Martin Marietta Scoops Up
Texas Industries March 2014
www.AggMan.com
13 19 25
Take care of your undercarriage Simulators offer safe training alternative Review our roundup of primary crushers
Baldor now offers the most complete line of large AC motors in the world. Baldor•Reliance® motors deliver ratings to 1,500 Hp from stock and custom motors available to 15,000 Hp, alongside ABB induction and synchronous motors up to 100,000 Hp. Every large AC motor is designed and built for superior reliability, energy savings and rugged performance. Plus, our large AC motor line includes both NEMA and IEC configurations assuring you the motor you need meets frame, enclosure and duty cycle standards for any application…anywhere in the world. One source for all your global motor needs. Only from Baldor and ABB. baldor.com
479-646-4711
• NEMA and IEC Designs
• Unmatched Quality
• Superior Reliability
• Global Sales and Support
©2013 Baldor Electric Company
Text INFO to 205-289-3782 or visit www.aggman.com/info
Download a QR reader app and scan this code for more information. http://qr2.it/Go/1031261
On Our Cover: Martin Marietta scoops up a high-value acquisition Cover photo by Therese Dunphy.
13
Through simple steps such as making wider turns and turning on level ground, operators can protect the undercarriage of their dozer and lower owning and operating costs.
5
Deister introduces the BFO-11224-EX2 mine-duty screen with its new series of geared exciters.
CONTENTS MARCH 2014 VOLUME 19, NUMBER 3
FEATURE ARTICLES
10
COLUMNS & DEPARTMENTS
Top Round Pick
With the acquisition of Texas Industries, Martin Marietta is poised to claim the top spot among U.S. aggregates producers.
13
Take Care of the Undercarriage
Daily walkarounds, preventive maintenance, and a focus on the health of its undercarriage will drive a dozer’s performance.
25
The Big Crush
When it comes to primaries, this is a round-up that can kickstart your processing operations.
30Sudden Impact
A new portable impact crusher allows an Arizona operator to streamline crushing operations; all while boosting production and lowering operating costs.
OPERATIONS ILLUSTRATED
19
Simulator training
Through technology-aided training, operators can focus on training equipment operators to perform tasks more efficiently while keeping iron out in the field and eliminating unnecessary fuel costs.
3 5 9 34
EDITORIAL Taking steps toward safety.
ROLLOUTS Case introduces the 1221F wheel loader, and other new equipment for the aggregate market.
DATA MINING The latest financial analysis of issues impacting in the industry.
ROCK LAW Under the influence: Do operators have to take the blame for intoxicated employees?
36
CLASSIFIED ADS Aggregate industry classifieds.
39
ADVERTISER INDEX See who’s who and where to find their products.
40
CARVED IN STONE Mother Nature and the U.S. Army add to the scenic adventures as a convoy winds through Missouri.
Purpose-built
from the ground up Material handlers from SENNEBOGEN - 44,000 lbs. to 750,000 lbs. Simple design‌ Lift more. Move faster. Save fuel. Run longer.
www.sennebogen-na.com Tel: +1-704-347-4910 Text INFO to 205-289-3782 or visit www.aggman.com/info
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
March 2014
Vol. 19, No. 3
aggman.com /AggregatesManager @AggMan_editor
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Online Managing Editor: Amanda Bayhi editorial@aggman.com
Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Linda Hapner production@aggman.com
Construction Media Senior VP, Construction Media: Dan Tidwell VP of Sales, Construction Media: Joe Donald sales@randallreillyconstruction.com
3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com
Corporate Chairman/CEO: Mike Reilly President: Brent Reilly Chief Process Officer: Shane Elmore Chief Administration Officer: David Wright Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Vice President of Events: Alan Sims Vice President, Audience Development: Stacy McCants Vice President, Digital Services: Nick Reid Director of 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 Publishing Company copyright 2014. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 707.4.12.5); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.
Taking Steps
TOWARD SAFETY
O
n Feb. 5, the Mine Safety and Health Administration (MSHA) released a new guide on ladder safety designed to provide greater clarity and assistance for complying with MSHA ladder safety standards. Hopefully, the guide will enable operators and regulators to be on the same page in terms of the agency’s expectations. “As with other compliance initiatives undertaken by the agency in recent years, I expect our ladder safety guide will result in improved compliance, more consistent enforcement, and, ultimately, reduced injuries and deaths of miners,” writes Assistant Secretary of Labor for Mine Safety and Health Joseph A. Main in a letter introducing the guidance. The guide will serve as the basis for a series of inspector training sessions, he says, and “will ensure that MSHA inspectors, miners, and mine operators are all working with the same information.” Like previous guidance issued for guarding, the topic is covered through images and explanatory text via a PowerPoint presentation. Some of the topics covered include the following: - Ladder design and installation; - Ladder construction and maintenance; - Requirements specific to fixed and portable ladders; - Underground ladders and travelways; and - The differentiation between ladder standards and safe access standards. Unacceptable practices highlighted in the guide include ladders that are too narrow, have missing rungs, are located too high off the ground, or don’t extend the minimum of 3 feet above landings. The agency also points out that a minimum toe clearance of 3 inches is required for fixed ladders. Suggested best practices include having ladders that are wider at the top for an easier dismount, as well as the use of spring-loaded and gravity-closing gates at the top of ladders in the place of chains because they are self closing. Mobile equipment operators should take note that fixed mobile equipment ladders are included in MSHA’s fixed ladder category and ensure that damaged ladders are repaired to avoid a violation of 30 CFR §§ 56/57.11003. For more specifics, review the guidance on MSHA’s home page at www.msha.gov. Be sure to review the notes that accompany the image as they offer pertinent information about what is (and is not) considered acceptable in each image.
3
takeaways from this issue:
1
U.S. cement clinker is expected to decrease by 19 percent, page 11.
2
Approximately 50 percent of the maintenance cost of a dozer comes from the undercarriage, page 13.
3
Simulator training not only saves on equipment wear and tear, but also on fuel costs, page19.
AGGREGATES MANAGER March 2014
3
With WEG W22 motors, you don’t need a special motor for severe duty. WEG W22 motors are designed to maximize performance, extend motor life, optimize cooling, produce low vibration levels that meet IEEE841 and have the highest service factor in the industry, making W22 motors suitable for the most demanding applications. And, you can find WEG W22 motors at your local Motion Industries location. Our local sales and service specialists are experts in application and technical support, providing the parts and the know-how you need to stay up and running. Scan this code with your smartphone for more information. http://esp.to/wqOakR
The brands you count on from the people you trust...that’s WEG and Motion Industries.
Call. 800-526-9328 Click. www.motionindustries.com Visit. Over 550 Locations Text INFO to 205-289-3782 or visit www.aggman.com/info
For
FREE Product Information Text INFO to
205-289-3782,
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
Your complete guide to new and updated equipment and supplies in the aggregates industry.
or visit
aggman.com/info.
Aggregates duty loader Case Construction Equipment introduces the Case 1221F wheel loader, the newest and largest model in the company’s F Series wheel loader line. Designed with an 11.9-liter Tier 4i engine that delivers up to 355 horsepower, the unit is built for aggregates and mining applications. Enhancements to the engine and transmission at maximum travel speed allow for increases to productivity of at least 18 percent and fuel efficiency of at least 8 percent. The unit is powered by a cooled exhaust gas recirculation engine with diesel oxidation catalyst and diesel particulate filter for clean burning power and more torque than prior models. The wheel loader has an operating weight of 66,800 pounds, with buckets ranging from 6.3 to 7.8 cubic yards. With a 6.8-cubic-yard bucket, the breakout force with tilt cylinder is 55,730 pounds. The machine is available with Z-bar and extended reach configurations. Four programmable power modes save fuel and increase available power. A standard four-speed transmission with manual kickdown offers maximum traction, as well as superior bucket penetration. Baldor | www.baldor.com
High-volume, mine-duty screen Deister Machine Co. rolls out its BFO-11224-EX2 Mine-Duty Screen. Offering the next generation in machine size and production output, the 12-foot by 24-foot, horizontal, single-deck unit is said to deliver day-to-day reliability and high-volume capacities in a variety of hard rock mining and mineral processing applications. The unit features the new Deister EX Series of geared exciters, which are designed to create the force output required to drive large screens. Geared exciters feature all-steel components, specially-coated bearing inner races to deter wear on shafts, and shafts that are case-hardened and ground for minimal wear. Deister Machine Co. | www.deistermachine.com
Tier 4i excavator Komatsu America Corp.’s PC170LC-10 excavator, with operating weights ranging from 38,100 to 41,5600 pounds, joins its dash-10 series. The excavator is said to improve performance with up to 5 percent more lift capacity with the standard counterweight, while an optional heavier counterweight offers up to 15 percent more lift capacity than the previous model. The unit offers a net 115 horsepower at 2,100 rpm, but is 10 percent more fuel efficient than its predecessor. All of the system’s major components are designed and manufactured by Komatsu, and the integrated design employs a closed center load-sensing hydraulic system that offers efficiency by using both variable speed matching and low speed matching technology. Enhanced working modes are designed to match engine speed, pump delivery, and system pressure to the application. The SAA4D107E-2 engine provides lower emissions and reduces fuel consumption. Komatsu America Corp. | www.komatsuamerica.com
Text INFO to 205-289-3782, or visit aggman.com/info.
AGGREGATES MANAGER March 2014
5
ROLLOUTS
Improved sand tank controls Eagle Iron Works’ new Mark VI controls are said to improve the accuracy and simplicity of the calibration process and enable quick and easy adjustments. In under a minute, the system can recalibrate products. It also remembers specific product calibrations, allowing it to switch back and forth automatically as the feed changes. The number of products that can be simultaneously produced has increased to five products, and the system can have a different percent retained, percent passing, or cumulative percent retained for each product. It will also predict the tons per hour of each product and the total feed coming to the classifying tank, as well as maintaining daily tonnage accumulators. After it brings a product within specification, the controls make sure the fineness modulus of the product falls within a specified minimum/maximum range. Eagle Iron Works | www.eiwllc.com
Upgraded off-highway trucks The new Cat 770G and 772G off-highway trucks were redesigned with major advancements in emission technology, transmission, and traction control systems; frame, drive-train, and cooling system enhancements; added operator amenities; and serviceability improvements. Available in Tier 2, Tier 3, and Tier 4 Final configurations, the engines can be programmed to achieve the customer’s specific fuel economy goals. Two programmable modes are available, Economy and Adaptive Economy, while a new auto neutral idle feature automatically places the transmission in neutral gear after the brake is applied for more than 15 seconds while in a forward gear. A new transmission control system, Advanced Productivity Electronic Control Strategy (APECS), offers improved shift quality, faster acceleration, better speed on grade, and faster cycle times. Also new is a four-post ROPS/FOPS structure that is integral to the cab, and the cab is resiliently mounted to the frame to dampen sound and vibration. Operator safety is enhanced with handrails, lighting, and a low-effort stair step system. Both trucks come standard with VIMS 3G, Cat’s Vital Information Management System, Truck Production Management System (TPMS), TMPH (Ton Mile Per Hour) / TKPH (Tonne Kilometer Per Hour) tire management system, and Product Link.
Specifications Engine Net power, hp Peak torque, lb ft Gross operating weight Nominal payload, metric tons Body capacity, cubic yards Top speed (mph), loaded Caterpillar | www.cat.com
770G Cat C15 477 1,711 157,000 pounds 40 33.9 45.7
772G Cat C18 550 1,988 181,000 pounds 52 40.8 49.2
Telescoping stacker A new 170-foot long SuperStacker, from KPI-JCI and Astec Mobile Screens, is the company’s latest model of telescoping stackers designed to minimize stockpile segregation and increase stockpile capacity. The new system is an addition to the new generation SuperStacker product line, which eliminates the echain, reducing field maintenance. It also features an updated Wizard Touch automation control system. KPI-JCI and Astec Mobile Screens | www.kpijci.com
6
AGGREGATES MANAGER March 2014
Side dump bucket The JRB side dump bucket, from Paladin Attachments, is designed to give wheel loader operators more flexibility than a standard bucket can offer in construction applications. It can dump from many angles, making it ideal for confined or hard-to-maneuver areas. One side of the bucket is shaped like a standard bucket to hold material while the other side has a 45-degree side-shoot dumping angle that allows for full side dumping. The bucket carries up to 4 cubic yards and is available in left- and right-hand dump functions. It features the JRB sequence valve that locks and unlocks the bucket cradle and side dump function to enhance safety and control during transportation and placement. Paladin Attachments | www.paladinattachments.com
Terex Ad To come soon
REDUCE COSTS OPERATING
because time is money TM
Telsmith’s Hydra-Jaw Crushers, four sizes engineered with advanced Hydra-Jaw TM technology allowing your crew to make frequent adjustments quickly and easily with remote fingertip controls. TM
The Telsmith Hyrdra-Jaw brings the reliability, productivity, and safety needed for your bottom line.
TM
ADVANCED HYDRA-JAW TECHNOLOGY Hydraulic toggle reduces maintenance and lowers operating costs with: • Fast, Safe Hydraulic Chamber Clearing • Tramp Iron Overload Relief & Auto Resets
SALES | PARTS | SERVICE Phone: 262.242.6600
• telsmith.com
Text INFO to 205-289-3782 or visit www.aggman.com/info © 2014 Telsmith, Inc.
Data
George H. Reddin is a principal in FMI’s Investment Banking practice. He can be reached at 919-785-9286 or at greddin@fminet.com.
M&A Activity Off to a Fast Start
A
fter a, relatively speaking, quiet 2013, merger and acquisition activity is off to a feverish pace in 2014. Divestitures by Lafarge and Vulcan, and a merger between Martin Marietta and Texas Industries led the way. We have been anticipating such activity and believe that the improved economy and housing rebound are the start of a more robust merger and acquisition market for 2014. The market collapse is now in the rear view mirror, and buyers are looking forward again.
Recent transactions
Martin Marietta Materials, Inc. signed a definitive merger agreement to acquire Texas Industries, Inc. for $2.1 billion in stock. Texas Industries shareholders will receive 0.7 Martin Marietta shares for each share of Texas Industries common stock they own at closing, with Martin Marietta shareholders expected to own approximately 69 percent and Texas Industries shareholders expected to own approximately 31 percent of the combined company. The combined company will operate under the name Martin Marietta
Materials and will be led by the Martin Marietta executive team. The transaction is expected to close in the second quarter of 2014. Bluegrass Materials Co., LLC acquired five aggregates quarries and related assets in Maryland from Lafarge S.A. for $320 million. Lafarge continues to divest of non-core assets, while refocusing on its core markets in the United States and Canada. Today, Lafarge operates a network of integrated positions, mainly located in Canada, the Great Lakes, and Mississippi River regions. Lafarge Canada Inc. acquired eight ready-mix manufacturing plants from James Dick Construction Ltd. The newly acquired ready-mix concrete plants will operate under the James Dick Concrete name. The plants are located in Alliston, Bolton, Brampton, Caledon, Hamilton, Oshawa, and Scarborough, Canada. Argos Cement LLC and Argos Ready Mix LLC will acquire assets of Florida Rock Industries, Inc. and Florida Cement, Inc. from Vulcan Materials Co. for approximately $720 million in cash. Vulcan is retaining all of its aggregates operations and cement segment’s ground calcium
Stock Report Company
U.S. On-Highway Diesel Fuel Prices Ticker
Current Value
52-Week 52-Week High Low
2/3/2014
One Week
One Year
United States
$3.951
+0.047 p
-0.071 q
East Coast
$4.070
+0.074 p
-0.018 q
New England
$4.305
+0.134 p
+0.068 p
Central Atlantic
$4.281
+0.137 p
+0.116 p
$3.868
+0.016 p
-0.133 q
Midwest
$3.942
+0.068 p
-0.036 q
Gulf Coast
$3.775
+0.003 p
-0.166 q
Rocky Mountain
$3.860
-0.003 q
+0.016 p
West Coast
Cemex, S.A.B. de C.V.
CX
$11.94 q
$13.17
$9.13
CRH plc
CRG
$25.44 q
$27.14
$19.83
Eagle Materials Inc.
EXP
$75.66 q
$81.95
$59.08
Granite Construction Inc.
GVA
$31.52 q
$37.74
$26.07
Heidelberg Cement AG
HEI
$73.48 q
$82.26
$61.68
Holcim Ltd.
HOLN
$71.72 q
$87.55
$69.40
Lower Atlantic
Martin Marietta Materials, Inc.
MLM
$106.36 p
$115.00
$93.03
MDU Resources Group, Inc.
MDU
$31.11 p
$32.27
$23.00
Texas Industries Inc.
TXI
$72.08 p
$77.40
$53.23
United States Lime & Minerals, Inc. USLM
$54.01 q
$62.50
$45.00
U.S. Concrete
$21.71 q
$23.60
$9.15
Vulcan Materials Co.
operations in Florida. The acquired assets are located in Florida and south Georgia, and include the Newberry, Fla., cement plant, Tampa and Port Manatee cement terminals and grinding facilities, 69 ready-mixed concrete sites, and 13 concrete block and building material sites. Vulcan will use the proceeds to initiate a tender offer to purchase $500 million of outstanding debt. In addition, the company exercised an option to purchase land containing 136 million tons of aggregates reserves in southern California for $117 million. Summit Materials LLC completed its acquisition of Alleyton Resource Corp. and its affiliate Colorado Gulf, LP, based in Houston. Alleyton operates five sand and gravel sites and has seven ready-mix concrete plants in the west Houston metropolitan area. The transaction was valued at $210 million. Irving Materials, Inc. acquired W.T. Congleton Co., which engages in manufacturing of readymix concrete. The company was founded in 1948 and is based in Lexington, Ky. Oldcastle, Inc. acquired gravel-quarrying assets from Turner Gravel, Inc. based in Turner, Ore. AM
USCR VMC
$59.05 q
$63.05
$45.42
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 2/3/14.
$3.994
+0.015 p
-0.172 q
West Coast less California
$3.902
+0.027 p
-0.174 q
California
$4.072
+0.004 p
-0.170 q
Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
AGGREGATES MANAGER March 2014
9
Following its acquisition of Texas Industries, the combined company anticipates aggregates volumes to increase by 4 to 5 percent and pricing to rise by 3 to 5 percent in 2014.
Top
Round Pick by Therese Dunphy, Editor-in-Chief
10
I
footprint, we will be even better positioned to deliver f its $2.7 billion acquisition of Texas Industries value to our shareholders and customers,” Nye said. goes through during the second quarter of this “Texas Industries’ aggregates operations are strategiyear as planned, Martin Marietta Materials Inc. cally located in high-growth markets and fit well into may soon take the top spot as the nation’s largour existing portfolio, and its cement operations will est aggregates industry producer. The acquisition — the biggest in Martin Marietta’s further diversify our product and customer mix.” The combined company anticipates annual aggrehistory — would result in a combined company with gate shipments of 143 million short tons — slightly nearly 7,000 employees, net sales of $2.9 billion, agmore than Vulcan Materials Co.’s annual shipments gregate reserves of 13.4 billion tons, and more than 400 quarries, distribution yards, ready-mix plants, and of 141 million short tons. In a near-term 2014 outlook, the presentation predicts volume growth of 4 cement plants. Details of the deal were spelled out by Ward Nye, president and CEO of Martin Marietta; Anne Lloyd, executive vice president and CFO of Martin Marietta; and Mel Brekhus, president and CEO of Texas Industries during a Jan. 28 presentation. “By uniting Martin Marietta’s and Texas Industries’ complementary assets and leveraging an The combined assets will result in a strong presence in many of the nation’s high-growth markets, including expanded geographic Texas, Florida, and California.
AGGREGATES MANAGER March 2014
Source: Martin Marietta Materials
With the acquisition of Texas Industries, Martin Marietta is poised to claim the top slot among U.S. aggregates producers.
MANAGEMENT tions. It is expected to close by the second quarter of 2014. to 5 percent and pricing growth of 3 to 5 percent. “We are confident that we have found the right partner,” While Martin Marietta has long held aggregates, ready-mix, Brekhus said. “This transaction will create a larger, stronger entity asphalt, and specialty product plants, the acquisition significantly with enhanced career and professional development opportunities increases its ready-mix market share in Texas (which boasts three for employees. I look forward to working closely with Ward and of the nation’s top 10 job growth markets) and establishes its the proven management teams of both companies to complete the presence in California, where cement consumption is expected to transaction quickly and to ensure a smooth transition.” AM enjoy double-digit growth over the next several years. The addition of cement to Martin Marietta’s portfolio of construction materials is significant. The presentation highlights that 18 U.S. cement facilities are forecast for closure due to an inability to meet regulatory standards or because compliance investment may not be financially justifiable. booth In addition, seven cement facilities have # 52990 been closed since 2008 due to local cyclical demand and the expectation of increasingly stringent emissions standards. The result, the presentation notes, is an anticipated 19-percent decrease of current clinker careduce carryback pacity in the U.S. market. Martin® SG “Through the significant investments Belt Cleaner Texas Industries has made in plant mod► Economical cleaner with a ernization and capacity expansion, it has one-piece heavy duty frame achieved leading positions in some of the ► Spring Tensioner maintains cleaning pressure while minimiznation’s highest growth markets while ing the need for adjustment maintaining a low-cost profile,” Nye said. ► Features an easy one-pin “As a result of this combination, we will be Designed for the aggregate industry. blade change poised to capitalize on the strength of our combined aggregates platform, as well as the significant upside potential in the infrasuppress dust structure, residential, and non-residential Martin® Surfactant Dust System construction segments.”
NEW
aggregate industry
solutions
As part of the acquisition, each Texas Industries share will be exchanged for 0.7 Martin Marietta share. The stock-for-stock, tax-free exchange includes a 15-percent premium to implied exchange ratio on Dec. 12, 2013, and a 13-percent premium to implied average exchange ratio during the 90 days prior to the announcement. Martin Marietta shareholders will hold 69 percent of combined venture, while Texas Industries shareholders will hold 31 percent. The agreement is subject to votes from shareholders of each company, as well as regulatory approvals and closing condi-
Automatic flow adjustment eliminates surfactant waste and reduces cost.
call 800.544.2947 visit martin-eng.com email info@martin-eng.com
MarEng_AggreMgr_hpi.indd 2 Untitled-18 1
►
Custom designed to meet individual customer requirements
►
Fully automated system maintains consistent treatment application
►
Effective surfactant solutions available to suit application
A GLOBAL COMPANY
® Registered trademark of Martin Engineering Company in the US and other select locations. © 2014 Martin Engineering Company. Additional information can be obtained at www.martin-eng.com/trademarks.
Text INFO to 205-289-3789 or visit www.betterroads.com/info
11
2/6/14 4:22 PM
AGGREGATES MANAGER March 20142/12/14 10:12 AM
WHEN WIGGLE ROOM IS AT A PREMIUM.
Small Footprint. Big Results. When space on the job site is at a premium, count on the Global Track product line to deliver maximum productivity in a compact and portable package. The Global Track line is engineered to efficiently handle huge production outputs. With the versatility to handle multiple applications, the Global Track line will never leave you and your crew hanging. For the KPI-JCI & Astec Mobile Screens dealer nearest you, visit kpijci.com/dealer-locator. Text INFO to 205-289-3782 or visit www.aggman.com/info
Booth 50327 Central Hall
Continuous turning on the same side can cause asymmetrical wear and accelerated wear. Make every effort to balance the direction of turns throughout the day. If it’s not possible, check for wear more often.
Daily walkarounds, preventive maintenance, and a focus on the health of its undercarriage will drive a dozer’s performance. by John Bauer and Brad Stemper
F
act: approximately 20 percent of the purchase price and 50 percent of the maintenance cost of a dozer sits in its undercarriage. That’s a lot of money tied to one component. Of all tracked machines, a dozer undercarriage experiences more force, abrasion, and resistance than any other piece of equipment. Keeping that undercarriage in good working order will go a long way toward reducing maintenance costs and optimizing your working hours. In this article, we will cover tips on how to prevent and minimize undercarriage wear, maximize undercarriage life, and lower owning and operating costs. We’ll follow that up with The Dozer Health Checklist. As with all equipment, it’s often the small stuff that can trip you up. Daily maintenance and upkeep is critical to overall machine health. Follow these
important steps to ensure overall machine health — and see how new technologies can help you keep track of your service demands.
The undercarriage and the operator The undercarriage of a dozer is built on a system of moving components: rollers, idlers, tracks, and other parts. What many don’t know is that how the machine is operated plays a critical role in the health of the undercarriage. Important operating tips include: • Make wider turns. Counter-rotation, or pivot turns, causes accelerated wear. Make wider more gradual turns, such as Y-turns, when possible. • Work up and down on slopes. Constant operation on a slope or hill in one direction can accelerate wear AGGREGATES MANAGER March 2014
13
EQUIPMENT MANAGEMENT
•
•
•
•
to idlers, rollers, and guide lugs by placing greater forces on one side. Travel straight up or down the slope. Turns are best performed on level ground. Some jobs require hillside work — for these situations, keep in mind that minimizing time on the slope will always pay off in reduced wear and load to the undercarriage. Alternate turning direction. Continuous turning on the same side can cause asymmetrical wear and accelerated wear. Make every effort to balance the direction of turns throughout the day. If it’s not possible, check for wear more often. Control track spinning. Unnecessary spinning can increase wear and decrease productivity. All regular service items should be checked at the intervals recommended by the manufacturer. Consult Decrease the blade or bucket load to avoid it. your owner’s manual. Limit high-speed and reverse travel. Higher speeds can cause more wear, as can unnecessary travel in reverse. Minimize unproductive high speeds and avoid excessive travel in reverse. Use caution when edges are encountered. Avoid loading just the side of the track pad, instead of the entire pad supporting the weight.
Proper maintenance pays dividends
Proper care of the undercarriage can significantly minimize maintenance costs, increase uptime, and impact the longevity of the dozer. Owners and operators should: • Ensure proper track tension. Monitor track Prevention is the best medicine — true for human health, as well as dozer performance. tension when the machine is in working conditions and adjust it accordingly. When steel tracks are too tight, overnight is removed. Optional covers and guards are available it accelerates bushing wear. When they’re too loose, it can create to help keep the undercarriage clean. instability, and, in the worst-case scenario, it can cause the tracks • Conduct daily inspections. Operators should inspect the underto derail. Proper tension also ensures the machine puts available carriage for excessive or uneven wear, as well as damaged or power to best use. Check the operator’s manual for specific track missing components. Any issues should be immediately adinspection and tensioning procedures. dressed to minimize further wear or damage. • Keep the undercarriage clean. At the end of the day, clean out • Follow the schedule. Conduct a complete undercarriage inspecmud and debris from the undercarriage since it can build up tion in keeping with the manufacturer’s recommendations. and accelerate component wear. Doing so at the end of the day More frequent inspections should be performed if the machine ensures that material that might freeze or dry up and harden is used in conditions that are more demanding than normal.
14
AGGREGATES MANAGER March 2014
Let’s go for 500 hours between oil drains. © 22001122 Chhev hevr evr vvrron o U.S.A A. IInc. All right htts reserv served. erv rved. ed All A ttrad trrrad tra addeem ema maaarrks m ks arree pro rrope oope ppeerty ttyy owne o ow d by Che C vrron Intellectuaal Proper Property ty LLC..
*
How do we do it? Delo® products utilize our specialized ISOSYN® Technology, which combines premium base oils, high performance additives and Chevron formulating expertise to provide superb diesel parts protection that rivals synthetic performance. All at an outstanding value. Delo products with ISOSYN Technology help provide extended service protection, maximize engine durability and minimize operating costs. Learn how Delo’s family of products can help you go further, visit ChevronDelo.com Fan us on Facebook
*Several major construction equipment OEMs support maximum engine oil drain intervals of up to 500 hours. Delo 400 has been utilized by construction and mining customers to achieve 500 hour oil drains in large Caterpillar 3516 and 3600 series engines along with Cummins off-road industrial engines such as KTA and QSK. Always follow OEM maintenance recommendations and utilize used oil analysis testing for any extended oil drain programs.
Text INFO to 205-289-3782 or visit www.aggman.com/info
THE LEADER IN TECHNOLOGY: THE NEW MC 110 EVO
MC 110 Z EVO Continuous Feed System
MC 110 R EVO High-tech jaw crusher
Direct drive via fluid clutch
ALL • BOOT
WIRTGEN AMERICA . 6030 Dana Way . Antioch, TN 37013 Tel.: (615) 501-0600 . www.wirtgenamerica.com
Text INFO to 205-289-3782 or visit www.aggman.com/info
51 0
LH
H
A CENTR
High production, quality product with maximum efficiency, the all new Kleemann EVO jaw crusher.
21
SEE IT!
EQUIPMENT MANAGEMENT
Dozer health checklist As it relates to the rest of a dozer’s operating systems, remaining consistent and adhering to recommended service schedules is important. One of the most important activities that a dozer operator can engage in on a daily basis is the “pre-flight check.” Before starting the machine, the operator should look for the following: • Check all lines and components for water or oil leaks. • Check that all visible nuts and screws are tightened. • Check for structural damage that may have happened overnight or since the last operation. • Check the oil level, as well as the coolant level at the overflow tank. • Check for clogging or damage to the radiator. • Check the engine accessory drive belt condition. • Check that the air filter restriction warning light is not illuminated. • Check the fuel tank, DEF tank (on dozers with selective catalytic reduction technology), and hydraulic reservoir levels. • Check that the hydraulic oil is clean. • Check that all battery connections are properly tightened. • Check the condition of the blades, cutting edges, and the ripper points. • Lubricate all grease points. Severe conditions, such as water immersion, may require more frequent greasing. Once you start the engine, it is also important to observe how the machine is running before beginning full operation. Factors to monitor include: • Did the engine start correctly? Are the exhaust fumes normal? Are there any unusual sounds? • Check for abnormal noise on the hydraulic components. • Check for water, fuel, or oil leaks. • Check that the audible alarm devices, working lights, and wipers are in working order. • Check that all hydraulic circuits are functioning correctly. It may seem like a lot of work, but these checks take a relatively short amount of time and may help prevent a more significant problem that causes downtime. Other important intervals to monitor include the following (be sure to check your original equipment manufacturer manual for machine-specific recommendations): 50 Hours: Drain water and sediment from the fuel filter every 50 hours; more often if conditions require or if fuel quality is poor.
First 100 Hours: (Note: these are specific to the first 100 hours of operation and are not regularly scheduled intervals). • Change the engine oil and filter. • Change the hydraulic oil filters, • Change the fuel filter. • Clean in-line DEF supply filter. 500 Hours: • Engine oil and filter replacement. • Fuel filter replacement. • Check battery fluid level. 1,000 Hours: • Change the oil in the final drive and the planetary drive. • Drain condensation from the fuel tank. • Clean the fuel tank cap. • Replace the hydraulic reservoir breather. 1,500 Hours: • Clean in-line DEF supply filter. • Replace the drive belt. 2,000 Hours: • Replace hydraulic oil filter. • Drain, flush, and replace engine coolant. • Change the hydraulic/hydrostatic drive system oil and filters. • Clean the reservoir suction screen. • Replace the engine primary and secondary air filter. In many cases, your dealer may assist you with this work through a planned maintenance contract or other agreement, but keeping track of these items is critical. A telematics system — common now to many manufacturers — automatically keeps track of these intervals and can alert the owner to impending service needs. Dealer service departments can also be granted access to the telematics system to help monitor and plan for maintenance. Bottom line: the bookkeeping on maintenance intervals has gotten much easier with the advent of these technologies and empowers the equipment managers to be proactive in ensuring optimal uptime and the profitability of your dozer, ultimately driving down your owning and operating costs. AM John Bauer is the brand marketing manager for Case Construction Equipment. Brad Stemper is Case Construction Equipment’s solutions marketing manager.
AGGREGATES MANAGER March 2014
17
TeleStacker Conveyor
N
EW
!
®
XTP AXLE CUTS 80% FROM SETUP
FB UNDERCARRIAGE = 17X LESS DEFLECTION ®
UP TO 30% HEAVIER THAN COMPETITORS
king of the hill Since 1997, our team of engineers, field managers, dealers and customers have worked to make the TeleStacker Conveyor the construction aggregate industry’s most valuable stacker. Our pursuit of excellence continues as we work together to defeat material segregation, accelerate road readiness and bring an end to wasteful maintenance. How can we help stimulate your production?
superiorindustries
Text INFO to 205-289-3782 or visit www.aggman.com/info
www.superior-ind.com
OPERATIONS ILLUSTRATED
PULL-OUT GUIDE by Kerry Clines, Contributing Editor
S i m u la t o r T r a i n i n g
The display shows view from cab of equipment.
Test operator skills.
Controls match those in mobile equipment.
Save fuel and wear and tear on mobile equipment.
Train in a safe environment.
OPERAT 1
Increased safety
The Whys and Hows of Simulator Training
S
imulators aren’t new to the industry, but many companies don’t understand the cutting edge training they offer for heavy equipment operators. Simulators are easy to use, cost effective, and allow operators to be well trained and comfortable before being placed in the cab of an expensive piece of equipment. They combine technology and operator instruction with rich graphics and realistic controls to help operators feel like they are in the actual machine, allowing them to become familiar with and memorize the machine’s essential operating techniques. “I think simulators are important for the overall training experience,” says Tom Whitworth, an account manager for Simformotion LLC, the licensee for Cat Simulators for Caterpillar Inc. “A simulator provides training in a virtual environment. It keeps the operator and other ground personnel out of the equation and out of harm’s way.” Training exercises on the simulator are measured and recorded for each operator’s simulator sessions. That way, the operator can see how well he/she performed. An instructor can check the results to determine if there are areas of inefficiency that need further instruction and additional training time. “We use our simulators almost every day here,” says Danny Turner, training and development coordinator at Aecon Mining in Alberta, Canada. “In the last AGGREGATES MANAGER
four months, we’ve had 250 trainees go through our training center.” The use of simulators allows operators to make mistakes without endangering themselves or the equipment. This is huge. No one wants to put a greenhorn behind the wheel of a haul truck or at the controls of a loader, excavator, or other expensive machine without knowing he/she can operate it correctly. “If you make a mistake on a simulator, it’s better than making one on a machine,” Whitworth says. “A trainer can immediately explain to the operator what he did wrong, give him instructions on how to do it correctly, and allow the operator to practice until he has mastered the operation.” One of the biggest benefits that simulators offer is the ability to track and keep records of each operator’s performance. “We can track time, usage, the speed at which the operator is going, and even how much material the operator is actually putting through,” Whitworth says. “Then you get a report of that operator that you can save to track performance throughout training.” Simulators also allow quarries to continue producing aggregate while operators are being instructed in the training room. No unnecessary equipment downtime is required. This is especially important when training someone to load a haul truck, which requires the use of more than one piece of equipment at the same time.
Simulator training increases the safety of man and machine by allowing equipment operators to train in the safety of a classroom. Operators can learn how to safely operate a piece of machinery, become familiar with the controls, and perfect difficult exercises before actually getting into the equipment, therefore, doing away with the risk of accident and/or injury to the operator or the machine.
4
Increased production
Training on a piece of equipment takes that machine out of production for the period of time necessary to ensure the operator can efficiently operate the machine. If multiple operators are being trained at the same time, it means multiple pieces of equipment will have to be taken out of the production cycle. Training an operator on a simulator leaves the equipment free to continue producing, loading, or moving aggregate.
TIONS ILLUSTRATED Simulator Training 2
Assess/refine operator skills
3
Training flexibility
Simulators are a good way to assess the skills of new hires without the risk of putting them into a piece of equipment. Check their skills, and, if you like what you see, continue to use the simulator to train the operators for a day or two to make sure they understand the unique challenges/ways of performing tasks and handling traffic patterns associated with your individual operation.
Simulator training offers great flexibility. Training centers can be set up in on-site classrooms or in a mobile trailer that can be moved from site to site. The training can be done any time, day or night, and in any weather conditions. Simulators can be used in conjunction with computer programs, allowing multiple operators to be trained at the same time, which speeds the entire training process and gets operators into the iron quickly.
5
6
Cost savings/sustainability
OUR EXPERTS
Tom Whitworth is an account manager for Simformotion LLC, the licensee for Cat Simulators for Caterpillar Inc., where he educates customers on how to integrate heavy equipment simulators as part of an end-to-end training program. Prior to Simformotion, he worked for MatchWare, Inc. as an educational advisor. Whitworth has a master’s in business administration from Eastern Illinois University.
Better maintenance Danny Turner is the training and development coordinator at Aecon Mining in Alberta, Canada, where he has spent the last three years developing a training and evaluation program to make the workforce safer and more productive. He has worked in construction for 40 years, operating every type of equipment ranging from small dozers and excavators to large hydraulic shovels in large mines.
Cost savings is the name of the game for any company that wants to continue doing business in this day and age. Simulators are one way producers can help keep expenses to a minimum. There are no fuel costs or equipment maintenance required when using simulators, and no engine hours are expended. If a loader operator is being trained to load a haul truck, it requires the use of two machines at double the expense, so the cost savings can be huge when using a simulator.
Some simulators include an inspection program that can help operators identify possible maintenance issues before they cause serious problems. The simulator leads the operator through a walk-around inspection of the machine that highlights what areas should be checked during both a pre-operation inspection and a post-operation inspection. The walk-around shows the operator what to look for in each area in order to prevent equipment downtime associated with unplanned maintenance. March 2014
OPERATIONS ILLUSTRATED Voices of Experience Tom Whitworth
“S
t
Danny Turner
t
imulators allow the operator to become familiar with the overall machine controls quickly without any hazard to the operator or machine, without taking the machine out of production, and without wasting money on fuel,” says Tom Whitworth, account manager for Simformotion LLC, the licensee for Cat Simulators for Caterpillar Inc. “You don’t want to do away with all of the operator’s iron time, but the simulator allows you to do away with a portion of it and keep track of it at the same time.” There are some things that can be done on a simulator that can’t be done on a machine. An operator learns to operate equipment from the safety of a classroom with a trainer nearby to answer questions and explain procedures. If the trainee does something wrong, the trainer can address it immediately and have the operator perform the operation the correct way. Cat Simulators training exercises contain benchmarks from Cat expert operators. The simulator software tracks training performance and generates a report each time an operator uses the simulator. Operator performance can be tracked from the time of hire and throughout his/ her training and employment. “A brand new operator will obviously have to spend more time on a simulator, but each one learns at a different pace,” Whitworth says. “One may only need 20 hours to learn all the controls, where another may need 40 hours or longer before feeling comfortable enough to get on a machine. The applications included in each simulator are the same operations used on actual jobsites, so the training translates seamlessly to real-world use.” An operator can get on a simulator and practice a particular exercise every three months or so to keep skills fresh. If there’s an operator that has a really bad habit, he/she can perform the exercise on the simulator until the bad habit has been corrected. “In the aggregate industry, there are some big companies with multiple locations that might not have enough operators at one location to justify buying a simulator,” Whitworth says. “So, some companies outfit trailers as mobile labs. Instead of making everyone come to one location, the trailer can be driven to different locations. It can be at one quarry for a couple of months and then moved to the next, cutting out travel time and machine downtime.” Much goes into the development of a simulator program, and customers determine what is developed next. “If our customers are interested in a particular machine, we have the ability to develop one,” he says. “We also offer custom simulation development. If a customer wants a certain machine model, environment, and particular training exercises, a simulator can be developed just for that customer.”
“W
e got our first simulator about two and a half years ago,” says Danny Turner, the training and development coordinator at Aecon Mining in Alberta, Canada. “Our original idea was to use it as an evaluating tool for new hires, and it worked out really well for that. Our new hires sometimes are not what they say they are. When we first started using the simulators, we only hired about 60 percent of the people who applied, because they couldn’t pass our simulators. Now, people seem to know we’re tracking this closely, and we are getting better quality people.” The company eventually purchased a dozer simulator and an excavator simulator, and set up a training center in August 2013. The simulators are now used for both evaluating new hires and for training and retraining. The training center includes E-learning computer programs, as well, which work well with the simulators to provide a complete training solution. “Simulator training is usually a one-time thing,” Turner says. “We bring in an operator for a full day. He’ll do computer training and then move to the simulator. By the end of the day, we’ve run him through many different programs. If he’s not comfortable, we’ll bring him back again the next day. It’s based on the individual. “Once the operator is finished with the simulator, the trainer takes him out in the field,” Turner continues. “There, the trainer goes through much the same scenarios as the operator performed on the simulator. If the trainer finds an area the operator is having trouble with, he will bring him back to the simulator to show him what’s being done wrong and how to do it right.” Aecon is located in the Fort McMurray area of Alberta and much of its work is performed in the oil sands. Because the oil sands are located in the boggy muskeg, most of the work is done in the winter when the ground freezes hard enough for large equipment to drive on it without getting stuck. This means that many of the company’s operators are on furlough for several months during the summer. When the operators return to work, they are sent to the training center for a refresher course before returning to their machines. “Simulators are a big investment,” Turner says, “but we’d be lost without them. You can see a return on the investment in a short amount of time. We push to our clients that there aren’t too many companies that use simulators and computer training before putting operators to work. And we promote the fact that we do.” AGGREGATES MANAGER
Modern Solutions and Products with Old Fashioned Service and Integrity
Hydrocyclones
Fine Material al Washers
Rising Current Separators
Dewateringg Cyclones
Coarse Material Washers
Fines Recovery
Text INFO to 205-289-3782 or visit www.aggman.com/info
Manufactured in the U.S.A. For Over 50 Years
www.metprosupply.com Toll free (888) 616 616--8226
Text INFO to 205-289-3782 or visit www.aggman.com/info
Supply by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
THE BIG CRUSH
When it comes to primaries, this is a round-up of crushers will kick-start your processing operations.
Diesel or electric impact plant The Grasan KRH1620 horizontal-shaft primary impact crusher plant is available in pit-portable and stationary models for high-volume aggregates and concrete/asphalt recycling operations. The crusher can reduce 24-inch limestone down to 6-inch minus in one step and produce a cubical-quality product at up to 800 tons per hour. The plant features a Hazemag 1620 APPH impactor with fully automatic hydraulic cylinder system for increased crusher capacity, smooth operation, and uniform products. The 50-inch high, 80-inch wide inlet accommodates incoming materials up to 36-inch cube. Grasan | www.grasan.com
Redesigned portable jaw crushers Kleemann offers two new jaw crushers, the Mobicat MC 110 Ri EVO and MC 110 Zi EVO. The MC 110 Ri EVO has a vibratory feeder with integrated grizzly, while the MC 110 Zi EVO incorporates a vibrating feeder with an independent, double-deck, heavyduty prescreen. The crusher inlet on each unit is 28 inches x 44 inches. The machines now boast lighter transport weight to ease portability. The redesigned machines include features such as the hopper walls integrated in the chassis and a fully hydraulic crushing gap adjustment. Kleemann | www.wirtgenamerica.com
Efficient performance Irock’s RDS-20 primary crushing plant is said to be a highly portable, easy-to-operate mobile unit. It combines a closed-circuit design, high-performance four-bar impactor, and heavy-duty components for reliability, increased efficiency, and the precision to produce a uniform, cubical product. It also is versatile enough for use across multiple industries and can process a variety of materials, including quarry rock, demolition debris, recyclable materials, and base rock for oil fields. Irock | www.irockcrushers.com
More performance, less maintenance
The new generation Vanguard Jaw Crusher is said to reduce maintenance and increase performance. The optional tramp iron relief system enables adjustment to the closedside-setting on the fly while providing overload protection from tramp iron events. KPI-JCI says the increased stroke, toggle angle, and flywheel inertia provide up to 25 percent more production, greater efficiencies, and lower fuel costs over competitive models. Components such as the common flinger collar, stress-relieved base frame, and machined saddle work to reduce cost of ownership. KPI-JCI | www.kpijci.com AGGREGATES MANAGER March 2014
25
Portable plant for severe applications
Consistent product shape
The new Terex Cedarapids CRJ3750 plant combines a large 37-inch x 50-inch JS Series jaw crusher with a high stroke, 52-inch x 20-foot vibrating grizzly feeder resulting in a high-production portable crushing machine. The unit is built tough, including a new hopper design, to handle severe primary crushing applications. The mobile plant is said to be easy to operate and maintain and offers new levels of reliability and convenience. Options include a rock breaker, folding hopper wings, hydraulic jacks, hydraulic deployed switchgear, and quad or 3+1 axle configurations. Terex Corp. | www.terex.com
The Powerscreen Trakpactor 320SR is a mid-sized horizontal impact crusher redesigned to offer operators excellent reduction and high consistency of product shape for performance in quarry and recycling applications. The crushing chamber features a 1130-mm x 800mm feed opening, hydraulically assisted closed-side setting adjustment, four-bar rotor and twin apron design, and hydraulic overload protection as standard. New to this model is an optional fully independent hydraulic pre-screen, which improves fines removal and reduces chamber wear costs. Powerscreen | www.powerscreen.com
Production-oriented processing Cemco’s Turbo 80 vertical shaft impact crushers are said to offer portability and productivity for processing a variety of aggregate materials and industrial minerals. The crushers can process materials up to 4 inches long-side dimension into a uniform, cubical, high-quality product and are available with powerful single or V-twin drive motors for high outputs of up to 275 tons per hour. The units can be equipped with a rotor and anvil ring combination or a shoe table rotor and rockshelf anvil. Internal components can be customized to meet customer requirements, and the machines can be mounted to a chassis or tracks. Cemco | www.cemcoturbo.com
Primary-secondary impactor
The Eagle Crusher UltraMax 69 HSI impactor performs the job of a primary and secondary crusher in a single unit, and comes with a lifetime rotor warranty on its three-bar, solid-steel, sculptured rotor. Featuring a large feed opening for high-volume production and ultra-high-reduction ratios, the unit is said to produce high-quality cubicle product with minimal fines. Available for stationary, skid-mounted, or portable applications, it crushes the toughest feed material including aggregate, recycled concrete with rebar, recycled asphalt, construction and demolition debris, and slag. Eagle Crusher | www.eaglecrusher.com
High-capacity cone crusher The FLSmidth Raptor 2000 cone crusher is a maximum capacity cone crusher that has been successfully applied in demanding, high-tonnage crushing applications. With improved head action for higher capacity, the 2,500-horsepower unit has fail-safe hydraulics for maximum reliability, integral countershaft assembly for direct drive and low maintenance, and enclosed counterweight assembly with replaceable non-contacting T/U seal arrangement and ductile iron eccentric. FLSmidth | www.flsmidth.com
26
AGGREGATES MANAGER March 2014
SUPPLY LINES
Re-engineered jaw crusher
Universal Engineering introduced the jaw crusher in 1906, and since then the technology has remained pretty much the same. When McLanahan Corp. purchased Universal in 2012, it began a total re-engineering to create a safer, simpler, and smarter jaw crusher. Re-engineering the attack angle and crushing stroke pattern increases capacity by 15 percent while minimizing wear on jaw dies. McLanahan has also calculated a new way to adjust the crusher’s close-side settings. The hydraulic rams are isolated from the crushing action allowing full automation, finger-tip control, and push-button adjustment — virtually eliminating toggle migration and reducing expensive operational costs. McLanahan | www.mclanahan.com
Designed for large-scale production Metso’s C120 jaw crusher has been designed for challenging large-scale aggregate, contracting, and mining processes. The crusher was developed on the basis of field experience from customer sites. Crusher cavity, kinematics, and operating parameters have been defined and optimized to guarantee productivity. Crusher height utilization has been optimized to achieve a steep cavity cross-section. Excellent nip angle high up in the cavity, together with an aggressive linear stroke at the bottom, ensure high throughput capacity and reduction. The unit is designed to be safe to operate and maintain. Metso | www.metso.com
Simply Reliable
Always Has Been, Always Will Be
Fine Material Screw Washers Sand Classifying Tanks Coarse Material Screw Washers Log Washers Portable Plants
A McLanahan Company
Road Based Mixers
129 East Holcomb Avenue, Des Moines, IA 50313 USA +1 (515) 243 1123 | eiwllc.com
VISIT US AT BOOTH 7910 Text INFO to 205-289-3782 or visit www.aggman.com/info EagleIron_AGRM0314_Pg.indd 1
27
2/14/14 1:17 PM
AGGREGATES MANAGER March 2014
NSSGA Young Leaders Ad To come soon
SUPPLY LINES
High throughput impactor Stedman Machine Co.’s Mega-Slam horizontal shaft impactor (HSI) handles large feed sizes that go beyond the range of secondary HSI crushers with capacity up to 1,200 tons per hour. The crusher is engineered for low maintenance and features simplified interior access to breaker bars, primary and secondary aprons, and sideliners, maximizing production uptime. Stedman’s HSIs feature thick housing liners, making them an economical necessity for many crushing applications, including: brick, gravel, and limestone. Stedman Machine Co. | www.stedman-machine.com
Reduces maintenance and operating costs
Built for demanding conditions
The Telsmith H3450 Hydra-Jaw is the newest in its line-up of Hydra-Jaw crushers. The 863-mm x 1,270-mm opening is capable of processing up to 598 metric tons per hour. The hydraulic toggle reduces maintenance and lowers operating costs with fast, safe hydraulic chamber clearing and tramp iron overload relief with auto resets. Telsmith | www.telsmith.com
Weir Minerals has launched its new Enduron line of comminution equipment, including crushers, screens, and feeders for the mining, sand, and aggregate industries. With an emphasis on enhancing mining productivity and safety, the new equipment is designed to maximize customers’ operational efficiency. Weir Minerals | www.weirminerals.com
Atlas Copco— Your full-line hydraulic breaker source
Built for demanding conditions Williams Patent Crusher’s exclusive Willpactor provides capacities up to 2,500 tons per hour. The Willpactor is built for demanding quarry requirements. Medium chrome or manganese blow bars are indexable and easily replaced. The manufacturer’s exclusive adjustable solid impact block allows product gradation control and is said to drastically reduce problems resulting from bridging. Moving this hydraulic breaker plate adjustment allows bridged material to fall into the path of the blow bars. Operation is not interrupted, and normal crushing continues with minimum lost production. Williams Patent Crusher & Pulverizer Co., Inc. | www.williamscrusher.com
See ww us a w.a t Co tlas nEx cop po, co. boo us/ th # con 519 exp 23 o
Need an efficient breaker? No matter the size, we have what you need.
•SB line—0.7 to 15 ton carriers •EB line—1 to 13 ton carriers •MB line—10 to 32 ton carriers •HB line—22 to 140 ton carriers Learn how you can increase your productivity, improve performance and decrease your total cost of ownership with Atlas Copco. Call or visit our website to find a dealer near you. 800-732-6762 | www.atlascopco.us
Text INFO to 205-289-3782 or visit www.aggman.com/info AGGREGATES MANAGER March 2014
29
Buesing Corp. recycles both recycled concrete aggregate and reclaimed asphalt pavement at its Phoenix-area operation. The 243 Complex consists of 243 Lime, a pulverized (or fine grind) limestone operation; 243 Quarry, a crushed limestone operation that, among its traditional rock markets, supplies high-calcium limestone to its sister operation, 243 Lime; and hundreds of acres of additional reserves that will ensure that the facility is producing high quality limestone for decades into the future.
Sudden Impact A new portable impact crusher allows an Arizona operator to streamline crushing operations; all while boosting production and lowering fuel costs. by Tom Kuennen
30
Concrete solution A new mobile impact crusher with self-contained screen is enabling an Arizona operator to leverage his demolition concrete and reclaimed asphalt pavement into a saleable product. In addition to crushing his own demolition concrete, he’s able to generate tipping fees from other contractors as they bring recycle material to his Phoenix-area plant. And he’s doing it all with a single, new Kleemann Mobirex MR 130 ZS mobile impact crusher with secondary screen, which became operational in summer 2013. “Recycling is something we’ve worked with for decades,” says Jerry Buesing, president and CEO, Buesing Corp. “We respected and bought products such as recycled concrete aggregate [RCA] and reclaimed asphalt pavement [RAP] principally
AGGREGATES MANAGER March 2014
because of the cost, but also the difference in the weight of the materials compared to virgin aggregate — and the ability to lay down and pave on it — is much better than a lot of natural aggregates.” That, he says, is because the percent of fractured faces of crushed, recycled products is higher than for many virgin aggregates, depending on the availability. “Many local governments and agencies specify a certain percentage of fracture,” Buesing adds. “Most of the aggregate sources here can meet that fracture spec, but not all, and barely meeting the fracture spec results in an unstable base material; you will have to keep it very wet to get on and pave it, but when you put down crushed concrete and grade it, it’s there to stay.”
APPLICATIONS
Concrete recycling operations The company operates its concrete recycling facility on an unincorporated 10-acre site within Chandler, convenient to major freeways. While it principally recycles demolition concrete, it also accepts RAP for processing. Buesing estimates he will process 100,000 tons of RAP each year, and more than 300,000 tons of RCA in a banner year. Trucks haul material to large stockpiles, which are reshaped by front-end loaders and excavators as they provide raw feed for the impactor. While the operator crushes its own demolition concrete, the majority of the concrete recycle feed comes from other sources, he says. “We reuse the material in our own construction when feasible; otherwise we sell it,” Buesing adds. “We have many customers, from the mom-and-pops to major contractors. We quote the materials delivered out of there to other contractors, and will deliver them F.O.B. to the job site. The smaller contractors will come in with pickup trucks or trailers and haul the material away.” The RCA is used for driveways, parking lots, pipe bedding, and bases of all kinds. From RAP, the operation typically will produce a half-inch rock that can be incorporated into asphalt mix that it sells. “RAP has not been as well accepted in the Phoenix area as it is elsewhere in the country,” Buesing says. “It’s used primarily as base aggregate, but also as an inexpensive surfacing for parking lots. If it’s treated, it will portray the same properties as hot-mix asphalt pavement. It won’t be as smooth and will be more easily eroded, but it does a pretty good job at it while being fairly dust-free.” RCA base material that meets spec typically will be 1.25-inch minus size, and that’s been Buesing’s mainstay. “We can do upgrading of the plant to produce even concrete aggregate, as it’s normally clean enough if screened,” Buesing says. And he’s looking forward to producing additional sizes of aggregate. “With this machine, we are planning on getting more aggressive in producing other products, and see if we can’t upmarket those, so rather than getting $5 or $6 a ton, we could get $8, $9, or $10,” Buesing says.
Fighting deleterious material The operation rarely encounters alkali-silica reactivity compromised concrete, he says. “One way of fighting that is in the way you handle your input into the plant,” Buesing explains. “All of our loads are inspected when they come in. Garbage in, garbage out. We do our best to inspect loads; we’ve sent trucks out to
The operation’s new Mobirex MR 130 ZS plant replaces a dual impact crusher set up and offers better production, as well as fuel savings. landfills so that it stays out of our plant. We also use a belt picker when we have any problems, but tightening up on dumping helps the most. Our guys have done a great job on this.” The impact crusher replaced a dual impact crusher set-up with 14 x 13 and 13 x 13 crushers. The assembly of the machines particularly impressed Buesing, he says. “I’ve been around equipment long enough to tell what it’s going to give you by how it’s built,” he notes. “Kleemann does an excellent job in the build, right on through the paint process.” That being said, versatility was of paramount importance. “The plant that we had was a stationary plant on wheels, and it took 12 loads to move it somewhere,” Buesing says. “The MR 130 gives us portability and mobility. We probably can produce as much or more with this one machine than we could with our two previous machines, with a fuel savings as well.”
Diverse business interests
Buesing Corp. is a major excavating and shoring contractor in the Southwest and is positioned in the energy industry, among others. “We’re involved in creating and grading solar energy sites and providing aggregates for road bases in the interior of these sites,” Buesing says. “We’ve driven well over a million piles at solar energy sites from northern California to San Antonio, Texas.” Buesing originally began as an excavating contractor, and migrated into highway and heavy construction in the 1970s. At that time, Buesing was involved in precast bridges and foundations, roadway grading and paving, and even concrete curb and gutter work. In addition to its other capabilities, Buesing now is active in deep excavations and shoring in the Phoenix area and building basement walls in these structures.
AGGREGATES MANAGER March 2014
31
Small footprint, big impact Mobirex impact crushers with integrated secondary screens such as Buesing’s are designed to produce large volumes of screened or “fractionated” RAP or RCA on a relatively small footprint and with an eye toward fuel economy. Mobirex impactors are said to be especially suited for RAP because they break up chunks of asphalt pavement or agglomerations of RAP, rather than downsize the aggregate gradation, while compression-type crushers such as jaws and cones can clog due to packing (caking) of RAP when the RAP is warm or wet. Contaminants such as soil are part of processing demolition concrete so the crusher’s integrated, independent prescreens remove dirt and fines before they ever enter the crushing circuit. This reduces equipment wear, saves fuel, and with some customers, creates a saleable fill byproduct. Also important for recycling, the lined, heavy-duty vibrating feeder below the crusher eliminates belt wear from rebar or dowel or tie bar damage. By having the feeder below the
CCuubbeeethteheAAgggmmaann Before material is processed, incoming loads are inspected to ensure that sub-quality material goes to the landfill rather than the crusher.
mmakaekseslelaeranrinnigngfufnu!n!
CC
onnect youth of your onnect withwith the the youth of your community through education. community through education. Whether sponsoring an open Whether youyou are are sponsoring an open house or presenting in the classroom, house or presenting in the classroom, Aggregates Manager community Aggregates Manager community outreach tools make learning outreach tools make learning fun.fun.
Cubee the AggMan makes learning fun!
Story of Cubee Aggregate” Coloring “The“The Story of Cubee the the Aggregate” Coloring BookBook and his aggregate friends take children on a magical CubeeCubee and his aggregate friends take children on a magical journey the quarry the community see how journey from from the quarry to thetocommunity to seetohow aggregates are in used our schools, and structures. aggregates are used ourinschools, roads,roads, and structures. It’s a great combined with 20 pages of coloring It’s a great story story combined with 20 pages of coloring fun. fun. For students in grades For students in grades K-3. K-3. $1.20-$1.85 per book, PricesPrices rangerange from from $1.20-$1.85 per book, basedbased on on quantity. Customize with company your company quantity. Customize booksbooks with your logo! logo!
Over Over 100,000 100,000 sold! sold!
C
onnect with the youth of your community through education. Whether you are sponsoring an open house or presenting in the classroom, Aggregates Manager community outreach tools make learning fun.
Call 800-430-4540 e-mail: Cubee@Aggman.com or visit www.Aggman.com
“You’re on Rock” Workbook “You’re on Rock” Workbook Twenty of earth science activities and puzzles Twenty pagespages of earth science facts, facts, activities and puzzles help help geologists, mining engineers and earth scientists juniorjunior geologists, mining engineers and earth scientists learn learn aggregates. aboutabout aggregates. For students in grades For students in grades 4-6. 4-6. $1.20-$1.85 per book, on quantity. PricesPrices rangerange from from $1.20-$1.85 per book, basedbased on quantity. Customize with company your company Customize booksbooks with your logo! logo!
Cubee AggMan T-shirts Cubee the the AggMan T-shirts Funkids forof kids all ages, this 100% pre-shrunk Fun for all of ages, this 100% pre-shrunk cottoncotton t-shirtt-shirt is a is a long-lasting reminder of event your event or presentation. long-lasting reminder of your or presentation. XS (2-4); Medium (10-12); (14-16); Sizes:Sizes: YouthYouth XS (2-4); Small Small (6-8); (6-8); Medium (10-12); LargeLarge (14-16); (34-36) AdultAdult Small Small (34-36) per t-shirt (plus 15% shipping & handling). Price: Price: $6.95$6.95 per t-shirt (plus 15% shipping & handling). Quantity discounts available. Quantity discounts available.
800-430-4540 CallCall800-430-4540
32
Cubee_AGRM0512.indd 1
AGGREGATES MANAGER March 2014
e-mail: Cubee@Aggman.com or www.Aggman.com visit www.Aggman.com e-mail: Cubee@Aggman.com or visit
4/12/12 2:40 PM
APPLICATIONS
crusher, it — not the belt — absorbs the impact of rebar dropping through the crusher. An efficient rebar magnet with maximum discharge capacity can be hydraulically lifted or lowered by means of remote control, providing more clearance for larger sizes of rebar if present. The flow concept of the EVO models is said to eliminate restriction to the flow of the material throughout the entire plant. With this Continuous Feed System (CFS), each step the material goes through in the plant is wider than the diameter of the one before it, eliminating choke or wear points. The CFS also keeps a choke feed to the crusher, eliminating stops/starts of the feed system, which improves production, material shape, and wear. Kleemann’s Contractor Line diesel-electric drive option has the crusher directly diesel-driven, with the conveyor troughs, belts, and prescreen electric-driven. This concept not only reduces diesel fuel consumption, but also results in significantly reduced exhaust emissions and noise levels. And mobile tracked crushers permit recycled material producers to relocate piles while staying open, selling from existing
Jerry Buesing, president and CEO (left), shown with Road Machinery Inc.’s Dave Kolesky, says he hopes to produce additional products with the new crushing system that may yield a better price per ton. piles while creating new ones, and improving traffic flow, while eliminating the need to move a stockpile with loaders or other equipment. AM This article courtesy of Kleemann.
The detail speaks volumes Accuracy, speed, safety. The Topcon GLS-1500 laser scanner makes non-contacting pile mapping and volume calculation easy and highly accurate. With maximum mapping detail, and its simple workflow, your increased efficiency will speak louder than words.
Get all the details. topconpositioning.com/scanning
Text INFO to 205-289-3782 or visit www.aggman.com/info Untitled-16 1
33
8/15/13 2:12 PM
AGGREGATES MANAGER March 2014
by Amanda E. Ferguson
Rock Do operators have to take the blame for intoxicated employees?
Under
THE INFLUENCE O
Amanda E. Ferguson is an attorney in Jackson Kelly PLLC’s Denver office, where she practices with the Occupational Safety and Health Practice Group. She can be reached at 303-390-0178 or via email at aeferguson@jacksonkelly.com.
34
n Jan. 1, 2014, Colorado became the first state to fully decriminalize marijuana. Washington will do the same later this year, and 20 other states have already legalized medical marijuana. As the spotlight hovers on marijuana use, many have expected clarification or at least comment from the Mine Safety and Health Administration (MSHA) on the subject. As yet, none has been forthcoming. In 2008, MSHA announced a proposed rule that would have established Part 66, containing alcohol- and drug-free mine regulations applicable to both metal/non-metal and coal mines. The rule would have required operators to establish drug and alcohol programs, including a written policy and employee education, and would have required miners testing positive on drug and alcohol tests to complete treatment before returning to duty. However, the agency never promulgated the final rule. Now that marijuana or medical marijuana may be legal in your state, what does it mean when an employee under the influence commits a violation? As operators know, the Federal Mine Safety and Health Act of 1977 (Mine Act) is a strict liability statute. As an operator, you are liable for violations committed by your employees, whether you knew what they were up to or not. In the only Federal Mine Safety and Health Review Commission (Commission) decision to consider the issue, the Commission imposed strict liability. In Mar-Land Industrial Contractor, Inc., 14 FMSHRC 754 (May 1992), a contractor’s employee at a cement plant performing structural steel work fell 52 feet and died. Investigators later determined that the worker failed to properly
AGGREGATES MANAGER March 2014
secure his belt lines. A toxicological analysis also showed evidence of cocaine in his system. MSHA cited general contractor Mar-Land under the fall protection standard, 30 C.F.R. § 56.15005. At the hearing, Mar-Land raised the defense that it should not be liable for the violation because the individual was under the influence of cocaine. The ALJ rejected that argument and upheld the violation. The Commission found that Mar-Land was strictly liable for the individual’s failure to wear his belt properly. They held that “[t]he fact that belts are not worn properly is a violation under [§ 56.150005] for which the operator is liable irrespective of employee misconduct.” The Commission’s holding in Mar-Land is limited to the standard at issue, but its reasoning is easily applicable to most other MSHA regulations. Arguing against strict liability for an impaired miner’s violation may be a losing battle, but the violation’s negligence finding is still up for debate. Ordinarily, an hourly miner’s negligence may not be imputed to the operator for penalty assessment purposes. But operators cannot rely on positive drug tests to excuse them of negligence altogether. Surprisingly, the Commission and its judges have been reluctant to equate a positive drug test with impairment. In several cases, the court refused to find that an employee’s positive drug test meant the employee was actually intoxicated because the operators failed to introduce evidence putting the test results into context. In one case, “the only evidence in the record regarding the side effects of the drug was a document printed off an internet website.” Jim Walter Res. Inc., 28 FMSHRC 983, 993 (December 2006). Similarly, the judge in
ROCKLAW Mar-Land also refused to find that the miner was impaired as a result of the cocaine in his system. There, the judge found that “there was no evidence in the record that the level of [the metabolite of cocaine] was sufficient to significantly impair [his] concentration and ability to properly secure his safety belt.” Even if an employee is impaired, if the operator lacks adequate training programs or fails to enforce its policies, the court may still find that operator negligent. The case of Weathers Crushing, Inc., 22 FMSHRC 1032 (August 2000), should serve as a cautionary tale. It was an employee’s first day at the portable crushing facility, and someone else instructed him to use the head of a sledgehammer to clear blockages in the crusher. Later, while clearing the crusher with a sledgehammer, the employee was injured and subsequently died. Marijuana and a pipe were recovered from his pockets, and a hospital drug test indicated marijuana and benzodiazepines in his system. Because the judge found the operator failed to properly train the miner, the new employee’s intoxication was irrelevant. In contrast, having a strong training program that is duly enforced lessens the risk of being found negligent for an intoxicated miner’s violation. In Newmont Gold Co., 20 FMSHRC 561 (May 1998), a haul truck driver backed through a berm at an elevated dumpsite. The post-accident drug test yielded positive
results for marijuana. MSHA cited Newmont for the driver’s failure to maintain control of the mobile equipment, and the judge upheld the violation. The judge, however, commended Newmont for its enforcement of its drug-free policy and noted the operator was “clearly seeking more help from MSHA” to “achieve its worthy goal of a drug-free workplace.” No doubt in response to Newmont’s drug-free policy, the Judge affirmed the Secretary’s negligence designation of “none.” Logically, MSHA and operators should still approach marijuana as an illegal drug that has no place on a mine site. Federal law prohibits marijuana possession and use, regardless of state laws that may decriminalize marijuana. Under the Controlled Substances Act, 21 U.S.C. § 812, marijuana is classified as a Schedule I controlled substance. U.S. Department of Transportation (DOT) regulations require drug and alcohol testing and prohibit the use of Schedule I substances for any reason. In mining, safety is everything. Operating a federally regulated mine means that marijuana use by miners is still unacceptable. And now more than ever, an operator’s training and employment policies must be strong, clear, and equally enforced. Operators should review their existing policies and, if necessary, clarify that marijuana use will not be tolerated in the workplace. AM
IT WILL CHANGE YOUR JOB SITE
Time wasted replacing pumps and performing maintenance on your lube equipment or cleaning up dreaded oil spills - slows down your job site and costs you money. That’s why Sage Oil Vac lube equipment features “no pump” designs that use low pressure compressed air to vacuum used oil and dispense new oil. Vacuum load product tanks up to 15 gallons per minute make for fast fluid changes and an enclosed clean system reduces the chance of spillage making it safer for your employees and the environment. It’s why Sage Oil Vac is fast becoming the preferred lube equipment of construction sites worldwide.
Full Line of High-Quality Lube Equipment:
• • • •
MOBILE LUBE TRUCKS MOBILE LUBE TRAILERS MOBILE LUBE SKIDS LUBEBUILDER SERIES
877-OIL-VACS • WWW.SAGEOILVAC.COM Text INFO to 205-289-3782 or visit www.aggman.com/info AGGREGATES MANAGER March 2014
35
Market Place To come soon
Market Place To come soon
NSSGA Membership Ad To come soon
Ad Index To come soon
by Bill Langer
Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at Bill_Langer@hotmail.com
In Stone
CONVOY
Mother Nature and the U.S. Army add to the scenic adventures as Route 66 winds through Missouri. Cause we got a little ol’ convoy rockin’ through the night. Yeah, we got a little ol’ convoy, ain’t she a beautiful sight?
I
From ‘Convoy,’ sung by C.W. McCall, 1975
f you remember this song, you might also remember ‘Rubber Duck’ talking about rolling up on Interstate 44 ‘like a rocket sled on wheels.’ Today, as we follow old Route 66 across Missouri, we travel along Interstate 44. Maybe we will see one of those convoys. Route 66 originally was a gravel road that followed a much older trail through Missouri, the Great Osage Trail. Before the Civil War, the trail was known as the St. Louis to Springfield Road. During the Civil War, a telegraph line was strung along its length, and it locally became known as the Wire Road. That moniker lasted until 1926 when, at Springfield, Mo., officials first named that section of road, as well as the rest of the Chicago-to-Los Angeles highway, U.S. Route 66. Our previous stop (last month) was at an underground storage facility created in a limestone mine. About an hour west of St. Louis, and a couple of miles off I-44, we will visit another underground limestone ‘mine.’ But this time, Mother Nature was the miner. The ‘mine’ began forming in limestone bedrock about 400 million years ago. Rainwater, combined with carbon dioxide given off by decaying vegetation, formed carbonic acid that percolated through fractures in the limestone. In doing so, it dissolved the rock, creating solution-enlarged openings. Over geologic time, these openings enlarged, forming caverns This circa 1942 photo shows construction of the Hooker Cut, with ceilings and floors liberally bejeweled with stalactites, stalagmites, which, at the time of its construction, was believed to be the rimstone dams, and draperies. Iron and manganese impurities and tandeepest road cut in the nation. nic acids stained the otherwise snowy white features with shades of red, orange, brown, gray, and black. That geologic process is responsible for the thousands of caves and springs that form a part of southern Missouri’s natural beauty. One such cave system is known as Meramec Caverns. In 1935, Lester Dill opened the caverns as a tourist attraction, possibly making it the oldest tourist stop along Route 66. My college roommate and I visited the caverns during the summer of ’65. When we returned to his Triumph TR4, someone had slapped a bumper sticker on it. It turns out that Dill also pioneered the use of bumper stickers. The adhesive used to attach stickers to cars had not yet been developed, so Dill would have “bumper sign boys” tie Meramec Caverns signs on the cave visitors’ cars giving the visitors a free souvenir and Dill free advertising. As we head west back on I-44, we don’t want to miss Hooker Cut. We take Exit 169 and turn west on County Highway Z, a back road that, at one time, was the most modern part of Route 66. During 1940, the U.S. Army broke ground for Fort Leonard Wood. Two years later, a new four-lane stretch of Route 66 was excavated through Hooker Hill in order to move equipment more efficiently to and from the Fort. It is said that the new road saved a full day’s travel for oversized loads of military equipment. It was a magnificent engineering feat. At 94 feet, Hooker Cut was, at the time, the deepest earth cut ever attempted in Missouri and was believed to be the deepest road cut in the country. We push on down I-44 and stop at Joplin near the western boarder of Missouri. During dinner, the locals regale us with stories about the record-breaking 234-truck Special Olympics truck convoy held in Joplin during September 2013. Now that would give C.W. McCall something to sing about. CONVOY! AM
40
AGGREGATES MANAGER March 2014
PROCESSING SOLUTIONS To make a buck in today’s challenging marketplace, you need to be more efficient and productive on every ton you process. At McLanahan, we’ve built our reputation on helping customers do more by custom engineering safer, simpler and smarter processing solutions – all with your bottom line in mind. Family-owned since 1835, McLanahan has experienced engineers on staff ready to solve your dry or wet processing needs. Our team is committed to helping you do more.
Joe Adams
Director of Safety McLanahan
Rob McGee
Director of Continuous Innovation McLanahan
Scott O’Brien
Director of Process Engineering McLanahan
Visit us at Booth 51756
mclanahan.com Text INFO to 205-289-3782 or visit www.aggman.com/info
For five days, the world’s top performers will be in Vegas.
143–700 HP
See you there. Visit Volvo Penta during the 2014 CONEXPO-CON/AGG in Las Vegas at South Hall Booth 83830 and in the North Hall Volvo Booth 10951. Our Tier 4 final solutions are smart choices with proven technology for maximum power and fuel efficiency. Come see why our engines will deliver performance you’ll be raving about for years to come. Learn more at volvopenta.com
Text INFO to 205-289-3782 or visit www.aggman.com/info