015 Aggregates Industry Atlas in pdf format. Order additional copies of the Aggregates Manager 2015 Aggregates Industry Atlas on CD or the printed version of the Atlas today!
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SUPPLYLINES by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Clean and Classified Washing and classifying equipment can solve myriad problems ranging from product dryness to fines recovery.
Classifying tank smoothens out feed fluctuations Designed to remove large volumes of excess water from feed material, EIW Classifying Tanks smooth out feed fluctuations and remove excess sand particles for a consistent in-spec product. Recently, the Mark VI computerized sand re-blending control system was introduced for this equipment. It makes stockpile calibration easier and faster, allowing for a varying number of controlled products, as well as calibrated tons per hour forecast of the products produced. Producers using the Mark VI system maintain tighter control of their products’ fineness modulus (F.M.). It can handle up to two tanks simultaneously and is said to make calibration simple, fast, and easy. Eagle Iron Works | www.eiwllc.com
Ruggedly built wash screens Elrus Aggregate Systems wash screens have been developed with more than 40 years of industry experience and design evolution. They feature heavy-duty side panel and carry deck construction, rotated cross tubes to maximize screen open area, integral wash bars, and easily replaceable inlet chutes and discharge lips. Units are available in a range of sizes from 3 feet by 6 feet to 8 feet by 20 feet. Elrus can custom design or configure to meet individual requirements. Elrus | www.elrus.com
AGGREGATES MANAGER / February 2016
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SUPPLYLINES Sustainable alternative to traditional washing systems The Hydro-Clean washing unit, from Haver & Boecker, is said to effectively clean deleterious material from aggregate, recycled, and other minerals while reducing water consumption by as much as 75 percent compared to traditional log washers. Taking feed material as large as 6 inches into its vertical drum, the Hydro-Clean employs high-pressure nozzles, rotating at 90 rpm, to spray as much as 90-percent recycled water on the material with pressures as high as 2,000 psi. The washer comes in three model sizes — the HC350, HC1000, and HC2000 — that process 18 to 360 tons per hour, depending on the application. Haver & Boecker | www.havercanada.com
Sand plant increases production, improves consistency McLanahan Ultra Sand Plants are said to help producers increase sand production, produce a drier product, and improve product consistency. Ultra Sand Plants combine Separators, dewatering screens, and a slurry pump to provide a 3- to 5-percent higher product yield over traditional fine material screw washers. The manufacturer says they produce a drier product and do not have the inherent inefficiencies of screw washers. Ultra Sand Plants operate efficiently, sending unwanted fines to waste streams and keeping product sized fines in the product piles. They also have the ability to separate and combine sand fractions, allowing users to blend coarse/fine sands as needed to meet product specifications. McLanahan | www.mclanahan.com
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It’s only $35 US in the USA and Canada, $45 US all others. To join, call us at 419-352-5616, or mail a check or money order to HCEA, 16623 Liberty Hi Road, Bowling Green, Ohio 43402. Join online and learn more about us at www.hcea.net.
AGGREGATES MANAGER / February 2016
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Dries and de-slimes sand The Phoenix/Kisa Bucket Wheel is designed for recovering, de-sliming, and dewatering sand and other granular materials. Many designs are available with the wheel diameter and bucket width determining the solids handling capacity, while the surface area of the slurry bath defines the hydraulic capacity. These bucket wheels are uniquely designed for solids recoveries of 99 percent or more with very low power requirements, even from dilute slurries such as dredger spoil. Dewatered solids are readily conveyable and stackable, having residual moistures that are said to be considerably lower than from dewatering screws. Phoenix Process Equipment Co. | www.dewater.com
Air classifying plant is completely mobile Sturtevant says its Whirlwind Mobile Air Classifier is the world’s first and only 100-percent mobile air classifying plant with integral collapsible conveyors. It is said to effectively remove excess fines from aggregate products bringing materials formerly considered waste materials into specification. The unit’s dry separation process eliminates the need for water typically used in washing plants, which is especially important in remote areas where water is not readily available. The Whirlwind Mobile Air Classifier is easy to transport with a rugged chassis frame and a heavy-duty, tri-axle suspension. It has three conveyors that hydraulically fold for transport and unfold for set-up. Sturtevant | www.sturtevantinc.com
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AGGREGATES MANAGER / February 2016 02.07.15 9/24/15 Untitled-14 9:2321:04 AM 1
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SUPPLYLINES Combination machine saves material from the waste pond Integrated into its Aggre-Dry Dewatering Washer, Superior says its fines recovery technology saves valuable material normally lost to a waste pond. The technology reroutes minus 25 mm material fines from an onboard dewatering screen back to the integrated sand screw. Depending on production rates, the extra material rerouted to the saleable stockpile can add tens of thousands of dollars to a sand producer’s bottom line. The Aggre-Dry Dewatering Washer is a single machine integrating a fine material washer and a dewatering screen. Sand processed through the equipment is stockpiled with a moisture content of just 8 percent, meaning the saleable product requires no drying time and can be accessed immediately. Superior Industries | www.superior-ind.com
Wash plant’s triple-deck screen has complete spray system Terex MPS says its TXW620HT horizontal wash plant features the highly efficient Cedarapids TSH 6-foot by 20-foot triple-deck screen with complete spray system. The highly portable plant incorporates a high capacity 36-inch by 25-foot twin screw. The unit also features an under-screen fines collection flume, washout, and hinged slurry box. The water spray system covers all three screen decks, slurry box, flume, and washout. Standard plants have top and middle deck over chutes and a bottom deck cross conveyor for multiple product capabilities. A middle deck cross conveyor and electrical panel are available as options. Terex Minerals Processing Systems | www.terexmps.com
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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 • Expert testimony
• Technical writing and review • Lecturer
Contact me at:
Bill-Langer@researchgeologist.com www.researchgeologist.com BillLanger_AGRM0115.indd 1
AGGREGATES MANAGER / February 2016
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APPLICATIONS by Del Williams
A New Approach to
Gravel Road Repair A linear road crusher rehabs gravel roads using onsite material at a fraction of the cost of traditional methods.
A
common gravel road repair and road building approach is to remove oversize rocks and bury subgrade problems, such as potholes or protruding rock, under additional gravel. But this “band
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AGGREGATES MANAGER / February 2016
aid� approach, which does not deal with underlying problems, is costly. It can require hauling in 200 to 300 percent more material than truly necessary to resurface a gravel road, only to have the problems resurface.
About 50 percent of the cost of any gravel road project comes from hauling in material; and the roughly $10,000 it costs to get a mobile crusher into a local pit can quickly rise if pit permitting and development is required.
Using a linear road crusher, some road contractors are finding that gravel roads can be repaired at a fraction of the cost of traditional methods.
While using a pit crusher makes sense on massive freeway projects and where stringent aggregate specifications for structures like bridges are well justified, there are better, more economic options for gravel roads, particularly remote ones.
Pit mining vs. linear crusher Sweet Grass County, Mont., depends on good gravel roads for much of its timber, oil, mining, and agricultural transportation. But maintaining these gravel roads was becoming too costly and difficult with traditional pit mining. “Previously, we used pits or, when the haul got too far, we’d push shale rock on the road and run it over with
vibratory rollers, trying to break it down to make a drivable surface,” says Cory Conner, Sweet Grass County public works director. Instead of burying near-surface subgrade problems under excess gravel from a pit, a growing number of counties and road contractors are discovering that linear crushers can repair a gravel road for significantly less money, while correcting the underlying subgrade problems. Unlike mobile rock crushers, which are stationary when operating, linear crushers move along the road being repaired, crushing oversize rock along it in a crushing chamber. The oversized rock, existing gravel, crushed rock, and natural fines (soils) are all windrowed together and processed through the crusher in one pass, which leaves the reduced material in place as a stable crushed layer. When used in on-road repair, it can help achieve “aggregate lock,” a natural binding of soil and gravel when wet, that can prolong the life of the road surface beyond that of cleaner gravel from a pit that may lack soil mixed in as a binding agent. Unsatisfied with the traditional approach to maintaining gravel roads and concerned about shortening the lifespan of the county’s vibratory rollers, Conner favored the linear crusher approach. After research and watching demonstrations of two on-road crushing systems, he chose a front loader-based design over a tow-behind design. “The tow-behind design would’ve required us to buy a dedicated tractor for about $400,000, while the Vanway linear crusher works with the front loaders we already have,” Conner says. Vanway International, a linear crusher manufacturer, makes machines capable of crushing any rock, including construction grade rock (110-210 MPa compression strength) such as traprock like basalt and gabbro, as well as quartzite, granite, and dense limestone. “The tow-behind also did not blend fines or crushed rock, so we would’ve had to do that manually,” Conner says, noting that the front loader can uniform-
ly crush rock to the size he needs, and blend it with fines. “We can just blade it, roll it out, and call it a finished product.” According to Conner, properly blending fines and crushed rock with the linear crusher is critical for Sweet Grass County to achieve the good gravel road surface sought. “Without blended crushed rock and fines, you’ll get rock pockets, rocks kicking out, washboard, or potholes,” Conner says. “Half your road will be a muddy mess, half will be nothing but rock because the fines will turn to mud or slime when really wet. When you lay crushed rock and fines in the right blend, you get a good, lasting driving surface that won’t easily dust up, kick off rocks, or allow water penetration and damage to the road surface.” After purchasing the linear crusher, Conner says, “We can take existing roads that are wearing out and rehab them without having to open a pit and do a whole DEQ pit process, then the whole reclaim process. We’ll save a lot of money using existing material on the road shoulder and surface. “Compared to our typical gravel road cost of about $20,000 per lane mile hauling from a pit, we expect to rehab the same road for about $5,000 to $7,500 per lane mile,” he adds. “We should be able to do about two to three times the road repair we’d done previously with the same crew, while extending the lifespan of our roads and vibratory rollers.” Travis Clark, operations manager for Roadtech, a contract road construction firm based in St. Maries, Idaho, also relies on a linear crusher for cost-effective gravel road repair and construction. “Compared to burying a road’s subgrade problems with gravel from a pit crusher, we can often repair the wear surface and correct subgrade problems for up to 66 percent savings,” Clark says. “All that material that’s been pushed off the edge of the road for years — from ditches, berms, subgrade, oversize — becomes our lift material,” Clark adds. “Our linear crusher usually runs at a cost comparable to a pit crusher, but doesn’t AGGREGATES MANAGER / February 2016
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Cubee the AggMan helping educate children about the importance of aggregate since 1998 “The Story of Cubee the Aggregate” helps teach children at the youngest ages about the important role aggregate plays in their daily lives. Geared for students in grades K-3, Cubee and his aggregate friends will take children on a magical journey from Cubee’s birthplace in the neighborhood quarry to his new home in the schools, roads and other structures that enrich our communities and our lives.
The “You’re on Rock” Workbook presents basic earth science information while emphasizing the vital role of the industry in our world. An aggregate activity book for junior geologists, mining engineers and earth scientists. Geared for students in grades 4-6.
Cubee the AggMan T-Shirts are available. To learn more about these great tools for community outreach, adopt-a-school programs, and receive sample copies of the coloring/workbooks,
Call 800-430-4540 e-mail: cubee@aggman.com
or visit www.AggMan.com
APPLICATIONS
need a pit, have set up costs, or need to be permitted.” According to Clark, when building remote gravel roads, the cost of hauling in gravel can quickly escalate the cost. “The farther away the road from the pit, the higher cost; and the more remote the road, the fewer the pits,” Clark says. “That’s when your price per mile of gravel road goes through the roof. “Fortunately, with a linear crusher your price stays constant,” he adds. “Without the material hauling cost, it costs the same per mile.” This allows the linear crusher to do remote projects for the same price as a local project.
Better roads for less According to Clark, the linear crusher has performed well for customers that require building or maintaining good gravel roads at lower cost. He says that, for years, a timber company in St. Maries, Idaho, had been struggling to keep a steep, 2-mile stretch of single-lane gravel road in shape with traditional blading and dust abatement. “For heavy logging truck use, the consistent 15+ road grade was challenging, the road profile was off, the aggregate was loose, and a big outcrop of rock near the top of the hill required lifting the road profile to go up and over it,” Clark says. “There weren’t enough fines in the road to bind the aggregate together, so dust abatement didn’t work very well.” The traditional approach to address the challenge would be to haul dirty gravel onto it, but that would have been costly — about $35,000 per mile of lane including dust abatement, according to Clark. Instead, Roadtech did the rock hammering, proper grader work, then used the linear crusher to break down oversized material and blend in the fines. “With the linear rock crusher, we were able to get the fines back in so dust abatement would hold in better,” Clark says. “They’ve been running on that road for three years now, and it’s holding up beautifully for them.”
A linear crusher moves along the road as it windrows together oversize rock, existing rock and gravel, and natural fines in one pass.
Improved road repair Roadtech has found that the linear crusher also cost-effectively performs gravel road repair in Ferry County, Wash. According to Clark, traditionally, the county only bladed many gravel roads with a grader because they lacked the funding to re-gravel them, and a grader’s capabilities are quite limited. “Traditionally, with a grader, when you pull out large rocks, it makes a mess. You’ll never get it compacted right again, and you’ll get ruts forming in your road,” Clark explains. “After pulling out the large rocks, you have to cast them over the side of the road, which widens your road and costs more to maintain.” As an alternative, the county now runs its own grading crew, and Roadtech follows with its linear crusher. “We can typically re-gravel and rehabilitate from 2 to 6 miles of gravel road for essentially $36,000 per week, plus crew cost,” Clark says. “With the traditional way of burying the problem, it would cost over $100,000 a week for a similar project.” According to Clark, this approach has allowed Ferry County to put in a new
maintenance protocol for their roads. “The linear crusher allows the county to work on roads they would normally have to wait five to 10 years to re-gravel,” Clark says. Clark explains that the county not only gets to reuse the material on the road, but also gets to correct the road. Essentially, this allows the county to pull the big rocks out, and use the grader to actually correct the road. This improves the road profile and water drainage, which lowers road maintenance costs, so they don’t have to blade it as often. “On a typical county road project, you’ll save roughly $15,000 per lane mile, plus about $2,500 per year per lane mile in gravel road maintenance,” Clark says. “With proper subgrade preparation, instead of burying the problem, you can gain an additional three to five years of road life. A linear crusher can also decrease how frequently you do general blade maintenance by about 50 percent.” AM Del Williams is a technical writer based in Torrance, Calif.
AGGREGATES MANAGER / February 2016
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by Kristin R.B. White
by Benjamin J. Ross
ROCKLAW
Will 2016 Bring More Criminal Prosecutions? DOJ and DOL may increase prosecution of worker safety-related cases through its “worker endangerment initiative.”
J
Kristin R.B. White is a member of Jackson Kelly PLLC’s Denver office, focusing on occupational safety and health and environmental law. She can be reached at 303-390-0006 or kwhite@jacksonkelly.com. Benjamin J. Ross is an associate in Jackson Kelly PLLC’s Denver office, practicing in the Occupational Safety and Health Practice Group. He can be reached at 303-390-0026 or bross@jacksonkelly.com.
40
ust prior to the end of 2015, the Departments of Justice (DOJ) and Labor (DOL) announced an expanded “worker endangerment initiative.” Under this initiative, the government plans to increase both the frequency and effectiveness of its prosecution of worker safety-related cases. DOJ’s Environmental Crimes Section of the Natural Resources Division now has the authority to pursue convictions under worker safety statutes and to use Title 18, which defines all forms of federal crimes, and environmental sanctions in conjunction with worker safety statutes in order to enhance penalties. The Federal Mine Safety and Health Act (Mine Act) is one of the statutes included in this plan. This initiative affects operators and contractors under Mine Act jurisdiction, and their agents, in two principle ways: an increase in § 110 investigations and harsher consequences for criminal violations of § 110(c) of the Mine Act. Section 110(c) of the Mine Act provides that “[w]henever a corporate operator violates a mandatory health or safety standard or knowingly violates or fails or refuses to comply with any order issued under this Act..., any director, officer, or agent of such corporation who knowingly authorized, ordered, or carried out such violation, failure, or refusal shall be subject to the same civil penalties,
AGGREGATES MANAGER / February 2016
fines, and imprisonment that may be imposed upon a person under subsections (a) and (d)” of § 110 of the Mine Act. Based on the power granted to MSHA by § 110, MSHA regularly investigates, and has the ability to charge, agents of an operator for health and safety violations whenever it cites an operator with an unwarrantable failure violation under § 104(d) of the Mine Act. Additionally, MSHA reviews fatal and serious injury accidents, § 107(a) imminent danger orders, and § 104(g) training violations for potential special investigations. MSHA can cite an agent for a civil § 110(c) violation when it determines that the agent knew or should have known about a violation of a standard or order under the Mine Act. A civil violation leads to a monetary penalty of up to $70,000. Section 110(d) allows MSHA to impose criminal penalties of up to $250,000 and a jail sentence of one year on an operator who willfully violates a mandatory health or safety standard or knowingly violates or fails or refuses to comply with any order issued under § 104 or § 107 of the Mine Act. For a second conviction, the punishment can be a fine of up to $500,000 and imprisonment for a maximum of five years for corporate directors, operators, and agents. “Knowingly” is defined in the criminal context as an act done volun-
tarily and intentionally and not because of mistake or other tion, even investigations of discrimination complaints, can be used for indictment of criminal charges against the innocent reason. agent. Section 110(e) imposes criminal penalties of up to Any investigation launched by MSHA can have seri$1,000 and six months imprisonment for providing advance ous consequences for an operator and its agents. The notice of a mine inspection, and § 110(f) imposes criminal new initiative highlights this and threatens more severe penalties of fines up to $10,000 and imprisonment of up consequences. Operators, therefore, must manage interacto five years for the falsification of any documents required tions with MSHA in a way that exposes their agents to the under the Mine Act. least liability possible and should seek representation durPreviously, criminal charges in addition to § 110(c) civil ing any investigations. Charges can often blindside agents monetary penalties were rare. Now, the DOJ/DOL initiative as conflicting interpretations may exist regarding whether may increase the likelihood that DOJ will prosecute safetya violation occurred under the Mine Act. Because the rerelated violations and add additional criminal charges to percussions of MSHA inspections can go beyond monetary § 110(c) cases. These additional criminal charges could inpenalties levied against the operator and can lead to felony clude felonies, as the announcement of the initiative noted charges and jail time for agents, operators, and their agents that safety statutes only impose misdemeanors. should be prepared moving forward into 2016. AM Recently, Donald L. Blankenship, the former CEO of Massey Energy, was found guilty in federal court of conspiring to commit mine safety violations, a misdemeanor charge carrying a maximum sentence of one year in jail. While he was acquitted of other more onerous felony counts, his prosecution illustrates the increased potential of criminal charges for mine safety violations. Beka-Max auto-lube is built to take the bumps and Defending against criminal charges grinds of a hard-working life on the road or off. in federal court brings the stress of Give your fleet the solution that keeps them on the job. threatened fines and jail time, and the • Cast aluminum base withstands impacts legal fees required to defend against and hot/cold cycles without leaking federal criminal charges are daunting. • No springs - eccentric gear drive resists Obviously, all operators and agents wear, fatigue and cold • Consistently precise grease dosing want to avoid even the potential of § Find out why industries are choosing 110(c) violations and criminal charges. today’s best-built auto-lube systems. The best way to do this is to train for Call 1.888.862.7461 or email us and carefully manage MSHA inspecat info@beka-lube.com. tions and investigations. Agents must know their rights and responsibilities when dealing with MSHA. Although § 110 investigations pose the most obvious risk, any interaction with MSHA 1 . 888. 862. 7461 can lead to citations and charges. For www.beka-lube.com example, statements made to MSHA B E K A - L U B R I C AT I O N S P E C I A L I S T S S I N C E 1 9 2 7 during any type of special investiga-
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AGGREGATES MANAGER / February 2016 1/20/16 9:47 AM
ADINDEX February 2016
Advertiser
Web
2016 NSSGA AGG1 Aggregates Expo
www.agg1.org
Aggregates Manager Community Outreach
www.aggman.com/community-outreach
38
Aggregates Manager Industry Atlas
www.asggmanatlas.com
30
Atlas Copco Construction Mining Technology
www.atlascopco.us
25
AZFAB, LLC
www.azfab.com
29
bauma 2016
www.bauma.de
20
Beka-Max of America, Inc.
www.beka-lube.com
41
Bill Langer - Research Geologist
www.researchgeologist.com
35
C.L. Dews & Sons Foundry
www.dewsfoundry.com
43
Clearspan Fabric Structures
www.clearspan.com/adam
43
Columbia Steel
www.columbiasteel.com
BC
Deister Machine Co., Inc.
www.deistermachine.com
IFC
Elrus Aggregate System
www.elrus.com
IBC
HCEA
www.hcea.net
32
Hillhead 2016
www.hillhead.com
17
John Deere Construction Equipment
www.johndeere.com/big
13
KPI-JCI and Astec Mobile Screens
www.kpijci.com
Kruse Integration
www.kruseintegration.com
43
Laser Technology, Inc.
www.lasertech.com/aggmb
28
Minexpo 2016 International
www.minexpo.com
19
NSSGA Membership
www.nssga.org
34
Phoenix Process Equipment Co.
www.dewater.com
33
Progressive Commercial Insurance
www.progressivecommercial.com
Pugmill Systems, Inc.
www.pugmillsystems.com
43
Snoby Separation Systems LLC
www.snobyllc.com
33
Stedman Machine Co.
www.stedman-machine.com/impact
43
Sweet Manufacturing
www.sweetmfg.com
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This index is provided as a service. The publisher does not assume any liability for errors or omissions.
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AGGREGATES MANAGER / February 2016
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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
The Glasshouse Mountains
A geological wonder.
“These hills…are remarkable for the singular form of their elevation, which very much resembles a glass house, and for this reason I called them the Glass Houses.” Captain James Cook, May 17, 1770
B
ack in 2004, my wife, Pam, and I had the pleasure of visiting Queensland, Australia, where I was a keynote speaker at the Annual Conference of the Institute of Quarrying. While we were there, our hosts and friends, Andy and Jo Stephens, showed us around the Queensland countryside. One fascinating place we visited was a tropical rainforest at Mary Cairncross Scenic Reserve. Andy cautioned us about leaches and ticks, both of which live in the rainforest. As if to prove his point, while Andy was walking through the forest, a tick took up residence on his bum. But that’s another story. The topic of this article is the Glasshouse Mountains, a group of 11 hills that we viewed from Mary Cairncross. Captain James Cook spied them in 1770 as he The Glasshouse Mountains were formed as the result of prolonged volcanic activity sailed his research vessel, HMS Endeavour, up the coast followed by millions of years of erosion. of what is now Queensland. The Glasshouse Mountains have been, and continue to be, of spiritual significance to the aboriginal people of the region, including the Gubbi Gubbi people. According to Gubbi Gubbi legend, the mountains are a family. Mount Tibrogargan is the father, Mount Beerwah (the highest peak at 1,824 feet) is the mother, and the other peaks are the children. One day, Tibrogargan saw the ocean flooding the coast, and he fled inland with his family. Tibrogargan told his son, Coonowrin, to help Beerwah and his sibA quarry in the lava near the Glasshouse Mountains with Mount Tibrogargan in the lings move to safety. Coonowrin was afraid and ran background. away. When his father found him, he hit him on the back of the head, resulting in Coonowrin’s crooked neck. Tibrogargan was ashamed of his son’s cowardice and turned his back on him, never to look on him again. However, the mountains didn’t form quite like the legend says. Sixty five million years ago, Australia was further south than today, and still part of the ancient super-continent of Gondwanaland. Much of Australia was covered in tropical rainforest similar to that at Mary Cairncross. Eventually, Australia separated from Antarctica and began drifting northwards. About 29 million years ago, southeast Queensland moved over a ‘hot-spot’ in the Earth’s mantle resulting in prolonged volcanic activity. Volcanoes spewed out lava flows, building up broad, gently sloping plains. A few million years later, magma was forced upwards through the older rocks, making large bulbous plugs and laccoliths, and filling volcanic necks. After millions of years of erosion, the surrounding softer sandstone rocks were worn away. The more resistant volcanic rocks are now exposed as the steep sided peaks of the Glasshouse Mountains. Some of the older lava is quarried today for aggregate, but much of the older lava was weathered into fertile soils that enable rainforests like Mary Cairncross Scenic Reserve to re-establish and thrive, ticks and all. This brings us back to Andy’s bum. We got to see the tick only after his wife, Jo, had carefully removed it. What a relief!
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AGGREGATES MANAGER / February 2016