Aggregates Manager March 2016

Yo u r Yo u r

g u i d e

t o

p r o f i t a b l e

g u i d e

t o

p r o f i t a b l e

p r o d u c t i o n

p r o d u c t i o n

y 2016 | www.AggMan.com

Award-Winning

Lafarge’s Spy Hill Plant Grows with

Check Out Our

Award-Winning

Calgary

Reclamation Projects

21 26 40

Achieve better fragmentation

21

Learn the economic and equipment considerations of underground operations

15 tips for a healthy undercarriage

32

Vulcan pilots NIOSH noise and dust technology

38

MSHA uses policy to revise workplace examinations

September 2015 www.AggMan.com

Worker endangerment initiative could lead to more criminal prosecutions

August 2013

www.AggMan.com

19 24 33

Track your truck fleet

10

Dolese Bros.’ Davis Quarry leverages its location

Eight tips for your drill

26

Five factors affecting fuel efficiency

35

Get more from your dewatering screen

Settlement motions spurned by ALJs

July 2015 www.AggMan.com

Cover_AGRM0715.indd 1

March 2016

26 Februay 2015

www.AggMan.com

32 36

Learn about new technologies for stockpile managemen

Bump payload withou increasing your fleet s Get ready for AGG1!

6/18/15 4:57 PM

www AggMan com

Lafarge’s Spy Hill Plant Grows with

Calgary

26 Februay 2015

www.AggMan.com

32 36

Learn about new technologies for stockpile management Bump payload without increasing your fleet size Get ready for AGG1!

Yo u r

g u i d e

t o

p r o f i t a b l e

p r o d u c t i o n

February 2016 | www.AggMan.com

Dredging Up Profits...

Cajun Style

Award-Winning

rch 2013

www.AggMan.com

20 27 42

Avoid common mistakes with a gyratory

21

Guarding guidance from MSHA and industry

Learn the economic and equipment considerations of underground operations

32

Vulcan pilots NIOSH noise and dust technology

y 2012

38

MSHA uses policy to revise workplace examinations

April 2015

www.AggMan.com

Review Intermat equipment debuts

19

Plan for a safe spring start-up

36

Prepare for MSHA’s fatality prevention focus

21 26 40

Achieve better fragmentation

15 tips for a healthy undercarriage Worker endangerment initiative could lead to more criminal prosecutions

January 2014 www.AggMan.com

9 17 30

Cat introduces new mid-size loaders Tips for safe dumping practices

More questions about POV enforcement

Check Out Our

Get your plant on site and running quickly

mber 2013

September 2015 www.AggMan.com

Drying up: 10 alternatives to settling ponds

14

Award-Winning

Reclamation Projects

20 www.AggMan.com

24 27

Improve plant performance through predictive maintenance

10

Avoid 10 crimes against your conveyors Be diligent with special assessments

July 2015 www.AggMan.com

Cover_AGRM0715.indd 1

23 www.AggMan.com

29 38

Dolese Bros.’ Davis Quarry leverages its location

26

Five factors affecting fuel efficiency

35

Get more from your dewatering screen

November 2013

Luck Stone tackles remote-control loading 10 Tips for Tires Crystalline silica: what does it mean for you?

6/18/15 4:57 PM

Improve safety and lower citations with proper house cleaning Extend the service of your cone crusher Get ready for MinExpo

www.AggMan.com

22 29 32

January 2014 www.AggMan.com

9 17 30

Cat introduces new mid-size loaders Tips for safe dumping practices More questions about POV enforcement

September 2014

13 16 34

www.AggMan.com

12 17 30

Check out our 20 tips from 20 years

Unimin’s successful and safe underground site

Revisit our Top Op: Southwest Rock Products’ Queen Creek operation

Tips for underground roof control

Address at-risk behaviors to improve safety

Get ready for country and rock to collide at AGG1 in Nashville

Competitive financing available through Daimler Truck Financial. For the Freightliner Trucks dealer nearest you, call 1-800-FTL-HELP. FTL /MC-A-1368. Specifications are subject to change without notice. Copyright Š 2016 Daimler Trucks North America LLC. All rights reserved. Freightliner Trucks is a division of Daimler Trucks North America LLC, a Daimler company.

HELPING TEX-MIX KEEP THEIR PAYLOAD MOVING WHILE LOWERING THEIR REAL COST OF OWNERSHIP. Tex-Mix is only as profitable as their trucks are reliable. That’s why they choose Freightliner. We design trucks for easy upfit, productivity and low maintenance. Backed by a support team that’s there when you need us. And because Tex-Mix trucks are equipped with the powerful Detroit DD13 ® engine and Detroit Virtual Technician onboard diagnostic system, TM

TM

it’s not only a tough truck, but also a smart one. Built to increase profitability and lower their Real Cost of Ownership.

We’re proud to say that’s why Freightliner has become the industry leader in work trucks.

To learn more about how Freightliner Trucks are working hard for Tex-Mix, visit FreightlinerTrucks.com/Tex-Mix.

Some companies have you choose power or fuel efficiency. You chose both.

Only Volvo delivers a true fuel efficiency guarantee so you never have to compromise on performance or productivity. And with CareTrack machine monitoring, you can focus your attention on more important things — like growing your business. Get the details at volvoce.com/smartfuel.

Grows with

Award-Winning

Calgary

Reclamation Projects

21 26 40

Achieve better fragmentation

15 tips for a healthy undercarriage Worker endangerment initiative could lead to more criminal prosecutions

September 2015 www.AggMan.com

21

Learn the economic and equipment considerations of underground operations

32

Vulcan pilots NIOSH noise and dust technology

38

MSHA uses policy to revise workplace examinations

August 2013

www.AggMan.com

19 24 33

Track your truck fleet Eight tips for your drill Settlement motions spurned by ALJs

July 2015 www.AggMan.com

10

Dolese Bros.’ Davis Quarry leverages its location

26

Five factors affecting fuel efficiency

35

Get more from your dewatering screen

Cover_AGRM0715.indd 1

26 Februay 2015

www.AggMan.com

32 36

Learn about new technologies for stockpile management Bump payload without increasing your fleet size Get ready for AGG1!

6/18/15 4:57 PM

An aggressive growth strategy, strong company culture, and loyal workforce allow Southwest Rock Products to not only survive the market downturn, but also expand its business.

PAGE 16

On Our Cover: Country and rock collide as AGG1 makes its way to Nashville.

Lafarge’s Spy Hill Plant Cover illustration by Sandy Turner, Jr. with Grows Calgary

26 Februay 2015

www.AggMan.com

32 36

Learn about new technologies for stockpile management Bump payload without increasing your fleet size Get ready for AGG1!

Yo u r

g u i d e

t o

p r o f i t a b l e

p r o d u c t i o n

February 2016 | www.AggMan.com

Dredging Up Profits...

Cajun Style

Award-Winning

20 27 42

21 September 2015 www.AggMan.com

Drying up: 10 alternatives to settling ponds

14

Learn the economic and equipment considerations of underground operations

Review Intermat equipment debuts

32

Vulcan pilots NIOSH noise and dust technology

19

Plan for a safe spring start-up

38

MSHA uses policy to revise workplace examinations

36

Prepare for MSHA’s fatality prevention focus

April 2015

www.AggMan.com

21 26 40

9 17 30

Achieve better fragmentation

15 tips for a healthy undercarriage Worker endangerment initiative could lead to more criminal prosecutions

January 2014 www.AggMan.com

Cat introduces new mid-size loaders Tips for safe dumping practices More questions about POV enforcement

Country and rock collide as AGG1 makes its way to Nashville.

PAGE 34

Check Out Our

Award-Winning

TABLE OF CONTENTS

Reclamation Projects

20

Improve plant performance through predictive maintenance

24 27

10

Avoid 10 crimes against your conveyors Be diligent with special assessments

July 2015 www.AggMan.com

Cover_AGRM0715.indd 1

Dolese Bros.’ Davis Quarry leverages its location

26

Five factors affecting fuel efficiency

35

Get more from your dewatering screen

November 2013

MARCH 2016 | 6/18/15 4:57 PM

www.AggMan.com

22 29 32

Luck Stone tackles remote-control loading 10 Tips for Tires

Crystalline silica: what does it mean for you?

VOLUME 21, NUMBER 3

FEATURE ARTICLES

23

29 38

19 24 33

Avoid common mistakes with a gyratory Guarding guidance from MSHA and industry

Improve safety and lower citations with proper house cleaning Extend the service of your cone crusher Get ready for MinExpo

9

13 16

12

Cat introduces new mid-size loaders

Unimin’s successful and safe underground site

17 20 Tips for3017Efficient Operations 30 Tips for underground roof control

Tips for safe dumping practices

More questions about POV enforcement

January 2014 www.AggMan.com

September 2014

www.AggMan.com

Address at-risk behaviors to improve safety

We’ve combed through 20 years of stories about operations to extract ideas that can make your plant more efficient — and profitable.

COLUMNS & DEPARTMENTS

Southwest Rock Products Award-Winning Check Out Our

Reclamation Projects

Track your truck fleet Eight tips for your drill Settlement motions spurned by ALJs

July 2015 www.AggMan.com

Join us as we revisit Southwest Rock Products’ Queen Creek 15 22 15 Plant — the winner of our online Top Op contest — to see 19 29 19 26 32 34 24 35how things have changed since our initial visit.

10

Luck Stone tackles remote-control loading

Dolese Bros.’ Davis Quarry leverages its location Five factors affecting fuel efficiency

Four tips to extend the life of your dredge

10 Tips for Tires

November 2013

www.AggMan.com

Crystalline silica: what does it mean for you?

February 2013

www.AggMan.com

Luck Stone shares information between engineers and plant personnel

Best practices for frac sand

Telematics give managers and mechanics insights into equipment

State ballot initiatives stir the pot for safety

Simulators reduce costs and improve operator efficiency

March 2015

www.AggMan.com

5 Editorial Celebration and contemplation.

Get more from your dewatering screen

22 Put People First

6 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook.

24

Lean Screening

9 RollOuts Komatsu America Corp.’s WA600-8 wheel loader, and other new equipment for the aggregate market.

34

Grab Your Boots and Head to Nashville for AGG1!

52

Crusher Bearings: Knowing the Basics Leads to Better Care

Cover_AGRM0715.indd 1

6/18/15 4:57 PM

Recognize that your people are your most valuable asset.

Invest in them, and they’ll take care of your equipment and your customers.

Increase value-added processing by maximizing open area and minimizing screen media changeouts.

Country and rock collide as the aggregates industry gathers for its annual convention and equipment expo.

By understanding the common bearing design types, maintenance personnel can better understand their impact on performance.

OPERATIONS ILLUSTRATED Mine Safety: Mitigating Fatigue

29

A blend of traditional management techniques and new technology can help protect workers, particularly those with rote responsibilities.

56 Rock Law Mediation offers operators an alternative to resolving alleged violations before the Federal Mine Safety and Health Review Commission.

58 Advertiser Index See who’s who and where to find their products.

59 Classified Ads Aggregate industry classifieds.

60 Carved in Stone Long used as a landmark by space crews, the Eye of the Sahara is likely the remains of a geologic dome.

Industry Focus. Powerful Results.

Where Vision Meets Value.

Select Assets of Eastern Industries, Inc. a division of New Enterprise Stone & Lime Co., Inc.

a subsidiary of

New Enterprise Stone & Lime Co., Inc.

have been acquired by

a portfolio company of BMC Enterprises, Inc.

a division of

has acquired select aggregate assets from

has been acquired by

has been acquired by

a division of Oldcastle, Inc. *Represented by FMI Capital Advisors

FMI Capital Advisors, a subsidiary of FMI Corporation, is the leading investment banking firm serving the Construction Materials industry. With over 100 completed transactions in Construction Materials, our industry focus enables us to provide our clients with valuable insight and advice. Clients gain access to our unparalleled network of industry contacts and relationships, deep market knowledge and technical expertise, based on decades of experience.

George Reddin | 919.785.9286 | GReddin@fminet.com

Scott Duncan | 713.936.4930 | SDuncan@fminet.com

WWW.FMINET.COM

March 2016

EDITORIAL

Vol. 21, No. 3

by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com

aggman.com /AggregatesManager @AggMan_editor

Celebration and Contemplation

Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Online Managing Editor: Bobby Atkinson editorial@aggman.com

Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Linda Hapner production@aggman.com

Construction Media Vice President, Construction Media: Joe Donald sales@randallreillyconstruction.com

3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com

Corporate Chairman: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Russell McEwen Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Vice President of Events: Stacy McCants Vice President, Audience Development: Prescott Shibles Vice President, Digital Services: Nick Reid Vice President, Marketing: Julie Arsenault For change of address and other subscription inquiries, please contact: aggregatesmanager@halldata.com.

Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2016. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them.

Publisher reserves the right to refuse non-qualified subscriptions.

Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

I

n March 1996, a new voice joined the aggregates industry, Aggregates Manager magazine. The first issue was launched at ConExpo-Con/Agg. While there, we also debuted the industry’s first publication website, www.aggman.com. It was an early acknowledgement that the Internet was going to be one way we shared information with the industry.

It was an exciting time, with many great minds focused on how to best communicate. The goal was to break from the mold of traditional business-to-business publishing and offer an insider perspective that was unabashedly pro-aggregates. At the same time, we like to have a little fun with our coverage and to push the industry on issues such as health and safety and sustainability.

Twenty years later, the same goals hold true. In addition to the print magazine, we offer social media streams — including our Facebook page and Twitter feed — and a daily newsletter keeps subscribers aware of industry news. Our print content is enhanced through the use of photo galleries and videos on our website.

Just as automation and technology have changed the way aggregate is produced, it also has led to an evolution in how we cover it. After 25 years of reporting on the industry — including 20 with Aggregates Manager — I continue to enjoy the challenge of being part of this vital industry and the wonderful people who comprise it. I hope to see many of you at AGG1, as our anniversary celebration continues throughout the month.

On a more serious note, I’d like to call your attention to the fact that March is also Colon Cancer Awareness month. Nearly 100,000 cases are diagnosed each year in the United States, making it the third-leading cause of cancer deaths. Of those cases, 90 percent are among people over the age of 50, but not all. Last June, I was diagnosed with Stage 3 colon cancer. One major surgery, two hospital stays, and approximately 600 hours of chemotherapy later, I’m relieved to have finished treatment. It’s not a journey I wish for any of you, so please talk to your doctor about having a colonoscopy. This preventive procedure can dramatically lower your risk.

Schedule one today…it just might save your life.

AGGREGATES MANAGER / March 2016

5

q

DATAMINING Stock Report Company

Ticker

Cemex, S.A.B. de C.V. CRH plc Eagle Materials Inc. Granite Construction Inc. Heidelberg Cement AG LafargeHolcim Ltd. ADR Martin Marietta Materials, Inc. MDU Resources Group, Inc. Summit Materials United States Lime & Minerals, Inc. U.S. Concrete Vulcan Materials Co.

CX CRG EXP GVA HEI HCMLY MLM MDU SUM USLM USCR VMC

Current Value

$4.39 p $23.69 q $52.93 q $37.11 q $67.83 q $6.99 q $131.38 p $16.55 q $14.77 q $50.38 q $46.94 p $93.08 p

52-Week High

52-Week Low

$10.48 $31.97 $88.81 $44.40 $87.07 $15.49 $178.67 $23.36 $28.57 $72.53 $62.82 $106.84

$3.64 $20.63 $45.03 $28.45 $65.63 $6.92 $108.31 $15.58 $13.12 $45.56 $27.16 $77.49

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 2/10/16.

U.S. On-Highway Diesel Fuel Prices 2/8/16

One Week

United States

$2.008

-0.023 q

-0.827 q

East Coast

$2.087

-0.024 q

-0.843 q

New England

$2.201

-0.018 q

-0.838 q

Central Atlantic

$2.224

-0.015 q

-0.818 q

Lower Atlantic

$1.959

-0.033 q

-0.863 q

Midwest

$1.929

-0.012 q

-0.840 q

Gulf Coast

$1.896

-0.021 q

-0.865 q

Rocky Mountain

$1.914

-0.055 q

-0.862 q

West Coast

$2.236

-0.037 q

-0.688 q

West Coast less California

$2.073

-0.044 q

-0.683 q

California

$2.369

-0.030 q

-0.692 q

Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes). .

6

AGGREGATES MANAGER / March 2016

One Year

Aggregates Industry Outlook 150 140

129.05

130.00

130.99

128.42

130

125.60

127.51

128.61

January 2016

February 2016

122.49

120 110 100

July 2015

August 2015

September 2015

October 2015

November 2015

December 2015

In February, the Aggregates Industry Outlook (AIO) showed incremental growth increasing 0.86 percent against January, to an overall score of 128.61 (with a score of 100 being neutral). A relatively mild winter has increased business for some operators, while others eagerly await the impact of the FAST Act. With presidential primaries well under way, national leadership weighs on the minds of many.

Comments: Eastern states have been experiencing seasonally warmer weather this winter, leading into more active construction/ work and contributing to increased sales volumes and production days that would have been halted to colder weather.

— Jerry Mock, CEO, Zanesville Materials LLC

With the expanding e-commerce trade, the need for warehouses and deliveries, as well as the passage of the federal transportation bill 2016 (the FAST Act), even in an election year, this should be a phenomenal year for aggregate sales.

— Daryl Zeiner, Sales Manager, The H&K Group

There are potential setbacks to the economy attributed, in my opinion, to government over-reach in regulatory burden and funding allocation for public works projects.

— Robert L. Stone, Manager of Sales and Compliance, Hunter Sand & Gravel, LLC

There appears to be an uptick in interest since mid 2015 in greenfield sites (in the Carolinas, Georgia, and Texas), particularly those with proven reserves and permits in place.

—O.F. “Russ” Patterson, III, title, Patterson Exploration Services

People are cautiously optimistic. The presidential election is a concern!

— Dave Shobe, Regional Sales Manager, Miller Wire Works, Inc.

AGGREGATES MANAGER / March 2016

7

BREAKING THROUGH THE STATUS QUO. THE 944K HYBRID IS TEARING DOWN THE WALLS OF CONVENTION.

You asked for more dependability. The 944K was subjected to more feld test hours than any John Deere construction equipment model ever built. You wanted better fuel economy. The 944K’s hybrid electric drive delivers up to 40% better fuel economy than conventional drivetrains.* You required support to meet the demands of high-production operations. So we supercharged our parts availability and technical expertise, plus added 24/7 remote monitoring capability utilizing John Deere WorkSight.™ To learn more, visit our website or your John Deere dealer. Together, we’re building big things.

* Actual fuel-consumption rates and savings will vary with machine application, utilization, operator, and model of competitive unit.

For proof, visit JohnDeere.com/Big

ROLLOUTS

Your complete guide to new and updated equipment and supplies in the aggregates industry.

by Bobby Atkinson | Online Managing Editor | BobbyAtkinson@randallreilly.com

Wheel loader offers better fuel efficiency

Komatsu America Corp. introduces its WA600-8 Wheel Loader with enhanced lockup torque converter function and SmartLoader logic for lower fuel consumption and faster travel speeds. The wheel loader has a 23.15-liter, 529-horsepower, Tier 4 Final, SAA6D170E-7 engine that uses up to 13 percent less fuel than the Tier 3 model.

The bucket capacity has been increased to 9.2 cubic yards. The WA600-8’s SmartLoader Logic, with the new lockup torque converter, activates in second, third, and fourth gear to improve acceleration, hill-climbing, and top speed. The cab features KOMTRAX Plus telematics which track fuel consumption, performance, KDPF status, and DEF-level data, among other features.

Komatsu America | www.komatsuamerica.com

Conveyor monitoring feature allows user to see belt wear

ContiTech’s new conveyor belt monitoring process allows users to actually see the belt wear in real time. The ContiAlert has a red bonding layer below the top cover that becomes exposed as soon as the belt is wearing thin and needs to be replaced. The system also has a calculator that tells users how much time is left on the current belt before it needs to be replaced. ContiAlert is available on the full line of ContiTech Select Conveyer Belts.

ContiTech | www.contitech.us

Impact beds protect conveyor systems

Asgco offers new Quarry Impact Beds to protect conveyor systems from damage. Featuring robust powder-coated steel supports and impact-absorbing rails, they are said to be able to withstand extreme abuse and keep operations moving. They are available in light duty and standard duty in either 4- or 5-foot-long beds, and are suitable for belt widths of 24- to 48-inches and belt speeds of up to 800 feet per minute.

Asgco | www.asgco.com

AGGREGATES MANAGER / March 2016

9

ROLLOUTS A new vertical-lift compact track loader

Takeuchi-US adds a new TL12V2 track loader to its lineup of track loaders. The vertical lift design marks a first for Takeuchi-US. It has 45-percent more operating capacity than its TL12 radial track loader. The machine comes with a Kubota 3.8L diesel Tier 4 Final engine with 111.3 horsepower and 284 foot-pounds of torque.

The unit also has a lower cross member for greater visibility and efficiency. A new track design minimizes noise and vibration.

Takeuchi-US | www.Takeuchi-US.com

Excavator boasts improved performance and productivity The LBX Co. introduces a new excavator — with an electronically controlled, 160-horsepower Isuzu Final Tier 4 engine — to its line.

The midsized Link-Belt 210 X4 has a 9-percent faster cycle time because of a new proprietary control valve that has a 40-percent larger hydraulic passage area. The cab is ROPS- and FOPS-certified and features a 7-inch LED monitor and easy-to-use controls. The excavator also comes with RemoteCARE GPS-enabled telematics for around-the-clock monitoring.

LBX Co. | www.lbxco.com

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.

10

AGGREGATES MANAGER / March 2016

Downhole tooling improves safety TT Technologies adds a new downhole tooling for its Grundodrill 4X compact HDD drill. The new downhole tooling system improves safety and simplifies drilling operations by allowing users to quickly and safely disconnect the sonde housing from the drill string after the pilot bore is complete. It has a specially made sub saver and clamp that locks into place so the operator can disengage the sonde housing more easily and quickly than in the past.

TT Technologies | www.tttechnologies.com

Mid-sized pump tackles heavy-duty drainage Grindex rolls out a new electric submersible pump for heavy-duty drainage applications. The Grindex Maxi H-Lite has a 25 kW motor. It weighs less and is slimmer than the full-sized Maxi.

It features the company’s proprietary hydraulics and a redesigned and optimized top cover with new cable entry that makes sure the junction chamber is free of water-ingress. The pump is made for confined spaces, and its lighter weight makes maintenance and installation much easier.

Grindex | www.grindex.com

PaneLiteTM is our new series of screen panels that contain a proprietary composite insert in place of the traditional steel one. This revolutionary insert reduces panel weight by 2 pounds per square foot while retaining excellent strength. PaneLiteTM screen panels have also exhibited extended wear life and increased anti-pegging characteristics in some applications.

Visit us in Booth 3742

March 22-24, Nashville Call us at 1-864-579-4594 or visit polydeckscreen.com/aggregate to ďŹ nd the Polydeck sales representative or dealer in your area.

AGGREGATES MANAGER / March 2016

11

CELEBRATING 20 YEARS OF KNOWLEDGE THAT RUNS DEEP Aggregates Manager celebrates two decades of amplifying the successes of every strata of the aggregates industry from crushed stone, sand & gravel operators to equipment manufacturers and dealers, and providers of services and supplies. Aggregates Manager has provided knowledgable support to the aggregates industry through key editorial coverage, timely expert analysis, and fostering a constantly active online community. We, at Aggregates Manager, look forward to delivering the vital information that streamlines your operations in 2016 and beyond.

AggMan.com

AggregatesManager

@AggregatesMgr

by Therese Dunphy, Editor-in-Chief

We’ve combed through 20 years of stories about operations to extract ideas that can make your plant more efficient — and profitable.

.com

s

www.Agg Man

Vulcan Material Co.’s Huntsville Quarry runs its plant from early morning until early afternoon to achieve significantly lower electricity rates. Its scales, however, remain open for customers during standard work hours.

21 30 36

Operations ideas to maximize profit per ton Six steps to keep hydraulic hammers going MSHA circ um regulatory vents review

2011

2

bility

Strategie

October

1

Sustaina

The BoDean Co.’s Mark West Quarry installed solar panels at its site, beginning by providing power to its office building. In 2011, it was able to run the entire plant on power generated from the solar array.

cover_use_no

box_AGRM1011

.indd 1

3

Operating in a water-sensitive area of Texas, Summit Materials’ Nehemiah Pit invested in dry dust suppression equipment to minimize dust while reducing water use. The system consists of sealed conveyors and dust collectors.

4

Martin Marietta’s Arrowood Quarry built 80-foot-wide haul roads to accommodate the trend toward larger haul trucks. It also uses 4- to 6-inch-thick rubber bedliners to extend the service life of their haul trucks by an estimated 15,000 to 20,000 hours.

5

By working with experts to retrofit equipment, Luck Stone has implemented the use of remote-controlled wheel loaders to safely access additional reserves and is developing autonomous haul trucks that will allow one driver to lead a fleet of trucks through the load-haul-dump-return route.

6

Rogers Group color-coded the two motor control center buildings at its Pottsville Quarry to streamline maintenance.

9/26/11

5:09 PM

AGGREGATES MANAGER / March 2016

13

7

Teichert Aggregates’ Vernalis Plant gets an estimated 25 percent of its power from a wind turbine on the site. A group of investors funded the turbine and pay for its maintenance, and the operation purchases power from it at favorable rates.

8

Walker Sand and Gravel used years’ worth of GPS tracking to adjust its fleet size. This has allowed it to deliver aggregates to more customers with fewer vehicles by maximizing their usage time.

9

Cemex built a maintenance facility near the pit of its 2,400-acre Balcones Quarry so mobile equipment wouldn’t have to drive back to the shop for servicing.

10

CalPortland organizes Energy Treasure Hunts to help their employees search for energy waste and efficiency problems, as well as learn about and embrace the concept of energy efficiency.

11

By sorting its customers by volume and determining its average margin, Capitol Aggregates can categorize its customers (high-volume/high-margin, high-volume/low-margin, low-volume/ high-margin, and low-volume/low-margin) and use an appropriate and cost-effective sales strategy for each.

12

Michels Materials uses only portable plants at its more than 100 Wisconsin quarries. By running portable primaries at the face and conveying material to the secondary and finishing plants, the company controls mobile equipment and fuel costs and achieves a more consistent feed.

13

CalPortland’s DuPont Pit uses two conveyors to transport material to its loadout dock on Puget Sound. The first is covered and protects material from the elements. The second is enclosed in a tube and prevents material from falling into the Sound. In 2005, the operation shipped 6.2 million tons of material via barge.

14

At its Davis Quarry, Dolese Brothers built a mobile structure for its gyratory crusher. In three days, it can be moved within 300 feet of the shot rock to lower transportation costs.

15

The Davis Quarry also installed a quick check-in lane for customers who are repeating their previous load. After confirming they are picking up the same load with no trailer changes, customers are automatically checked back in for a quicker pick up.

16

Lafarge’s Calera Quarry uses color coding to differentiate the level of safety training among its staff. New hires wear green stickers on their hard hats, while those who have completed safety training get gold stickers. This allows new hires to easily identify mentors and reminds more experienced miners to watch out for new workers. In addition, company employees wear green vests while contractors wear orange so both are easily identified from a distance.

14

AGGREGATES MANAGER / March 2016

17

By installing a camera at its jaw crusher, Martin Marietta’s Guernsey Quarry was able to move from having three operators in its processing plant to one.

18

Use of overland conveyors allows Staker Parson’s Reynolds Pit #2 to save money. With only one gear box, one tail pulley, and one head pulley, they provide an economical alternative to mobile equipment or regular conveyors.

19

Lehigh Hanson’s Romeoville Quarry reduced its energy consumption by 10 percent over two years by taking steps such as relining crushers, reducing operating hours, working around peak hours, and installing photocells on lights around the plant.

20

Implementation of Total Process Reliability principles, such as reporting and tracking protocols for maintenance and repair and establishing key performance indicators to codify goals, led to a 30-percent reduction in maintenance costs at Baker Rock Resources’ Beaverton, Ore., quarry.

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15

PLANT PROFILE

by Kerry Clines | Contributing Editor

Southwest Rock Products Join us as we revisit Southwest Rock Products’ Queen Creek Plant, winner of our online Top Op contest, to see how things have changed since our initial visit.

A

s a part of Aggregates Manager’s 20th Anniversary celebration, we held an online contest to allow our readers to vote for their favorite plant profile from the past 10+ years. More than 1,000 votes were cast in the Top Op contest, and many were surprised by the outcome, but no one was more surprised than Chris Reinesch, Sr., managing part-

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AGGREGATES MANAGER / March 2016

ner of the winning operation — Southwest Rock Products’ Queen Creek Plant in Arizona.

“It’s an honor to receive the award,” Reinesch says. “We take a lot of pride in our operations, and it’s nice to get some positive attention for our company.”

Reinesch was amazed and humbled by the support he received from his customers, vendors, and associates, and

by how many knew the Queen Creek site had won the contest. This became apparent during a recent visit to the Arizona State Land Department when a couple of the agents congratulated him on winning the contest. “We asked how they knew about the contest and that we had won, and, interestingly enough, they said they go to the Aggregates Manager website all the time,” Reinesch says.

Southwest Rock Products’ Queen Creek Plant in Arizona was voted the Top Op of the last 10+ years by our readers.

The operation When we made our first visit to the Queen Creek operation in late 2009, Southwest Rock Products was a fairly small family-owned and operated company. It’s still owned and operated by Reinesch and his partner/nephew, Steven Hood, but it has grown quite a bit over the last few years through an aggressive business model.

The downturn in the economy was a struggle for the company, as it was for everyone, but as the economy stabilized, it opened up the door for expansion. “It was time to go out and acquire additional mineable properties,” Reinesch explains.

“Some were locations that were previously mined to some degree. It was a great opportunity for our company.”

The Queen Creek facility has been

in operation for approximately 14 years.

Reinesch purchased the 86-acre property back in 2000. “I thought, if I got 40 feet of mineable material out of this site, I’d have my return on the investment,” he says. “We’re much deeper than that now, and the deeper we go, the better the quality of the aggregate. We’ve probably only consumed half of the reserves that are here, so it has proven to be a good investment.”

The alluvial deposit is part of the Queen Creek Wash, which is a mix of sand, gravel, and some clay. It isn’t the best deposit in the state, but Reinesch has been successful in making it into a quality product. It’s impossible to mine just one layer of material, so a dozer rips up the ground, shaves off a mixture of all of the layers, and pushes it down the

slope. By the time everythingl reaches the bottom, it’s a workable blend of material.

Unlike many larger aggregate companies, Southwest Rock Products has only portable equipment. “Nothing we do is with stationary equipment,” Reinesch explains. “If you build plants on what I call iron sticks, when and if the economy slows down, you’re stuck there and have to wait for a reason to start the plant back up. We can put together nine different portable crushing and screening plants, which can go to any site, make a stockpile of material, and move on to the next site. It’s not good for employees or a company when the equipment isn’t in operation.”

Having portable equipment helped the company during the economic AGGREGATES MANAGER / March 2016

17

PLANT PROFILE area, so all of the equipment is now in Arizona. In addition to mining newly purchased properties and leased properties, the company does the sand and gravel production for some of the largest companies in the industry and does a large amount of custom crushing for projects all over the Southwest.

Photo courtesy of Southwest Rock Products.

The material

Photo courtesy of Southwest Rock Products.

A bird’s eye view of Southwest Rock Products’ Queen Creek Plant in Arizona.

A belly-dump truck unloads material through a grizzly into the storage area of one of the ready-mix companies located on site at the Queen Creek operation.

downturn. When work died out in town, they took the equipment and did custom crushing for companies in Arizona and surrounding states. They even found work at some of the larger copper mines in the state. All of this allowed the company to survive.

“It comes back to a company culture of strong work ethic and determination,”

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AGGREGATES MANAGER / March 2016

Reinesch explains. “Whenever things are down, you can find a way. We were early to modify the business plan by pursuing other opportunities such as recycling material. We’ve tried to grow this company in a lot of ways. I don’t want to have any of our equipment sitting idle.”

With the economy on the upswing now, work has greatly picked up in the

Approximately 50 percent of the aggregate produced at the Queen Creek facility is used as base material. The rest is used by two independent ready-mix companies, which are located on site.

Material supplied to the ready-mix plants is transported by belly-dump trailers and dumped through grizzlies into storage areas.

Queen Creek is what you might call an old school operation. In an industry that is fast becoming high tech, this can present problems, but Reinesch says one thing that helps him stay competitive with other companies is the quality of his loader operators, which he says are some of the best. The buckets on the loaders have been enlarged so that a truck can be filled in two passes. There are no bucket scales on the loaders, however. Reinesch says that, in his experience, bucket scales have proven to be unreliable and can hinder the loader operators from developing their skills.

“We have several good loader operators, some that have been with our company since almost the beginning,” Reinesch notes. “The trucking industry has noticed, and they appreciate our quick cycle times.”

Leftover concrete from the ready-mix companies is used to make large blocks that are used as retaining walls and perimeter safety fencing. Return concrete and waste from the ready-mix plants are recycled back through the crushing plant, so nothing goes to waste.

“Once we get to the bottom of the pit and all the way to the back of the property, we’ll move our processing equipment to lower levels,” Reinesch says. “Then we’ll mine where the plant once was.”

The Queen Creek site is the central hub for repair and maintenance for all of

the company’s equipment. After completing a job, the equipment is brought in for maintenance before it goes to the next job. This includes mechanical maintenance, welding, fabrication, and painting.

A little more than a year ago, Reinesch entered into a partnership with a friend who set up a painting/sandblasting operation on site. “He’s just getting started, but he’s already extremely busy and had to add two additional employees,” Reinesch notes. “In addition to work for our company, he does work for a multitude of other industries.”

Safety and the environment “We’re top notch in making safety a priority at our company because of our managers, supervisors, and our environmental/safety director,” Hood says. “This is the best team this company has ever had, and they have taken us to a new level of employee safety and environmental compliance.”

Southwest Rock Products is big on conservation and shrinking its envi-

ronmental footprint. The wash plant at the Queen Creek operation uses a large amount of water from an onsite well each year to wash aggregates for use in the ready-mix operations.

To decrease the burden on the aquifer for this operation, a recycling system was developed to reclaim and reuse water. Dirty water from the washing process enters a tank where an environmentally friendly polymer is added to allow the mud in the water to sink. This separation allows the mud to be placed in a pond and the cleaner water to be reused.

One challenge faced by Southwest Rock Products is protecting its employees and the environment from excess nuisance dust. “We have numerous operations in Maricopa County, which has some of the most strict dust-control regulations in the United States,” Reinesch says. “To comply with these regulations, we frequently conduct dust sampling at each one of our sites. We train our operators on personal protective equipment and how to fine tune

our water spray bars to reduce nuisance dust while maintaining a quality product.”

Dealing with the Mine Safety and Health Administration (MSHA) can be challenging. Reinesch meets with the MSHA supervisor of Arizona, on occasion, in order to build a positive relationship with the agency and discuss any issues.

“MSHA knows we’re trying to do what’s right to keep our employees safe and to be in compliance with federal regulations,” Hood says, explaining that the goal is to have zero lost-time accidents and get zero citations during MSHA inspections.

“In the last few years, our safety/ environmental director has made great improvements in our company’s safety and environmental compliance,” Reinesch notes. “He goes out and performs frequent safety audits at each of our locations, and our employees participate, because they know we’re serious.”

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19

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PLANT PROFILE

A new shop allows mechanics to stay out of the hot Arizona sun while performing maintenance and repair on equipment, which is important since the Queen Creek operation handles the maintenance for all of its operations.

The team There are approximately 70 employees working for the company, counting all of its locations. “We’re pretty proud of the fact that during the economic downturn, we didn’t lay anybody off,” Hood says. “There was some attrition during that period, but the last thing we wanted was to have to lay off good employees.”

The Queen Creek operation runs two 12-hour shifts. “We expect a tremendous amount out of our employees,” Reinesch explains. “Our employees enjoy being able to earn extra money by working overtime, and I don’t mind paying it.

That little incremental cost is nothing compared to the consistency and the dependability of the person running that crusher or wash plant. When you have quality people, you don’t have problems.

You get better production and better maintenance of the equipment.”

The production manager and supervisors who work for Southwest Rock Products have an average of eight years of experience with the company, as some have been at the company since the beginning. Many of the supervisors have gained great insight into the industry, having been trained directly by Reinesch and Hood, who have 72 years of experience in the industry and know it takes dedication and a solid work ethic to be a supervisor at the company.

Material is pushed down the slope by a dozer, loaded into a crusher by a loader, and then carried up a conveyor system to the processing plant.

Those supervisors pass that knowledge along to every employee. “We wouldn’t be where we are today without them,” Reinesch says.

All of the buildings and improvements at the operation have been constructed by the employees. Reinesch says it helps keep the employees busy, expands their skills, makes them a more versatile employee, and saves the company money.

A large maintenance shop was recently built at the facility, which allows the mechanics to work on equipment without being exposed to the extremely hot sun

in summer, which can be a miserable 122 degrees at times.

Reinesch and Hood understand that employees are the lifeblood of any company. “Finding and retaining quality employees has been a priority for our company,” Reinesch says. “We have been lucky enough to employ some of the best in the industry and strive to make Southwest Rock Products a place where people want to work. Recognition from this article is a reflection of their efforts to make this a company to be proud of.” AM

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AGGREGATES MANAGER / March 2016

21

PLANT MANAGEMENT

by Wade Lippert

Recognize that your people are your most valuable assets. Invest in them, and they will take care of your equipment and your customers.

W

hat does it take to run a successful operation and have it continue to grow and prosper? The answer is already working for you: It’s the employees you entrust to operate your equipment and manage your dayto-day operations.

I was once asked who I thought the most important person in my business was. Naturally, I said the customer.

I was wrong. The correct answer is your employees. Why? It’s simple. Who takes care of your customers? Your employees do. This is true for all parts of an operation, even though some employees may never contact your customers. Keeping your equipment running smoothly affects your reputation, financial outcome, and, yes, your customers.

So answer this question: Who do you want running your equipment?

Someone who cares about your success — which, in turn, translates to their success — or someone who cares nothing about it?

The answer is simple, and yet, too often, steps are not taken to recognize and invest in these valued employees.

We speak often about best maintenance practices and how to apply them to your equipment, but we should not neglect to mention how this knowledge

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AGGREGATES MANAGER / March 2016

should be incorporated into your operation. Employers must invest in their team members, helping them grow their knowledge and having them take part in the decisions and the outcome of the operation.

Investing in education through factory education (like our PRO Training program) and on-the-job training creates a safer, more dedicated employee. The investment quickly pays for itself with reduced downtime and increased efficiency. Of course, investment requires total commitment, one that is ongoing. Try viewing employee investment like putting gas in a car — filling it up just once is not enough to keep it going long-term.

Once educated, employees are better equipped to manage responsibilities that will improve morale and minimize downtime. There are a number of programs you can implement, but whatever you decide, always keep simplicity in mind. Something that is hard to follow usually means it won’t get done.

Below are the three programs I suggest implementing into every operation. These can be easily managed by educated and involved employees.

1. Maintenance repair log. A maintenance repair log can be a simple document that briefly explains the

Investing in employee education helps to create a safer, more dedicated workforce.

problem, the severity of the problem, whether or not parts are needed, the estimated time to repair, and a completion date. These day-to-day records can be used to schedule the repairs based on severity, and as producers know, scheduling downtime helps control maintenance costs. In most cases, problems can be corrected in their infancy, creating a

proactive, rather than reactive, maintenance approach. A repair log also provides accountability for completion and ensures that even the most minor repairs don’t get overlooked.

2. Lubrication schedule. A good lubrication schedule and check sheet can work in a similar fashion. A lubrication schedule logs each piece of equipment and records the grease type, intervals, location, and amount required, followed by a check mark with initials verifying completion once tasks are completed.

3. Wear parts list. Maintaining an up-to-date wear parts list is crucial in helping producers determine what and when to stock before the parts are needed, rather than waiting for the part to wear out before ordering.

Just like the repair log, producers can also schedule the replacement work without interrupting too much of their operating or uptime.

Individual methods will vary as each operation is unique. You will de-

Three programs every operation should use include maintaining a maintenance log, a lubrication schedule, and a wear parts list.

velop and improve on your maintenance program as you go. Documentation is important for recording historical data and developing improvement methods, but it should not be time-consuming.

Keeping your maintenance program accurate and simple is key to streamlining the process and achieving a rewarding payoff. AM

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Untitled-19 1

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AGGREGATES MANAGER / March 2/8/16 2016 9:28 AM

EQUIPMENT MANAGEMENT

by Carol Wasson

Lean principles requires operators to reduce waste and improve process flow.

Lean Screening Increase value-added processing by maximizing open area and minimizing screen media changeouts.

L

ean manufacturing is fully focused on reducing waste and improving process flow, while strengthening value-added issues, exceeding customer needs, and boosting profitability. Within aggregate and mining operations, one example of “lean screening” is the use of properly-specified modular synthetic (poly-

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AGGREGATES MANAGER / March 2016

urethane or rubber) media. In even the toughest wet or dry screening applications, operations may realize greater wear life, consistent gradations, and a significant reduction in maintenance costs and downtime. These time- and labor-saving benefits provide maintenance personnel with valuable time for other core tasks.

“Nowadays, it’s all about yield — specifically, the yield of critical products.

It’s about achieving efficient separating and sizing that delivers the most value,” says Tod Eberle, key account manager for Polydeck Screen Corp. He explains that today’s producers are highly attuned to the inventory control of their key saleable products. “Years ago,

producers could sell almost everything they made — and they didn’t mind dealing with waste products or working an extra hundred hours a year to make more of a particular product. But today, they’re smarter. They understand that product yield and ultimate control over gradations is imperative. Every ton that an operation cannot maximize means more time in production and more by-products that are not as marketable,” he says.

Eberle is an aggregate industry veteran who spent more than 20 years as a producer before joining Polydeck. “I had specified their media for a number of plants, and I found that I could tweak a deck in fine increments, completely controlling the gradations and yield percentages, because I had so many variations to work with. They offered options in polyurethane and rubber; different durometers and hardness; different opening sizes and shapes; and media for higher wear life and open area,” he says.

Ensure peak performance To ensure optimal process flow over the long term, the right screen media specification strategies must be employed upfront. Eberle says that detailed data must be gathered on the material type, tons per hour, and desired gradations.

Further analysis examines issues such as blinding or plugging and pegging problems, as well as bed depth and carryover. Due to the modularity of the Polydeck screen panels, he says, “There are many options in sizing openings at various points on the deck, such as placing a few larger openings at a critical point on the deck to allow just enough coarse material through to make a particular spec, for example.

“Also, to maximize wear life and gradation accuracy, there are simple ways that panel types can be moved around to take advantage of where material stratifies and passes through the deck, Eberle says. “Additionally, we can employ various surface features such as

Modularity of synthetic screen media allows easy installation or replacement of screen panels.

dams and skid bars to control flow and provide cleaner material, while increasing throughput.”

Key to a successful lean screening strategy, says Eberle, is focusing on the bigger picture — from crushing to stockpiling. “And, in between, we examine the screening circuit as a whole,” he says, noting that some manufacturers offer producers the opportunity to complete a “screen performance evaluation” prior to specifying and installing new media. “We combine our engineering expertise with high-tech electronic instruments to measure and evaluate all aspects of a screen’s operation.” He explains that the evaluation examines the screen’s G-force; stroke; deflections (aberrations in its movements); critical frequencies; support structure integrity, and more. “Subsequently, we issue our findings with recommendations to bring the screen up to its peak screening performance in the particular application,” he says.

From more than 1,000 screen panel design options, the screen media is correctly matched to the vibrating

screen parameters, making sure that the circuit will keep pace with the crushing side. Eberle stresses that all the product mixes are reviewed so that any potential gradation inconsistencies and plant bottlenecks can be identified and adjustments can be made. “After we’ve identified critical processing statistics, we can run ‘what-if’ scenarios to optimize media specifications to the application; and to determine how any changing variables within the screening operations will affect overall efficiency,” he says.

Reduce waste and downtime Time management skills are essential to the lean processing mission. “There are producers out there who really don’t understand the value of repair and maintenance time,” says Eberle. He stresses that it’s common to replace wire cloth decks on a weekly basis. “Producers are all too familiar with the need to shut everything down, pull workers from other jobs, bring in a crane and switch out the wire cloth.

It’s a lengthy job,” he says.

Alternatively, the wear characteristics of synthetic media allow operations to

AGGREGATES MANAGER / March 2016

25

EQUIPMENT MANAGEMENT

The use of modular screen panels allows aperture sizes and shapes to be customized in one-foot square increments to achieve a specific product spec.

An effective solution like these anti-blinding screen panels can substantially reduce maintenance time when compared to traditional screen cleaning.

Balancing wear life with open area is an important consideration in maximizing product throughput.

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AGGREGATES MANAGER / March 2016

avoid changeouts throughout a season or even over multiple seasons depending upon the application. As a result, the wear life of synthetic media delivers a gain of significant hours for maintenance personnel to focus on other value-added tasks; and for the operation to increase its yield of critical products. Again, the latter is integral to lean screening.

There are also the issues of blinding and pegging. Eberle says that a producer may choose wire cloth for its open area, yet the deck will blind up within days or weeks, resulting in a dramatic loss of throughput, and increased downtime.

Modular synthetic panels can be very competitive with wire cloth on open area, says Eberle, adding that producers should consider that the open area in wire cloth is often overstated. He explains that many wire cloth catalogs list percentages of open area, which figure in all the openings in a section of wire cloth. However, upon installation, a portion of those openings is blocked by bucker bars, crown rubber, clamp rails, and center hold-downs. This means that the open area is significantly different, causing calculations to be off as much as 40 percent. “It’s also important to note that, in the case of conventional synthetic media brands, the open area is often calculated by ignoring the border. The conventional panel has a large border or dead area around the perimeter that is not taken into account, and in this case as well, the open area is overstated,” he says.

As to the issue of waste, Eberle says that producers who run wire cloth do one of two things. They run it until

it catastrophically fails and contaminates the stockpile; or to avoid the latter, they pull the deck too early. Either choice wastes both time and money.

“One of the biggest benefits of synthetic media is that you rarely have a catastrophic failure. Instead, synthetic media gives you a warning of any wear via gradation creep,” he says. “As you take QC samples, watch for subtle changes in gradations. Usually, when your samples become coarser, you’ll most likely detect some wear in the panels. In most cases, you simply change out a panel or two, and you’re up and running again,” he adds.

For efficient inventory control, it’s a good idea, says Eberle, to keep records on what, where, and when panels are replaced. “By documenting the wear life of each panel, operations can better forecast any needs for replacement panels, allowing them to plan ahead and budget for yearly screen costs,” he says.

Lastly, lean screening is rarely seen in operations that choose to do nothing else, but what they have always done.

“Adhering to the same old wire cloth routine may seem a comfortable choice, until you look at the bigger picture. The goal is the highest yield of quality products, and the best use of your valuable time,” says Eberle.

Ultimately, lean screening gets the right products to the right stockpiles at the right time — to achieve optimum process flow, production flexibility, and customer satisfaction. AM

Carol Wasson is a veteran writer and aggregates industry expert.

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PULL-OUT GUIDE

By Mary McCaig-Foster, Contributing Editor

March 2016

Keep Workers Awake and Alert

Repetitive tasks and unchanging scenery can cause fatigue.

Fatigue-related incidents can be more serious than non-fatigue-related incidents.

Poor sleeping and eating habits are also a cause of fatigue.

In-cab technology and common-sense best practices can help prevent and mitigate fatigue.

OPERAT 1

Dangers of fatigue

Worksite Safety: Mitigating Fatigue

A

s an underlying cause of incidents and accidents, fatigue can be a sneaky culprit to monitor and mitigate, says Walter Tharp, manager of environment, health, and safety for Irving Materials, based in Greenfield, Ind. “It can be the result of working long hours or doing tiring tasks, and it also can be the results of personal sleep habits or situations at home. What fatigue affects is our ability to mentally process information. Workers can lose their ability to concentrate, and it dulls their responses to hazards,” he says.

According to Todd Dawson, manager of Fatigue Solutions for Caterpillar, fatigue is often something that’s viewed as being a problem with lazy, unmotivated, or uncaring people. “But we all can experience fatigue,” Dawson says. “Whether we might work on a night shift, and our circadian rhythms are working against us, or we’re operating under stress; life just gets in the way. It’s human nature to experience fatigue at least some of the time.”

For an office employee, fatigue may not present many on-the-job hazards (although it can affect the commute home). For aggregates workers in the plant, fatigue can result in serious incidents and accidents. In fact, fatigue-related incidents can be more severe that non-fatigue-related incidents in that the fatigued worker often will fail to make any corrective actions or maneuvers. And as a precursor AGGREGATES MANAGER

to sleep, in the brief span of time before actually falling asleep, a driver is operating similarly to someone who is legally intoxicated.

“Spending 22 hours awake is equivalent to having a 0.08 percent of blood alcohol content,” Dawson says. “Even a distracted or drunk driver will typically attempt to correct if he’s drifting or approaching a traffic stop.”

While it has historically been difficult to monitor fatigue among workers, Jamie Ross, head of safety, risk, and security at Newcrest Mining in Melbourne, Australia, says that there are signs managers can watch for amongst their workers. These include small errors, lapses and slips (dropping tools, picking up the wrong item); poor hand-eye coordination; loss of attention (not hearing things said by others); slow reaction times; bad moods; and yawning or visible drowsiness.

In applying technology to the issue, it makes sense that an available automated system might primarily focus on the worker’s eyes — including the momentary eye closure that often is involved. Dawson says that the Cat Driver Safety System (DSS) is in-cab, camera-based technology for rolling equipment that monitors facial features, especially the driver’s eyes. “The DSS uses algorithms to determine if you’re closing your eyes more than a blink,” he says. “It also looks at head orientation and gaze to monitor distraction. And it can provide an alert — an alarm or seat vibration — to wake the driver.”

Fatigue can be insidious in that most people experiencing it don’t recognize when they have passed beyond feeling tired to momentarily closing their eyes. In moving vehicles, fatigue-related incidents can be more severe in nature than non-fatigue-related incidents because, often, no corrective actions or maneuvers are taken. Even a distracted or impaired driver will typically attempt corrective action.

4

Life gets in the way

Sometimes workers create their own fatigue by staying up too late or drinking alcohol before bed, which can affect sleep. Diet, babies or young children, a spouse’s schedule, and other life situations can shorten a sleep cycle. So can a shift length, time off between shifts, the length of a commute, and conditions such as insomnia and sleep apnea. All of these situations can lead to fatigue.

TIONS ILLUSTRATED Keep Workers Awake and Alert 2

Cause and effect

Fatigue can be caused by many things — some of which can be controlled and some of which cannot. Circadian rhythms naturally put workers at risk for fatigue if they are working between the hours of midnight and 6 a.m.

The post-lunch “dip” between noon and 3 p.m. represents another physiological decline in workers’ ability to remain alert. Seasonal changes, with shorter days and longer nights, also can cause fatigue.

5

Technology solutions

In-cab technology for equipment operators now allows for camera-based systems that can measure such things as the length of time a driver’s eyes are closed for more than a standard blink. This technology can also look at head orientation and gaze. If it determines a driver is experiencing fatigue, the system provides an alert such as an alarm or a vibration to warn the driver and wake him up.

3

EXPERTS

Repetitive tasks

Working conditions and repetitive tasks are culprits for causing fatigue. Haul truck drivers often experience fatigue from following the same slow, up-down ramp throughout a shift, where nothing truly changes in their line of vision. In these situations, drivers may try to distract themselves by rummaging around in the cab, or playing with a smart phone — but distraction also is dangerous.

6

OUR

Best practices

Fatigue is best managed by prevention. Workers should try to follow healthy diet and fitness practices, get adequate sleep, work regular hours, avoid excessive drinking prior to sleep during the work week, and avoid stressful activities outside of work. If fatigue sets in for a worker, a manager might offer him a chance to rest, allow him to change tasks, move him to a different area onsite, or change his shift.

Over the past 20 years, Todd Dawson has become one of the leading experts in developing and implementing comprehensive fatigue risk management systems in large and complex environments. As manager of Fatigue Solutions for Caterpillar, Dawson has assisted companies with fatigue mitigation due to PHMSA regulations. He holds a bachelor’s degree in biological anthropology from Harvard University.

Walter Tharp, P.E., is manager of environment, health, and safety (EHS) for Irving Materials, which is based in Greenfield, Ind. With 25 years in the aggregates industry, Tharp has worked in the safety field for close to 35 years. His first safety-related job was in loss control for an insurance company, which needed a civil engineer to service its construction division.

Jamie Ross, head of safety, risk, and security at Newcrest Mining in Melbourne, Australia, is also the mind and voice behind MiningMan.com, a website devoted to advancing leadership, safety, and productivity in mining. A mining engineer, Ross has spent more than 15 years in operational, technical, and leadership roles in mining operations throughout Australia, the United States, and China.

March 2016

Voices of Experience Jamie Ross

W

orker fatigue is a topic not usually dealt with during on-the-job safety behavior observations, says Jamie Ross, head of safety, risk, and security at Melbourne, Australia-based Newcrest Mining. “It is a difficult thing to observe for, and the very fact that someone is being ‘observed’ can tend to ‘wake’ them up and mask any behavioral signs of fatigue,” he notes.

While it can be difficult to observe and recognize signs of fatigue, the causes and consequences of fatigue are certainly something that should be discussed with teams one-on-one — and the best time to do that is during safety toolbox talks. “There are some convenient times and situations that can act as prompts to discussing fatigue,” Ross says. These include: • Last shift of the week or tour; • When people may be about to drive long distances at the end of the shift; • During any night shift or a shift where the person had a particularly early start; • At the end of a very long shift; • On jobs with repetitive work; • Working in hot and humid conditions; and • Following an incident where fatigue was thought or known to be involved.

The following factors are the key contributors to work fatigue: • Poor quality of sleep or inadequate sleep before shifts; • Working irregular hours and night shifts; • Drinking prior to sleeping; • Extended physical or mental exertion at work; • Strenuous or stressful activities outside work; and • General health and fitness.

“The discussion can also cover what controls a person or work team are putting in place to manage fatigue, but, in general, the hazards of fatigue are best managed by prevention rather than managing it once it has set in. Some controls that are possible if a person is feeling fatigued include rest, changing jobs, working in cooler areas, avoiding working alone, and avoiding any highrisk jobs or driving,” Ross says.

AGGREGATES MANAGER

Walter Tharp

F

atigue not only can cause workers to lose their concentration, but in worst-case scenarios, it can actually cause a worker to fall asleep. “Haul truck drivers often experience fatigue due to the fact that their jobs can become boring and repetitive,” says Walter Tharp, environment, health, and safety manager for Greenfield, Ind.-based Irving Materials. “When you begin doing your job by rote, then you can stop actively thinking about what you’re doing. Your mind can wander.”

Outside influences for fatigue include natural circadian rhythms and seasonal changes — with shorter days affecting a worker’s sleep cycles. Longer days in summer can mean longer shifts, however, which also can lead to fatigue.

Tharp says that advancements in mobile equipment have helped to reduce fatigue in operators. “Twenty-five years ago, truck and loader cabs had little insulation for noise and temperature, and there was no air conditioning,” he notes.

“Improvements in these areas alone have created better work environments and have made operator and driver jobs less tiring to do. Noise reduction in particular is important, as noise can cause stress, which leads to fatigue.”

Foremen and site managers at Irving Materials are encouraged to actively be involved in their crews’ activities and to get to know crew members well, so that actions that seem out of the ordinary will be noticed and monitored. “The best chances of mitigating fatigue lie in our ability to recognize it and assist our workers,” Tharp says. “Our managers should know their crews well enough that they will recognize if a worker seems fatigued. They can try to identify the cause of the fatigue, and get the worker assistance if necessary.”

Tharp says Irving Materials also works to reduce fatigue among workers by discussing healthy habits during safety meetings. Managers emphasize the need for proper diet and getting enough rest, as well as tips for separating the home environment from the work environment.

Todd Dawson

“W

e’re very bad at recognizing how fatigued we are,” says Todd Dawson, manager of Fatigue Solutions for Caterpillar. “We usually can’t tell when we have gone from ‘I’m tired’ to ‘I’m dangerously tired.’ And we can easily slip from there to ‘my eyes closed, and I drifted off the roadway.’”

According to Dawson, the gold technology standard for monitoring fatigue is the EEG. “Unfortunately, it’s a challenge to take that technology into a mobile job because it requires having electrodes hooked to your skull during your shifts.

No one wants that,” he says.

To help in monitoring and mitigating fatigue, Cat has looked into other ways to measure a worker’s level of tiredness.

“Most sleep studies require another person to interact with the subject,” Dawson explains. “But technologies have come out that require little to no interaction with drivers.”

One such technology, called the Driver Safety System (DSS), is an in-cab, camera-based system that monitors features on the driver’s or operator’s face. The system can determine if the driver has closed his eyes for more than a mere blink or if his gaze has become distracted, and it will provide an alarm or a seat vibration to warn and wake the driver.

Another system available is called the Smart Band. It is a wearable device similar to a FitBit, which the user wears at all times. A 3D accelerometer captures movement of the wearer, and translates it into patterns of waking and sleeping. Together with information about that worker’s shift schedule, the Smart Band can help to build a picture of that worker’s quantity and quality of sleep over 30 days. If it becomes apparent that the worker’s sleep patterns are cause for concern, managers can use this information to help the worker gain better sleep quality.

“Of course, technology is a great help.

But workers still should know the signs of fatigue. And it is best for operations to advance a culture where workers feel they can ask for assistance — or even a break,” Dawson says.

READY TO WORK

Visit us at Booth 1013

MC1000, MC1300, MC380X & MC450X Cone Modules

MJ42 and MJ47 Jaw Modules

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Canica速

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MV2000 VSI Modules

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MHS6203 & MHS8203 Horizontal Screen Modules

Jaques速

Modular Electric Crushing & Screening Solutions Pick and choose modules to fit your specific needs or we can tailor a system for you.

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Strong Heritage, Strong Future.

Terex, the Terex Crown design, Cedarapids, Canica, Simplicity, and Jaques are trademarks of Terex Corporation or its subsidiaries. Copyright 2016 Terex Corporation.

AGG PREVIEW

by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com

Aggregate producers can see more than 140,000 square feet of equipment exhibits and choose from more than 60 educational sessions at this year’s AGG1 Aggregates Academy & Expo.

Grab Your Boots Photo credit: Nashville Convention & Visitors Corp.

and Head to Nashville for AGG1!

Country and rock collide as the aggregates industry gathers for its annual convention and expo.

I

t’s time to finalize your plans to attend AGG 1 Aggregates Academy & Expo, which is, once again, co-located with the World of Asphalt.

The event is scheduled for Tuesday, March 22, through Thursday, March 24, at Nashville’s Music City Center.

AGG1 focuses exclusively on the aggregates industry and offers education sessions from industry experts in virtually all segments of the aggregates industry, including operations, health and safety, environmental, reclamation, automation, management, leadership, and sales and marketing. Exhibitors will display their equipment on over 140,000 square feet of exhibit space.

During downtime, attendees can explore the Belle Meade Plantation, tour

34

AGGREGATES MANAGER / March 2016

the Country Music Hall of Fame, take a ride on General Jackson Steamboat, or visit the Grand Ole Opry (Rascal Flatts performs on March 22).

Educational opportunities AGG1 Academy will offer more than 60 expert-led educational sessions and seminars ranging from beginners classes that teach the basics to seminars that explore advanced concepts and technologies. The sessions are organized into four focus areas: • Operations and Production; • Automation, Tech, and Software; • Business Management; and • Environment, Safety, and Health.

An all-access package ($1,295) includes admittance to all NSSGA activities

not requiring a separate admittance fee, including the Opening Celebration/ Concert ticket, entrance to all AGG1/WOA exhibits on show days, and unlimited access to all AGG1 education sessions (except specially priced programs). The professional package ($995) includes admittance to all NSSGA activities after 4:30 p.m. on Monday, March 21, not requiring a separate fee, including the Opening Celebration/Concert ticket, entrance to all AGG1/WOA exhibits on show days, and unlimited access to all AGG1 education sessions. The leadership package ($895) includes admittance to all NSSGA convention activities not requiring a separate fee, including the Opening Celebration/ Concert ticket, and entrance to all AGG1/ WOA exhibits on show days.

AggMan is the lead sponsor for the Opening Celebration

Enjoy authentic country music while visiting Nashville.

Photo credit: Nashville Convention & Visitors Corp.

Photo credit: Nashville Convention & Visitors Corp.

Exhibits will be on display at the Music City Center.

On Monday, March 21, from 7 to 10 p.m., the National Stone, Sand & Gravel Association will host what it calls “the ultimate networking event.” Held at the Music City Center, the event will include food, drinks, and live music. The cost of the event is included in all AGG1 All Access Pass and Annual Convention registration packages. There is a $75 event ticket option for those only attending the AGG1 Expo. Aggregates Manager, which marks its 20th anniversary in March, is the gold sponsor of the event.

Maggie Rose will kick off the live music. Rose moved to Nashville at 19. Shortly thereafter, she released her debut album “Cut to Impress” (2013) which yielded two singles — each of which made Billboard’s Hot Country Songs chart. She is working on a new album set to come out in 2016.

Following Rose is headline entertainer Phil Vasser.

His career includes the release of eight albums, two ASCAP Songwriter of the Year trophies, recognition as the Billboard Country Songwriter of the Year, countless hits as a singer and songwriter and a mantle full of awards, and the launch of his own Rodeowave Entertainment label.

Vasser has hit the Top 5 seven times with songs like “Carlene,” “Last Day of My Life,” and “American Child” and topped the charts with “In A Real Love” and “Just Another Day in Paradise.” Known as one of Nashville’s top tunesmiths, his songs other artists have taken to #1 include “My Next Thirty Years” by Tim McGraw, “She’s Right On The Money” by Alan Jackson, and Jo Dee Messina’s “Bye, Bye” and “I’m Alright.”

New artist David Nail had a hit with Phil’s “The Sound of a Million Dreams,” which Billboard named the #1 song in its Top 10 Country Songs of 2012. AM

Photo credit: Nashville Convention & Visitors Corp.

A tour of Rogers Group, Inc.’s Rutherford Quarry will also be offered on Monday, March 21, from 11 a.m. to 2 p.m. The plant provides limestone to the area and has earned two NSSGA Stars of Excellence for community relations and environmental stewardship. A separate registration fee of $60 applies for the tour, and it is limited to the first 150 registrants.

NSSGA Annual Convention The National Stone, Sand and Gravel Association’s Annual Convention will be held in conjunction with AGG1, beginning March 20 and running through March 23.

Convention attendees can attend networking sessions and committee meetings. Be sure to check the convention schedule to learn more about which meetings are open to attendees. Tickets to the ROCKPAC Reception and Mercedes Drawing, held Wednesday, March 23, at the Musician’s Hall of Fame, are available for purchase during the annual convention. AM

The ROCKPAC Reception and Mercedes Drawing will be held on March 23 at the Musicians Hall of Fame. A separate ticket is required for admission.

AGGREGATES MANAGER / March 2016

35

AGG 1 PREVIEW Aggregates Academy Tuesday, March 22 7:30-9:00 a.m.

• T41 An Up-Close and Personal Look at Aggregate Variability in a Silo • T42 Alkali Silica Reactivity in Concrete • T43 Aggregate Ticketing Innovation • T44 Legally Effective Incident Investi-

gations • T45 Belt Conveyor Solutions: Improving Transfer and Dust Control • T46 Using Quality KPIs to Improve Product Consistency and Reduce a Company’s Exposure to Risk • T47 Primary Crushing: Best Maintenance Practices and Application

• T48 Geotechnical & Structural Geology: Stay Safe, Make More Money

9:30-11:00 a.m.

• T51 How to Control Dust from Aggregate Processing Plants

2:00-3:30 p.m.

• T61 Empower Employees to Speak Up and Listen Up • T62 Fine Aggregate Production with VSI Crushing and High Frequency Screening • T63 Technology and ROI in the Aggregates Production and Supply Process • T64 Successful Community Relations through Social Media and Proper Risk Management Practices • T65 Washing and Classifying 101 • T66 Maximizing Screening Efficiency • T67 How Proper Preparation Leads to Efficient Portable Plant Setup and Start Up

Wednesday, March 18 10:30-11:30 a.m.

• W51 Innovative Solutions for Highwall Instability • W52 Coarse Aggregate Scrubbing and Feed Preparation • W53 The Plot Thickens: Tailings, Thickener Type, and Application • W54 Particle Size Reduction for Aglime Production • W55 New Tech in an Old Business • W56 Beyond Compliance: The Evolving Safety Culture • W57 Standards and Practices for Belt Conveyor Safety • W58 Metal Detection 101

2:00-3:30 p.m.

• W61 Streamlining Environmental Compliance Using Mobile Devices • W62 Understanding How MSHA’s Different Citations and Orders Affect My Company • W63 The New Standard for Corporate Conservation: Embracing Accessibility, Enhancing Credibility, and Driving Change • W64 How to Stop a Quarry in Four Easy Steps

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AGGREGATES MANAGER / March 2016

• W65 Transforming Big Data into Big Results • W66 Rock Solid Messaging – How Communications Can Take Your Company to the Next Level and Improve Operations • W67 Screening 101 • W68 Case Study: Filter Press vs. Settling Ponds

Wednesday, March 18

Thursday, March 19

NSSGA General Session II Education sessions

8:00 – 10:00 a.m.

10:30 – 11:30 a.m.

2:00 – 3:30 p.m.

Exhibits open 10:30 a.m. – 5:00 p.m.

AGG1 Happy Hour Reception 4:00 – 5:00 p.m.

Education sessions

7:30 – 9:00 a.m.

9:30 – 11:00 a.m.

Exhibits open

9:00 a.m. – 2:00 p.m.

ROCKPAC Reception and Mercedes Drawing 6:00 – 8:00 p.m.

Thursday, March 19 7:30-9:00 a.m.

• TH41 Changing the MSHA Refresher Training Process • TH43 Modern Conveying and Its Impact on Product Quality and Operating Expenses • TH44 Drones and Stockpiles • TH45 Educational Outreach and Community Relations • TH46 Inventory Management: Reconciling Your Inventory from Production to Reporting

9:30-11:00 a.m.

• TH51 Internet of Things: Beyond the Marketing and Hype, What Does It Mean for the Aggregates Industry?

• TH52 Measuring the Effectiveness of your Hearing Conservation Program • TH53 Environmental and Safety Management Systems • TH54 Dedicated Contract Fleet Maintenance Programs • TH55 Crisis Management • TH56 Customer Success Stories: Process Improvement in Crushing and Screening Operations

NEED TO MOVE IT WE CAN HANDLE IT

CWW Conveyor Systems LLC (“CWW”) headquartered in Hillsville, VA, focuses on sales and support for former Caterpillar conveyor systems products. Whether you are looking for a new conveyor system or replacement components, CWW has the knowledge and expertise to provide you with the best solution for your application.

Belt Terminal Groups

Extend belt life while reducing operating costs

Convention/AGG1 Schedule

Rock Dusters Rolls and Idler Assemblies

Exalon® Rolls Surface Conveyor Systems

Belt Cleaners

Monday, March 16 Operations Tour of Rogers Group’s Rutherford Quarry 11:00 a.m. – 2:00 p.m.

NSSGA General Session 4:30 - 6:30 p.m.

NSSGA Opening Celebration 7:00 - 10:00 p.m.

Underground Conveyor Systems

107 Raintree Road Hillsville, Virginia 24343 +1-800-457-7655 www.cwwconveyors.com ConveyorSales@cwwconveyors.com

Tuesday, March 17 Education sessions

Exhibits open

Pulleys

7:30 – 9:00 a.m.

9:30 – 11:00 a.m.

2:00 – 3:30 p.m.

11:00 a.m. – 5:00 p.m.

CWW-101B.indd 1 Untitled-6 1

37

AGGREGATES MANAGER / March 2016 10/1/15 2:46 PM

10/2/15 9:40 AM

AGG 1 PREVIEW

AGG1 Product Preview Here is a sampling of the equipent and services attendees will find on display at the show.

Editor’s note: For more products and introductions from AGG1, check out our coverage at www.aggman.com.

Deister Machine Co.

Deister Machine Co., Inc. will highlight its new Deister Two-Mass Electromechanical Vibrating Feeder. Designed to allow greater control over high-capacity feed rates, it is said to lower costs per ton in a wide variety of aggregate applications. It features a machine weight that is more robust. Units incorporate a high-profile infeed lip and a heavy-duty formed deck with replaceable liners. A simplified drive is designed with an easy-access exciter frame, which houses the single vibrator motor. This results in higher bearing life and also eliminates the need to replace belts. Additionally, units feature energy-efficient pre-compressed steel transmission springs which are not susceptible to temperature or shelf life, and heavy-duty spring isolation assemblies for suspension or support mounting. The unit is available in a wide range of deck sizes and capacities and is backed with 24/7 parts and service support.

www.deistermachine.com | Booth 2404

Derrick Equipment Co.

Derrick Equipment Co. will feature its HI-G Dewatering Machine, which is said to provide the most cost-effective solution to handling fine solids separation. With its custom-designed, two-chambered sump arrangement, sand slurry pump, and plumbing/electrical requirements, Derrick’s HI-G Dewatering Machine is suitable for all applications where performance and dependability are required.

www.derrick.com | Booth 1556

Dredge Central, LLC

Dredge Central, LLC will highlight this low-hour and lightly used 12inch DSC Dredge, which is now available at DC’s facility in Tennessee.

The ladder length is 41 feet, for a maximum dredging depth of 30 feet.

The heavy-duty Metso dredge pump has 14-inch suction, 12-inch discharge, and 36-inch impeller. The diesel engine is a Cat 4312DITA and is rated 750 horsepower at 2,100 rpm. The Twin Disc reduction gear is a model MG-5202 and has a 3.48:1 reduction ratio. The cutting module is rated 90 horsepower, 0-28 rpm, with a 38-inch backring.

Hydraulic winches control the swing, ladder, and spuds.

www.dredgecentral.com | Booth 1046

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AGGREGATES MANAGER / March 2016

Dyno Nobel

Dyno Nobel will feature two of its top differentiated products, Differential Energy and DigiShot Plus, which are said to offer overall cost saving benefits to stone producers. Differential Energy features TITAN 1000rE, along with a proprietary end-of-hose gassing technology, to deliver specific densities of gassed emulsion throughout the blast hole in a single pass. This technology allows for the user to match the proper density to the geology in the ground, helping to reduce overbreak and fines. DigiShot Plus is a surface mining electronic initiation system. Besides precise electronic timing, DigiShot Plus is designed for large blasts, and its blasting boxes have the capability for remote firing with a maximum capacity of 7,200 detonators with up to 15 detonators per hole.

www.dynonobel.com | Booth 2742

Eagle Iron Works

For more than 140 years, Eagle Iron Works has offered customers reliable, easy-to-operate equipment to handle washing and classifying applications. EIW will showcase these solutions and be on hand to discuss how they can optimize an operation. Show attendees will be able to see 3-D models of Eagle Iron Works equipment, including a Dual Fines Screw Washer, EIW Mixer, Log Washer, and Water Scalping Tank.

www.eagleironworks.com | Booth 2414

Eriez

Eriez says its Heavy Duty Electromagnetic Model B Vibratory Feeders handle high volumes of aggregate materials quickly and efficiently. Besides a variety of standard trays, special trays with screens, grizzlies, dust covers, abrasion-resistant liners, heated liners, and other customizations are also available. With their energy-saving intermeshed AC/permanent magnet drive, these feeders are the workhorses in Eriez’ stable of vibratory feeders and conveyors. The feeders are available in nine models with capacities to 850 tons per hour. Models 65B, 75B, and 85B are in stock.

www.eriez.com | Booth 1651

Excel Foundry & Machine

Excel Foundry & Machine will spotlight its Super Nut jack-bolt tensioning nut. Designed for MP, Sandvik, and Gyratory-Style Crushers, it ensures precise uniform preload and eliminates the need for a torch ring. Excel says it has created a solution that is safer and faster to install and remove, while protecting the threads of the locking nut and the head. The Excel Super Nut is said to make liner changes quick, easy, and safe.

www.excelfoundry.com | Booth 1404

AGGREGATES MANAGER / March 2016

39

AGG 1 PREVIEW

Flexco

Flexco will highlight its FMS Medium-Duty Secondary Cleaner at AGG1. Made with heavy-duty steel with a corrosion-resistant powder coating, the FMS is said to be ideal for use on mining conveyors with belt speeds up to 1,000 feet per minute. It can be used for belt widths ranging from 18 inches to 72 inches, with additional sizes available upon request. The thin, hard edges of the 6-inch-wide metal blades deliver high cleaning efficiency and long wear life, while the spring tensioner ensures that there is consistent blade-to-belt interaction and constant pressure on the belt.

www.flexco.com | Booth 2941

GeoSonics/ Vibra-Tech

GeoSonics/Vibra-Tech says its Re:mote Monitoring Technology is the first fully automated monitoring system with web-based data access and smart phone apps. Re:mote continuously collects data while keeping project personnel notified through email/text. Whether an operator needs vibration, noise, dust, geotechnical, or environmental monitoring, Re:mote monitoring capabilities bring the field to them — saving operational time and resources.

www.geosonicsvibratech.com | Booth 1707

Haver & Boecker

Gilson

Gilson says its SS-21 Silent Sifter pairs industry-leading sieving performance with noise control, for accurate and quiet operation. Its patented silencing technology features noise levels 7-10dB lower than any other rotary sifter in the industry for added worker protection. This advanced unit includes a floor stand mounted on locking swivel casters for controlled mobility. www.globalgilson.com

Booth 2132

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AGGREGATES MANAGER / March 2016

Haver & Boecker will showcase its Hydro-Clean washing unit, which is said to effectively clean deleterious material from aggregate, recycled, and other minerals while reducing water consumption by as much as 75 percent compared to traditional log washers. While other washing methods require as many as three wash screens, the unit only requires producers to have one wash screen for its discharged material. The washer comes in three model sizes that process 18 to 360 tons per hour, depending on the application: the HC350, HC1000, and HC2000. As part of its ongoing focus on customer service, the company will launch a new Hydro-Clean service program during AGG1. www.havercanada.com | Booth 2822

AGG 1 PREVIEW

Irock Crushers

Irock Crushers is highlighting its TS-522 Heavy Duty Screener. This screener, one in a line of five models, is suitable for medium- to large-scale operations and is ideal in applications such as recycling, sand and gravel mining, or as a part of a crusher circuit. Built for high productivity, the screener is said to feature extra hopper capacity, class-leading screening area, and the highest stockpiling capability of any screener this size. It is powered by a 129-horsepower Caterpillar C4.4 engine and is capable of processing materials at a rate of up to 670 tons per hour.

www.irockcrushers.com | Booth 1614

John Deere

John Deere will feature its 944K Wheel Loader. Equipped with a 536-horsepower, PowerTech EPA Interim Tier 4 engine, coupled with a hybrid-electric drive, the loader is said to deliver up to 40-percent fuel savings compared to conventional drivetrains.

The hybrid-electric drive system is designed to be more dependable, and the wheel loader is an excellent choice for maintaining stockpiles and heaping hoppers in quarry operations. Brushless A/C generators and motors, water-cooled brake resistors, and solid-state power electronics deliver reliable, long-term performance. The reduced engine speed range increases wear life over conventional drives. The hybrid-electric drive recaptures energy while slowing the loader when the operator lets off the accelerator and lessening the load on the engine. www.deere.com | Booth 2622

Kemper Equipment Kemper Equipment will highlight its full-service, all-in-one supplier approach to equipment, parts, and service for the aggregates industry. The company designs and builds material handling projects, as well as upgrades crushing, screening, and conveying systems. The company says its experts work with operators to learn their specific needs in order to understand specific applications and to design the best solutions. www.kemperequipment.com | Booth 2965

Kespry

Kespry will feature its automated commercial drone solution that operates right-out-of-the-case and enables its commercial customers to collect, analyze, and share essential aerial information. To achieve high standards of safety, productivity, and reliability, Kespry controls the design of each critical component. It says this attention to integrated design and reliability provides superior efficiencies and accelerates the delivery of advanced functionality. www.kespry.com | Booth 1559

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AGGREGATES MANAGER / March 2016

Aggregate Drones

Automatically calculate aggregate stockpile volumes...

www.kespry.com/aggregates

AGG 1 PREVIEW

Kleemann/Wirtgen

Kleemann will exhibit the Mobirex MR 110 ZSi EVO 2 impact crusher at the Wirtgen booth. It is said to offer the highest technologies in aggregate production and construction materials recycling. Tier 4 final emissions compliant, it is especially well suited for processing RAP and recycled concrete aggregate (RCA). EVO 2 represents the continuing evolution of the successful EVO Contractor Line, with additional benefits in terms of economy and operational safety. The unit has a crusher inlet opening of 43.3 inches, which provides feed capacities of up to 350 tons per hour.

www.wirtgenamerica.com | Booth 2504

Komatsu America Corp.

Komatsu will showcase its WA500-7 Yard Loader, configured to use larger, flat floor buckets to load re-handled material into on-highway trucks. The loader is designed to minimize the number of passes required to load 24- to 26-ton on-highway trucks. Additionally, this machine can be used in load-and-carry or stockpile applications. It is not intended for face loading. Features include a large diameter bucket cylinder for increased bucket forces, heavier additional counterweight for increased stability and tipping loads, large diameter rims and low-profile tires for increased stability, brake cooling for use in longer distance load-and-carry applications, and full rear fenders.

www.komatsuamerica.com | Booth 3830

Joy Global

Joy Global will highlight its HD-1500 (CEMA D+) and the SDX-2200 (CEMA E+) conveyor idler rolls, which exceed load ratings for their respective CEMA class by up to 40 percent. The HD-1500 idler is rated up to 1,500 pounds, and the SDX-2200 idler is rated up to 2,200 pounds.

These increased load ratings are achieved by pairing the company’s patented engineered shaft with tapered roller bearing technology, which has a high dynamic load rating, allowing both idlers to use the complete load rating of the bearing. Adding this shaft to a ball bearing idler, common in the industry, would only decrease weight and would do nothing for increased material handling capacity or extended spacing. www.joyglobal.com | Booth 2522

Luff Industries

Struggling to remove and replace impact idlers in your load zone? Luff Industries has the answer with its removable endplate design. Said to be perfect for tight, confined spaces, the bolted end plate is easily removed from the frame. Once it is taken off, the impact rollers merely slide out without requiring any other component in the loading zone to be taken off or adjusted. It offers a quick and simple solution that could save time and lower downtime costs. www.luffindustries.com | Booth 1207

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AGGREGATES MANAGER / March 2016

McCloskey International

McCloskey International will feature its I44R recirculating impactor. It combines the productivity of a 44-inch impactor with the versatility of a full screening and recirculating system, allowing operators to produce a crushed and screened final product with one machine. New features include straighter impactor side walls for better material flow, a re-designed under pan that delivers more throw and enhanced material movement, and an all-new feed boot on the main conveyor to accommodate more material flow from the underpan.

Compact and portable, it is said to provide the level of production required to complete the project rapidly.

www.mccloskeyinternational.com

Booth 1248

Martin Engineering Co. Martin Engineering Co. will feature a solution that prevents carryback released by secondary conveyor belt cleaners from sticking to the rear slope of the discharge chute.

The Martin Vibrating Dribble Chute uses material disruption to cause sludge and fines to fall from the chute wall and back into the main discharge flow. Operators report a reduction in maintenance hours, equipment replacement, and downtime, lowering overall cost of operation. It is comprised of a low-friction polyurethane sheet, steel mounting bracket, and powerful vibrator.

www.martin-eng.com

VISIT US AT BOOTH 2214

Booth 1416

mclanahan.com

AGGREGATES MANAGER / March 2016

45

AGG 1 PREVIEW

McLanahan Corp.

McLanahan Corp. will showcase its washing and classifying, fines recovery, and water management systems, as well as its full line of safer, simpler, and smarter processing solutions. Also, the company will introduce several new pieces of equipment and innovations in crushing and screening equipment. The booth will include an array of 3-D models of McLanahan’s complete equipment range for both wet and dry processing.

www.mclanahan.com | Booth 2214

Metso Minerals Industries, Inc.

Metso will exhibit its heavy-duty Nordberg C150 jaw crusher, which it says is designed to be the leading jaw crusher in the 50-ton weight class. The unit has been developed for the most demanding large-scale mining and quarrying applications. The feed opening, with long, steep crushing cavity, allows large coarse feed material up to 40 inches in size. Metso says the Nordberg C150 is built of premium components. The main frame structure is based on unique pinned and bolted connections without welded seams. www.metso.com | Booth 1721

Philippi-Hagenbuch, Inc.

Philippi-Hagenbuch, Inc. will highlight its Aggregate HiVol Body. The truck body, developed specifically for use in quarry environments, fits on all brands of off-highway, rigid-frame haul trucks and accommodates all types and consistencies of material. Quarry applications require hauling materials with varying degrees of abrasion and cohesion, exposing trucks to severe working environments, with the rear third of the body encountering the most wear as more material passes over it in the unloading process. This disproportionate wearing can significantly shorten the longevity of the body. Aggregate HiVol Bodies are designed to match the life of the truck with options available for highly abrasive materials. The design also decreases material carryback in environments that process sticky material. www.philsystems.com | Booth 2452

Phoenix Process Equipment Co.

The Phoenix/KISA Bucket Wheel is designed for recovering, de-sliming, and dewatering sand and other granular materials. Many designs are available with the wheel diameter and bucket width determining the solids handling capacity, while the surface area of the slurry bath defines the hydraulic capacity. These Bucket Wheels are designed for solids recoveries of 99 percent-plus, with very low power requirements, even from dilute slurries such as dredger spoil. Dewatered solids are readily conveyable and stackable, having residual moistures that are considerably lower than from dewatering screws. www.dewater.com | Booth 1021

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AGGREGATES MANAGER / March 2016

Rohr-Indreco Dredge Systems Rohr-Idreco Dredge Systems will highlight its full range of deep-digging, electric suction, clamshell, and bucket ladder dredges. With more than 50 years in the industry and 400 dredges worldwide, the company says it offers a wide variety of custom solutions for an operator’s dredging requirements.

Energy efficiency and low cost of operation are key in its dredge systems. www.rohridreco.com | Booth 2759

Sandvik Construction

Sandvik Construction will showcase its QI341 mobile impact crusher, while at the same time displaying its Driller’s Office and TIM3D V2 surface drill software, Bretec breakers, and tools offering. The Sandvik QI341 was built using Sandvik’s Prisec technology. Capable of operating in primary and secondary applications, it has been designed with productivity, mobility, minimal environmental impact, and user friendliness at its core. Sandvik Driller’s Office software is a surface drilling planning and data management tool that covers drill plan design, drilling data management, and reporting.

Sandvik TIM3D V2 is a drill rig navigation system consisting of four essential operations: rig navigation, feed alignment, drilling, and reporting.

www.construction.sandvik.com | Booth 1856

Screen Machine Industries LLC

Screen Machine Industries LLC will unveil the newest addition to its extensive product line, the Spyder 514TS. This unit is a patented, track-mounted reverse style screening plant designed for secondary screening of rock, sand and gravel, and other materials. Equipped with a 5-foot x 14-foot double-deck screen with Smooth Start Technology, this heavy-duty machine is capable of producing up to three different sized finished products simultaneously. The 514TS can be used as a stand-alone screen, or in conjunction with a crusher and offers the ability to close circuit the oversized material back into the crusher for further reduction without the need for additional conveyors.

AIM FOR UPTIME The new RigScan audit program uses cutting edge tools to increase your safety and equipment availability.

We’ll identify rig problems before they sideline production.

800-732-6762 www.atlascopco.us

www.screenmachine.com

Booth 3206 AGGREGATES MANAGER / March 2016

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AGG 1 PREVIEW

Stedman Machine Co.

Stedman Machine Co. will highlight its line of size-reduction equipment, which provides access to the best equipment for the process, instead of modifying the process to fit the equipment. The manufacturer says it works with customers to determine the best, most cost-effective, efficient size-reduction method and equipment for specific applications. Stedman’s size-reduction equipment includes: Cage Mills, Grand Slam, and Mega Slam Horizontal Shaft Impactors; V-Slam Vertical Shaft Impactors; Hammer Mills; Aurora Lump Breakers; Micro-Max; and Vertical Roller Mill Air Swept Fine Grinders. Support services include system design and 24-hour parts and service.

www.stedman-machine.com | Booth 1710

Terex Minerals Processing Systems Terex Minerals Processing Systems will have its experts in its booth to highlight its latest crusher and screen updates, its many new portable plants, and its new modular line.

The company will also launch the new Terex Cedarapids CRC1150 portable cone plant. The cone plant is said to deliver big production at an affordable price. The highly mobile plant features the new TC1150 cone crusher that uses high-efficiency roller bearings and boasts several notable advancements that enhance performance and functionality.

www.terexmps.com | Booth 1013

Thor Global Enterprises Ltd. Thor Global will introduce its Hammer Axle, which, it says, cuts set-up and tear down time in half. Thor’s Fold Up Hammer Axle allows operators to switch from radial to transport mode at the push of a button. Both outriggers sit on a walking beam to provide balanced pressure to ground on unlevel terrains. The manufacturer says the axle has the widest radial footprint in the industry, providing greater structural stability. Select models have been redesigned to accommodate the Hammer Axle design. It is currently available on all 36-inch telescopic conveyors up to 150 feet. www.thorglobal.ca | Booth 2860

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AGGREGATES MANAGER / March 2016

Quality. Performance. Reliability.

Materials Testing Equipment you can depend on!

Supreme Manufacturing, Inc. Supreme Manufacturing, Inc. will highlight its product line, including floating clamshell dredges, bottom dump barges, clamshell buckets, fixed leg or radial stacking conveyor systems, floating conveyors, overland conveyors, screen supports, bins, and hoppers.

Gilson Test-Master® Testing Screens TM-5 and TM-6 • Counterbalanced drive provides a smooth, quiet operation

www.suprememfg.net

Booth 1665

• Integral hopper makes sample handling easy and efficient • Built-in digital timer offers maximum test repeatability

800.444.1508 • globalgilson.com

BEKA-MAX SYSTEMS

TAKE A THUMPIN’ & KEEP ON PUMPIN’ Superior Industries

Beka-Max auto-lube is built to take the bumps and grinds of a hard-working life on the road or off.

Give your fleet the solution that keeps them on the job.

• Cast aluminum base withstands impacts and hot/cold cycles without leaking • No springs - eccentric gear drive resists wear, fatigue and cold • Consistently precise grease dosing Find out why industries are choosing today’s best-built auto-lube systems.

Call 1.888.862.7461 or email us at info@beka-lube.com.

Superior Industries will spotlight its new Patriot Cone crusher, its first solution for bulk material processing.

Besides a commitment to service and convenient access to wear parts, its key advantages include inverted tramp relief cylinders to protect the hydraulic cylinders from contamination during operation. In addition, a tramp relief system allows fewer accumulators, which minimizes maintenance and reduces opportunity for failures. Spiral bevel gears, rather than straight tooth ones, create more efficient transfer of horsepower and less vibration.

1 . 888. 862. 746 1

www.superior-ind.com

www.beka-lube.com

Booth 2904 B E K A

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L U B R I C AT I O N

S P E C I A L I S T S

S I N C E

1 9 2 7

AGGREGATES MANAGER / March 2016 Untitled-18 1

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1/20/16 9:47 AM

Quarrying + Construction + Recycling 28 – 30 June 2016 Hillhead Quarry Buxton Derbyshire, UK

Seeing is believing...

Hillhead 2016 @hillheadshow #hillhead2016 Follow us now

www.hillhead.com

AGG 1 PREVIEW

Vulcan On-Board Scales

Vulcan On-Board Scales will showcase its dump truck weighing system, which complements an expanding line of on-board weighing systems designed to eliminate overweight fines and to help operators increase revenue by maximizing every load. The manufacturer says benefits include: maximizing every load while staying legal; saving time loading, weighing, and re-loading; options to display gross/net weight or axle weights; accuracy typically within 1 percent of gross vehicle weight; rugged load sensors in the rear hinge and on the front lift cylinder; and improve safety and reduced contingent liability. www.vulcanscales.com | Booth 2660

Weir Minerals

Weir Minerals will highlight its Durex wire screen media. For more than 50 years, Weir says the Durex wire screen media line has led the industry in innovation and excellence. Its wire cloth is said to be made from high-quality materials and manufactured for abrasion resistance and extended wear life. This allows producers to maximize uptime, alleviate unplanned downtime, and realize a lower operational cost per ton. www.weirminerals.com | Booth 2528

The PHOENIX/KISA Bucket Wheel for dewatering & classification of sand, gravel & other granular bulk materials

BOOTH #1021

Stop by & see our demo unit in Nashville!

2402 Watterson Tr, Louisville, Kentucky 40299 p: 502.499.6198 f: 502.499.1079 phoenix@dewater.com www.dewater.com

AGGREGATES MANAGER / March 2016 Untitled-14 1

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1/8/16 8:38 AM

EQUIPMENT MANAGEMENT

Crusher Bearings: Knowing the Basics Leads to

Better Care

By understanding the common bearing design types, maintenance personnel can better understand their impact on performance.

52

AGGREGATES MANAGER / March 2016

H

igh shock loads and severe contamination make rock and aggregate crushers among the toughest applications for precision components—particularly roller bearings. The harsh environments in which crushers operate present a big challenge to bearing performance and present a constant threat to long, reliable equipment life.

Keeping machine availability high and cost of ownership low in these conditions requires a commitment to proper care, including routine inspection and re-lubrication of roller bearings in compression and impact crushers. Knowing the common types of bearings used in crushing equipment can help operators and maintenance personnel understand how different designs impact performance.

Compression crushers In compression crushers, high startup torque, shock loads, and vibration demand high-performing anti-friction bearings that can operate reliably with minimal heat generation.

Jaw crushers. Most operations prefer jaw crushers for primary crushing. A large feed opening allows these crushers to receive larger-sized material than most other types of machines. Bearing speeds and loads are generally moderate, but, on occasion, the load spikes as uncrushable material passes through the chamber.

In a typical jaw crusher, two outer bearings located on either side of the main frame support an eccentric shaft, while two inner bearings support a moveable jaw. These are commonly known as “pitman” bearings. The reciprocating motion of the shaft moves the pitman against a second, stationary jaw. As material reaches the bottom of the chamber, it fractures as it becomes wedged between the jaws.

Jaw crushers typically use spherical roller bearings, chosen for their ability to manage high radial loads and the presence of misalignment. Spherical roller bearings self-align and, thus, better compensate for shaft deflections and seat misalignment.

Cone crushers. Cone or gyratory

CRUSHER BEARINGS: QUICK REFERENCE JAW CRUSHERS

CONE CRUSHERS

HAMMER MILLS AND VERTICAL AND HORIZONTAL IMPACTORS

TYPICAL MACHINE LIFE

10-30 years

20-30 years

20 years

TARGET BEARING LIFE

2-10 years

6-10 years

2-10 years

COMMON BEARING TYPES

Spherical

Radial Cylindrical, Tapered Thrust, Cylindrical Thrust

Spherical, Spherical Housed Units

Main: 22, 32 or 33 series

Upper/Lower Radial: Cylindrical

Hammer Mill: 23 and 32 series/housed

(100-500 mm; straight/tapered bore)

(230-475 mm; straight bore)

(100-500 mm; tapered bore preferred)

Eccentric (Pitman): 31 or 32 series

Upper Thrust: Tapered Thrust (430-970 mm)

(100-400 mm; straight/tapered bore)

(100-500 mm; straight bore)

Lower Thrust: Cylindrical Thrust (430-970 mm)

Horizontal Shaft: 31 and 32 series/housed Vertical Shaft: 22 and 23 series

(100-400 mm; straight/tapered bore)

Pinion Shaft: Tapered (55-130 mm)

Typical equipment performance based on customer experience and field knowledge.

crushers use a variety of specialized bearings specifically designed for each model. Like jaw crushers, these machines — common in primary, secondary, and tertiary crushing circuits — also operate at moderate speeds under heavy loads and experience significant load spikes.

In a standard cone crusher, the main shaft is housed in a frame attached to a mantle. A pinion (counter) shaft assembly drives a bevel gear that rotates the cone. As material presses against the bowl liner by the mantle or cone, it is crushed into smaller pieces that fall through to the bottom.

Most cone crushers have two radial bearings and two axial bearings. The radial bearings are most commonly special cylindrical roller bearing designs, featuring two rollers per pocket with differing roller lengths. The axial bearings typically combine a tapered thrust bearing and cylindrical thrust bearing.

Impact crushers Hammer mills and vertical and horizontal impact crushers. Secondary crushing circuits commonly use hammer mills and vertical and horizontal impact crushers and experience high rotational speeds and variable loading conditions. They tend to use spherical roller bearings for flexibility and to accommodate misalignment.

In hammer mills and horizontal

crushers, spherical roller bearings in solid or split pillow block housings generally support the impactor shaft on both sides. Spherical roller bearings are a common choice because of their ability to handle the combination of radial loads and shaft misalignment that occurs during crushing.

Pillow blocks protect bearings from contaminants and provide support for the bearing during the crusher operation. Pillow block bearings are often lubricated; the grease provides lubrication for the bearing and a layer of protection for external contamination.

Better bearing care If operators must frequently replace damaged bearings or suspect they simply are not getting the life out of their bearings that they expect, a few simple steps to follow and options to explore can improve the performance and uptime of machines in crushing circuits.

Lubrication. Poor lubrication is a leading cause of bearing failure in most industrial applications including crushers. A proper re-lubrication schedule is critical to maintain appropriate bearing operating temperatures, which affect lubricant viscosity and life. As a general rule, a lubricant should maintain a minimum viscosity of 105 SUS (21.8 cSt) at the bearing operating temperature.

In most cases, the OEM collaborates AGGREGATES MANAGER / March 2016

53

RISING STAR?

2016 NSSGA Young Leaders Annual Meeting | JW Marriott | Austin, Texas

The 2016 NSSGA Young Leaders Annual Meeting in Austin, Texas will shine with a lineup of the industry’s stars: Hal F. Williford Jr., President & CEO, Memphis Sand & Gravel Co. Karl Watson Jr., President, CEMEX USA Mark Helm, President, Dolese Bros. Co. Jon Morrish, President & CEO, Lehigh Hanson, Inc. Richard Szecsy, President, TACA Michael W. Johnson, President & CEO, NSSGA

REGISTRATION

NOW OPEN! 2016 NSSGA Young Leaders Annual Meeting

April 27 – 30, 2016 Austin, Texas

Young Leaders in the industry will have the opportunity to tour one of the first quarries in the state of Texas to implement a dry dust-suppression system, reducing water usage by 80%. Industrial Asphalt’s KBDJ Conservation Land & Quarry (Summit Materials) is an Austin, Texas-based mining company committed to protecting the environment.

This is one event every rising star in your organization should attend.

For more information and to register, visit nssga.org or contact Shannon Grace at 800-342-1415 ext. 1072 or email sgrace@nssga.org.

www.nssga.org

EQUIPMENT MANAGEMENT

Figure 1. Cylindrical, tapered, thrust, and plain bearings can all be commonly found in a cone crusher.

— or days — of unscheduled downtime.

Bearing fit on shaft and in housing.

Proper fitting of roller bearings to shafts and in housings is also critical to performance. If the fit is too tight or too loose, problems, including creep, excessive vibration, and premature failure may occur.

Recommended fit values should be re-visited each time crusher bearings are replaced or repaired. For instance, a shaft that has been reused repeatedly can be slightly smaller than the day the machine was commissioned. An undersized shaft — even at extremely small scales — can cause improper bearing fit and cause premature bearing failure.

Also, over time, bearing housings can

Figure 2: Common bearing damage modes.

with the bearing manufacturer to develop a recommended re-lubrication schedule. Operators and maintainers should follow the OEM re-lubrication schedule to help maximize the bearing life.

They also should take further care not to over-lubricate bearings. In grease lubrication systems, over-greasing can lead to excessive heat generation from lubricant churning. The excessive heat breaks down the lubrication and can cause premature bearing failure.

Mixing different greases or other lubricants should also be avoided, as this can result in breakdowns and may cause premature failure. To ensure that re-lubrication practices remain on point, one call to a qualified expert can save hours

get worn or become out of round. Both conditions can cause improper bearing support and premature failure.

If concerns about proper shaft and housing dimensions arise, operators should consult an expert to evaluate the proper bearing shaft and housing fits.

Damage analysis. Upon replacement, thorough bearing inspection can uncover issues with the shaft or housing fits, lubrication or re-lubrication activity, or contamination from poor sealing. Conducting an in-depth bearing inspection and determining the failure mode provides the opportunity to address the root cause of the bearing failure, helping to improve bearing performance with a replacement.

Crusher bearing damage often relates to contamination, improper lubrication, and fretting (metal-to-metal wear). Refer to Figure 2 to identify common modes: • Abrasive wear and debris denting are two of the most common damage modes caused by contamination.

Typically, abrasive wear appears frosty gray [A]. Debris particles also can dent the surface of the races and rollers [B], which can lead to spalling damage. Frequent re-lubrication helps to purge contamination from the bearing. Persistent contamination problems could be a sign of improper sealing.

• Inadequate lubrication can be caused by improper viscosity, too little or too much lubricant, or lubricant breakdown. Inadequate lubrication can result in fine grain spalling [C], heat damage [D], and oxidized lubricant staining [E].

• Fretting or fretting corrosion normally affects the bore [F] or the outer diameter of a bearing. It typically results from a loose fit, leading to relative motion between the bearing and the shaft or housing. Corrosion that results from fretting should be removed from the bearing area because it is abrasive and will damage the bearings and seals. Using the proper shaft and housing fits should minimize the amount of fretting damage to the bearing.

Training. Often, problems with bearing performance stem from insufficient on-the-job training or repeated misinformation. Both bearing suppliers and OEMs often offer on-site learning and training opportunities. An annual refresher, including proper fitting and care, proper sealing, and lubrication, can benefit even the most seasoned personnel.

Given the demanding life of crushers, proper maintenance practices, including re-lubrication and a committed inspection schedule, can greatly extend the life of roller bearings and machine reliability. AM

Article courtesy of The Timken Co.

AGGREGATES MANAGER / March 2016

55

by Benjamin J. Ross

ROCKLAW Settling MSHA Cases Through Mediation Consider these tips to successfully navigating a mediator-led negotiation.

H

Benjamin J. Ross is an associate in Jackson Kelly PLLC’s Denver office, practicing in the Occupational Safety and Health Practice Group. He can be reached at 303-390-0026 or bross@jacksonkelly.com.

56

earings before the Federal Mine Safety and Health Review Commission to resolve alleged violations issued by the Mine Safety and Health Administration (MSHA) are time consuming and costly, and have uncertainty in their outcome. Either the operator pays counsel for representation at the hearing, or it uses valuable time and effort to represent itself.

Either way, the judge determines the outcome of a hearing. The vast majority of cases assigned to Commission judges, however, do not go to hearing. Rather, the mine operator and MSHA, usually both represented by counsel, negotiate and agree to a settlement.

The assigned judge is never involved in settlement discussion directly, but a judge may appoint a third party mediator to help MSHA and the mine operator reach a settlement. The mediator is not an independent operative paid by the parties; the mediator is an attorney that the Commission employs.

There are mediators in the Commission’s Washington, D.C. headquarters and attorney advisors who advise judges in Washington, D.C., Pittsburgh, and Denver act as mediators.

In some cases, another Commission judge will act as a mediator.

Mediator assignment Most cases do not involve mediators, and the parties do not have a right to their services;

AGGREGATES MANAGER / March 2016

judges assign mediators at their discretion.

Sometimes, a judge will assign a mediator without input from the parties because the judge believes doing so will resolve a case.

Judges will sometimes, however, assign a mediator at the request of the parties. This request should be supported by both parties or the judge is unlikely to agree. A formal motion is generally not required; the parties can request a mediator via email or during a conference call with the judge. The judge is more likely to grant such a request if the parties demonstrate that they have discussed settlement, desire to settle the case, and believe that a mediator may facilitate that settlement.

Some judges, furthermore, include information about requesting a mediator in their Prehearing Order. Parties should always review a Prehearing Order, and doing so before requesting a mediator is critical. If the Prehearing Order has no information about mediation, contact the judge’s attorney advisor or law clerk to ask how the judge assigns mediators.

Mediator role Once assigned, each mediator uses a different process based upon the mediator, the judge, the parties, and the case at issue. There are commonalities, however, between most mediations. The mediator is a neutral third

party who does not represent either the operator or MSHA. The mediator’s goal is to settle the case. Some mediators will require the parties to sign a mediation agreement that states the parameters of the mediation, describes the role of the mediator, and requires the parties to state that they agree to mediation and desire to settle the case. Some mediators will simply explain these topics via telephone or email and ask the parties to agree informally.

All the communication or information given to a mediator is confidential; the mediator cannot share the information with the judge or the opposing party without consent of the disclosing party. The mediator should explain the confidentiality requirements of their role in the initial call or the mediation agreement. If the mediator does not address confidentiality, the parties should ask about it.

The mediator does not have the authority to impose a binding settlement agreement upon the parties. Instead, the mediator helps the parties reach an agreement that both are willing to accept. The mediator may lead discussions between the parties to induce settlement and resolve disputes, may relay offers from one party to the other, or may suggest settlement terms.

The most useful service a Commission mediator supplies is knowledgeable, third party insight into the case.

Commission mediators specialize in Mine Safety and Health Law and have intimate knowledge of how the assigned judge applies that law. Mediators use this knowledge to advise the parties how the judge would likely decide the case at issue after a hearing. Sometimes mediators will openly present to both parties how they believe the judge would rule and suggest a reasonable settlement agreement based upon that information. Other times, the mediator will evaluate the strengths and weaknesses of each party’s argument with only that party present.

Tips I have acted as a mediator for Commission judges in dozens of cases and also received training as a private mediator of general disputes. As well, I have discussed the parameters, process, and strategies of mediation with Commission mediators and judges. Based on this experience, here are a few tips about the Commission’s mediation process:

• A mediator can be most helpful when the parties have a poor relationship, the operator is unrepresented, the parties believe an outside opinion would force settlement, or if one party insists upon an unreasonable outcome that the judge is unlikely to award. If you reach an impasse in settlement discussions and any of these situations exist, consider requesting the help of a mediator. Remember: since a mediator’s decisions are not binding, both parties must endorse the mediation.

• Be honest with the mediator. Explain the situation, state why you disagree with the disputed issues, and be clear about what you want out of a settlement. Do not give the mediator only your “opening offer” for settlement with MSHA; tell the mediator the bottom line as well as what your opening offer is. If both parties disclose this information to the mediator, the process will be faster and easier for everyone involved.

• Ask questions of the mediator. Think of the mediator as free legal advice. The mediator may not represent you, but they can give insight into the judge’s thinking and explain the law and its application to your case. If you want an evaluation of your position or both parties would like the mediator to give their opinion about the outcome of the case, you should ask the mediator for these things. Once the judge assigns a mediator, utilize the mediator.

• Using a mediator may also make the judge more receptive to any extension requests made by the parties.

Most Commission mediations occur over the phone, although some instances, such as a large, global settlement of multiple dockets, may warrant an in-person mediation.

Private mediators are often not lawyers and may ask questions that lead parties to a resolution. However, they are trained to refrain from giving their advice or opinion because their advice or opinion on legal issues would often be counter-productive. If the parties to a Commission proceeding desire a third-party mediator, they should seek a Commission mediator with knowledge of the subject. If you represent your company or if you are an attorney representing a mine operator, consider requesting a mediator when the parties reach an impasse in settlement negotiations; it may save you the cost and aggravation of a hearing. AM AGGREGATES MANAGER / March 2016

57

ADINDEX March 2016

Advertiser

Web

2016 NSSGA AGG1 Aggregates Expo

www.agg1.org

ASGCO

www.asgco.com

41

Atlas Copco Construction Mining Technology

www.atlascopco.us

47

Beka-Max of America, Inc.

www.beka-lube.com

49

Bill Langer - Research Geologist

www.researchgeologist.com

59

C.L. Dews & Sons Foundry

www.dewsfoundry.com

59

CDE Global, Ltd.

www.cdeusa.com

19

CWW Conveyor Systems, LLC

www.cwwconveyors.com

Elrus Aggregate System

www.elrus.com

FMI Corp.

www.fminet.com

20

37 IBC 4

Freightliner Trucks

www.freightlinertrucks.com/Tex-Mix

Gilson Company, Inc.

www.globalgilson.com

49

Hazemag USA, Inc.

www.hazemag.com

28

Hillhead 2016

www.hillhead.com

50

John Deere Construction Equipment

www.johndeere.com/big

Kespry, Inc.

www.kespry.com/aggregates

KPI-JCI and Astec Mobile Screens

www.kpijci.com

27

Kruse Integration

www.kruseintegration.com

59

Laser Technology, Inc.

www.lasertech.com/aggmc

23

McLanahan Corp.

www.mclanahan.com

45

Midwestern Industries

www.midwesternind.com

36

NSSGA Young Leaders

www.nssga.org

54

PHOENIX Processing Equipment Co.

www.dewater.com

51

Polydeck Screen Corp.

www.polydeckscreen.com

11

Progressive Commercial Insurance

www.progressivecommercial.com

10

Pugmill Systems, Inc.

www.pugmillsystems.com

59

Rice Lake Weighing Systems

www.ricelake.com/truckscales

BC

SDLG North America

www.sdlgna.com

15

Stedman Machine Co.

www.stedman-machine.com/impact

59

Stockpile Reports

www.stockpilereports.com

51

Terex Minerals Processing Systems

www.terexmps.com

33

Volvo Construction Equipment

www.volvoce.com/smartfuel

This index is provided as a service. The publisher does not assume any liability for errors or omissions.

58

Page

AGGREGATES MANAGER / March 2016

IFC-1

8 43

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To advertise here call

WEAR PARTS

CALL 1.877.339.7339

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CL Dews_AGRM0113_PG.indd 1

12/12/12 3:43 PM

Experience: Retired November 2011 following 41 years with the U.S. Geological Survey

New 300 tph

• 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.

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12/16/14 1:21 PM

59

CARVED IN STONE

Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at Bill_Langer@hotmail.com

The Eye of the Sahara Long used as a landmark by space crews, this 5-mile rock formation is likely the remains of a geologic dome.

A

while back, I was involved in a mineral resource appraisal of the Islamic Republic of Mauritania, a country in northwestern Africa. My role was to describe the geology and market potential for development of about 15 industrial minerals including two of my favorites — aggregate and dimension stone.

Mauritania has about 4,760 miles of roadways, 540 miles of which are paved. The roads, particularly those in the countryside, are dilapidated, and the extreme desert climate makes maintenance difficult. Road construction is a top priority for the government.

Unfortunately, Mauritania has a real problem finding sources of quality aggregate.

There is plenty of sand; not much gravel. And although there are a number of rocks that may be suitable for use as crushed stone, many are not near population centers where the aggregate is needed.

Dimension stone is another story. There is a railroad line for carrying iron ore from the mines at Zouérat to the port at Nouadhibou.

Some potential sources of dimension stone occur near the rail line. If space can be made available on the rail line, dimension stone might be marketable. I think some of the A quarry in the lava near the Glasshouse Mountains with Mount Tibrogargan in the background. rocks are downright gorgeous. Of course, the attractiveness of any particular rock considered for use as dimension stone is subjective and can be best explained as being “in the eye of the beholder.”

And speaking of the eye of the beholder, let’s get to the real topic of this article — the “Eye of the Sahara.” While that moniker might sound like the sequel to the adventure movie Romancing the Stone, it’s not. The Eye of the Sahara is a massive, 25-mile diameter circular rock formation that stands out in the desert (and on the geologic map I was using) like a target. It is easier seen from above than from the ground and has long been a landmark for space crews.

The Eye was once thought to be the result of a meteorite impact. However, it lacks shattered glass or shocked quartz associated with high-energy impact craters. A subsequent theory is that it is a volcanic caldera, but the area lacks any of the defining characteristic of volcanoes.

The reigning theory at the moment is that the Eye of the Sahara is the result of differential erosion of a geologic dome.

About 100 million years ago, as the supercontinent Pangaea broke up and the Atlantic Ocean opened up, an intrusion of magma slowly pushed up from the earth’s mantle into the crust, creating a dome.

Over millions of years, the dome slowly shed layers of rock under the erosive power of wind-blown sand. Resistant quartzite beds mark the rings as high ridges while less resistive beds eroded into valleys.

Today, the geologic feature is exposed as a relatively flat cross-sectional bulls-eye with the oldest rocks peeking out of the center with younger rocks occurring as rings getting progressively younger as one moves outward from the center of the Eye. This NASA photo clearly shows the high, circular quartzite ridges and low soft-rock valleys. The yellow areas on the left are windblown sand. Vegetation in the drainage channels is green, and blue shows areas of temporarily ponded water.

I suspect it is unlikely you will ever fly over the Eye in a spacecraft. Instead, try visiting it via Google Earth. In the search box enter the coordinates 21 08’, -11 24’. Zoom out to an eye altitude of 50 miles.

How cool is that!

60

AGGREGATES MANAGER / March 2016

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