Next Gen excavators PG6
|
High-tech blasting PG17
Your guide to profitable production
|
MSHA’s Scofflaw Program PG28
February 2019 | www.AggMan.com
Super
Aggregates plans for growth near the
Windy City
10
Get ready for AGG 1
12
Improve your haul cycles
— Smarter. Faster. Empowered. Your passport to a world of mechanical design
DodgeÂŽ Passport is the new, easy-to-use online selection program for Dodge mechanical power transmission products. Passport significantly improves productivity and ensures cost-effective and reliable selections through - real-time pricing and availability - performance-matched components - quote-to-order capabilities Start your journey now. With Dodge Passport. dodgepassport.abb.com
Astec Mobile Screens expands the multi-frequency technology that debuted on its GT205 plant.
PAGE 6
On Our Cover: Tory Pease, president, Super Aggregates, doubles processing and stockpiling capabilities at Marengo operation. Cover photo by Kerry Clines.
At AGG1, producers will be able to see the latest new equipment for the aggregates industry and attend educational sessions that focus on workforce issues.
PAGE 10
TABLE OF CONTENTS FEBRUARY 2019 |
VOLUME 24, NUMBER 2
FEATURE ARTICLES
COLUMNS & DEPARTMENTS
10
3 Editorial Sensible governance and shutdowns..
Indianapolis Plays Host to AGG1 Aggregates producers gather for networking and education at AGG1 Aggregates Academy & Expo and the NSSGA Annual Convention.
12 Improve Your Haul Cycles
Lower your cost per ton by paying attention to haul road design and maintenance.
22 Building Toward the Future
Super Aggregates prepares for future Chicago growth at its Marengo dredging operation.
OPERATIONS ILLUSTRATED
17
Technology-based Blasting
The use of drones, electronic blasting, and fragmentation analysis can improve blasting operations.
4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook. 6 RollOuts Caterpillar’s Next Gen excavators, and other new equipment for the aggregates market. 28 Rock Law Through its Scofflaw Program, MSHA’s pursuit of unpaid fines could lead to mine closures for operators whose penalties are more than 30 days delinquent. 31 Advertiser Index See who’s who and where to find their products. 31 Classified Ads Aggregates industry classifieds. 32 Carved in Stone Bill Langer commemorates his golden anniversary with the gift of a column dedicated to his wife, Pam.
Staying on top
United. Inspired.
Smart and precise efficiency With the SmartROC T45, you’re in control. Based on a proven control system for consistency job after job, the SmartROC T45 will revolutionize your fuel consumption, improve your availability, and provide you with the documentation you need to be on top of your business. 844-437-4762
epiroc.us
February 2019
EDITORIAL
Vol. 24, No. 2
by Therese Dunphy, Editor-in-Chief, tdunphy@randallreilly.com
aggman.com /AggregatesManager /AggManEditor
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Senior Editor: Kerry Clines Online Editor: Wayne Grayson
Sensible governance and shutdowns
editorial@aggman.com
Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Leah Boyd production@aggman.com
Construction Media Vice President, Construction Media: Joe Donald sales@randallreillyconstruction.com
3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com
Corporate Chairman Emeritus: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Kim Fieldbinder Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Senior Vice President, Acquisitions & Business Development: Robert Lake 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 2019. 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.
A
s this issue of Aggregates Manager headed off to the printer, the federal government was midway through the fourth week of its latest shutdown. Marked by the uncompromising posture of both Democrats and the President, no end seems to be in sight. This partial shutdown impacts an estimated 800,000 federal workers. Of these, 380,000 are considered non-essential and are not working during the shutdown. Among these non-essential workers are all but 70 of the 8,032 employees of the U.S. Geological Survey and more than 20,000 U.S. Department of Transportation employees. Fortunately for aggregates producers, that figure includes none of the 2,682 employees from the Federal Highway Administration, which is funded by the Highway Trust Fund rather than annual appropriations. This particular shutdown marks the third government shutdown of President Donald J. Trump’s administration. It was preceded by earlier shutdowns that took place on Feb. 9, 2018, and Jan. 20-23, 2018. But, President Trump has a long way to go to catch up with President Ronald Reagan, who had eight government shutdowns during his tenure. Similarly, President Jimmy Carter served as commander in chief through numerous shutdowns — five in 25 months. Up until the current shutdown, the longestrunning government shutdown had taken place in late 1995 and early 1996, when Bill Clinton was president. While government shutdowns are by no means a new phenomenon, they had been pretty rare in recent years. Since that prolonged shutdown of President Clinton’s tenure, only one took place between 1996 and 2017: a 16-day shutdown in 2013 over a piece of legislation known as the Affordable Care Act, more commonly known as Obamacare. Government shutdowns highlight the partisan behavior of elected officials with those who work for the government bearing the greatest burden of said behavior. Not surprisingly, “essential” federal employees don’t seem to be happy about working without pay. The American Federation of Government Employees filed a lawsuit, claiming a violation of the Fair Standards Act on the behalf of these workers. A similar case was filed in 2013, with employees being awarded twice the back pay they were entitled to on a regular pay scale. But it’s not just federal workers who are affected by government shutdowns. Standard & Poor estimates the shutdown will cost the economy $1.2 billion per week, and a 2014 Congressional Research Service report calculates that every week the government is shut down costs the economy 0.1 percentage points of GDP. As Republicans and Democrats battle over who will win the war of the wall, the rest of the nation stands to lose both in terms of economic momentum and sensible governance. AM
AGGREGATES MANAGER / February 2019
3
mining
Company Cemex, S.A.B. de C.V.
Diesel Fuel
Prices 1/7/19
United States $3.013 One Week -0.035 One Year +0.017
New England $3.216 One Week -0.018 One Year +0.139
Central Atlantic $3.242 One Week -0.044 One Year +0.033
Lower Atlantic $2.921 One Week -0.044 One Year +0.034
Midwest $2.869 One Week -0.038 One Year -0.078
Gulf Coast $2.821 One Week -0.020 One Year +0.036
Rocky Mountain $3.026 One Week -0.045 One Year +0.052
West Coast $3.528 One Week -0.034 One Year +0.134
West Coast less California $3.180 One Week -0.066 One Year +0.093
California $3.805 One Week -0.008 One Year +0.167 Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
$5.07
$4.47
52-Week High $8.51
CRG
$27.04
$24.84
$37.87
EXP
$65.75
$57.00
$122.49
Granite Construction Inc.
GVA
$42.45
$38.55
$68.58
HEI
$62.71
$59.32
$110.04
HCMLY
$8.43
$7.80
$12.59
Martin Marietta Materials, Inc.
MLM
$179.17
$150.75
$241.33
MDU Resources Group, Inc.
MDU
$23.99
$22.73
$29.62
Summit Materials
SUM
$14.42
$11.25
$34.06
United States Lime & Minerals, Inc.
USLM
$71.72
$68.60
$85.95
U.S. Concrete
USCR
$34.92
$27.68
$84.95
Vulcan Materials Co.
VMC
$103.55
$82.52
$141.20
Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 1/7/19.
COMPANY SPOTLIGHT
East Coast $3.069 One Week -0.041 One Year +0.044
52-Week Low
CRH plc
LafargeHolcim Ltd. ADR
U.S.
CX
Current Value
Eagle Materials Inc. HeidelbergCement AG
On-Highway
Ticker
F
or the third quarter of 2018, U.S. Concrete, Inc. (USCR) reported consolidated revenue of $404.3 million, a 14-percent increase and all-time quarterly high. “We are pleased to report record results for the third quarter, which, for the second straight quarter, included all-time highs in consolidated revenue and aggregate products volume and revenue,” said William J. Sandbrook, chairman, president, and CEO, in a press release. “We continue to believe these trends reflect favorably on the demand in the markets we serve. “While the September 2018 weather presented a major obstacle for the quarter, we continue to be excited about the opporU.S. Concrete, Inc. (USCR) tunities available to us for growth and margin expansion. We started the third quarter on a very positive note with strong volumes and revenue in July and August. However, September weather, including record rainfalls yet again in the Dallas/Fort Worth market, provided margin challenges, as we maintain certain fixed costs necessary to meeting recurring demand and our existing backlog,” he added. One example of this is the need to continue to pay truck drivers, regardless of deliveries in bad weather, to ensure continued employment in that tight sector. On the ready-mix concrete side, revenue increased 7.0 percent to $346.2 million and volumes grew by 5.8 percent. Sandbrook said the company has a backlog of 70 projects with a size of 20,000 yards or more. U.S. Concrete’s aggregates products performed quite well: revenues increased 155.4 percent to $53.5 million while volumes increased 113.8 percent to 3.2 million tons. Both are all-time quarterly highs and attributable to its acquisition of Polaris Materials. “Our Polaris Materials acquisition continues to provide the significant returns that we expected, but on a more accelerated pace than we originally contemplated,” Sandbrook said. “We are excited about the opportunity we have to capitalize on the import permit we recently obtained, which will allow us to increase the amount of product we import from Polaris at our Long Beach, Calif., terminal. We are well-positioned to benefit from our increased vertical integration and aggregates exposure and the steady multi-year cyclical recovery that we believe has substantial remaining runway in our vibrant markets.” Source: Market Watch
Data
STOCK REPORT
AGGREGATES INDUSTRY OUTLOOK The January Aggregates Industry Index registered its largest increase in more than a year, surging 14.89 percent from December to 138.10. Responses were given during the federal government’s partial shutdown over funding of border security and the construction of a wall between the southern United States and Mexico. The month’s most significant turnaround is for quarterly sales predictions, with a 22-percent increase in positive ratings, followed by six-month sales predictions, with a 15-percent increase in positive ratings.
Aggregates Industry Outlook 150 138.44
145
135.83
134.94
140
132.22
130.86
130.68
135 130
138.89
138.10 134.72
125
132.73
130.65
120 115
120.56
110 105 100 Feb. 2018
March 2018
April 2018
May 2018
Abundant rainfall has slowed aggregate sales for the month of December. — Van Stockstill, President, Consolidated Aggregates
June 2018
July 2018
Aug. 2018
Sept. 2018
Oct. 2018
Nov. 2018
Dec. 2018
Jan. 2019
Looks like a wet winter will hold down sales until spring. — Nathan Wanstrath, Harris City Quarry Manager, New Point Stone Co. Inc.
Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.
QUARTERLY CRUSHED STONE & SAND AND GRAVEL REPORT Quantity Crushed Stone 3rd qtr. 2018
Percent change
New England
14,200
-4.6
14,100
14.3
Middle Atlantic
47,400
5.3
14,300
2.2
East North Central
66,100
2
40,100
6.9
West North Central
41,500
-1.4
48,900
4.9
South Atlantic
88,600
6
18,100
11
East South Central
39,400
4.3
9,040
10.4
West South Central
60,000
0.2
32,800
13.3
Region/Division
Northeast:
Midwest:
South:
West:
Quantity sand and gravel 3rd qtr. 2018
* thousand metric tons
Percent change
Source: U.S. Geological Survey
Mountain
18,600
-2.7
58,300
7.4
Pacific
25,400
2.3
50,300
8.3
TOTAL
405,000
3.5
289,000
7.5
* thousand metric tons Source: U.S. Geological Survey
ROLLOUTS
Your complete guide to new and updated equipment and supplies in the aggregates industry.
by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Lowers operating costs Caterpillar introduces the Next Gen 336 and 336 GC excavators, designed to balance productivity with lower fuel consumption and maintenance costs. Integrated Cat Connect Technology is said to increase operating efficiency by up to 45 percent over traditional grading operations. The standard Cat Grade with 2D system provides guidance for depth, slope, and horizontal distance to grade through the standard touchscreen monitor. Standard Grade Assist automates boom, stick, and bucket movements so operators can stay on grade with single-lever digging. Cat Payload precision makes loading more efficient, while an E-fence feature prevents the machine from moving outside operator-defined set points. The 336 is up to 15 percent more fuel efficient than the machine it replaces. With extended and more synchronized service intervals, the excavators can also lower maintenance costs by 15 percent over prior models; for example, the new air filter has double the dust-holding capacity over the earlier design. Three cab packages are available to keep operators comfortable. All include standard features such as keyless push-button start and touchscreen monitor. Caterpillar | www.cat.com
New line offers smooth shifting Case Construction Equipment rolls out its all-new C Series motor graders, including the 836C, 836C AWD, 856C, and 856C AWD. Designed for precision and safety, an Ergopower transmission and torque converter provide smooth automatic shifting, and a 100-percent automatic differential lock combined with automatic no-spin power splitting transfers torque from a slipping tire to one with more traction without operator intervention. The AWD models feature a “Creep Mode” that engages the front wheels at the push of a button. This allows the machine to move at slow speeds for applications with tight tolerances. The motor graders also feature high precision load-sensing hydraulic circuits. A direct-activated axial piston pump delivers only the required amount of hydraulic pressure where it is needed. Direct-mount hydraulic controls increase lever rigidity and reduce play in the system, giving the operator positive feedback and better control from the hydraulic system during precision applications. The motor graders are available with machine control-ready from the factory for all major suppliers of machine control technology.
Case Construction Equipment | www.casece.com
Track-mounted conveying solutions Superior Industries Inc. adds two new tracked conveyor models: a 75-foot tracked stacker and an 8- by 16-foot tracked feed hopper. At 34,000 pounds, the tracked stacker is said to be one of the heaviest models available in its class and can handle rates of up to 1,000 tons per hour. Hydraulic power controls the tracks, folds, and discharge height, while crossbracing built into the undercarriage ensures structural rigidity and stable back travel. The portable feed hopper processes up to 800 tons per hour from an 8-cubic-yard, reinforced hopper. A bi-directionally dumping grizzly is equipped with adjustable grizzly bars and can be set at one of five preset angles. The hopper’s drive and backstop are hydraulically controlled in addition to the discharge conveyor’s fold and raise features.
Superior Industries Inc. | www.superior-ind.com
6
AGGREGATES MANAGER / February 2019
Expanded multi-frequency screen offering Astec Mobile Screens expands its multi-frequency technology to all of its 5-foot wide, two-deck screens, including the portable PTSC205 plant and GT145 track screen. The multi-frequency technology combines a conventional two-bearing vibrator — traditionally used on an incline screen — with a high frequency vibrator on the bottom deck. The combination of the two systems creates a screen that operates with a higher G-force. The increased screening energy also enables the unit to process material with a higher moisture content. The technology debuted on the GT205 plant. Astec Mobile Screens | www.kpijci.com
Connected technology for dust collection Donaldson Co., Inc. unveils web-connected technology that monitors industrial dust, fume, and mist collectors and notifies operators to take early, cost-saving maintenance actions. The smart technology uses sensors and a controller to gather real-time data from a collector, apply analytics in the cloud, and relay insights back to the operator through a web-based dashboard and email or text alerts. Proper maintenance such as timely filter changes or earlier hopper cleaning can help prevent larger problems, assist in optimizing performance, and aid in reducing total dust and fume management costs over time. The technology can be installed on new or existing dust and fume equipment. Donaldson Co., Inc. | www.donaldson.com
Update older screens Haver & Boecker offers a conversion kit for older model H-Class vibrating screens. H-Class models V-50 and older can be updated to the current V-85 H-Class model to reduce operating noise to levels below 100 dBA, gain better control over the running frequency, and decrease maintenance costs by up to 50 percent. Prior to conversion, a Haver service technician will inspect the machine to determine if it is eligible for an upgrade. The conversion kit includes the heavy-duty welded bridge, A/C drives, controls, and optional rubber dust covers for hot or cold applications; it can be installed in one day.
REDUCE
www.kpijci.com
Haver & Boecker | www.havercanada.com AGGREGATES MANAGER / February 2019
7
ROLLOUTS Designed for rehandling applications Caterpillar introduces the 990K Aggregate Handler, which is designed to handle greater payload in aggregates yard applications. With as much as a 25-percent payload increase — compared to the standard 990K — the new loader facilitates faster loading of trucks and rail cars, as well as more material movement in load-and-carry and stockpile management applications. The unit has a payload of 22 tons and a full turn static tipping load of 96,426 pounds. Additional counterweight maintains machine stability. The 990K Aggregate Handler is available in standard lift configuration with a 13-foot, 6-inch dump clearance and in high-lift configuration with 15-foot dump clearance. The loader is powered by a Cat C27 engine with 699 horsepower. Lower engine speed helps drive lower fuel consumption, with additional efficiencies from ECO Mode, engine-idle shutdown system, and engine-idle kickdown/ auto-resume system. Caterpillar | www.cat.com
Dust suppression for hammers NPK dust suppression kits are available for the PH1, PH2, PH3, and PH4 hydraulic hammer in redesigned enclosed brackets. These models of hammers, manufactured after the fourth quarter of 2018, are built with the new design elements that allow the hammers to dispense water with the addition of a hose and a couple of fittings. An integrated water spray nozzle eliminates the need for manual spraying. Located in the bracket of the hammer so that it is safe from flying debris, the nozzle is aimed at the point where the hammer’s tool makes contact with the breaking area. This, combined with a wide spray angle, provides dust suppression coverage.
NPK | www.npkce.com
Dump beds for multi-purpose truck ARDCO launches its AMT Dump Beds for the Articulating Multi-Purpose Truck (AMT). Offering payloads of 10 to 20 tons, volume upgrades for lighter materials, and tire options to suit extreme conditions where other ADTs can’t perform, the beds can be added or removed from the modular AMT platform as needed. The AMT 600 dump bed provides a payload of 20 tons and a standard dump capacity of 16 cubic yards. Side boards can be added to increase capacity to 24 cubic yards when handling low-density material. The AMT 400 has a 10-ton payload and 8-cubic-yard dump capacity that increases to 12.5 cubic yards with side boards. Both models have a 70-degree dump angle at full dump height, with a raise time of 12.5 seconds and a lower time of 13.2 seconds. ARDCO | www.ardcomfg.com
SIZE
www.kpijci.com
AGGREGATES MANAGER / February 2019
9
AGG PREVIEW by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Indianapolis Plays Host to
Aggregate producers can attend more than 64 education sessions at AGG1 this year.
AGG1
Aggregates producers gather for networking and education at AGG1 Aggregates Academy & Expo and NSSGA Annual Convention.
A
GG1 Aggregates Academy & Expo, which is co-located with the World of Asphalt, is scheduled for Tuesday, Feb. 12, through Thursday, Feb. 14, at the Indiana Convention Center in Indianapolis, Ind. AGG1 focuses exclusively on the aggregates industry and offers education sessions from industry experts in segments across the aggregates industry. Attendees will also see equipment displays covering more than 63,000 square feet of exhibit space. The AGG1 Academy & Expo will highlight new products, technologies, and services in a wide range of categories including: conveyors, crushing, dredges, drilling and blasting, earth moving, heavy equipment, health and safety, plants,
10
AGGREGATES MANAGER / February 2019
screening, site planning, trucking and hauling, vibratory equipment, and washing equipment. New this year is the Rock & Road Talks Presentation Stage, located at the center of the expo hall. Exhibitors will be able to highlight their products and services at the stage.
Educational opportunities AGG1 Academy will offer more than 64 expert-led educational sessions and seminars ranging from beginner classes that teach the basics to seminars that explore advanced concepts and technologies. The sessions are organized into four focus areas: • Automation, Technology, and Software;
• Business Management and Leadership; • Environment, Safety, and Health; and • Operations and Production. A full conference pass (unlimited educational sessions) and show badge is $660. The show badge itself is $80, while educational tickets may be $100 for a single session or $260 for three sessions.
NSSGA Annual Convention The National Stone, Sand and Gravel Association’s Annual Convention will be held in conjunction with AGG1, beginning Feb. 10 and running through Feb. 13 at the JW Marriott Indianapolis. Convention attendees can attend networking sessions and committee
More than 63,000 square feet of exhibit space will showcase the newest equipment for aggregates producers.
meetings. A special focus on workforce issues will carry throughout both the convention and an assortment of educational seminars at AGG1. At the annual membership meeting on Feb. 12, Rich Karlgaard, publisher and futurist with Forbes Media, will address the workforce of the future. Byron Reese, a futurist and CEO and publisher of Gigaom, a technology resource company, will highlight how technology will impact aggregates producers in the years to come. AM
Convention/AGG1 Schedule Monday, Feb. 11
NSSGA General Session Operations Tour: Dig Indy
7:30 – 9 a.m. 11 a.m. – 2 p.m.
Tuesday, Feb. 12
NSSGA Annual Membership Meeting Education Sessions AGG1 Ribbon Cutting Education Sessions Exhibits Open ROCKPAC Donor Appreciation Event
7 – 9 a.m. 7:30 – 9 a.m. 9:30 – 11 a.m. 10:45 – 11 a.m. 2 – 3:30 p.m. 11 a.m. – 5 p.m. 6 – 8 p.m.
SHAPE
Wednesday, March 7 Education Sessions
NSSGA Board of Directors Meeting Education Sessions Exhibits Open Rock and Road Reception
7:30 – 9 a.m. 9:30 – 11 a.m. 10 a.m. – 12 p.m. 2 – 3:30 p.m. 11 a.m. – 5 p.m. 4 – 5 p.m.
Thursday, March 8 Education sessions Exhibits open
7:30 – 9 a.m. 9:30 – 11 a.m. 9 a.m. – 1 p.m.
www.kpijci.com
AGGREGATES MANAGER / February 2019
11
SPECIAL REPORT by Carlos Lazo
Improve Your
Haul Cycles When considering haul road maintenance, keep in mind that haul roads extend to both the loading face and the dump point.
Lower your cost per ton by paying attention to haul road design and maintenance.
H
aul road design, construction, and maintenance have a huge impact on truck haulage cycle efficiency, costs, and production. Design factors, including road materials, grades, curve designs, and traffic layout, play critical rolls in efficient truck haulage. But proper maintenance of roads — to ensure smooth surface conditions, low rolling resistance, and consistent grades — is equally important to achieving lowest cost per ton of material hauled.
12
AGGREGATES MANAGER / February 2019
As an example of the importance of haul road design and maintenance, a 5-percent increase in rolling resistance can result in as much as a 10-percent decrease in production and 35-percent increase in production cost. Though 5-percent rolling resistance doesn’t sound like much, it is equivalent to about 2 inches of tire penetration. Good haul road design, construction, and maintenance reduce fuel burn, help minimize tire heating and damage, and
reduce wear on truck components. The results are lower operating and maintenance costs and less downtime.
Motor graders play critical role Motor graders are not only critical to maintaining haul roads, but also to building haul roads to the right specifications, which, in turn, enables the roads to resist damage and provide optimum hauling conditions for longer periods. Motor graders are the best grading
THE RIGHT CRUSHER FOR YOUR OPERATION.
From Reduction to Shaping Your ability to turn virgin material and waste product into high quality aggregates requires equipment with unmatched power and precision. From reducing shot rock to sizing and shaping fine sand, we design and manufacture the most versatile and efficient crushers. Not sure what you need? Let our experts partner with you to apply the ideal solution.
Visit us at Agg1/WOA to learn more. Booth 29127
KPI-JCI and Astec Mobile Screens
Astec Industries Companies
700 WEST 21ST STREET • YANKTON, SD 57078 USA • 800.542.9311 • FAX 605.665.8858 • kpijci.com
SPECIAL REPORT
The economics of haul road maintenance are clear: a 5-percent increase in rolling resistance can cause a 10-percent decrease in production and a 35-percent increase in production costs.
machines for ensuring that cross slopes and cross falls are built to specifications. Building to spec helps ensure that roads drain water efficiently, which reduces the formation of potholes and washboards, and reduces the need for frequent haul road maintenance. Motor graders are also the best machines for building superelevated curves. Such curves help trucks maintain proper weight distribution and constant speed, reducing the frequency of transmission gear shifts and braking for less wear on truck components. After roads are built, the motor grader is the most efficient tool to keep them in good condition. Motor graders provide smooth roads, constant grades, and reduced rolling resistance. They also can maintain safety berms and drainage ditches, and, with their fast travel speeds, graders can be dispatched to quickly clean up rock spillage from haul trucks. With a good haul road construction and maintenance program, trucks can run at their optimum performance level while minimizing frame racking, transmission shifting, and braking. Tire life can be extended, too. Saving just half the life of one truck tire justifies many hours of
14
AGGREGATES MANAGER / February 2019
motor grader operation. Mine managers should measure the value of their motor graders based on the benefits in performance and cost reduction they see in their hauling fleet.
The road to high productivity Proper road design is the first step in ensuring good truck productivity and low operating costs. Critical elements are grade, cross-slope, and superelevation of curves. The goals are to maintain proper weight distribution of the load and to minimize lateral forces on tires. The same design that enhances truck productivity also reduces component wear and optimizes fuel burn, as the truck remains stable at optimum speeds. The steeper the grade, the more weight bears on the rear tires. The goal is to keep the weight distribution at about one third on the front tires and two thirds on the rear duals of a typical rigid frame hauler. Ideally, the grade would not exceed 8 percent. The grade should be constant and the road smooth to minimize rapid weight distribution changes, minimize transmission shifts, and maintain higher average speed. Such a road also promotes smooth braking when trucks are
returning to the loading area. Optimum road design also helps to minimize spillage of rocks on the road. Approximately 75 percent of tire failures are caused by cuts from rocks and impacts with rocks. Roads must also drain properly to reduce slippery conditions and to help minimize rolling resistance. On flat terrain, the minimum cross-slope maintains drainage for the expected rainfall at the mine. If conditions permit, consider a 2-percent constant cross-slope. Four-percent cross-slope can be used in rainy areas. Alternatively, the road should be crowned slightly to drain water to both sides of the road. On grades, minimal cross-slope or crowning is needed, because the grade itself helps direct water off the road. Corners should have the maximum practical radius to help maintain truck speed and to minimize side force on tires. Side force generates heat in the tires and reduces casing life. High side forces scuff the tires and accelerate tread wear, too. Corners should be constant and smooth to reduce steering corrections, operator fatigue, and component wear. If truck speed exceeds 10 mph, the curve should be superelevated to negate
SPECIAL REPORT
A motor grader, such as this Cat 160M2, is the most efficient machine to build and maintain haul roads.
centrifugal force that puts side loading on the truck. The amount of superelevation needed depends on curve radius and the speed at which it is negotiated. Tables published in the Caterpillar Performance Handbook show the amount of superelevation required to produce zero lateral forces for given curve radii and truck speeds. Superelevation greater than 10 percent should be used with caution, due to the potential for slipping toward the lower edge of the roadway in wet conditions when truck speeds may be reduced. In addition to countering centrifugal forces, corners should be designed so that truck operators can see and avoid obstacles when traveling at normal speeds. The same consideration should be given to crests of hills. These calculations should use the worst-case scenarios, such as smallest obstacle, highest expected speeds, and longest stopping distances. Road width is another factor that affects safe operating speeds and can help minimize tire contact with safety berms and spilled rocks. On one-way roads, road widths of 2 to 2.5 times the width of the widest truck used at the site are recommended. On two-way roads, road width
should be a minimum of 3 to 3.5 times the truck width on straight sections and 3.5 to 4 times in corners. Remember, too, that the haulage road extends to the loading face and to the dump point. Bench widths should be adequate for a loaded truck to clear the loader under full acceleration and for an empty truck to avoid tight, high speed turns. The minimum bench width should equal the machine turning radius plus space needed for the safety berm. Dump points should have enough space for the truck to align properly with a minimum of maneuvering.
Building haul roads to spec There’s no substitute for a motor grader to build and maintain haul roads to exacting specifications. Long wheelbase, center-mounted moldboard, and the ability to move the moldboard through a wide range enable a motor grader to blade precisely and quickly. Training motor grader operators in proper road construction and maintenance is important, but onboard technology can reduce the burden on operators and help improve haul road quality. For example, the factory integrated Cat GRADE with
Cross Slope system allows operators to easily maintain desired cross slope as the system automatically controls one end of the blade. Another technology, the Digital Grade Slope Meter, shows the slope of the blade on the integrated display screen in the cab to inform the operator and reduce the need for manual grade checking. Grade control technologies include fully automated blade control systems available on many motor grader models. Other technologies, such as Stable Blade and Auto Articulation, are available to aid operator performance and productivity. Stable Blade senses blade bounce and adjusts the machine to reduce manual throttle use and rework, and Auto Articulation improves maneuverability and performance in tight working spaces. Make the best use of your motor graders to build and maintain haul roads to the proper specifications, and see the results in greater truck productivity and lower truck operating costs. AM
Carlos Lazois is an application specialist, motor graders, with Caterpillar Inc.
AGGREGATES MANAGER / February 2019
15
Connecting Global Competence
THE HEARTBEAT OF OUR INDUSTRY
All Keyplayers. All Trends. All Innovations.
YOUR VISIT. YOUR BUSINESS. YOUR TICKET.
bauma is more than the world’s leading trade fair: it is the heartbeat of the industry. With around 600,000 participants, additional halls and larger space. For even more business.
Munich, April 8–14, 2019 www.bauma.de Contact: Trade Show Services GACC New York, Inc., kvogelsang@tssworldwide.com, Tel. +1 646 437 1013
OPERATIONS ILLUSTRATED By Therese Dunphy, Editor-in-Chief
Technology-Based Blasting
Start with safety.
Fly drones before and after the blast.
Use electronic initiation to lower vibration levels.
OUR EXPERTS
Evaluate site hazards.
Alex Tyson is a field engineer for the DynoConsult group of Dyno Nobel, where he has spent the last 6 years. He received a bachelor’s degree in chemistry from the University of California, Berkeley. Tyson worked for several years as a science teacher before returning to grad school at Missouri S&T where he received a master’s degree in explosives engineering.
Randy Dies is an area manager for Blue Water Industries, where he is responsible for five operations: three in Tennessee and two in Alabama. He began with the company in early 2018, but has worked in the aggregates industry for 33 years.
Jason Nichols is the senior product marketing manager for Kespry. He previously worked for TopCon and as a geologist in California mines and aggregate operations. Nichols has a bachelor’s degree in geology from San Jose State and a master’s degree in GIS from the University of Southern California. He is a professional geologist in the state of California.
AGGREGATES MANAGER / February 2019
17
Eliminate the Unknowns for Safer Blasting
T
he quality of a blast is typically judged based on a few simple factors: meeting the desired production capacity, achieving good fragmentation of the rock, and minimizing the impact of the blast on the operation’s neighbors. These are all important factors, but first and foremost, a quality blast is a safe blast. “It always starts out with safety,” says Randy Dies, area manager for Blue Water Industries. “You have to have a safe program and consider your neighbors. After that, it’s about performance.” Alex Tyson, field engineer for Dyno Nobel, agrees: “The main theme that we often talk about is turning as many unknowns into knowns as possible, because blasting itself is inherently dangerous.” Eliminating the unknowns begins with familiarity with the site and establishing common goals for the blast. Frequently, a site overview is established via a drone flight that collects data that can be incorporated into the blast. Creating a 3D map of the quarry allows a mine planner to have a solid understanding of the critical structures and location information. Visuals and data gathered from the drone flight can be used in conjunction with historical data about the operation and the deposit itself. After data is gathered and factors such as hole size, blasting agents, production goals, and restrictions due to environmental concerns are determined, a blast pattern can be created.
1
“When the blaster shows up on the day of the blast, they have had their training and their safety meetings to assess hazards on site,” Tyson says. “Once that’s all done, only then can blast hole loading begin.” Before the blast is initiated, the blast zone is cleared in preparation for the shot. An additional buffer space between the blast area and miners creates a safe zone for them to continue work in other parts of the operation during the blast. “Once the blast is conducted, they’ll fly the drone in order for them to get an assessment of how the blast went,” says Jason Nichols, senior product marketing manager, Kespry. “They will also measure the amount of the material that was blasted and take a quick look at the face after that particular blast.” The post-blast assessment may be the area where modern technology has had the greatest impact, Tyson says. “In the past, the assessment of a blast would be that, if things didn’t get hit, if you had few neighbor complaints, and had rock on the ground, you’d call it a successful blast,” he notes. “Now, we’ve got tools to be able to assess fragmentation in real time or close to real time. We’re able to measure the productivity of equipment that’s digging on that blast. We’ve got relatively inexpensive high-speed videography, which means we’re able to assess that blast in a more objective and data-driven way than ever before.”
Determine the right blast pattern
Use historical data about the operation and its geology to understand the blasting needs. Once bench height, hole size, and blasting agent are known, the blast pattern can be established. Once a pre-work safety meeting is complete, holes can be prepared for the blast. Bulk blasting product should be continuously measured to ensure the product is delivered exactly as planned.
18
AGGREGATES MANAGER / February 2019
2
Initiate the blast
Once holes are stemmed and the blast is tied in, the blast site is cleared. Electronic detonation allows for precision timing, which can not only improve fragmentation but also dramatically lower vibration levels. Measure vibration around the perimeter of the operation or at nearby neighbor’s properties.
3
Create a 3D model
Using drone technology and mine planning software, operators can create a 3D representation of the quarry. A cross section can be created across the site or multiple benches and used for comparison to an existing design or image set. Spot elevations can be checked, and a comparison tool (see inset) allows operators to measure the exact cut volume (red) and muckpile (blue) of a blast.
4
Quantify the results
Once the blast has been completed, a second drone flight can capture the volume of material blasting. With the higher resolution capabilities of newer drones, images are captured up to ½ centimeter per pixel. Data can be entered into third-party software for fragmentation analysis. Insights gained can be used to continuously improve the process.
AGGREGATES MANAGER / February 2019
19
Voices of Experience Alex Tyson
Randy Dies
Jason Nichols
P
W
W
roducers sometimes view drilling and blasting as a standalone segment of operation rather than evaluating processing in a more holistic manner, but that may not be the most cost-efficient approach. “Part of what we’re trying to do is get out of the silo mentality,” says Alex Tyson, field engineer for the DynoConsult group of Dyno Nobel. One of the big challenges, he says, is to understand how activities before and after drilling and blasting are all inter-related. For example, investing in the chemical energy created by the blast is one of the most cost-effective ways to create rock fragmentation. “What we’ve found as we’ve been able to collect a lot of data over the years and track these things more closely is that, for a lot of operations, spending a little more money on the front end of the drill and blast cost often reduces — to a much greater degree — the downstream costs to get your target product,” Tyson explains. For example, an explosives technology such as Differential Energy, which can tune a density and velocity to deliver the energy where it’s needed, may be a wise investment to achieve the desired fragmentation. “Often, we’re talking about an order of magnitude cheaper to precisely chemically crush versus conventional mechanical breakage,” he says. Electronic detonators provide another area where precision can enhance the blasting process. “We’re starting to see the advantages that come with the precision of the electronic detonator over a non-electronic detonator, and what ends up driving our decisions is our ability to measure them as well as we do,” Tyson adds. “Because we’ve got the technology to be able to assess the efficiency and productivity of a blast, we can start doing some really interesting work with vibration minimization and fragmentation optimization.”
20
AGGREGATES MANAGER / February 2019
hen assessing how well a shot performed, Randy Dies, area manager for Blue Water Industries, says that his evaluation is based on several factors: safety, yield, and ground control. “The focus is on whether throughput is what we need it to be,” he says. “Fragmentation also has a big effect all the way through the process. If you overshoot the material, you’re going to have fines that you may have a hard time selling. If you don’t shoot well enough, your productivity is going to suffer.” Ground control is another important factor, Dies says: “Some of these formations tilt or fall off in one direction or the other. You need to have some benchmarks so you don’t wind up overdrilling, which creates sub drill, or blasting too deep, which may cause you to run over loose material you will have to deal with on the next bench.” During his career, Dies has seen the shift from electric detonators to electronic ones. “Electronics, to me, is the only way to go,” he says. “It’s the safest way to blast. There’s no question about whether a cap went off or not. With that electronic system, we absolutely know.” Another benefit is the ability to optimize timing, which minimizes vibration. “Those systems are really impressive,” Dies says, noting that vibration readings typically fall by half with the addition of electronic timing. That translates to fewer neighbor complaints and a better avenue to address any that might take place. To achieve better blasting, Dies says that constant communication with the blaster is essential. “We give our input if we’re not happy with the shot, but we try to let folks know when we are happy, too,” he says. “I try to meet with them quarterly to evaluate our progress and set some goals for improvement.”
hile drones are now routinely used for stockpile measurements at many operations, the greater accuracy achieved in newer drone systems, such as Kespry’s 2S drones, makes them suitable to mine planning activities, including stripping, haul road construction, and blasting, among others. Prior to the latest generation of drones, the positional accuracy was somewhere between 30 and 50 centimeters. The new generation achieves accuracy of 2 to 5 centimeters, which meets the tighter tolerances required for mine planning. “The data that’s being collected is captured throughout the entire project lifecycle of the mine all the way from the conceptual study to reclamation,” says Jason Nichols, senior product marketing manager, Kespry. To leverage the most value from drones, Nichols recommends that producers ensure they have the ability to fly as frequently as possible. During the drilling and blasting process, this means a flight before blasting to gather rich topographic information that can be uploaded into third-party mine planning software to update the mine plan. Once the blast takes place, the drone will again fly the site to assess how the blast went and to measure the amount of material blasted. “Being able to fly frequently — without being restricted on a certain number of flights or a certain amount of users — really opens up the doors for mine planners and surveyors to optimize the site,” Nichols says. “Mine planning and blasting is just the precursor to establishing a production schedule to balance their entire operation based off a forecast.” He recommends drone flights on a weekly basis and, potentially, as often as every other day, depending on the blasting schedule and stripping operation. “I think that’s where you’re really starting to see an increase in the profitability, because now you’re understanding how much material needs to be removed or has been removed,” Nichols says.
MAXIMUM FINES RECOVERYIT TAKES MORE THAN A PIECE OF EQUIPMENT
With a McLanahan Ultra Fines Recovery System you can keep 30,000 tons or more from going to the pond, giving you more usable product. The Ultra Fines Recovery System includes dewatering screens, cyclones, sumps, pumps and a structure all engineered to your specifications by McLanahan. With McLanahan, you get years of experienced process engineering coupled with an analytical lab, all supported by a dealer network to provide local parts and service.
mclanahan.com
PLANT PROFILE by Kerry Clines | Senior Editor
Building toward the Future
Super Aggregates prepares its Marengo dredging operation for future Chicago growth.
S
uper Aggregates, co-owned by Dan Plote of Plote Construction and Jack Pease, has been a sand and gravel producer in northern Illinois and southern Wisconsin since 1970, offering a wide variety of products. Its Marengo Materials LLC dredging operation lies just west of Chicago in the small town of Marengo, Ill. “This facility was previously owned by Prairie,” says Chris Alby, sales representative for Super Aggregates. “They operated it for quite a while, and they started to update the plant, but stopped. It had been dormant for a while when we purchased it in 2016.” “When we bought the property a few years ago, there was a 100-acre lake,” says Tory Pease, president, Super
22
AGGREGATES MANAGER / February 2019
Aggregates. “We stripped around 8 acres — about 2 feet of black dirt on top. We’ve just about got that mined, so we’re stripping another 8 acres heading north this winter.” The water table is close to the surface in the area, so the black dirt being stripped off sometimes falls into the water, requiring the stripping crew to use berms to help keep the water back. Once it is stripped off, the black dirt is stockpiled on the other side of the pond, where it is eventually pulverized and sold for top soil.
Upgrading the operation Super Aggregates had big plans for the future of the operation, which included being ready to supply materials as
Super Aggregates’ Marengo Materials dredging operation, which lies just to the west of Chicago, is stockpiling material for future growth.
the Chicago suburbs expanded in that direction. Immediately after purchasing the operation, the company set about doubling the size of the processing plant by adding a crusher and a second wash screen. It also greatly increased its stockpiling capabilities by building a high-volume radial stacking conveyor for stockpiling its concrete sand and 3/4inch gravel, which are the main products produced at the facility. “One of the big things we did different from everybody else was to build massive stockpiles,” says Alby. “You’ve seen elevated conveyors, but nothing this high. We were trying to get the conveyors elevated as much as possible
to stop the wheel loaders from driving on the stockpiles, creating contamination and fines.” The massive stockpiling system includes a 125-foot-long, 270-degree radial stacker set on top of a concrete track elevated 55 feet above the ground. This makes it possible to create a 95-foot-high stockpile capable of holding as much as 350,000 tons of material. The concrete track for the conveyor was poured on the ground and then lifted into place with a crane. The stockpiling system also features large metal pipes with holes cut into the sides all the way down to allow the material to run out without having to fall
more than 15 feet (which is the limit in Illinois) from the stacker conveyors. Each pipe is welded to a massive concrete foundation for stability. The system’s concrete arch not only allows the creation of a huge stockpile, it decreases the amount of time spent double handling the material and reduces the number of employees needed to run the operation. Only two employees are required to be on site when the plant is in operation — one on the dredge and one in the loader. “Tory himself built that system with his father’s engineering,” Alby notes. “He did all the construction in house. Tory is so innovative. He always finds a way.” AGGREGATES MANAGER / February 2019
23
PLANT PROFILE
After purchasing the operation in 2016, Super Aggregates set about doubling the size of the processing plant by adding a crusher and a second wash screen.
“My dad dreamed all this up and got it built, and I put it together,” Pease says, adding that his father sketched it out by hand. “He said, “Let’s see how good you are, if you can make it all line up when
24
AGGREGATES MANAGER February 2019
you start at one end and get to the other end.’ He made everything ahead of time, and I had to make the pieces fit. I moved it around a little bit to make it line up, but it fit.”
The improvements were completed by March 2018, increasing the operation’s production capacity to 450 tons per hour. The focus then shifted to stockpiling enough material to get through the winter, because the dredge and processing plant shut down from December to March because of freezing conditions. Once temperatures drop below about 28 degrees Fahrenheit, the ice builds up on the pulleys and belt rollers, making it impossible to continue operation. “We’re just trying to give ourselves a large enough surge pile to, hopefully, get those big landfill jobs that take 300,000 to 400,000 tons,” Pease explains. “We try not to have to move the material twice. We want to take it from the water, put it in the stockpile, load it in a truck, and send it out the gate, and, hopefully, not move it in between.”
Dredging and processing All the action at the operation begins with an electric dredge, which was redesigned by Custom Dredge Works. The dredge’s
chain ladder drive just drops down into the water, chain saws the ground to 100 feet down, then lifts back up and moves over a bit. The dredge, which is powered by a 7,000 volt extension cord, requires only one operator. “This dredge was 20 years old when we bought it,” Pease notes. “We completely dismantled and refurbished it. It has all new electric components and was repainted.” All the water and material sucked up by the dredge goes through a pipeline to the top of the dredge box in the processing plant. Weirs inside the dredge box help to knock down the power and force of the water. The material is then separated from the water and fed through the plant for sizing, crushing, screening, and washing before being placed into the appropriate stockpile. Everything is shipped out of the plant by truck. The company owns approximately 80 trucks, and during busy times, has 100 or so brokers who come in and haul the product out. In addition,
Super Aggregates built a massive stockpiling system that includes a 125-foot-long, 270-degree radial stacker set on top of a concrete track elevated 55 feet above the ground, which makes it possible to have a 95-foot-high stockpile that will hold as much as 350,000 tons of material.
some customers haul product with their own trucks. Alby says an average of 100 truckloads of product goes out every day,
but during the busy season, it can be as much as 300 truckloads a day. There’s no one in the scale house
Protecting the rig that runs your business! Hit the : road with
Flexible payment plans Downtime reimbursement Online certificates
col lect ! th e m a l l
1-800-PROGRESSIVE PROGRESSIVE.com Progressive Casualty Ins. Co. & affiliates. All coverage subject to policy terms.
AGGREGATES MANAGER / February 2019
25
PLANT PROFILE
The electric dredge’s chain ladder drive drops down into the water, chain saws the ground to 100 feet down, then lifts back up and moves over a bit.
The recycling plant
The water and material sucked up by the dredge goes through a pipeline to the dredge box on top of the processing plant, where weirs knock down the power and force of the water before it hits the screen.
at the operation. All the transactions are done through cameras and an automated system. The truck drivers who frequent the facility call on their cell phones as they pull up to the scale. They’ll give their truck number, say what company they want, and state what product they’re after. They pull up on the scale to check their weight, and the cameras verify the material. They then pull over and go up to the scale house to sign a copy of their ticket. The same system is at every Super Aggregates operation.
26
AGGREGATES MANAGER February 2019
“The facility has the capability of doing sales anywhere from 500,000 to 600,000 tons per year,” Alby explains. “Right now, our sales are about half that. We have three different contracts, one is a very large ready-mix producer. That’s why we built all this, to show those guys that we are ready and capable.” Employees currently work 8 to 10 hours a day, but if the operation needs to ramp up production, it will do whatever it takes to meet those needs. Alby says the company would add an extra shift and hire more people, if necessary.
There is a concrete recycling plant on site that the company owns and operates. The concrete comes from roads, construction jobs, foundations, curb. etc. The concrete is run through a processing plant that consists of a jaw crusher with a magnet to remove rebar and other metals, one or two transfer conveyors, and a stacker. The material is made into a CSO 1 product, which is basically a 4-inch minus. The Illinois Department of Transportation requires 12 inches of that product prior to the 6- to 8-inch road base on every road in the state. “When you’re out this way where there’s no rock, the recycled product fills some of the need,” Alby explains. “Typically, we have a guy here with a breaker breaking at the same time the loader is grabbing the rock. When we get an order, it goes out by bulk. It’s not hard for us to bring in two guys and quickly put down 4,000 or 5,000 tons a day. It’s a real simple, self-contained Lippmann plant.”
Safety and training All the employees at Super Aggregates go through MSHA (Mine Safety and Health Administration) training prior to beginning work. One person is designated to be in charge of the safety program, including tool box talks and such, for all of the company’s operations in the area. The safety coordinator goes by each
PLANT PROFILE operation to check things and make sure everyone is up to date on training. “He just walks through each operation double checking everything — fire extinguishers are on the towers, log books are in the loader, etc.,” Pease explains. “He’s there to supply the guys with anything they need, and he does all the books to make sure everyone is up to par on training.” “Other than that, we have eight hours of refresher training every year, as well as CPR training,” Alby adds. “We try to do our refresher training in increments. We want the employees to take it all in. We do it on site rather than in a classroom, so it’s specific to the individual plant.” Because it is a dredging operation, all employees on the water or within a few feet of the water are required to wear a flotation device. Two boats are also required on site, so when the dredge operator takes one boat out to the dredge, another boat is available for someone to go out to rescue him, if there’s an emergency.
The operation is also kept neat, clean, and free of possible hazards. The signs at the front entrance were updated to look nice and provide contact information.
Equipment List • Twinkle 800-horsepower all electric dredge with 40-foot chain and 100-foot ladder
Looking to the future
• Deister 8x20 triple-deck screen
Super Aggregates is a growing company. In 2007, it had three pits and one recycle yard. By 2018, it had increased the number of pits to nine. “We’ve gone through a wonderful expansion,” Alby says. “We’ve got two more in the holster that we’re working on, also.” “They’ll eventually be putting in on and off ramps on Highway 90, which is just a couple miles down the road,” Pease notes. “We’re hoping to get some of that business. Chicago will be growing out this way, too, so we hope to get some of that business as well.” The Marengo Materials site has at least another 30 to 40 years of reserves, depending on demand. When the reserves are all used up, there won’t be
• Deister 5x16 double-deck screen
LET'S BUILD
• Kolberg 40-foot classifiers (2) • Kolberg 54-inch sand screws (2) • Kolberg 48-inch sand screw • KPI 42x33 impact crusher • TCI & Kafka conveyors much reclamation involved. The dredged out area will become a 350-acre lake. Pease’s father is a land developer in the area and has turned previous quarries into residential subdivisions. “There’s not a more beautiful spot to live in,” Pease says, adding that he and his brother have built their homes in one of their old 60 quarries. “It’s finished, and the water is beautiful and clean.” AM
YOUR IDEAL
STRUCTURE
for nearly 40 years clearspan
has been helping companies maximize profits with superior building solutions
To find out how we can help with your structure needs visit or call www.clearspan.com 1.866.643.1010
Energy Efficient
Superior Warranties
Expert Project Managers
No Money Down Financing, Terms Up To 7 Yrs and As Low As 5.99% on buildings AGGREGATES MANAGER / February 2019
27
by Benjamin J. Ross
ROCKLAW Understanding MSHA’s Scofflaw Procedure MSHA’s pursuit of unpaid fines could lead to mine closures for operators whose penalties are more than 30 days delinquent.
W
Benjamin J. Ross is an associate in Jackson Kelly PLLC’s Denver office where he practices in the Mining Law industry group, focusing primarily on litigation and workplace health and safety. He can be reached at 303-390-0026 or bross@ jacksonkelly.com.
28
hen appointed, Assistant Secretary of Labor David G. Zatezalo stated that one focus of his tenure would be collecting outstanding mine safety fines from “Scofflaw” operators who were behind on payments. He wrote an Op-Ed regarding his intention to strengthen the Mine Safety and Health Administration’s (MSHA) Scofflaw Program that appeared in The Intelligencer Wheeling News Register on March 6, 2018, and on MSHA’s website on March 7, 2018. Assistant Secretary Zatezalo explained that, since MSHA launched the Scofflaw Program in 2007, $67 million in delinquent penalties had accrued. The Assistant Secretary said he believes that these unpaid penalties are unfair to miners and mine operators alike. Miners deserve safe workplaces, and operators who do not pay fines gain an unfair competitive advantage. Assistant Secretary Zatezalo vowed to collect the penalties, likening the delinquent penalties to speeding tickets, where a failure to pay results in further repercussions. He stated that MSHA would pursue these fines using every means under the law and could even force operators to cease production. Assistant Secretary Zatezalo expounded on two points: first, mine operators must arrange to pay their penalties to stay out of the Scofflaw Program, which suggests that MSHA may accept payment agreements and not always require
AGGREGATES MANAGER / February 2019
payment in full; and second, operators must pay miners even during the time where MSHA closed their mine due to non-payment of penalties. But the Assistant Secretary did not mention rulemaking or cite to regulations or the Mine Act to explain what law MSHA would use to collect fees in this manner, only that it may issue citations and shutdown orders. He also did not explain what would qualify as a “Scofflaw” or whether there was a specific dollar amount, number of days past due, or number of outstanding penalties that would qualify a mine for such status. Despite this dearth of communicated information, MSHA developed an internal plan and quickly began to pursue Scofflaws. On Oct. 23, 2018, it issued a news release proclaiming that the Scofflaw Program reclaimed $5.2 million in unpaid mine safety and health fines from 49 mine operators. Although MSHA still has not promulgated rules or issued guidance explaining the logistics or legal basis of the Scofflaw Program, its actions provide insight into its strategy. The first step MSHA takes is to send the operator a letter notifying it of unpaid penalties. Although operators are unlikely to be happy to receive one of these letters, MSHA’s practice of sending these letters is good news for mine operators: MSHA will not place operators into the Scofflaw Program without notice.
The letter to the operator details the total amount owed and encloses a breakdown of all unpaid assessments. The letter further states that the operator must provide a check for the full payment of outstanding penalties or a signed Installment Plan with Treasury within 30 days. It provides contact information for MSHA’s Scofflaw Program so the operator can discuss payment options. Warning that if the operator fails to take these actions, MSHA will consider appropriate enforcement action, including filing for an injunction in a United States District Court to compel payment or issuing the operator a § 104(a) citation for violating Federal Mine Safety and Health Review Commission orders to pay penalties. Although MSHA may not deal with each case uniformly, it seems to take a standard course of action with operators who do not pay or establish payment plans within 30 days of receiving the initial Scofflaw letter. First, MSHA sends a second Scofflaw letter to warn the operator of its failure to pay and threaten further enforcement. Second, MSHA issues a § 104(a) citation to the mine operator pursuant to § 110(j) of the Mine Act, which requires: Civil penalties owed under this Act shall be paid to the Secretary for deposit into the Treasury of the United States and shall accrue to the United States and may be recovered in a civil action in the name of the United States brought in the United States district court for the district where the violation occurred or where the operator has its principal office. Interest at the rate of 8 percent per annum shall be charged against a person on any final order of the Commission, or the court. Interest shall begin to accrue 30 days after the issuance of such order. 30 U.S.C. § 820(j). This section of the Mine Act clearly deals with penalties and specifically allows MSHA to pursue those penalties through United States district courts as the Scofflaw letter suggests. But it does not provide MSHA with the ability to issue a § 104(a) citation or shut down a mine, however temporary it may be. MSHA may be overstepping its authority with these actions, but so far, no courts have reviewed whether the Mine Act allows MSHA to issue citations and closure orders. Presumably, MSHA chooses to use the Mine Act in this way because it is procedurally easier and faster than petitioning the court, and it allows MSHA to issue a § 104(b) order to close mines for violating the § 104(a) citation that it issued under § 110(j) for failure to pay the penalties. And, MSHA has followed through on its threats, issuing § 104(a) citations written for violation of § 110(j) for Scofflaw viola-
tions and following with the issuance of § 104(b) orders to close mines for failure to abate the § 110(j) violation by paying the penalties. MSHA is serious about Scofflaws and its goal is to shut down mines for failing to pay penalties. Entering into a payment agreement or paying all outstanding fines seems to be all that a mine operator must do to terminate a Scofflaw § 104(b) order. While we have seen how MSHA deals with operators that it deems to be Scofflaws, there still is no information about how MSHA determines whether an operator is Scofflaw. It is possible that any unpaid penalty that is delinquent for more than 30 days may cause MSHA to designate an operator as a Scofflaw and send a Scofflaw letter. Even mines with a single relatively small, recent, unpaid penalty are not safe, as MSHA has written Scofflaw letters to those operators and pursued further enforcement after those letters. Mine operators that receive § 104(a) citations or § 104(b) orders for Scofflaw violations can challenge whether MSHA has the authority to issue those violations, but it may be easier to avoid Scofflaw status instead. Operators should be vigilant in paying their penalties, contesting citations in a timely manner, responding to Scofflaw letters, and generally reviewing and acting upon their mail. AM
Experience: Retired November 2011 following 41 years with the U.S. Geological Survey • USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present
Services Offered: Applied geology and geological research for construction rocks and minerals, with an emphasis on aggregates. • Resource evaluation • Expert testimony
• Technical writing and review • Lecturer
Contact me at:
Bill-Langer@researchgeologist.com www.researchgeologist.com AGGREGATES MANAGER / February 2019
BillLanger_AGRM0115.indd 1
29
12/14/16 8:54 AM
ELECTRIC UTILITY FLEET MANAGERS CONFERENCE
Advancing Strategies for Fleet Improvement WILLIAMSBURG, VA
JUNE 2-5 2019
WILLIAMSBURG LODGE & CONFERENCE CENTER Join fleet professionals from investor-owned electric utilities, electric cooperatives and electrical contractors from across the U.S. and Canada at the industryʼs premier educational event featuring: • Presentations by industry experts, manufacturers and fleets • Roundtables where fleet professionals and representatives from manufacturers and service providers share best practices • A drive-through utility equipment demonstration and an exhibition of the latest equipment and services for utility fleets Register at EUFMC.com
SPONSORS LEADERSHIP
PLATINUM
ADINDEX ADINDEX | MARKETPLACE January 2016
Advertiser
Web
Aggregates Manager Community Outreach Advertiser Web Aggregates Manager Industry Atlas
www.aggman.com/community-outreach Page
52
www.aggmanatlas.com
54
ABB Motors & Mechanical
dodgepassport.abb.com
baumaBeka-Max of America, Inc.
bauma.de
Baldor Electric Co.
Page
www.baldor.com
Bill Langer - Research Geologist
IFC
7 & 28
16
www.beka-lube.com www.researchgeologist.com
57 55
Bill Langer
researchgeologist.com
29
Clearspan C.L. Dews & Sons Foundry
clearspan.comwww.dewsfoundry.com
27
59
Clearspan Fabric Structures DRM Production
www.clearspan.com/adam na.hazemag.com
IBC
59
Breaker Technology, Inc.
Elrus
www.rockbreaker.com
CWW Conveyor Systems, LLC
www.cwwconveyors.com
elrus.com/controlling
Elrus Aggregate System
www.elrus.com
EpirocFlexco
epiroc.us
FMI Corp.
www.flexco.com
jvibratoryequipment.com
Kleemann KPI-JCI and Astec Mobile Screens
wirtgen-group.com/america www.kpijci.com
Kespry, Inc.
www.kespry.com/aggregates
Kruse Integration
15 2
7, 9, 11, 13
59
mclanahan.com www.luffindustries.com
21
Moist Martin Tech Sprocket & Gear, Inc.
moisttech.comwww.martinsprocket.com
31
www.belting4conveyors.com
www.midwesternind.com
Progressive
progressive.com
25
NSSGA Membership EUFMC
EUFMC.com www.nssga.org
30
www.motionindustries.com
59 55 22 47 IFC 26
www.polydeckscreen.com
18
Pugmill Systems, Inc.
www.pugmillsystems.com
59
Rock Systems, Inc.
www.rocksystems.com
59
Rulmeca Group
www.rulmeca.ca
Scott Equipment
www.scottcompanies.com
SDLG North America
www.sdlgna.com
Stedman Machine Co.
www.stedman-machine.com/impact
Superior Industries
www.superior-ind.com
Terex Minerals Processing Systems
www.terexmps.com
Moisture Sensors from Lab to Line. Topcon Positioning Systems Product Inspection Volvo100% Construction Equipment
Non-Contact
Instant Measurements
World of Asphalt 2016
World of Concrete 2016
www.MoistTech.com
Polydeck Screen Corp.for errors or omissions. The publisher does not assume any liability
4
www.kruseintegration.com
McLanahan Luff Industries, Ltd
Motion Industries, Inc.
9
8
kpijci.com
Midwestern Industries
IBC
24
KPI-JCI
Linear Rubber Products
25
BC 2
www.fminet.com
JVI Equipment
27
www.topconpositioning.com www.volvoce.com/smartcare
www.worldofasphalt.com +1 941.727.1800 www.worldofconcrete.com
This index is provided as a service. The publisher does not assume any liability for errors or omissions.
Get the 2018 Aggregates Industry Atlas and the Atlas Download. To order, visit https://store.randallreilly.com
To
19 33 21
advertise
59 17
BC
here call
20 13
Pete Austin
41
42
(205)248-1258 AGGREGATESMANAGER MANAGER // February January 2016 AGGREGATES 2019
31
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
Our Golden Anniversary
Our long-time contributor honors his wife with the gift of a column dedicated to her.
T
his month, my wife, Pam, and I celebrate our fiftieth wedding anniversary — our golden anniversary. I spent a lot of time trying to think of something gold to give to Pam. Instead, I have decided to take the lead from “Your Song,” recorded by Elton John in the 1970s. To paraphrase, the lyrics go something like this: My gift is my [article] And this one’s for you… And you can tell everybody this is your [article] Let me explain why I have resorted to this simple gift. Even though gold is relatively scarce in the earth, more than 3,000 tons of gold are mined every year. Gold is concentrated by geologic processes to form commercial deposits of two principal types; lode deposits and placer deposits. Lode deposits are the targets for the “hardrock” prospector seeking gold at the site of its deposition from mineralizing solutions. Placer gold is the stuff people “pan” for. Concentrations of gold eroded from lode deposits are carried downstream as flakes, grains, or nuggets, and subsequently are concentrated in pockets containing stream bed sediments where the current slackens. Gold can survive being eroded from rock and carried downstream because it is a “noble” metal — it does not oxidize under ordinary conditions. In addition, pure gold is relatively soft and is the most malleable of metals. Because of these special properties, gold does not have to be smelted to be used and was among the first metals to be mined and turned into useful objects. Over 5,000 years ago, artisans in Egypt lavishly decorated tombs and temples with gold and golden objects. In ancient America, gold had both symbolic and spiritual meaning in Aztec society. Strange though, because the word for gold in Aztec dialect is teocuitlatl, which means excrement of the Gods. Gold has a variety of applications. In 2015, approximately 41 percent of the gold consumed for commercial products was for jewelry, but I would not dare buy jewelry for Pam without her approval. So, gold jewelry is out. About 34 percent of gold was used in solid state electronic devices. Those devices use very low voltages and currents that are easily interrupted by corrosion at the contact points. Gold is a highly efficient conductor that does not corrode, so it is used to plate the metal contacts on integrated circuits. Pam is quite happy with her flip phone, so electronics are out. Ten percent of gold was used for official coinage. No way would a gold coin make an appropriate anniversary gift. Three percent of gold is used in dental and medical applications. Gold alloys are used in dentistry for fillings, crowns, and bridges because it is chemically inert, non-allergenic, and because less inert materials might have an adverse effect on long-term health. I doubt a gift certificate to the dentist is what Pam has in mind. And speaking of health, one of the most ingenious uses of gold is to remedy a condition where a person cannot close their eyes completely. The condition is treated by implanting small amounts of gold in the upper eyelid. Gold is very heavy, and it weighs down the eyelid, helping it to fully close. Hmmm. Nope. I can imagine Pam rolling her eyes right now. The remaining two percent of gold is used for things like making glass red, coating the visors on astronauts’ helmets, gold nanoparticles, and so forth. They even put gold on ice cream cones and in champagne. Ummmm, nope. So, Pam can tell everybody this is her article. Happy Anniversary! AM
32
AGGREGATES MANAGER / February 2019
ROCK CRUSHING AT ITS FINEST. Since 1946 the name HAZEMAG has been linked with many accomplishments in impactor design and control technology. Today’s impactor is different. It’s better. It’s more user friendly, and it’s easier and less expensive to maintain. It offers optimum and continuous control over product size, and can do much more. In fact today’s impactor, the Hazemag Impactor, can do things never before possible. With over 50 years of experience in design and application of impactors, the future of impacting technology is now here.
YOUR PARTNER IN THE AGGREGATE INDUSTRY. ENGINEERED TO BE DEPENDABLE AND RELIABLE.
Visit us at: Booth #36088
HAZEMAG USA INC. P.O. BOX 1064 Uniontown, PA 15401 Phone: 724.439.3512 Fax: 724.439.3514 E-mail: info@hazemag.com
HAZEMAG CANADA INC. 1 Marconi Court, Unit #10 Bolton, ON L7E 1E2 Phone: 905.857.9623 Fax: 905.857.3025 E-mail: info@hazemag.ca
N A . H A ZE M AG.CO M
Control Towers By providing a 360° view and complete control of your spread, ELRUS Control Vans & Towers can significantly increase production. A centralized operating station offers the added benefit of improved safety for everyone onsite. ELRUS control towers are available in Pop-Up and Stationary. Pop-Up Tower Sizes: 6x8’ & 6x10’ Stationary Tower Sizes: 6x8’, 6x10’, 6x12’ 8x10’ & 10x14’
INCREASE PRODUCTION
www.elrus.com/ms612-screen 1-877-404-7741
info@elrus.com
IMPROVE SITE SAFETY
AGGREGATE SYSTEMS
CRUSHING • SCREENING • WASHING https://www.elrus.com/controlling