Neighbor relations PG25
|
Cone crushers PG45
|
Green aggregates PG52
February 2017 | www.AggMan.com
Your guide to profitable production
30
Industry partners with NIOSH on air quality
38
Right-size your hauler fleet
48
MSHA attempts to broaden ‘working place’ definition
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A combination of mine conditions, operating parameters, and equipment options should be analyzed to determine the most cost-effective haul truck options.
PAGE 38
On Our Cover: LafargeHolcim’s Marblehead Quarry ships the bulk of its material out via freighter and barge. Cover photo courtesy of Marblehead Quarry.
Haver & Boecker’s new portable F-class vibrating screen features a base frame that attaches to a custom-built chassis for quick setup and teardown.
PAGE 10
TABLE OF CONTENTS FEBRUARY 2017 |
VOLUME 22, NUMBER 2
FEATURE ARTICLES
16
Quarry on the Lake
30
Partnership Helps All Breath a Little Easier
38
From its location on Lake Erie, Marblehead Quarry has been supplying aggregate for cities along the great lake since 1891.
A metal/non-metal underground mining crew partners with NIOSH to study air quality in enclosed cabs and improve worker health.
Right-Sizing Your Hauler Fleet
Intelligent tools can help determine the most cost-effective option for your fleet.
45 Second Stage Standouts
When it comes to achieving the right particle shape, cones are crucial. This lineup can help you sort through options for secondary and tertiary crushing.
COLUMNS & DEPARTMENTS 5 Editorial Equal opportunity citations. 6 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook. 8 State and Province News A roundup of the latest news in North America. 10 RollOuts Superior Industries’ new Alliance Low Water Washer, and other new equipment for the aggregates market. 48 Rock Law ALJs reject MSHA’s attempt to expand ‘working place’ through citations that broaden its traditional definition. 50 Advertiser Index See who’s who and where to find their products.
OPERATIONS ILLUSTRATED
25
Developing Neighbor Relations
Community relations programs aren’t always about money. Sometimes, it can be as simple as channeling your employees’ passions into the workplace.
51 Classified Ads Aggregate industry classifieds. 52 Carved in Stone Aggregates and the environment: Aggregates can be part of a roofing system that keeps your home cool.
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February 2017
EDITORIAL
Vol. 22, No.2
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
aggman.com /AggregatesManager /AggManEditor
Equal Opportunity Citations
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Contributing Editor: Kerry Clines editorial@aggman.com
Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Linda Hapner production@aggman.com
Construction Media Vice President, Construction Media: Joe Donald sales@randallreillyconstruction.com
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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 2017. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.
E
ach month, I comb through consumer news media for reports on the aggregates industry. It’s a good way to see not only what is happening with issues such as permit requests around the nation, but it’s also an opportunity to see how the industry is portrayed in the mainstream news. Much has been made of the media during recent months, and some of those comments undermine the public’s faith in their integrity. Here’s the thing: media is made up of people. People are human, and, therefore, far from perfect. That doesn’t mean they are dishonest, but their perspective may be influenced by personal experiences and preferences. That’s why the same story may be reported in a very different manner on Fox News than on CNN. Find a journalist you trust and follow him or her. That’s what we strive to be at Aggregates Manager: a trusted source for industry information. But, I digress. Back to those news stories. This month, one caught my eye. It was a story about a county-owned aggregates operation that was nearly shut down after a Mine Safety and Health Administration (MSHA) inspection. In a familiar scenario, its problem began with a guarding citation. The inspector cited the operation for failure to have a guard rail on a cattle crossing that ran through the property. Equal citations, or is it protections, for all. While cattle crossings may be a unique rationale, guarding citations are all too familiar for operators. Over the last five years, a cursory inspection of 2016 MSHA citations at surface operations shows that sand and gravel operators received 3,243 guard-related citations, while crushed stone operators received 2,114. Near the top of both lists is standard 56.14107(a) — Moving machine parts. In 2016, 1,728 citations of this standard were issued to sand and gravel producers and 1,089 citations were issued to crushed stone producers. While the trigger for these citations is sometimes surprising, the standards themselves vary little from year to year. Since 2012, the standards most commonly cited at surface sand and gravel operations have included the following: • 56.14107(a) – Moving machine parts; • 56.12004 – Electrical conductors; • 56.14132(a) – Horns and backup alarms; • 56.14100(b) – Safety defects; examination, correction, and records (correcting them in a timely manner), and • 50.30(a) – Preparation and submission of MSHA Form 7000-2 — Quarterly Employment and Coal Production Report. While the ranking within the top five standards has changed, those five have consistently been the top five sources of citations for the last five years. For surface stone mines, the standards most frequently cited are remarkably similar: • 56.12004 – Electrical conductors; • 56.14107(a) – Moving machine parts; • 56.14100(b) – Safety defects; examination, correction, and records (correcting them in a timely manner); • 56.14132(a) – Horns and backup alarms; and • 56.2003(a) – Housekeeping. Before your next inspection, take a look around your operation with these standards in mind. It may help you avoid a little paperwork of your own. AGGREGATES MANAGER / February 2017
5
mining U.S.
On-Highway
Diesel Fuel
Prices 1/9/17
United States $2.597 One Week +0.011 p One Year +0.420 p
Company Cemex, S.A.B. de C.V.
New England $2.677 One Week +0.012 p One Year +0.342 p
Central Atlantic $2.813 One Week +0.037 p One Year +0.463 p
Lower Atlantic $2.526 One Week +0.012 p One Year +0.410 p
Midwest $2.547 One Week +0.007 p One Year +0.451 p
Gulf Coast $2.448 One Week -0.003 q One Year +0.368 p
Rocky Mountain $2.541 One Week +0.006 p One Year +0.407 p
West Coast $2.873 One Week +0.026 p One Year +0.447 p
West Coast less California $2.774 One Week +0.017 p One Year +0516 p
California $2.953 One Week +0.032 p One Year +0.391 p Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
CX
Current Value
52-Week Low
52-Week High
$7.80 q
$3.50
$9.35
CRG
$33.84 q
$20.46
$36.32
Eagle Materials Inc.
EXP
$99.32 q
$45.03
$103.16
Granite Construction Inc.
GVA
$54.55 q
$35.69
$62.18
Heidelberg Cement AG
HEI
$90.71 p
$61.42
$99.87
LafargeHolcim Ltd. ADR
HCMLY
$10.54 q
$6.92
$11.66
CRH plc
Martin Marietta Materials, Inc.
MLM
$220.56 q
$108.31
$236.41
MDU Resources Group, Inc.
MDU
$28.65 q
$15.58
$29.92
Summit Materials
SUM
$24.03 p
$12.96
$25.00
United States Lime & Minerals, Inc.
USLM
$73.83 q
$48.41
$78.15
U.S. Concrete
USCR
$61.00 p
$40.42
$69.66
Vulcan Materials Co.
VMC
$123.61 q
$78.83
$138.18
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 1/10/17.
COMPANY SPOTLIGHT
East Coast $2.648 One Week +0.021 p One Year +0.419 p
Ticker
U
.S. Concrete U.S. Concrete (USCR) reported that its third quarter revenue from aggregate products increased 16.7 percent to $22.1 million, with the average sales price increasing 13.0 percent to $11.93 per ton. Its ready-mixed concrete revenue rose 12.6 percent to $297.9 million, with the average sales price increasing 6.1 percent to $132.70 per cubic yard. Overall net income for the third quarter was $38.0 million, compared to net income of $1.6 million in the third quarter of 2015. Those results include the recognition of a $21.8 million non-cash derivative related gain compared to a $26.9 million non-cash derivative loss in the third quarter of 2015. “We continue to successfully build strong leadership positions in our major metropolitan markets and strengthen our footprint through accretive acquisitions, which has led to the record results we are reporting this quarter,” Bill Sandbrook, president and CEO, said in a press release. “During the quarter, consolidated revenue increased 11.3 percent to $328.6 million on both higher volume and selling prices in both ready-mixed concrete and aggregates…. we produced these record results for the third quarter even with a significantly higher than normal level of rainfall in north Texas in August of 2016.” During the third quarter, U.S. Concrete acquired two ready-mixed concrete businesses in New York. “Our acquisition pipeline continues to provide opportunities for selective, accretive growth in both our ready-mixed concrete and aggregate platforms, and we are very focused on the potential to enter into new major metropolitan areas,” Sandbrook said. In early January, the company closed its offering of $200 million of senior notes due 2024. The notes were issued under the same indenture as the $400 million aggregate principal amount of the company’s 6.375 percent senior notes due 2024, issued in June 2016. According to MarketWatch, the company plans to use net proceeds from the offering for general corporate purposes, including funding the purchase price of future acquisitions to expand its business.
Source: Market Watch
Data
STOCK REPORT
AGGREGATES INDUSTRY OUTLOOK For the second month in a row, the Aggregates Industry Outlook gained ground, moving up 1.48 percent in January to an overall score of 124.24. The lowest expectations were given in regards to sales for the current quarter. At an average score of 3.45, that number is still positive, particularly considering the sales period being evaluated is the January-March window, which is typically among the slowest sales of the year. The strongest responses, on the other hand, were for sales predictions for the next six months and the next year. Those tied at an average score of 3.91, a strongly optimistic number.
Aggregates Industry Outlook 140 131.68
127.51
136 132
124.24
126.03 122.43
128
119.44
124 120
128.99
128.15
128.61
109.80 111.42
116
108.08
112 108
111.00
104 100
Jan. 2016
Feb. 2016
The East Coast is being impacted more this year than last year with colder temperatures. This is slowing projects that have already started and delaying those that have not.
Mar. 2016
Apr. 2016
May 2016
Jun. 2016
Jul. 2016
Aug. 2016
Sept. 2016
Oct. 2016
Dec. 2016
Jan. 2017
Feb. 2017
The outcome of the election, combined with a strong stock market and stable oil prices, has spread optimism throughout the market. — Rob Van Til, Managing Partner, River Aggregates, LLC
— Daryl Zeiner, Sales Manager, The H&K Group
There is some trepidation that the promises of the incoming administration will actually be able to enact the transportation plans within the next 12 months (or some portion of them that will have an impact). Additionally, in the Texas/Louisiana markets, oil pricing and production are key economic drivers, and how OPEC and Russia respond over the next 12 months is being watched carefully. — Kevin P. Black, Vice President/General Manager, Southern Aggregates, LLC
Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.
CENSUS CONSTRUCTION DATA 11/1/2016
10/1/2016
% change Oct. 2016- Nov. 2016
% change Nov. 2015- Nov. 2016
Residential
469,669
464,890
1
4.1
Non-residential
712,427
706,546
1
5
Office
76,197
74,688
2
27.5
Commercial
76,081
75,862
0
12.4
Health Care
41,789
41,823
0
-1.5
Educational
92,402
90,131
3
9.1
Transportation
42,232
42,646
-1
-8.5
Power
92,645
92,076
1
-0.8
Highway and Street
94,821
93,761
1
10.5
Sewage and Waste Disposal
21,032
21,393
-1.7
-7.7
Manufacturing
75,223
74,017
-1
-8.1
Type of Construction
Seasonally adjusted annual rate. (Millions of dollars. Not all sub-categories of non-residential construction are included.) Source: U.S. Census Bureau
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
ARIZONA According to the National Stone, Sand & Gravel Association, CalPortland hosted Rep. Martha McSally at its cement plant and Twin Peaks aggregate plant in Rillito in late November. “Having our members of Congress tour our operations shows them the importance of quarries and aggregates to our infrastructure and construction industries,” Steven Regis, CalPortland’s senior vice president of corporate services, said in a press release. “We were able to have good conversations about the overwhelming number of regulations facing our industry and the need to revitalize the economy, both nationwide and here in Arizona.” Specifically, they addressed OSHA’s crystalline silica rule, air quality, and safety, among other issues.
CALIFORNIA The USDA Forest Service and County of San Bernardino released for review a joint California Environmental Quality Act and National Environmental Policy Act Draft Environmental Impact Report/Environmental Impact Statement for Mitsubishi Cement Corp.’s South Quarry Project. According to Victor Valley News, Mitsubishi plans to develop a new limestone quarry to the south of its existing operation in Lucerne Valley on the north slope of the San Bernardino Mountains. The project area includes 153.6 acres, with a 128-acre quarry.
CALIFORNIA A citizens group, the Point San Pedro Road Coalition, is battling Marin County, which unanimously approved San Rafael Rock Quarry’s request to import and recycle asphalt in 2013. The group took the county to court over its decision, the Marin Independent Journal reports. Marin Superior Court Judge Paul Kaakenson ruled against the county and ordered the quarry to stop recycling asphalt. Both the county and the quarry are appealing the ruling to the 1st District Court of Appeals. Aimi Dutra, spokesman for the quarry, told the newspaper that it can no longer receive RAP, which is an environmentally sound practice and requested by many Caltrans and municipality projects.
KANSAS A county-owned quarry in Neosho County was nearly shut down following a Mine Safety and Health Administration (MSHA) inspection. According to The Chanute Tribune, the operation was cited for failure to have a guard rail on a cattle crossing going onto the property. The inspector told officials to install guard rails by the end of the following Thursday and arrived to inspect it at 8:30 a.m. The county road and bridge supervisor told county counselors that the county has used that entrance for 25 years, and suggested that counselors “should nicely complain” when one suggested they challenge the citation.
MARYLAND While Aggregate Industries’ Travilah Quarry in Rockville still has an estimated 60 years of reserves, officials there are eying a potential reclamation use as water storage for the D.C., Maryland, and Virginia markets. WTOP reports that the Washington Aqueduct would only have one to two days of water storage if the Potomac River ever became unavailable or undrinkable. The quarry site could currently hold about a 14-day supply. Tests at the site show that there are no naturally occurring minerals that would make water stored there unsafe for consumption. “All quarries have a finite life span,” Richard Freedman, director of land and environment for Aggregate Industries’ Mid-Atlantic region, told the news outlet. “It’s a long way away, but we’re always interested in the conscientious repurposing of our property. I don’t know if it will end up being a reservoir, but that’s a possibility the company would explore and be receptive to.”
MICHIGAN The Huron County Planning Commission is waiting for further information from Wallace Stone Co. regarding its request to permit additional property. According to the Huron Daily Tribune, public comments during the commission’s most recent meeting regarded specifics such as setbacks and concerns about blasting. The operator is seeking 85 additional acres to be permitted, but the acreage is split among three different townships. Eric Gardy, operations manager of the quarry, told the newspaper that the additional acreage would extend the life of the property from five years to 20-25 years.
ILLINOIS
NORTH CAROLINA
The Illinois Association of Aggregate Producers’ Public Information and Education Committee will host its annual Illinois Teacher Workshop: Rock, Minerals & Mining in Today’s Society on July 17-19. According to the association, teachers in grades K-12 and junior college will be given the opportunity to refresh their knowledge of earth science and learn about the importance of rocks, minerals, and mining in everyday life. The workshop will include mine tours, informational materials, and hands-on activities. Anyone interested in sponsoring a teacher to attend the workshop should visit the website at www. iaap-aggregates.org/workshop.htm.
Elmwood Strong, a citizens group, is working to stop a future quarry from being opened in Elmwood. The Statesville Record & Landmark reports that the group has made multiple requests of the Iredell County Planning Board. It first requested for a “moratorium on all polluting industries.” When that request failed, it asked for setbacks of 1,500 feet from property lines for quarries. The planning board instead opted for setbacks ranging from 50 feet for areas such as the extraction area, pit, office building, and parking to 300 feet from any blasting, crushing, or processing sites. Maymead, a Tennessee-based construction materials company, recently purchased a property there for $2.246 million. The property is the site of a former quarry, but is currently zoned for agricultural use.
8
AGGREGATES MANAGER / February 2017
SOUTH DAKOTA
Specialized Steel Solutions for the Aggregates Industry
The Pennington County Planning and Zoning Board, which reversed its decision to issue an operating permit to Croell Redi Mix when confronted by a standing-room only crowd that objected to it, found itself on the losing end of one lawsuit and faces substantial financial damages in another. KOTA TV reports that Seventh Circuit Judge Matthew Brown sided with Croell Redi Mix in its lawsuit against the county. Croell awaits a decision in its lawsuit for $10 million in damages. The company’s attorney said that suit will now proceed. “As each day goes by and until that construction permit is in our hands and Croell is allowed to proceed with the utilization of its property, as the law allows them to do, those damages are mounting every single day,” attorney Tom Brady told the news outlet. Pennington County officials declined comment.
TENNESSEE Plans for the expansion of Aggregates USA’s Sullivan County quarry were approved at the end of 2016. According to the Herald Courier, the expansion will extend the quarry’s reserves by five additonal years. The Sullivan County Board of Zoning Appeals also approved a surety bond should the operator go out of business or vacate the property unexpectedly. Most of the 16 people who spoke about the expansion request were in favor of it.
VERMONT The body of a missing Bennington College student, Hadil Marzouq, was found under the ice at Dorset Quarry, MassLive.com reports. Police continue to investigate the drowning incident, and no determination has been made on the manner of her death. Marzouq was reported missing on Dec. 18. The native of Palestine was a junior at the college and majored in public action and conflict resolution.
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WISCONSIN The owner of Wingra Stone and Redi-Mix says he’s not happy with changes a legislative study committee wants to make to burial site protections. According to WMTV, owner Robert Shea wants to mine Ho-Chunk Nation burial mounds located in his Wingra Stone quarry in Dane County. He needs a permit since the mounds are in the state historical society’s burial site catalog and faces opposition from the tribe. The committee was formed by lawmakers to revise burial site protections. It recently finalized a bill that would require the historical society director to consider evidence to catalog a site and allow property owners to fight a cataloging decision at hearings. Shea, who was part of the committee, said the changes don’t go far enough and weaken the rights of property owners.
www.astralloy.com
Toll-free: 1.866.587.6970 Sales: 724.230.5100 sales@astralloy.com Astralloy Steel Products is a wholly-owned subsidiary of Nucor Corporation, the largest producer of steel in the United States.
AGGREGATES MANAGER / February 2017
9
ROLLOUTS
Your complete guide to new and updated equipment and supplies in the aggregates industry.
by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
New option for washing crusher fines Superior Industries, Inc. introduces its new solution for processing crusher fines right next to the crushing circuit, the Alliance Low Water Washer. The unit accepts a dry feed directly from the crushing circuit and processes material into a higher value manufactured sand. It is said to use up to 80 percent less water than the traditional screw/screen combination. An agitator section is positioned at the front end of the screen where water is added to the dry feed and mixed, producing a thick slurry. The slurry is then dumped onto a dewatering screen with a series of spray bars to help clean and wash out the fines. The end result is a saleable manufactured sand with approximately 8 percent moisture content. The unit processes up to 300 tons per hour, with an option for custom-designed machines for higher throughput.
Superior | www.superior-ind.com
Secondary crushing for high-volume sites Johnson Crushers International’s Kodiak K500+ crusher is a 500-horsepower, remote-adjust cone crusher suitable for secondary and tertiary crushing of high-production operations. The Kodiak line, including the K200+, K300+, and K400+, features a hybrid cast/fabricated base frame design, automated control system, patented liner retention, patented thread locking ring, and anti-spin cone brake. The line also includes replaceable brass thread inserts, patented internal counterweights, a heavy-duty tramp iron system consisting of pressure relief valves rather than accumulators, and brass v-seat liners.
Johnson Crushers International | www.kpijci.com
Portable vibrating screen offers quick setup Haver & Boecker’s new portable F-Class vibrating screen features a base frame that attaches to a custom-built chassis, as well as a hydraulic system to position the vibrating screen. These features allow teardown and setup within 30 minutes. The unit offers up to three screen decks. The vibrating screen features a double eccentric shaft design, supported by four double-spherical roller bearings and the Ty-Rail quick-tensioning system.
Haver & Boecker | www.havercanada.com
10
AGGREGATES MANAGER / February 2017
Blasthole drilling rig for mid-range needs The Atlas Copco DM30 II blasthole drilling rig, modeled after the DM45 and DML, is said to be ideal for the large quarry market. It features a 30-foot drill pipe changer and a standard four-rod carousel. With a starter rod under the rotary head, it has a total depth capacity of 145 feet. Powered by a Cummins Tier 4 Final engine, it has an Atlas Copco 1050 cfm high-pressure compressor and is capable of both rotary and down-the-hole applications. Other features include an ergonomic interior design, spacious electric-over-hydraulic cab, I-beam frame, increased decking and component access, and improved rod handling and breakout.
Atlas Copco | www.atlascopco.us
High height portable screen plant Irock’s TS-512 tracked screening plant, suitable for small and medium production needs, features two two-bearing decks, a 12- by 5-foot top deck, and a 10-foot, 4-inch by 5-foot bottom deck. Interchangeable screen media offers versatility over end product size. The unit has a 12-cubic-yard hopper and a Cat Tier 3 engine that allows the screen to process up to 400 tons per hour. Its three conveyors sort up to three product sizes into stockpiles 16 feet, 5 inches high, which the manufacturer says is the tallest in the industry. Components are hydraulically powered for quick setup and teardown.
Irock | www.irockcrushers.com
Photogrammetry software optimized for drone photos Eos Systems Inc. introduces new photogrammetry software optimized specifically for photos taken with drones or unmanned aerial systems. PhotoModeler UAS 2016 software creates 3D models, measurements, and maps from these photos. The software includes features such as post processing kinematics, volume objects, full geographic coordinate systems support, multispectral image support, and control point assist. The new version is suited for stockpile volume measurement, reclamation, surface model creation, slope analysis, and more.
EOS Systems Inc. | www.photomodeler.com
AGGREGATES MANAGER / February 2017
11
ROLLOUTS Mill separates, cleans, and polishes sand Superior Industries, Inc., launches its new Attrition Mill as part of its line of washing and classifying machinery. The machine provides a solution for sand applications, including disintegration of conglomerates, material separation, and surface cleaning and polishing. The mill features urethane-coated tank and propellers, as well as round tubs to eliminate swirling or corner material collection. A large, watertight sealed door eases maintenance by eliminating the heavy lifting that comes with drive removal. Powered by a 50-horsepower engine, the machine is said to provide capacities ranging from 75 to 120 tons per hour in a quiet, energy-efficient machine.
Superior Industries, Inc. | www.superior-ind.com
Off-highway trucks reduce fuel consumption Komatsu America Corp. rolls out the HD465-8 and HD605-8 off-highway trucks. Equipped with 724-horsepower Tier 4 Final SAA6D170E-7 engines, the trucks are estimated to reduce fuel consumption by up to 7 percent on the HD465-8 and up to 12 percent on the HD605-8 when compared to their predecessors. The models have payload capacities of 61 and 69 tons, respectively. Standard features include a 7-inch LCD monitor, dedicated rearview monitor, fast-fill system, an engine compartment light, and a premium heated and ventilated operator’s seat with air suspension.
Komatsu America Corp. | www.komatsuna.com
Camera indicator for mobile equipment Hirschmann MCS introduces a new camera indicator that can be used on all types of mobile equipment. It provides a direct view of the application, allowing the operator to have a constant visual of any situation. The camera is compatible with the company’s 4.3-inch and 7-inch color graphic vScale consoles and offers the option of horizontal or vertical camera orientation. It also features an IP68/IP69k protection class rating and is shock and vibration resistant.
Hirschmann MCS | www.hirschmann-usa.com
Exciters extend bearing life Haver & Boecker says its new line of Haver Exciters contributes to improved screening performance, including the largest static moment range on the market. It makes four exciter models with eight weight configurations each. The exciters, which drive the movement of the vibrating screen, contain dedicated spherical roller bearings designed specifically for vibrating screens. The exciters are standard on all new Tyler XL-Class vibrating screens.
Haver & Boecker | www.havercanada.com
12
AGGREGATES MANAGER / February 2017
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15
PLANT PROFILE by Kerry Clines | Contributing Editor
Quarry on
L
afargeHolcim’s Marblehead Quarry, located in Ohio on the shore of Lake Erie, is more than 100 years old. It is comprised of what, originally, were several small quarries, which supplied aggregate for the Village of Marblehead and Danbury Township during the late 1800s. At the turn of the century, the 2,500-acre property was acquired by Kelleys Island Lime and Transport Co. It was then purchased by Chemstone Corp. in 1955, which leased it to Standard Slag Co. in 1962. Standard Slag eventually purchased the quarry in 1983. Six years later, in 1989, Lafarge North America acquired Standard Slag,
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AGGREGATES MANAGER / February 2017
taking over the plant and its day-to-day operations. Shortly thereafter, Lafarge invested $12.5 million in facility upgrades and automation, building a new processing plant and boat loading facility at the quarry’s dock.
Marblehead Quarry today The updated facility currently has the ability to produce more than 4 million tons of construction aggregate annually, making it one of the largest and highest producing quarries in Ohio and on the Great Lakes. Most of the materials produced at the quarry, approximately 98 percent, are shipped by freighters or barges, while area customers pick up ag-
gregate by the truckload for construction projects, as well as personal use, in the amount of nearly 100,000 tons. “We always try to supply the local markets with aggregate, even though that’s only 2 percent of our business,” explains Jeff Grashel, plant manager. “We used to have the trucks go down in the yard, which was a 4-mile round trip. We had to constantly maintain the haul road, water it, and treat it. In 2012, we built a truck loadout yard for the local communities, which is open year round. We’ve seen an increase in truck sales because of the reduction in drive time, so there have been some additional benefits to putting in the yard.”
the Lake From its location on Lake Erie, Marblehead Quarry has been supplying aggregate for cities along the great lake since 1891.
The processing plant at LafargeHolcim’s Marblehead Quarry in Ohio, located on the shore of Lake Erie.
When the company designed and built the yard, several things were taken into consideration. They finished out the roads, one coming into the quarry leading to the new truck loading yard and one going out from the scale and scalehouse. Now, the truckers come in on one side of the scalehouse, receive their loads from loaders in the new yard, and circle around to the scale to get weighed, pick up a ticket, and exit on the other side of the scalehouse. Haul trucks fill the stockpiles in the yard from the backside, so they remain separated from the customer trucks, thereby minimizing any traffic problems. The result is a smooth circular flow of truck traffic in and out of the facility.
“Our trucks haul from our finished piles in the plant, so it added a little bit of cost, but we recoup that in the increase in tonnage hauled by OTR trucks,” Grashel explains. “It’s very cyclical. We may see a thousand tons a day go out on customer trucks, but the local projects are hit or miss.”
Operations “The facility and the site have a tendency to be challenging,” Grashel says. “We have large cap rocks and oversized that we have to deal with, so we separate them out at the face and set the large stuff aside for secondary breakage. A third-party contractor manages all the larger stones and rip rap production sales for us.”
The contractor stages the oversized rock in piles according to size, and then hauls them across the road in the Village of Marblehead to the dock area where a crane is used to set them on barges. From there the rock is shipped to Cleveland and Lorain, primarily for shoreline protection, most of which is done by the U.S. Army Corps of Engineers. The quarry normally runs two haul trucks in the pit that are fed by two 992 loaders. Tandem loading of haul trucks is most efficient in the pit, except when working in tight corners. The primary crusher is an impactor, which Grashel says is unique for a quarry the size of Marblehead, as most high-production quarries AGGREGATES MANAGER / February 2017
17
PLANT PROFILE
Because of varying flows of material coming from the primary, a bin is used to regulate the feed to the rest of the circuit to prevent any surges.
The dry circuit is a fractionated plant that produces three main products, which are either sent directly to the vessels at the dock or used as a blend for the next plant.
use gyratory crushers. Because of varying flows of material coming from the primary, a bin is used to regulate the feed to the rest of the circuit to prevent any surges. “Everything is automated, including the scales and sampling points,” Grashel
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AGGREGATES MANAGER / February 2017
notes. “We have one guy in the primary, one guy in the tower who operates the dry circuit, a series of ground personnel, and maintenance men who float around. We operate roughly 5 miles of conveyor, including ship loading and everything
from end to end.” The dry circuit is a fractionated plant that produces three main products — 4x2, which is made to order as needed, and 2x0 and 1x0, which are either sent directly to the vessels at the dock or used as a blend for the next plant. The “Hill line,” as they call it, carries material to the next processing plant or load out surge. “The stacker does double duty — everything on the right goes straight to the ships, and everything on the left is surge for the wash plant,” Grashel explains. “There are four 1961 vintage overhead galleries leftover from the 1960’s plant. They can hold upwards of 80,000-plus tons of product. We still use three of the four today.” The wash plant separates fractions, producing 2x1, 1x1/2, 1/2x1/4, and manufactured sand. All of the products are placed in stockpiles over tunnels so that blends can be created. Everything going out to the vessels is tested at the quality control lab, where personnel do manual cuts and quick gradations every thousand tons, making adjustments as needed as they load the vessels. Lab personnel are in constant communication with loader operators and the shuttle operators feeding the vessel. The conveyor that feeds the dock’s boat loadout area crosses the main road in the Village of Marblehead, which has a full-time population of approximately 1,000 and a summertime population that soars because of tourists. The conveyor is enclosed where it passes over the road and has the name of the quarry operation on its side. Mainly river-class boats are loaded at the loadout facility. “They berth on the west side and shift up and down along the dock as we load it,” Grashel says. “There’s someone in the tower who is communicating with the lab technician checking the samples, loader operators back in the plant, and a mate on the vessel. “We usually load one vessel a day, which can take anywhere from 10 to 12 hours, depending on products and shifts. The average size load is 17,000 tons; for the occasional larger freighters it is upwards of 30,000 tons. We can also load smaller barges that go to the islands, and
PLANT PROFILE
Helping the Environment Back in the 1900s, the quarry supplied flux stone for the steel industry, so there is an area where the spoils from mining flux stone have been piled. Rather than these piles just being eyesores and overburden to current operations, they have become a prime habitat for the Lakeside Daisy. “Over the years, the Lakeside Daisy has grown on these spoils piles, and it’s something we work with on a regular basis with Fish & Wildlife and the Ohio Department of Natural Resources (ODNR),” Grashel explains. “These are natural resources, and we work proactively to transplant and protect the species.” The wildflower is only found in a small area on the Marblehead Peninsula, and is a threatened species on the Rare Native Ohio Plants Status List. They usually bloom for the first two weeks in May, around Mother’s Day, featuring 9-inch-tall flower stalks with inch-and-a-quarter-diameter bright yellow blooms. “They’re everywhere on the spoils piles, so we’ve been working since 1994 to transplant them,” Grashel notes. “We try to find areas to put the daisies and the seeds as we move the spoils piles. I have groups of volunteers two or three times a year that come out to actually pick the seeds and transplant the main plants. We donated 15 acres on the other side of the property to the state back in 1996 as a daisy preserve. We’ve had great success transplanting the daisies at the state park on Kelleys Island. “From an environmental standpoint, that’s one of the biggest things we do — managing the Lakeside Daisy and working with Fish & Wildlife, and we’ve been doing it for a long time,” Grashel says. “That’s the biggest piece of our Wildlife Habitat Council award, but we also put in birdhouses for the Blue Jays, make brush pile habitats for rabbits, and put up raptor perches for the bald eagles on this site.” The quarry has been permitted to go an additional 54 feet deeper in the pit, so life expectancy for the quarry has been greatly extended. However, the material below the current floor is a bit different in quality, so personnel are already discussing how it will have to be managed differently.
Embracing the community
Three of the four 1961-vintage overhead galleries leftover from the 1960s plant are still being used and can hold upwards of 80,000-plus tons of product.
have loaded some small 500-ton barges that come in for aggregate.” There is a nice maintenance shop on site where in-house mechanics manage the maintenance on almost everything, including working on equipment. At the welding shop, fabricators can build just about anything. “That’s one of the things I’m most proud of, my people and our health and safety record,” Grashel says. “They have a
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AGGREGATES MANAGER / February 2017
lot of experience in this facility. I’ve been here for 24 years and am proud of the experience that we share together.” The dolomitic limestone deposit at the quarry is used mostly for construction. The primary markets for the aggregate are Cleveland, Windsor, Detroit, and, from time to time, Erie, Pa. One of the largest projects the quarry has been supplying aggregate for during the last three to five years is the Essex Parkway in Windsor.
“We’re very conscious of being good neighbors, it’s very high on the list,” Grashel says. “You have a 100-year-old quarry in the heart of a resort area, so we have to be very cautious. We encompass the majority of the center of the entire peninsula. We get a lot of tourists through here in the summer, and Kelleys Island, which is full of summer homes, is just a ferry ride away.” The third-party contractor that handles the larger stones at the quarry uses haul trucks to carry the material to the dock. When they do so, they have to cross the main street through the Village of Marblehead. As part of the quarry’s ongoing commitment to the community, the site bought a sweeper truck that is
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Image courtesy of Marblehead Quarry
PLANT PROFILE
A conveyor that feeds the dock’s loadout area is completely enclosed where it crosses the Village of Marblehead’s main road, and the quarry operation name is on its side.
the lighthouse festival at the Village of Marblehead,” Grashel says. “The tour provides an opportunity for the community to come out and see our operation. We get a lot of visitors not just from the company, but from outside the company as well. We’re not that remote.”
At the dock loadout facility, vessels berth on the west side and shift up and down along the dock as they are loaded. A person in the tower stays in contact with the lab technician checking the samples, loader operators back in the plant, and a mate on the vessel.
Safety and the workforce
used, as necessary, to ensure no tracks or spillage is left on that main road. Quarry personnel were also thinking of their neighbors when, a few years ago, they switched from the typical beeping back-up alarm on their equipment to using white noise back-up alarms that sound like quacking. That was done as an aftermarket fix, but the company orders new equipment with the white noise alarms. This change also is beneficial from an employee safety perspective, as it provides an alternate sound to alert employees who may have become too accustomed to hearing the truck’s traditional backup alarms. “We won an award in 2010 for the landscaping around our scale and entrance in general,” Grashel notes. “We took advantage of that when we built the new loadout yard in 2012. We had a ribbon cutting and a family day.” Long-term plans at the quarry include building an overlook for the community to enjoy during tours. “We do anywhere from 10 to a dozen tours with colleges and local high schools annually, and do one tour every year that coincides with
The quarry is staffed seven days a week from mid-March to mid-December. Production takes place five days a week, and a skeleton crew works on weekends. There are three production shifts with 24-hour operations, except on Tuesday and Thursday when maintenance is performed on the impactor during the day shift. All three production shifts operate Monday, Wednesday, and Friday. A swing crew works different shifts to allow people to be off. Grashel says he has to be creative running a seven-day-a-week operation. Once the lake freezes over in the winter, operations shut down for three months. There is still some truck shipping going on, as well as stripping activities, and maintenance is performed during that time, but the crew is reduced by half. “We’re coming up on three and a half, almost four years — 500,000 manhours — without an LTI (lost-time incident),” Grashel notes. “Obviously, we pride ourselves on that. We have MSHA regulations, but we’re really focused on trying to understand safety behaviors and risk tolerance. “Our near-miss program encourages
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AGGREGATES MANAGER / February 2017
employees to identify safety issues, bring them to the table, and talk about them as a group,” Grashel continues. “That’s something that’s really important to us, and we’re really focusing on that right now. Safety is all about buy-in.” The quarry currently employs 60-plus employees in season, and nine of those have more than 40 years of experience. “I think my employees have a lot of knowledge to share with each other and new people coming in,” Grashel says. “We transfer knowledge, and that’s something I’m very proud of.” AM
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PULL-OUT GUIDE By Tina Grady Barbaccia, Contributing Editor
February 2017
Developing Neighbor Relations Emphasize safety and be sure visitors have closed toe shoes and a hard hat for their visit.
Create a safe lookout point for visitors to the operation.
Keep the operation neat and tidy to create a good first impression.
Use material to create a natural barrier from the high wall in areas where visitors may be.
OPERAT
Dev
1
Get involved with schools
Community outreach can build community support
B
uilding community and neighbor relations may seem daunting for aggregates operators starting from scratch, but it can be as simple as channeling employees’ passions into the workplace. “You don’t need to have money to donate,” explains Alan Burnette, director of resource development for Lehigh Hanson’s South Region. “We found that in our own cataloguing and tracking of events, most people in our industry are already doing community relations and just don’t realize it. Even at the grassroots level, it is important to be involved.” Formation of a neighborhood advisory group for the homeowners and businesses surrounding Lehigh Hanson’s Crabtree Quarry has been well received. It provides a forum for the quarry’s neighbors to air concerns and provide feedback while involving employees. This has helped elevate community relations with quarry neighbors — and has become an important recruiting tool. “People’s ears perk up when I share what we do in community relations,” Burnette says. “It’s a big part of attracting and retaining talents. We all want to be involved in something bigger than ourselves that is more than just a paycheck.” Rogers Group’s Rutherford Quarry and Pottsville Quarry hosts a “BBQ in the Pit” to build neighbor relations and involve employees’ families. A big tent is set up in the pit, AGGREGATES MANAGER
and a barbeque meal is served. “We invite all local politicians, neighbors, and employee families,” says Derek Roberts, vice president of aggregates for the South Central Division of Rogers Group. “It lets everyone put their feet on the quarry floor and see what you are all about.” Bringing people into the operation like this has been invaluable, Roberts says, because it provides an avenue to start building relationships. “When you are ready to make something happen at your site, you may be in a bind if you don’t have relationships because you aren’t different from anyone else,” he says. Rogers Group’s Lawrenceburg Quarry in Lawrenceburg, Tenn., built neighbor relations while helping a dream come true for Abigail, a young girl with Down’s Syndrome. She loves baseball and dreamed of building a rubberized ballpark for children with special needs so they wouldn’t get hurt if they fell. The sales manager for the operation met Abigail’s father when he inquired about stone for the field and parking lot. He told the sales manager about her quest to raise money to make the ballpark a reality. Rogers Group decided to get involved, and with Abigail’s parents, they raised more than $400,000 for the project. “We were able to donate all the materials, all the stone needed under the field, and handle the site work,” Roberts says. “It was pretty amazing to be involved in a project like this.”
Making monetary donations is important, but getting directly involved in projects builds relationships and helps the community view the supporting organization as an asset. On Earth Day, Rogers Group’s Lacey Springs operation employees worked with third grade students at Lacey Springs Elementary to plant new flowers and update landscaping in front of the school. Working with the kids during their classes not only contributed to the community, but allowed some of the employees to work alongside their own children.
4
Provide face-to-face interaction
When initiating neighbor relations, begin with smaller organized events that provide face-to-face interaction, such as a cookout. From there, expand on what worked and revisit any areas that could use improvement. Smaller-scale events, such as a barbeque open house, allows attendees to give both positive and negative feedback so changes can be implemented to improve the overall community experience. During these events, be transparent about daily business operations. This is an opportunity to create knowledge about the aggregates industry and its processes and procedures, which will, in turn, help to ensure a lasting relationship between the producer and the community.
TIONS ILLUSTRATED
veloping Neighbor Relations 2
Solicit employee input on causes
3
OUR
EXPERTS
Get to know local politicians
Tony Halloran is operations manager for StoneCo, an Oldcastle company. He has been with the 100th Street operation for 24 years.
Inviting employees to suggest a cause to support provides opportunity for their personal fulfillment while strengthening ties to the community. Incorporating personal interests also boosts employee participation. Promoting a culture that works together and welcomes input from employees from the plant level on up can be an important recruiting tool and method of employee retention. Lehigh Hanson’s Princeton, N.C., operation sponsored a Habitat for Humanity House, with more than 800 hours put into its construction. One employee, who didn’t live in the area, even took vacation to assist with the project.
5
Team up with the city or county
Lehigh Hanson received an award for its twice-yearly “Big Sweep Pickup,” where employees and their families from multiple local quarries teamed up with Wake County, N.C., to clean up the Crabtree Creek which flows through its Crabtree Quarry operation. More than 6,000 pounds of trash were removed from the creek. Employees spent the day with their families while helping the local community improve the environment.
Get to know and work with local politicians, such as the county commissioner and city council members, and let them know your operation would like to become active in the community. They are familiar with the needs of a community and are able to put operations in touch with the proper people to help address those needs. This acquaints operational personnel with local decision-makers. Get employees involved in the process. If help is needed from the politician, the message will then be from several individuals, not just the company as a whole.
6
Educate the public
Taking every opportunity to educate the public about the aggregates industry is invaluable. When hosting school tours, consider having an outline that each operation can follow to provide consistency in the message. The tours should cover safety, equipment used, blasting, uses of stone, how concrete is made, and rock types such as sedimentary, igneous, and metamorphic. This will both teach children and give proper information to any parents or other chaperones in attendance. It also provides an introduction should a negative concern arise that needs to be addressed.
Alan Burnette is director of resource development for Lehigh Hanson’s South Region with his office in Atlanta, Ga. He has held this position for five years and started in the industry with a Hanson predecessor company in 1989. Burnette holds a bachelor of science degree in natural resources/environmental management from Ball State University and a law degree from Indiana University-Indianapolis.
Derek Roberts is vice president of aggregates for the South Central Division of Rogers Group. He serves on the membership committee for the National Stone, Sand & Gravel Association (NSSGA) and is a past chairman of NSSGA’s Young Leaders group.
February 2017
Voices of Experience Tony Halloran
W
hen it comes to community and neighbor relations, the biggest lesson learned is that even the smallest gesture goes a long way with customers, vendors, and the local community. When a neighbor who lives right by the quarry was moving, some employees of the StoneCo 100th Street location went over to help. “Neighborly interactions are inevitable in our business,” says Tony Halloran, operations manager for Oldcastle’s StoneCo’s 100th Street location in Byron Center, Mich. “We try to stay really close knit, especially with the neighbors close to us. If we hear they need something, we’ll try to provide equipment, labor, or whatever they need.” When an employee was picking up his daughter at school, he learned about the school’s plans to add reading stones for its students. He mentioned it at work, and StoneCo donated them to Coldwater Elementary. “We encourage that with our guys,” Halloran says. “We want them to bring it to work, and we’ll see what we can do.” Whether it’s supporting a local school, giving scouts a tour of the quarry, or hosting a barbeque, Halloran says it’s important to seek out community events for sponsorship or volunteer opportunities, especially when it’s important to an employee. “It gives them pride knowing that their company will stand behind them, support causes important to them, and even help out their own children,” he says. “Employees are 100-percent invested in our events, as the communities in which we serve are also the communities in which they work and live.” Employee engagement in StoneCo events also provides face-to-face interactions for many of the front-line employees who do not have the opportunity to interact with customers, vendors, and the local community on a daily basis. “It provides networking opportunities that exposes us to additional service opportunities to extend stewardship to the community,” Halloran says. “It gives them a stake in it.” AGGREGATES MANAGER
Alan Burnette
B
uilding good neighbor relations is about more than just writing a check or simply donating material. “While the financial component is important, it doesn’t really create the kind of involvement that builds relationships,” says Alan Burnette, director of resource development for Lehigh Hanson’s South Region. “If someone is asking for a donation for a fun run, ask how else you are able to help. Are you able to help with registration so you’re not just a stone provider or someone just writing a check? There is not always involvement with investment.” Genuine investment in neighbor relations is about individual involvement and collaboration. At the Lehigh Hanson Princeton Quarry in Princeton, N.C., several employees volunteered to participate in Habitat for Humanity, putting in more than 800 man hours. Don Harvey, who runs the Princeton Quarry, worked extensively with his location’s team on Habitat for Humanity. “We ended up having an entire crew, including some people from the regional office, so there were employees from all levels,” Burnette says. “They spent their personal time and strengthened their bond as a team. They hammered nails side by side.” Employees’ families and other community members also participated, building both a company and community culture where people work together. At Lehigh Hanson’s Crabtree Quarry in Raleigh, N.C., Plant Manager Jim Hilton organizes the semi-annual “Big Sweep” cleanup effort for the Crabtreek Creek that runs through the quarry. “Twice a year, we rent canoes and kayaks to pick up trash in the river,” Burnette says. “Being a good neighbor is a ‘want to, not a have to’ for our employees.” Burnette says that community involvement and operational transparency are absolutely essential for construction materials producers: “We can’t be scared to engage with neighbors who don’t understand or don’t want a mining operation in their area. Even if we agree to disagree, we want to make sure we are responsible operators.”
Derek Roberts
D
ifferent communities have varying focuses and needs. Understanding what is important helps build good neighbor relations and transforms the operation into a valued community asset, says Derek Roberts, vice president of aggregates for the South Central Division of Rogers Group. The communities near the Rogers Group’s Lacey Springs, Tanner Quarry, and Pottsville Quarry operations have a heavy focus on education, so Rogers Group “adopted” these local schools. Through their partnership with the schools, teachers are free to send requests to the various operations. The requests are compiled before Rogers Group employees sit down with the principal to prioritize them. “This streamlined everything and helped us give back,” Roberts says. “It gave the principal some input and helped him see what the teachers were asking for.” Direct involvement with the schools also provides a big opportunity for education. “When we do school tours at the quarry, we have a lot of parents who come along as well,” Roberts says. “The parents and teachers seem to learn as much as the kids.” The tour can then segue into an opportunity to educate parents and allows the operation to build relationships with them outside the school environment. If a call is received about dust or noise, or a blasting complaint is made, it too can be turned into an educational opportunity. “The more we are able to educate them, the more they seem to understand we are not so bad,” Roberts says. “If we get a blast complaint, we follow up with the homeowner and partner with our seismic company. We put a seismograph in their yard so they can see the numbers measured and correlate it to what they feel. Once they understand what we are doing is in a controlled atmosphere and the calculations that go into it, they are okay with us being a neighbor.”
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SPECIAL REPORT by Andrew Cecala and John Organiscak
A metal/non-metal underground mining crew partners with NIOSH to study air quality in enclosed cabs and improve worker health.
O
ver a four-year period, a mine manager and mining crew at two underground limestone mines had a significant impact on assisting National Institute for Occupational Safety and Health (NIOSH) researchers in reducing contaminants and improving the air quality in enclosed cabs of mobile mining equipment. Because of this positive cooperative working relationship, NIOSH researchers were able to evaluate the following: • The impact of a powered intake air unit versus a static design, • Use of an in-cab pressure monitor to determine the integrity and functioning of filtration and pressurization systems, • Changes in air quality using different filter configurations and filter dust loading characteristics in the filtration and pressurization systems, and
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AGGREGATES MANAGER / February 2017
• HEPA versus MERV 16 quality filters on the air quality inside the enclosed cabs.
Gaining partners Over the past 15 years, the Pittsburgh Mining Research Division (PMRD) for NIOSH has partnered with many different companies and organizations to improve the health of miners working inside enclosed cabs of mobile mining equipment. In addition, NIOSH has also partnered with an array of different surface and underground metal/non-metal mining companies to perform research studies on reducing dust/contaminants and improving the air quality inside of enclosed cabs. After the completion of one of these studies, the results were published and presented at the SME Annual Meeting. When the presentation ended, Doug Hardman, president of J.H. Fletcher Co., approached the NIOSH researcher and
J.H. Fletcher Co. face drill and roofbolter machine were evaluated at two different underground limestone mines over four years.
informed him of his company’s desire to build upon NIOSH’s research with the design of its filtration and pressurization system with the goal of improving the air quality to miners working in its equipment. From this conversation, a cooperative working relationship was established with J.H. Fletcher Co. and this longstanding relationship continues to this day. Initially, shop testing was performed on a few different pieces of Fletcher’s mining machinery at its headquarters and manufacturing facility in Huntington, W.Va. Next, engineers with Fletcher’s metal/non-metal underground sector laid the groundwork for testing at an actual mine site to evaluate two new pieces of its equipment equipped with the newly designed filtration and pressurization system. This cooperating site was the Sidwell Mining Co. underground limestone mine, south of Zanesville, Ohio. NIOSH’s point of contact was Ted DiNardo, the mine manager at this relatively new underground limestone mine. From November 2010, through July 2011, NIOSH performed research during 13 different visits to this mine. Unfortunately, at the end of December 2011, DiNardo informed the researchers that the Sidwell underground mine was closing and all its underground assets, including the equipment, were being sold to the nearby Shelly Materials Co. (part of Oldcastle Materials/CRH). However, as part of the sales agreement, all of the original Sidwell underground employees, including DiNardo, were offered jobs with Shelly, which was opening a brand new mine only 4 miles away from the previous site. Once the new underground mine progressed to an extent where testing could be performed, NIOSH continued its research with the mine manager and underground mining crew. Fortunately, since the same two pieces of equipment tested at the previous mine — a single-boom face drill and roofbolter machine — were purchased, NIOSH was able to continue its research on the exact same equipment. From April 2013, through the completion of research in November 2014, NIOSH traveled to this underground limestone mine on 19 different occasions as a part of this cooperative research effort.
Making research advances As a result of this cooperative research effort, advances were made in four areas.
1. The impact of a powered intake air unit versus a static design. It was determined that a powered intake air system was the optimal design over a static type system. On a powered unit, the intake air has its own fan, so the air is delivered at positive pressure through ductwork to the main HVAC unit. One benefit to this is that a known quantity of intake air is always provided to the enclosed cab. Obviously, as the intake filter loads with dust, the intake air quantity decreases, but there is a known and reliable air quantity range from a clean to a fully loaded filter. The intake air is a critical component in the enclosed cab’s positive pressurization level along with the cab’s integrity (ability to be reasonably sealed). In a static design, the actual intake air quantity is more variable based upon the loading rate of all the filters used in the system, and it is difficult to determine or control the intake-to-recirculation air ratio. Because of this, the actual amount of intake air delivered to the enclosed cab is variable and is dependent on numerous factors. Having a known quantity of intake air delivered to the enclosed cab is not only of great benefit in creating positive cab pressurization, but is critical in regards to CO2 levels and ensuring the equipment operator does not become asphyxiated while working in the enclosed volume. NIOSH researchers believe a minimum quantity of at least 25 cfm of intake/outside air per person should be maintained to dilute CO2 quantities exhaled by each worker. Since almost all enclosed cabs in the mining industry are designed for a single operator, a recommended lower limit for pressurized intake air would be somewhere around the 40 cfm range in order to achieve a minimal cab pressurization, while also ensuring a level of safety in regards to the CO2 issue. A good rule of thumb for an acceptable pressurized intake air range would be between 40 and 140 cfm. Another advantage with a powered intake air unit is it can AGGREGATES MANAGER / February 2017
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SPECIAL REPORT be designed to minimize dust loading on the intake filtering unit by using one of two proven techniques: (A) a self-cleaning filter technique, or (B) a centrifugal design which spins out the over-sized dust particles (>5.0 microns) before reaching the intake filter. A common self-cleaning method is to use a reverse-pulse or back-flushing technique in which a compressed air system is activated to blow the dust cake off the intake filter. This reverse-pulse can be used either on a regular time interval or based upon a differential pressure across the filter. With the centrifugal design, the system spins the oversized particles out of the unit and back into the atmosphere to minimize the number of particles being deposited on the intake filter. This system has an approximately 90 percent efficiency with particles greater than 5 microns. Both the self-cleaning and centrifugal techniques have been tested and shown to be very effective at providing a known quantity of intake air to the enclosed cab while minimizing dust loading on the intake filter.
2. Use of an in-cab pressure monitor to determine the integrity and functioning of filtration and pressurization systems. With any new filtration and pressurization system, the starting positive pressure should be established and recorded. Then, over time, as the system filters load with dust and contaminants, the intake airflow decreases, which also decreases the cab’s positive pressure. Since filter loading rates are different in all cases based on contaminant levels where the equipment is located in the mine, using a filter cleaning or changing schedule based on time is not the preferred method, because a mechanical filter becomes more efficient as it loads with dust and contaminants and develops what is commonly known as a “dust cake.” Knowing the positive pressure of the cab provides the equipment operator or maintenance personnel with the ideal filter changing time based upon the required intake airflow. The enclosed cab’s positive pressure will be highest with new filters and then as the filters load with dust, the intake airflow will decrease, which also directly decreases the cab’s positive pressure. Once the cab pressure decreases to the point where the intake air is at the minimal level, it signifies that a new intake filter needs to be installed. Conversely, a rapid increase in positive cab pressure also indicates a system failure. This could include such things as a hole or tear in the filter media, a clog in the recirculation system such as a plastic bag or a rag covering the recirculation inlet, or even a maintenance worker removing a used filter and then forgetting to replace it with a new one. It is also possible, over time, for the cab integrity to be compromised by a damaged door, window gasket, or seal being damaged or removed. An in-cab pressure monitor provides the most real-time indication of the cab’s performance over time. There are a number of commercially available pressure gauges that have an alarm option to signify that the intake filter needs to be changed. Using one of these pressure gauges is a very effective way to monitor the cab filtration and pressurization system functionality.
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AGGREGATES MANAGER / February 2017
3. Changes in air quality using different filter configurations and filter dust loading characteristics in the filtration and pressurization systems. Different filter combinations were evaluated in both pieces of equipment during the testing performed at the Shelly Materials Co. mine. Table 1 shows the various combinations and the resulting protection factors on the roof bolter machine. These tests were performed under static conditions which indicates that no one was entering or exiting the enclosed cab during the particle count testing, and thus no dust was allowed to enter by opening the cab door, nor was anyone inside the enclosed cab to stir up any in-cab dust sources. Because of this, these protection factor (PF) values are at their highest. Table 1: Roof bolter protection factors with various filter combinations.
FILTER COMBINATIONS Used Used intake, intake and recirculation, recirculation and final filters filters PROTECTION FACTORS
3
PROTECTION FACTORS
76
New intake and final filters
Used intake and final filters
PROTECTION FACTORS
PROTECTION FACTORS
300
465
These results provide a significant amount of insight into the effectiveness of the various filters in the system. Obviously, the lowest PF measured was when testing a used intake and recirculation filter combination with no final filter. In the next evaluation, a final filter was added to the system, resulting in a significant increase in the protection factor from a value of 3 to 76. Somewhat surprising was the huge increase in the next two combinations when the recirculation filter was removed from the system. A PF of 300 was achieved with a new intake and final filter, which was a substantial increase over the previous values. The researchers do not believe this would be typical with most filtration and pressurization systems, but for this system, adding the recirculation filter into the system was detrimental because the recirculation filter was under-sized, which significantly reduced the recirculation airflow and thus, the air cleaning potential of the system. A negative aspect of not having the recirculation filter in the system is that dirt and dust from inside the cab is drawn into and is deposited in the HVAC system, thereby increasing maintenance issues. An alternative solution to improving this cab filtration system would be to increase the size of the recirculation filter to increase its airflow capabilities. Finally, note the significant increase in the protection factor from 300 to 465 when evaluating a used intake and final filter. As stated previously, a mechanical filter becomes more efficient as it loads with dusts and contaminants and creates a dust cake, which results in a significant increase in the air quality and the resulting PF.
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SPECIAL REPORT
A note of appreciation NIOSH would like to state its gratitude and appreciation to the following individuals for their assistance and friendship during this research: • Ted DiNardo, mine manager, Sidwell Mining Co. and Shelly Materials Co., • Jerry Siddle, face drill operator, Sidwell Mining Co.; Mine Foreman, Shelly Materials Co., • Jay White, roofbolter operator, Sidwell Mining Co.and Shelly Materials Co., • Harry Montell, face drill operator, Shelly Materials Co., • Adam Drake, equipment operator and blast crew, Sidwell Mining Company and Shelly Materials Co., and • Tom Appel, mine engineer, Shelly Materials Co.
Jay White, Adam Drake, Harry Montell, Jerry Siddle, Ted DiNardo, and Tom Appel (left to right) all played an important role in NIOSH’s research.
In addition, NIOSH would like to acknowledge Douglas Hardman, president; Ward Morrison, retired product manager; and Sean Farrell, former product engineer, Rock & Industrials Minerals Products Division, with J.H. Fletcher & Co.; for their assistance and long-standing support of this research effort over a number of years. The cooperation and dedication of all these individuals was instrumental in the success of advancing the science to improve the air quality inside of enclosed cabs of mobile mining equipment.
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4. HEPA versus MERV 16 quality filters on the air quality inside enclosed cabs. When most health and safety professionals today think about filtration efficiencies and their correlation with protecting workers’ health, the normal assumption is the higher the efficiency of a filter, the greater the protection afforded to workers. The term HEPA quality was established by the U.S. Department of Energy and signifies a filter that has a 99.97 percent filtering efficiency for ≥ 0.3-micron particles. The Minimum Efficiency Reporting Value, commonly known as a MERV rating, is a comparative value designated by American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) to compare the effectiveness of different filtering efficiencies. A MERV 16 rated filter must be capable of at least a 95-percent filtering efficiency on 0.3- to 1.0-micron particles, thus being significantly less efficient than HEPA rated filters, which must meet a 99.97-percent filtering efficiency on 0.3- to 1.0-micron particles. Going against normal assumptions, for this testing, NIOSH hypothesized that HEPA quality filters were too restrictive for the mining industry and speculated that the MERV 16 rated filters were the optimal choice. To test this hypothesis, both MERV 16 and HEPA quality filters were evaluated in the filtration and pressurization system of the roofbolter and face drill machines at the Shelly Materials Co. mine. Testing was started in May 2013 using a MERV 16 intake and final filter and repeated on roughly a monthly
basis until November 2013. In May 2014, this test was repeated with all aspects being identical except now using the HEPA quality filters. Statistically, at the 95 percent confidence level, there was no difference between the PF values for either the face drill or the roof bolter machine using both types of filters. However, since the MERV 16 rated filters were less restrictive, they provided greater airflow and cab pressurization. In addition, since these filters are less costly and do not have to be replaced as often as the HEPA filters, it was concluded the MERV 16 filters were the optimal choice for both pieces of mining equipment in this case study comparative analysis.
Sharing results Throughout the four years of testing highlighted in this article, there were constant discussions with J.H. Fletcher Co., Sidwell Mining Co., and Shelly Materials Co. to provide updates on the results of the research being performed. These discussions were also held with the miners on a monthly basis when the NIOSH researchers were performing their testing. Periodically throughout the study, a lunch-time meeting was scheduled during which Ted DiNardo would have the mining crew come out to the mine office for lunch and allow the NIOSH researchers to provide the crew with a PowerPoint presentation showing updates of the research results obtained during this testing. These meetings were always well received and provided a two-way flow of information.
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SPECIAL REPORT The white areas of the inside filters represent what the miner would be breathing inside the enclosed cab through his working shift. The dark areas of the outside filters represent what the miner would have been breathing if there was no filtration and pressurization system to clean the air before entering the enclosed cab. Based on these findings, it is not difficult to comprehend the tremendous impact of the improved air quality from the filtration and pressurization system and the long-term effects on improving the health of miners and minimizing the potential for developing silicosis, black lung, chronic obstructive pulmonary disease, or any other types of lung diseases. AM
Figure 1: Respirable dust filter cassettes from inside and outside the enclosed cab of a face drill machine during testing on July 30 and 31, 2014, at underground limestone mine.
At one of the last meetings, one slide that had a tremendous impact on the miners was comparing the outside and inside gravimetric dust filters for the face drill machine for July 30 and 31, 2014 (Figure 1). Since these gravimetric samples were taken with a 10-mm Dorr-Oliver cyclone device, they represent the particles that are approximately 10 microns and less in size that would deposit into the inner regions of a miners’ lungs.
Andrew Cecala is the principal supervisory mining engineer for the dust, ventilation, and toxic substances branch of NIOSH’s Office of Mine Safety and Health Research. John Organiscak is a senior research engineer. They are based at NIOSH’s Pittsburgh, Pa., office.
Disclaimer
Mention of any company or product does not constitute endorsement by the National Institute for Occupational Safety and Health. The findings and conclusions in this report are those of the authors and do not necessarily represent the views of NIOSH.
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EQUIPMENT MANAGEMENT by Eric Yeomans
Right-Sizing
Your Hauler Fleet Intelligent tools can help determine the most cost-effective option for your fleet.
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AGGREGATES MANAGER / February 2017
I
s bigger always better? When it comes to articulated haulers, the industry certainly seems to be moving in that direction. While 30- to 40-ton-capacity haulers still make up the majority of the market, many manufacturers have rolled out 45-ton trucks in the last few years, and 2016 gave way to the largest yet — the 60-ton A60H from Volvo. While these capacity increases can boost production numbers, and ultimately reduce cost per ton, there are many more factors at play that must be evaluated by a fleet manager to ensure the site is able to reap the rewards of a larger machine. An articulated hauler is only as effective as its supporting machines — the excavators, loaders, and crushers. Evolving site conditions can also factor into proper fleet sizing. What once was the perfect combination of machines may not be in the future as haul routes or crushing sites change. Thus, properly sizing a hauler requires looking at the site and the fleet holistically, and continuing to monitor fleet utilization over time. Fortunately, many equipment dealers and OEMs offer a range of technologies and services that can make this an easier process than ever before.
Site simulation One of the best ways to gain a holistic view of the operation is to conduct an analysis via site simulation software — a process typically completed with the help of an equipment dealer and/or OEM. The process begins by gathering all necessary data points on jobsite conditions. The following will outline, step-by-step, the actual data from a site simulation conducted by Volvo Construction Equipment and a local dealer for a Virginia limestone quarry owner who was evaluating whether four 60-ton articulated haulers would pose efficiencies over five 43-ton articulated haulers.
Step 1: Jobsite conditions The first step is completed with the help of a handheld GPS device that records and logs site information along the haul route — including haul distances, curves in the haul road, and road gradients — factors that all affect cycle times. This data is then imported as a GPX file into a site simulation software program. In the example below, the haul route is 7,286 feet from loading point to dumping site. Once GPS data is imported, the fleet manager works hand-in-hand with the OEM or dealer to input a number of jobsite-specific factors, including material information, such as bank density, swell factor, loose density, and the estimated average percentage of bucket fill. The software also allows for selection from several categories of ground conditions in order to calculate rolling resistance of the equipment — a key factor in estimating cycle times and fuel efficiency levels.
Material
Bank Density (pound/ cubic yard)
Swell Factor
Loose Density (pound/ cubic yard)
Bucket Fill Factor (%)
Excavation Class
Limestoneblasted
4,960
1.35
3,100
95
Class 4
Step 2: Operating hours Next, annual working hours (per machine) are estimated by taking into consideration total scheduled shifts per year, average shift duration (minus non-operating delay per shift), and then subtracting estimated scheduled maintenance. In this instance, the quarry owner estimated 95 percent machine availability, which amounts to 240 8-hour shifts (or 1,824 operating hours) per machine, per year. A combination of mine conditions, operating parameters, and equipment options should be analyzed to determine the most cost-effective equipment options.
Step 3: Equipment specifications After incorporating GPS information and manually entering jobsite factors, the team then inputs equipment model information, including number of machines, model numbers, and bucket size(s). The software will automatically pull the necessary equipment specifications in order to run a production simulation. The team can then run reports with various combinations of equipment models AGGREGATES MANAGER / February 2017
39
EQUIPMENT MANAGEMENT total operating hours, and production levels, the team can evaluate cost to operate (including labor and fuel consumption) versus production levels. In the presented scenario, a fleet comprised of four 60-ton trucks versus five 43-ton trucks resulted in an estimated savings of 25.6 percent in operating cost.
Step 5: Cost to operate
Understanding not just the distance, but also road gradients and curves, helps operators to more appropriately plan their hauling equipment.
for the loading and hauling units — comparing them side-by-side to arrive at the solution that delivers the best production at the lowest operating cost.
Step 4: Production analysis review The final production analysis includes data points such as average cycle time, average bucket passes to fill hauler, estimated average fuel consumption per hour, and, ultimately, a comprehensive fleet analysis outlining fleet production per year in cubic yards. Machine utilization can be further reviewed in a cycle time breakdown, outlining exactly how the hauler is spending time during each cycle, including average load queue time, average spot time at the loading unit, average travel time, average spot time at
40
AGGREGATES MANAGER / February 2017
dump, and average dumping time. In the scenario of the Virginia quarry, the simulation surprisingly showed the cycle times slightly shorter with the 60ton trucks (9 minutes, 19 seconds) versus the 43-ton trucks (9 minutes, 32 seconds) due to less travel time. In addition, each haul resulted in 9.2 percent more material, which meant fewer cycles and lower fuel consumption, despite the 60-ton truck’s larger engine. The site simulation analysis also shows a difference in fuel consumption of the loader (a Volvo L350F with 9.1 cubic yard bucket), between the two scenarios, burning more fuel in gallons per operating hour when loading five 43-ton trucks versus when loading four 60-ton trucks. Looking at the important figures of fuel consumption, number of machines,
These figures represent only a part of the picture of total operating cost, however. The dealer or OEM should also work hand-in-hand with the customer to determine total cost of ownership based on a proposed purchase agreement and/ or financing structure for both scenarios. Other costs to consider include: depreciation schedule, taxes, insurance, estimated resale value, service plans, tire replacements, and maintenance costs. The results of a cost analysis as in-depth as what is available with site simulations will help fleet managers determine if they need more machines or could benefit from a different size or even type of machine based on all of the information provided. Once arriving at the most efficient scenario and moving ahead with the recommended fleet structure, it’s important to continue monitoring utilization over time — as haul routes and tasks change with an evolving jobsite. This can be done by once again leveraging the expertise of the equipment dealer and OEM to monitor machine utilization via telematics, but also to make use of the haulers’ on-board weighing data to spot any potential inefficiencies.
Long-term monitoring Telematics adoption has been slowly on the rise in the aggregates industry, yet many are still only using its most basic functionality to respond to alarm codes and monitor machine hours for service planning. However, the technology offers significant opportunity to track machine utilization and ensure the fleet is perfectly suited to the individual site and its production goals. One of the biggest operating factors to keep close watch of is idle time. If idle time on the loading unit (wheth-
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EQUIPMENT MANAGEMENT are also outfitted with on-board weighing systems that can help ensure the operators are loading the hauler to the correct payload on every cycle. Furthermore, this data can be integrated with telematics programs to allow the fleet manager visibility into complete payload management by truck and by operator, providing the ability to identify whether inefficiencies are indeed a result of incorrect fleet sizing, or in fact, could be corrected with some basic operator training.
Intelligence = Profit
Before assuming that bigger is automatically better, consider operating costs such as labor and fuel consumption against the backdrop of production levels.
er a wheel loader or excavator) is hovering over 40 percent, that generally points to one of several problems – either the crusher is too small to keep up with the demand, the loading unit (or its bucket) is
too small, the trucks are too big, or there are too many trucks. Ultimately, arriving at the best possible solution may once again warrant another site simulation. Many late-model articulated haulers
With so much real-time data at your fingertips — and OEMs continuing to provide more optimal size classes that open up new opportunities — spending some time to right-size your fleet may be one of the best decisions you make for your operation’s bottom line. AM Eric Yeomans is Volvo Construction Equipment’s product manager for GPPE Products.
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Second Stage Standouts When it comes to achieving particle shape, cones are crucial. This lineup can help you sort through options for secondary and tertiary crushing.
Secondary crushing for high-volume sites Johnson Crushers International’s Kodiak K500+ crusher is a 500-horsepower, remote-adjust cone crusher suitable for secondary and tertiary crushing of high-production operations. The Kodiak line, including the K200+, K300+, and K400+, features a hybrid cast/fabricated base frame design, automated control system, patented liner retention, patented thread locking ring, and anti-spin cone brake. The line also includes replaceable brass thread inserts, patented internal counterweights, a heavy-duty tramp iron system consisting of pressure relief valves rather than accumulators, and brass v-seat liners. Johnson Crushers International | www.kpijci.com
New crushing line for natural stone With its PRO line, Kleemann is developing plants to meet the needs of natural stone processing. The Mobicone MCO 11 PRO, the first crushing plant in the PRO lineup, can process up to 518 short tons per hour. The diesel-electric drive is said to be efficient, to offer the option of an external power supply, and to create excellent linkage options with other crushing and screening plants. The fully automatic gap setting makes it possible to make adjustments during operations. The Continuous Feed System adapts the feed conveyor to maintain an optimal filling height, while a brand new operating concept incorporates all components and functions within a 12-inch touch panel. Kleemann | www.wirtgen-group.com
High throughput capacity McCloskey International says the C44 Cone Crusher demonstrates its focus on quality components, durability, and reliability. With its 44-inch cone and 440-horsepower power unit, the C44 offers high material capacity and throughput, large stockpile capacity, an excellent reduction ratio, and customer-focused features. The unit’s crushing chamber is built to be reliable in the toughest conditions, producing material ranging from 3/8 inches to 8 inches. The cone can be used as a standalone crusher or in conjunction with other machines as part of a crushing circuit. McCloskey International www.mccloskeyinternational.com AGGREGATES MANAGER / February 2017
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SUPPLYLINES Effective compression crushing reduces wear McLanahan’s MSP Cone Crusher utilizes improved factors of performance to enhance the proven Symons Principle. This principle, combined with a balanced eccentric, higher speeds, fulcrum point position, and stroke, allows the MSP to outperform other cones, McLanahan says. By creating more effective compression crushing, the MSP Cone Crusher reduces liner wear, reducing wear costs, allowing higher product yield, and resulting in decreased overall cost per ton. The patented dust seal system is equipped with an auto-greaser and protects the crusher’s dust-sensitive parts, leading to longer service life, fewer spare parts changes, and lower maintenance costs. All operations are fully automated. McLanahan Corp. | www.mclanahan.com
Intelligent second-stage crushing Optimizing the secondary step in the crushing process means more money for operators. Sandvik says its latest high-precision cone crusher for second stage crushing is more than the next generation of crushers. It is an intelligent, uncompromising piece of power built to produce more. The unit is said to offer up to a 25-percent greater reduction ratio while reducing recirculation by 50 percent with the same high-value product. Sandvik | www.sandvik.com
Inverted tramp relief system protects hydraulic cylinder rod Superior Industries says the simple design of its Patriot Cone Crusher’s inverted tramp relief system ensures the hydraulic cylinder rod seal is not exposed during operation. This greatly reduces chances of contamination and failure. The tramp relief system has fewer accumulators to minimize maintenance and opportunity for failure. If an accumulator does fail, an internal relief valve provides instant relief. When mounted for portability, the crushing plant includes Vantage Automation and Level Assist for quick setup. Superior Industries Inc. | www.superior-ind.com
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AGGREGATES MANAGER / February 2017
Anti-spin feature extends manganese life The newest model in Telsmith’s line-up of T-Series crushers that were originally introduced in 2012 is the T500, which is designed to deliver maximum uptime availability while also minimizing maintenance costs. This 500-horsepower crusher contains a 14-inch maximum feed opening and is capable of processing between 314 and 854 tons per hour. Features, such as anti-spin and fewer cylinders than competitive crushers, are said to provide improved reliability for maximized processing. Telsmith | www.telsmith.com
Get the the most current information with the 2016 Aggregates Industry Atlas and the Atlas on CD. While the printed version of the Aggregates Manager 2016 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.
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by Kristin R.B. White and Adam J. Schwendeman
ROCKLAW
To Be or Not to Be a ‘Working Place’ ALJs reject MSHA’s attempt to expand ‘working place’ through citations that broaden its traditional definition.
T
Kristin R.B. White is a member of Jackson Kelly PLLC and manages the Denver office. She can be reached at 303-390-0006 or kwhite@ jacksonkelly.com. Adam J. Schwendeman is an associate in the firm’s Charleston, W. Va., office. He can be reached at 304-3401077 or aschwendeman@ jacksonkelly.com.
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he Mine Safety and Health Administration (MSHA) and the Secretary of Labor (the Secretary) have recently cited metal/ non-metal operators for failing to conduct workplace examinations of elevators that are used by miners to travel to places in the mine. MSHA cites the mine operators under 30 C.F.R. § 56.18002(a), which requires that “a competent person designated by the operator shall examine each working place at least once each shift for conditions which may adversely affect safety or health. The operator shall promptly initiate appropriate action to correct such conditions.” The operators have argued that they were not required to conduct workplace examinations of the elevators each shift because, absent work being completed on or near the elevators, the elevators were not working places for the purposes of § 56.18002(a). Working places are defined in the regulations as any place in or about a mine where work is being performed. 30 C.F.R. § 56.2. In each cited case, the elevators were merely being used to transport miners to working places, but were not working places in and of themselves. The Secretary’s argument rests on his
AGGREGATES MANAGER / February 2017
broad interpretation of the definition of ‘working place’ contained in § 56.2 and, in particular, the word ‘work’ contained within that definition. The Secretary argues that the elevators at each mine were ‘working places’ because miners used those elevators each day to travel throughout the plant. The Secretary urged the Administrative Law Judges (ALJs) to grant the agency deference and adopt the broad interpretation that mere travel constituted “work.” When challenging the enforcement actions, the operators argued that the Secretary’s new interpretation was overly broad and constituted a substantive rule change because it impermissibly expanded the working place examination requirement into areas such as travelways and, potentially, the entire mine, regardless of whether work was performed in those areas. Furthermore, the Secretary failed to present any evidence that work was being performed, had been performed in the past, or would occur on or near the elevators in the future. Instead, the Secretary merely presented evidence that miners traveled in the elevators to gain access to working places throughout the plant. The operators also argued that MSHA failed to provide adequate and proper notice of its
terpretations of what constitutes a working place in a mine. new interpretation before issuing a citation. Therefore, the Moreover, MSHA’s proposed workplace examination regulacitation was in violation of due process. tion, which would require examinations to occur before work The various ALJs who have heard the cases have agreed begins, did not redefine or add any clarity to the current with the operators’ positions and found that the Secretary’s definition of working place. attempt to conflate ‘work’ and ‘travel’ was inconsistent with As a result, it is recommended that a mine operator the regulatory scheme, was overly broad, and would imgather information early to support any potential challenges permissibly expand the requirement to conduct workplace to workplace examination citations believed to have been examinations into travelways and other areas where work incorrectly issued. During inspections or closing conferences, is not performed. Based upon this finding, the ALJs have questions and discussions with inspectors as to why an concluded that the Secretary failed to meet his evidentiary area is being considered subject to the workplace examinaburden of establishing that these elevators were working tion standard are helpful if a challenge to a citation is filed. places because the Secretary merely presented evidence Further, a mine operator should seek to gather facts and that miners traveled in the elevators daily. The ALJs condocuments supporting its position that the area being chalcluded that mere travel or use of the elevators did not lenged does not meet the definition of a working place. This amount to work. Independent of these determinations, the type of support would include proof of the lack of ‘work’ ALJs also concluded that MSHA failed to give proper and performed presently, in the past, or in the future in the area adequate notice of its change in interpretation, therefore at issue. AM violating the operators’ due process rights. The ALJs concluded that such ‘legislation through enforcement’ was impermissible and SEE US AT vacated the workplace exam citations. CONEXPO Booth # See, for example, Ash Grove Cement G72213 Co., Docket No. WEST 2014-963 (ALJ Barbour, Aug. 4, 2016). Since MSHA reissued its program BEKA auto-lube is built to take the policy letter regarding the workplace bumps and grinds of a hard-working examination regulation in July 2015, life on the road or off. Give your fleet operators have seen an increase in the solution that keeps them on the job. the frequency of citations being writ• Cast aluminum base withstands ten under §§ 56/57.18002(a). Proimpacts and hot/cold cycles gram Policy Letter No. P15-IV-01. It without leaking appears that the agency has looked • No springs! Eccentric gear drive resists wear, fatigue and cold for opportunities to expand the appli• Consistently precise grease dosing cation of the workplace examination Find out why industries are choosing standard by applying the standard today’s best-built auto-lube systems. to areas that traditionally have not Call 1.888.862.7461 or email us been considered ‘working places’ in a at info@beka-lube.com. mine. Operators have seen workplace examination citations issued not only as to elevators, as discussed here, but also to offices, storage rooms, 1.888.862.7461 www. beka-lube.com and travelways. Operators should be aware that current case law does not BEKA - LUBRICATION SPECIALISTS SINCE 1927 always support these broad, new in-
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2017-01-10 9:04 AM
AGGREGATES MANAGER / February 2017 1/12/17 1:39 PM
ADINDEX February 2017
Advertiser
Web
Aggregates Manager Atlas Data/CD Products
www.aggmanatlas.com
47
Aggregates Manager Community Outreach
www.aggman.com/community-outreach
44
Astralloy
www.astralloy.com
9
Atlas Copco Construction Mining Technology
www.atlascopco.us
24
BekaWorld (formerly Beka-Max of America)
www.beka-lube.com
49
Bill Langer - Research Geologist
www.researchgeologist.com
51
C.L. Dews & Sons Foundry
www.dewsfoundry.com
51
Clearspan Fabric Structures
www.clearspan.com/adam
51
Conexpo-Con/Agg 2017
www.conexpoconagg.com
41
Cowin & Company, Inc.
www.cowin-co.com
43
Cummins, Inc.
www.cumminsengines.com/conexpo
29
Curry Supply
www.currysupply.com
15
Deister Machine Co., Inc.
www.deistermachine.com
Elrus Aggregate System
www.elrus.com
Excel Machinery
www.excelmach.com
37
Hazemag USA, Inc.
www.hazemag.com
19
John Deere Construction Equipment
www.johndeere.com/pushback
BC
Kespry, Inc.
www.kespry.com/aggregates
33
KPI-JCI and Astec Mobile Screens
www.kpijci.com
21
Kruse Integration
www.kruseintegration.com
51
Liebherr Construction Equipment Co.
www.liebherr-conexpo.com
13
Martin Sprocket & Gear, Inc.
www.martinsprocket.com
14
NSSGA Conexpo Registration
www.nssga.org
36
NSSGA Membership
www.nssga.org
42
Polydeck Screen Corp.
www.polydeckscreen.com
35
Progressive Commercial Insurance
www.progressivecommercial.com
34
Rice Lake Weighing Systems
www.ricelake.com/truckscales
Sandvik Construction Mobile Crushers & Screens USA
www.construction.sandvik.com
Sepro Mineral Systems Corp.
www.seprosystems.com
43
Sweet Manufacturing
www.sweetmfg.com
51
Trimble Loadrite
www.aggregates.trimble.com
23
United Employment Assoc.
www.unitedemployment.com
51
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 2017
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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
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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
Really Cool Roofing Aggregates can be part of a roofing system that keeps your home cool.
L
ast summer, I installed a peel-and-stick underlayment topped with a white mineral rolled roofing cap sheet to the new roof on the extension my son-in-law, Rob, and I added to our existing covered porch. When I asked my granddaughter, Delaney, (who was 11 years old at the time) to help me apply a white elastomeric coating on the original tan roof, she replied, “Cool. I’d love to help!” Cool, indeed. On a typical summer afternoon, a clean white roof that reflects 80 percent of sunlight will stay about 55°F cooler than a gray roof that reflects only 20 percent of sunlight. Putting a white coating on our roof probably gave it reflectance properties that would classify it as a cool roof. Actually, the first roofing project I ever undertook was about 55 years ago when my dad and I re-shingled the roof on our house with white three-tab asphalt shingles. I can personally testify that white materials have historically been a popular cool option for roofs for quite some time. But a cool roof does not necessarily have to be white. Sunshine includes ultraviolet, visible, and near-infrared light, and about half of the sun’s energy is invisible near-infrared light. There are new cool-colored dark roofs that look like traditional dark roofs, but better reflect near-infrared light. So how does aggregate fit into the picture? The answer probably is obvious to many of you. Coarse sand, either natural or manufactured sand from crushed stone, serves as granules for roofing material including shingles, such as those on my childhood house, or rolled roofing, such as on our new porch roof. Some granules are coated; others are natural. But most start with coarse sand. Slightly larger aggregate is used on flat built-up roofs (BUR). Commonly referred to as ‘tar and gravel’ roofs, BUR are composed of alternating layers of bitumen and reinforcing fabrics. They are topped with a layer of pea stone, either natural or crushed. And, if the stone is white, it can be a cool roof. Stone-ballasted roof systems, which began appearing in the 1970s, are another way to cover flat roofs. Although stone-ballasted roofs appear similar to BUR, there are major differences. Ballasted roofs are ‘loose-laid,’ which means the membrane, thermal barrier, and rock are all laid down without fastening them to each other. Obviously, the membrane seams are sealed, and it is secured to the parapet and at roof penetrations, but it is not adhered to the roof deck or the layers beneath it. The key to the entire system is the aggregate ballast that is placed on top of the membrane weighs down all the components to hold them in place. The stones in a ballasted roof are at least an inch in diameter and applied much more heavily than a BUR. The weight can vary from 10 pounds per square foot (the minimum allowed by code) to 25 pounds or more. Unless the aggregate is white, ballasted roofs do not meet the traditional requirements of reflectivity and, therefore, have not been officially recognized as a cool roof. However, the mass of the ballast acts as a heat sink and simulates the performance of a traditional cool-roof surface with high solar reflectance and high thermal emittance. So next time you are looking for an environmentally friendly application of aggregate, the answer might be lying right over your head. How cool is that!
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AGGREGATES MANAGER / February 2017
Over the life of a screen plant, operating costs will exceed the original purchase price many times over.
Smaller plant with production that matches larger screens.
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Requires less screen cloth.
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Lower power requirements.
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Sets up in minutes.
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Simplified maintenance & service.
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Screen changes on all three decks in under 2 hours.
• • • •
=
PRODUCTIVITY DOWNTIME
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Cost Advantages of the MS612
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THEY SAY TO LET SLEEPING DOGS LIE. NO MENTION OF CATS THOUGH. PRESENTING THE 1050K. A WAKE-UP CALL FOR THOSE WHO’VE RESTED ON THEIR LAURELS LONG ENOUGH.
With the 1050K, you’re not just getting a long-overdue choice in dozers this size. You’re getting the incredible pushing power of a proven hydrostatic drive. And Eco mode to reduce fuel consumption by up to 25% without limiting productivity. Deere designed. Deere manufactured. And backed by a robust service and parts program dedicated exclusively to the productionclass market. The choice is yours. Bet you haven’t heard that in a while. For details, visit your local dealer or our website. JohnDeere.com/PushBack