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May 2014

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Tips and tricks to select the right mobile screener Six steps to building better berms ALJs offer alternate opinions on pre-shift exams and MSHA inspections

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On Our Cover: New excavators offer options for your material handling.

Cover photo by Frank L. Junior.

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When considering what portable screen machine best suits the needs of your operation, consider factors such as throughput, number of screen decks, and deck options.

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Terex’s CFJ3750 plant combines a JS Series jaw crusher with a 52-inch by 20-foot vibrating grizzly feeder to create a high-production portable crusher.

CONTENTS MAY 2014

VOLUME 19, NUMBER 5

FEATURE ARTICLES

6 15

Screeners 101: Sifting Through the Facts

Tips and tricks to select the right mobile screener.

Excavator Options

A bevy of new excavators round out existing offerings in this equipment category.

WEB EXCLUSIVES Visit www.aggman.com for expanded editorial coverage.

Mind Over Media Maintain the right mindset in synthetic screen media maintenance and efficiency.

OPERATIONS ILLUSTRATED

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Building Better Berms

From material height to travelways to drainage, there is more to building a proper berm than dumping some stone alongside the road.

COLUMNS & DEPARTMENTS

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EDITORIAL A merger of equals.

AND PROVINCE NEWS A roundup of the latest news in North 4 STATE America.

Terex Cedarapids’ CFJ3750 portable crusher, and other new equipment 24 ROLLOUTS for the aggregate market.

MINING The latest financial 31 DATA analysis of issues impacting in the industry.

LAW Administrative law judges take different viewpoints on pre-shift examinations 33 ROCK and MSHA inspections.

ADS Aggregate industry classifieds.

36 CLASSIFIED INDEX See who’s who and where to find their products.

38 ADVERTISER IN STONE The trek along Route 66 travels through the small oil towns of 40 CARVED Oklahoma.

Experience the Progress.

Liebherr Crawler Excavator Stage IIIB/Tier 4i.  New maintenance concept for reduced downtime and increased efficiency  Excellent cab-comfort and layout for reduced operator fatigue and increased productivity  Rugged design for demanding applications and increased reliability

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The Group

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

May 2014

Vol. 19, No. 5

aggman.com /AggregatesManager @AggMan_editor

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

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

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by Randall-Reilly Publishing Company copyright 2014. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406.

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Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 707.4.12.5); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

A MERGER OF Equals

A

s we wait for Martin Marietta’s acquisition of Texas Industries to clear regulatory approval, another industry merger is set to change the face of the construction materials market — both domestically and globally. On April 7, the leadership teams at Holcim and Lafarge announced plans for a “merger of equals.”

According to a joint press release issued the day of the announcement, the combined company, known as LafargeHolcim, “would have an enhanced presence in the global building materials sector with a number one position globally across cement, concrete, and aggregates and new opportunities to optimize production and commercial networks.”

Weeks prior to the announcement, each company released its 2013 annual business results. Combined, the two companies produced or sold 275.7 million tons of cement and 346.3 million tons of aggregates.

In terms of domestic production, U.S. Geological Survey rankings of U.S. aggregate producers recently listed Lafarge North America Inc. as the sixth largest U.S. producer, while Holcim Group/Aggregate Industries fell just below as the seventh largest producer.

Those ratings are based on 2012 production. Since that time, Lafarge has steadily divested a number of its aggregate operations.

• In September 2012, it sold cement, concrete, and aggregate assets in Missouri and Oklahoma to Eagle Materials for $446 million.

• In January 2013, it sold six quarries in Georgia for $160 million.

• In June 2013, it sold its North American Gypsum subsidiary to an affiliate of Lone Star Funds for $700 million.

• In January 2014, it sold five quarries and related assets in Maryland to Bluegrass Materials for $320 million.

The aggregate assets retained by Lafarge are largely centered around the Great Lakes region, where there is little overlap with Holcim’s aggregates operations. To clear antitrust hurdles, the companies say they plan to sell additional assets valued at approximately $6.9 million, but two-thirds of those divestments are likely to occur in Europe.

While production — particularly cement — will likely remain over capacity as assets are sold to competitors to avoid market monopolies, the combined company touted its ability to offer best-in-class R&D, and this might be the deal’s biggest impact on the construction materials industry.

The Economist reports that the two companies “reckon they have enough firepower to make cement less like a commodity and their business more like a service.” By offering high-margin products and consultative services to construction firms, it says, LafargeHolcim “may prove far more profitable than just selling cement by the bag.”

Product differentiation is an area currently being explored by aggregate, as well as cement, producers. If this “merger of equals” moves construction materials away from the commodity mindset, it may prove of value to the industry as a whole.

AGGREGATES MANAGER May 2014

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State & Province

NEWS by

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

Alabama

Kane Barker, an assistant professor of chemistry and chair of the Department of Natural Sciences at Shorter University, received the 2013-14 Vulcan Materials Teaching Excellence and Campus Leadership Award. CVN News reports that the $1,000 award is given to a junior faculty member who displays strong campus leadership, creative course development, pioneering teaching methodology, and instruction support, along with model classroom teaching. The professor must also be helpful in advising students and illustrate a willingness to spend individual time with students to assist them academically. Barker holds a Ph.D. in analytical chemistry from Georgia Tech and teaches chemistry, quantitative analysis, instrumental analysis, inorganic chemistry, and scientific literacy.

To keep up to date with this breakdown of news in the United States and Canada, visit www.AggMan.com for daily updates.

Connecticut

According to myrecordjournal.com, York Hill Trap Rock Quarry Co. has received tentative approval for a permit to discharge storm water runoff from its mining activities into Harbor Brook, as well as groundwater in the Quinnipiac River watershed. Flood Control Implementation Agency Chairman Phil Ashton told the news agency that it was a “normal permit” needed because sediment could run into the brook. He added, “I’d be more concerned from the (sand) and runoff from the streets.”

Georgia

Flowery Branch City Council unanimously approved the 41-acre expansion of Vulcan Material Co.’s quarry.

AccessNorthGa.com reports that all parties were able to resolve concerns regarding the impact of zoning and annexation of adjacent properties in order to facilitate the agreement. Mayor Mike Miller told the news outlet that Vulcan committed to make additional efforts to beautify the corridor along Hog Mountain Road so that residents would not feel a negative impact from the expansion.

California

The South Coast Air Quality Management District installed a new air quality station on the grounds of Valley View Elementary School in Duarte. According to The Pasadena Star-News, the station will monitor PM10 particles near the boundary between the school and Vulcan Materials Co.’s operation. The city of Duarte previously spent $750,000 to bar the neighboring community of Azusa from allowing the operations to be moved to the location. Barbara Goodrich-Welk, Vulcan’s manager of external affairs, told the newspaper that the project’s emissions are “below AQMD thresholds established to govern air quality,” but understood residents’ concerns.

“We applaud the city of Duarte for monitoring and working with the AQMD,” she said, “and we are confident in our operations and the environmental management systems we’ve put in place to safeguard human health.”

Colorado

Martin Marietta’s acquisition of former Lafarge operations in Colorado appears to be yielding strong dividends. The Coloradoan.com reports that its study of funds collected through the Keep Fort Collins Great Tax, a .85-percent sales tax approved in 2010, shows that the company received almost $10 million in contracts for street work throughout the city. To date, $21.5 million have been spent on street maintenance and repair work. Road improvements were a top priority for funds generated by the voterapproved measure. To date, the city has collected $65 million and anticipates proceeds of approximately $240 million over its 10-year life.

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AGGREGATES MANAGER May 2014

Idaho

An April fire at a site in Star damaged three semi trucks belonging Idaho Sand and Gravel. According to KTVB.com, the company had 17 trucks at the site when the fire broke out. Investigators found no evidence of arson. All signs pointed to an electrical issue in the cab of one of the trucks.

An Idaho Sand and Gravel employee said the fire caused more than $500,000 in damage.

Maine

Hughes Brothers is suing the town of Eddington over a moratorium that would impact its plans for a quarry there.

WABI TV5 reports the operator applied for a permit last fall.

Janet Hughes, the company’s environmental manager, told the television station that the planning board assured them that a initiative on future quarry applications would not affect them, but then held a secret session which changed the moratorium — making it retroactive for 180 days. On April 8, voters approved the moratorium. Hughes told reporters that the town would be better off to allow it to move forward with the permit it requested; otherwise, it would have to proceed with plans for a smaller operation that is closer to houses.

Michigan

New York

Actor Jeff Daniels is speaking out against ready-mix producer McCoig Materials’ effort to open a mine north of Chelsea. Radio station 89.1 WEMU hosted Dr. Lynn Walter, professor emerita of geology at the University of Michigan, to discuss environmental impacts of sand mining on its program, Issues of the Environment. The radio station’s website reports that the mine would be located on land owned by the Donald and Janet L. Cunningham Trust. It reported that a state law, Act 110, says, “an ordinance shall not prevent the extraction, by mining, of valuable natural resources from any property unless very serious consequences would result from the extraction of those natural resources.”

Five men were arrested for riding motorcycles in a sand bank in Schaghticoke. The Record notes that the five — Angelo Losavio, Shane Stiles, Shane Dominy, Nicholas Slish, and Joshua Coreno — were riding on stockpiles of mason sand at the Fane sand and gravel bank and causing material contamination. Each was charged with criminal trespass and criminal mischief.

North Carolina

Missouri

Hunt Midwest Enterprises Inc. announced that it sold its interest in Hunt Martin Materials LLC to its joint venture partner, Martin Marietta Materials Inc. Kansas City Business Journal described the joint venture as the region’s largest supplier of crushed limestone. The business includes 40 locations with 16 fixed and portable plants. “This sale is a strategic reallocation of resources to continue the expansion of our real estate development activities and geographic reach of Hunt Midwest Real Estate Development Inc.,” Don Hagan, CFO for Hunt Midwest, told the news outlet.

Martin Marietta Materials earned the top aggregates producer slot in InformationWeek’s “Elite 100” list, which ranks the nation’s most innovative users of business technology by evaluating “core areas of operations, including technology deployment, IT budgets, businesstechnology infrastructure, and IT strategies.” The magazine considers companies with a minimum of $250 million in annual revenue.

According to the Triangle Business Journal, Martin Marietta was recognized for creating an automated weighing and payment system that allows some of its quarries to run with no ticketing staff.

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5

Screeners 101:

Sifting through the

Facts

Tips and tricks to select the right mobile screener.

by Sean Donaghy

6

Y

ou get out what you put in. While this old saying is true with most projects, jobs, or life challenges, it couldn’t be further from the truth in the screening business.

In a screening operation, producers need to separate the dirt from the stone and size it into a sellable product. Ultimately, you need to separate the good from the bad to find your profit.

Portable screening plants are a major part of the business for aggregate producers, road builders, and contractors in rock mining, quarry, demolition, and recycling

AGGREGATES MANAGER May 2014

operations. These screeners separate all kinds of valuable materials from waste, so they can be recycled and repurposed for use in a range of applications.

Any producer can tell you how important quality screeners are to a business, but what’s right for one producer may not fit the bill for the next. And, while it seems the only thing separating one mobile screener from another is the color and a logo, there are a multitude of factors to sift through, from overall type and size to small, highly customized design modifications. With new technologies and

development of advanced screen media, producers need to do their research and take advantage of the ever-growing options and choices.

Selecting the right screener takes time, research, and a clear idea of the goals of the operation.

Size it up

The first step to selecting a screener is to consider whether the company’s production has been maxed out or will continue to grow, because there’s nothing more important than sizing the equipment to match the operation.

Understanding the application,

TECHNOLOGY

Higher stockpiling capabilities serve as a time saver, as producers can run for longer periods of time without having to move material.

materials, and desired production is crucial.

With plenty of research and consideration of desired production, size and abrasiveness of material, as well as the number of end size products, a producer can find welloutfitted screeners that align with the goals of the operation.

Keep the company’s goals in mind during the selection process. Calculate projected annual sales and break the number down to tonnages per month. For example, if a company can sell 750,000 tons per year, its screeners need to sort 62,500 tons per month. If the screener is in operation three days per week (approximately 13 days per month), 8 hours per day, the operation will require a machine capable of screening

around 600 tons per hour.

This rate is key to the success of a business. In the previous example, a screener that processes 300 tons per hour limits profits and caps the company’s growth potential. On the other hand, a machine with a potential output of 900 tons per hour likely will come with extra expenses but no added value.

Another factor to keep in mind is the end product. The majority of machines are twodeck screeners capable of sorting two sized products and an oversize product. Others feature three deck screens that produce an additional sized product.

Also consider that screen boxes vary in size and design. For example, a few screen-

er/scalpers will be labeled “high energy.”

What exactly does it mean, and what is the benefit? A high-energy screen box runs faster and produces a higher stroke than a standard screen box. Many customers notice that the more efficient, lively stroke boosts a machine’s output and produces a cleaner product in comparison to a standard screen box. Be on the lookout for these standout features, and determine what is best for your organization before looking any further into the details.

Scalp or screen

There are two main types of screeners: scalpers and standard screens. Several main differences separate a scalping plant AGGREGATES MANAGER May 2014

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ideal choice for creating a finished product — especially when the producer needs smaller materials to meet specifications.

In fact, scalping screening plants are commonly used to process scrap metals, separate recyclables at old slag dumps, and extract rock from dirt on a construction site.

Afterward, producers pull in a standard screen to perform the meticulous work.

While these units have their differences, the style of screener isn’t the only factor one must consider. Plenty of other little factors can make a big difference.

Hopper size The optional apron feeder, a belt made of metal, is for producers working with large or abrasive material.

The standard belt feeder is suitable for sand and gravel operations. It is cost efficient and will hold up well in numerous applications.

from a standard screening plant. Standard screens have a tipping grid or livehead over the feed hopper to stop large material from going into the hopper. The feeder belt speed can also be adjusted in order to help produce a clean, sized finished product. These screens are at home in a sand and gravel pit, a quarry, and recycled concrete and asphalt jobs, as they often are considered “finishing screens” because they’re capable of producing specific sized end products.

For applications that aren’t all about

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AGGREGATES MANAGER May 2014

the specific sizes, there is another option.

A scalping screening plant feeds material directly onto a screen as it comes out of the hopper, which eliminates blockages due to oversized, contaminated, and dirty material. The machine is ideal for demolition contractors preprocessing materials like recycled concrete or reclamation applications. Scalping screening plants also are designed to handle much larger, heavier material in larger crushing operations or for producing a gabion stone in a quarry. They are versatile, but aren’t an

Let’s start where the tough gets going — the hopper. This portion of a screener fluctuates in size and durability. The industry standard hopper is 12 feet wide with an option to upgrade to a 14-footwide hopper. Very few manufacturers offer a 14-foot-wide hopper off the bat, but a wider hopper is more important than one might realize.

Obviously, the wider the hopper, the easier it is to feed the machine. Just an extra 2 feet can capture more product and prevent spillage. The size becomes most pertinent when pairing the screener with the loading machine. For example, excavators or equipment with a narrow bucket are ideal for loading a 12-foot hopper, but a 14-foot hopper is wide enough to accommodate a wider bucket. By comparison, a wheel loader bucket can hold approximately twice as much as an excavator bucket. The extra 2 feet of loading space makes a huge difference, so using a wheel loader is a simple way for a company to pick up extra production.

Livehead and tipping grid

Producers can add a livehead or tipping grid to a screener above the hopper.

While they perform a similar duty, they are very different. A tipping grid is the

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Consider the number of decks on a potential screener. A three-deck screen offers an option to produce an additional product compared to more common two-deck units.

appropriate solution for preventing larger materials from traveling into the hopper and through the screener. This hinged grid catches larger materials, and producers can clear them by manually tipping the grid via a remote control. Although this is an affordable option, it can become a chore, particularly in wet or dirty applications where the tipping grid may become plugged frequently.

The other option, a livehead, is essentially a vibrating screen that attaches to the hopper. This piece of equipment is suitable for heavy-duty applications with dirty, wet, and/or sticky material. The unit can be used for two purposes: to scalp dirty material off and eliminate the need for manual cleaning or to size material going into the machine so producers can produce an additional sized product.

Although these units are designed to boost production and create an additional product, they become a hindrance if used in the wrong application. These are built with thick bars that limit the open area, so operations processing finer materials might discover material on the ground

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AGGREGATES MANAGER May 2014

that should have been in the hopper.

Further, screeners with 14-foot hoppers would not be used to the full potential, as the livehead measures 12 feet, leaving 2 feet of the hopper unusable.

Apron feeder vs. belt feeder

From the hopper, material is fed onto a standard belt feeder. The standard belt feeder works well for sand and gravel operations. It is cost efficient and will hold up well in numerous applications. However, for producers working with metal, large rock, or any abrasive material, a standard belt feeder is likely to tear or break. These more heavy-duty applications require an apron feeder, which is essentially a belt made of metal.

Screen media

It seems there are just as many types of screen media as there are materials to screen. Most screens feature a typical wire mesh screen media for different sizing applications. However, there are a few heartier options for producers working

with abrasive materials.

First, operations working with abrasive materials may want to consider stainless steel as an alternative to regular wire mesh.

Although the cost is nearly twice as much, stainless steel offers a higher wear resistance and longer wear life that is worth the extra cost.

Another replacement for the standard screen for certain scalping jobs is bofar bars.

Bofar bars, formed of long bars with spaces between, are designed for materials such as recycled concrete that commonly contain a lot of dirt and miscellaneous material.

Although bofar bars do a certain amount of sizing, the process doesn’t necessarily end with thoroughly sorted product.

Punch plates are another option. These plates are essentially a piece of sheet metal with spaced holes for heavier applications.

Punch plates are better for sizing in comparison to bofar bars and are very durable, customizable, and affordable.

Finally, finger decks work for reclamation, landfill jobs, or any other type of screening where clogging, blinding, or breakage may be an issue. Finger decks can

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Machine design

Impact or sleigh bed conveyors provide more support and are more durable for handling heavy products like large rock. The impact bed is solid and runs the width of the conveyor to best accommodate the impact.

accommodate high-impact loads mixed with recycled waste and debris.

Stockpiling

It looks like “just” a pile of rock, but stockpiling is an art. Essentially, this is what producers work for — large piles of neatly sorted, valuable product that is ready for selling, using, or building.

The cone-shaped piles are formed of ton after ton of material, and, the taller the cone, the wider the base, and the more tonnage the entire pile contains. This additional tonnage is the reason why stockpiling height is so important. A stockpile consisting of a typical rock mixture might hold approximately 228 tons if the pile is 8 feet high with a top width of 2 feet and a base width of 16 feet. By increasing the height of the pile by only 9 inches, the total weight of the stockpile will increase 29 percent, to approximately 295 tons.

Higher stockpiling capabilities serve as a time saver, as producers can run for longer periods without having to move material. This is why screener conveyors with the potential to stack even 8 to 10 inches higher can make a significant difference in an operation.

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AGGREGATES MANAGER May 2014

Conveyors

Conveyors take quite a beating. Conveyors commonly incorporate rollers, which can be hot spots for damage and reduced wear life when large materials are being processed.

Rollers can break under the pressure, and belts become punctured. As an alternative, some manufacturers offer an impact or sleigh bed conveyor. These conveyors provide more support and are more durable to handle heavy products such as large rock.

The impact bed is solid and runs the width of the conveyor to best accommodate the impact of material and prevent belt damage.

Further, most discharge conveyors measure about 48 inches wide. The industry offers belts up to 63 inches wide, which helps prevent clogging. Because the screener is wide and gets funneled down to the conveyor, machines with smaller conveyors create a bottleneck effect. The material begins blinding in the corners, narrowing the opening. This creates productivity and maintenance problems, forcing producers to shut down and clean it out. Look for a machine that has less (or no) restriction as it transitions onto the discharge belt. A free flowing machine with a low drop height is the best option to minimize wear and keep productivity elevated.

Producers can get more bang for their buck when they choose a machine that is taller, bigger, and more rugged. More robust machines often offer features that boost convenience and productivity, such as larger access areas. Double paneled engine compartments allow mechanics more space when performing service on the machine.

Dual fuel nozzles provide fueling access from both sides of the machine — a big advantage when working on a smaller site.

Some manufacturers build units with access to the engine from both sides, as well.

This way, when the unit is parked alongside a wall, fueling and maintenance can still be performed from the opposite side.

Customer support

Customer support becomes pivotal when parts or repairs are needed. The availability of wear parts and service can make or break an operation’s numbers for any given month. Choose a manufacturer with a good reputation not only for quality equipment and durable components, but also for quality customer service. Some companies offer 24-hour online parts look up and ordering with live service support. Along those same lines, consider the equipment warranty when making a screener selection.

Countdown to the purchase

Purchasing the wrong screener can cause problems, slow production, and result in revenue losses. Taking the time now to sift through the facts and separate the good from the bad will prevent headaches, downtime, and loss of production later. AM Sean Donaghy is the national sales manager at Irock. He has more than 20 years of experience in the crushing business and has been with Irock for seven years.

MEMBERSHIP MAKES A DIFFERENCE It’s time to rebuild America. None of us can do it alone, but together we form a powerful voice that will be heard from the heartland to Capitol Hill.

You can be a part of this effort by becoming a member of the National Stone, Sand & Gravel Association. We are the only national organization focused solely on the interests of the aggregates industry. So join us today and make a difference.

For more information on how to join, call (800) 342-1415, email info@nssga.org, or visit our website at www.nssga.org.

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Supply

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

EXCAVATOR OPTIONS A bevy of new excavators round out existing offerings in this product category.

Built for rugged conditions

Saves fuel with auto idle

The Doosan DX350LC-3 excavator features a 281-horsepower engine, a 77,603-pound operating weight, and a 41,667-pound arm digging force. Built for the most rugged conditions, this excavator features significant power and performance increases to go along with its Tier 4 interim status. A new boom float option allows the boom to move freely up and down without hydraulic flow, while a temporary reset button offers the ability to momentarily disengage the float, allowing hydraulic flow to activate the boom.

Doosan Infracore | www.doosaninfracore.com

Weighing in at 105,822 pounds, Liugong’s 950E is one of its largest crawler excavators.

It features the manufacturer’s Intelligent Power Control System (IPC) to provide more accurate matching and control over engine speed and main pump flow for more powerful and smoother operation. Six selectable work modes optimize fuel consumption, while an auto idle function reduces engine rpms to 1,000 rpm once the machine has been at rest for seven seconds. The unit is powered by a Cummins QSM11 375 Tier 3 diesel engine.

Liugong | www.liugong.com

Tier 4 final unit reduces fuel consumption

Offers heavy-duty undercarriage

Cat’s 374F excavator uses its ACERT C15 engine to meet Tier 4 Final emission regulations and burns 13 percent less fuel than its D Series predecessor. With a net power rate of 472 horsepower, the engine uses a combination of emission control technologies, including electronic management of fuel injection/intake air systems and Cat exhaust aftertreatment systems to meet requirements without impacting performance. Two power modes — standard and economy — allow the operator to select an engine speed that meets the application needs. The unit has a maximum digging depth of 31 feet, 7 inches and a maximum reach of 46 feet, 8 inches.

Caterpillar | www.cat.com

With 359 net horsepower, Komatsu’s PC490LC-11 is powered by its Tier 4 Final SAA6D125E-7 engine and features an operating weight between 105,670 pounds and 110,220 pounds. The unit has a heavy-duty undercarriage and counterweight to maintain the same high-lift capacity and lateral stability as its predecessor. The operator can select Lift Mode, which raises hydraulic pressure to increase lifting force up to 7 percent. The machine is also equipped with the Komatsu Equipment Management Monitoring System.

Komatsu | www.komatsuamerica.com AGGREGATES MANAGER May 2014

15

SUPPLY LINES

Offers faster cycle times Case Construction Equipment introduced its new CX350D, the first of its D Series to be shown in North America, during ConExpo-Con/Agg 2014. The unit, which will be available in early 2015, is said to offer significant advances in power, fuel savings, operation, and control, while meeting Tier 4 Final regulations. It has a combination of cooled exhaust gas recirculation, selective catalytic reduction, and diesel oxidation catalyst technologies, which helps maximize uptime and performance. Cycle times are said to be 8 percent faster, while fuel efficiency is 10 percent greater. The excavator is rated at 268 horsepower and weighs in at 82,400 pouonds.

Case Construction Equipment | www.casece.com

Delivers high digging forces The EC380E crawler excavator from Volvo Construction Equipment features a Tier 4 Final engine and is said to combine superior efficiency, productivity, and durability for maximum profitability in quarry applications. The engine delivers high digging and breakout forces alongside reduced emissions and a 9-percent improvement in fuel efficiency. Hydraulics are matched to the engine and controlled by an advanced system that provides on-demand flow and reduces power losses within the circuit. The machine weighs 36 to 43 tons, depending on configuration, and operates at 306 horsepower.

Volvo Construction Equipment | www.volvoce.com

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AGGREGATES MANAGER May 2014

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Offers straight travel

Redesigned hydraulic system

Kobelco’s SK500LC weighs 111,800 pounds and has a bucket capacity of 2.48 cubic yards. It features a 345-horsepower HINO engine. The machine is said to have topclass digging forces, with a maximum bucket crowding force (with power boost) of 57,500 pounds. ECO mode controls the engine and hydraulic pressure to reduce fuel consumption. Three modes — H (heavy workload), S (balanced workload), and ECO (light workout and fuel savings) — are available. The manufacturer says the excavator offers straight travel, which allows it to lift the rated lift chart while walking, to enhance productivity and safety.

Kobelco Construction Machinery USA | www.kobelco-usa.com

Hyundai’s R 1200-9 is its biggest excavator. New to the North American market, it has an operating weight of 260,140 pounds and is powered by a fuel-efficient 740-horsepower Cummins QSK23-C engine. It boasts a dig depth of 26 feet, 3 inches, a bucket digging force of 125,540 pounds, and a bucket capacity of 8.76 cubic yards. The redesigned hydraulic system provides operators with improved controllability, while improved pump flow minimizes fuel consumption.

Hyundai Construction Equipment Americas, Inc. | www.hceamericas.com

Polydeck Sales and Applications professionals are your partners in improving your screening operations. Many of them have worked on the producer side of the industry so they’ve got the experience and know-how to ask the right questions and gather the necessary data. Then they’ll work with you to ensure you are getting maximum performance from your screens.

Will your synthetic screen media producer do that?

Call us at 1-864-579-4594 or visit polydeckscreen.com/aggregate to find the Polydeck sales representative in your area.

Text INFO to 205-289-3782 or visit www.aggman.com/info AGGREGATES MANAGER May 2014

17

© 2014 Chevron U.S.A. Inc. All rights reserved. All trademarks are property owned by Chevron Intellectual Property LLC or their respective owners.

*Delo 16 piece tool kit with qualifying purchase. Minimum volume

requirements apply. Available April 1 to May 31, 2014 while supplies last.

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PULL-OUT GUIDE

by Kerry Clines, Contributing Editor

OPERATIONS ILLUSTRATED Building Better Berms

Keep stockpile berms in good shape.

Build berms along haul roads by drop-offs.

Allow for drainage.

Design roads to accommodate berms.

Material removal can undercut stockpile berms.

OPERAT 1

Use a stable material

Good Barriers Improve Safety

A

berm is defined as a mound or bank of earth used as a barrier or to provide insulation. This is especially true at aggregate operations. A good berm keeps mobile equipment safely on the haul road and away from the edge of drop-offs, stockpiles, settling ponds, and dump points. It also serves as a buffer zone between the operation and the surrounding area, providing a noise break and something nice for neighbors to look at rather than a processing plant.

According to the Mine Safety and Health Administration (MSHA), berms must be maintained on the outside edge of all haul roads where a drop-off exists of sufficient grade or depth to cause a vehicle to overturn or endanger persons in equipment, and at dump points where there’s a danger of equipment overturning or going over the edge.

MSHA provides many rules, regulations, and best practices about where to put berms and how high they should be. How to build the berm, as well as what material to use, is left up to each individual operation, but there’s more to constructing a good berm than just piling up dirt.

A well-constructed berm, once put into place, should only require occasional maintenance to keep it in good shape. However, it must be constructed with a material that resists AGGREGATES MANAGER

settling and provides drainage for the roadways.

“In our sand and gravel operation, we have ideal materials for building berms,” says Jim Tweedy, plant superintendent at CalPortland’s Pioneer Aggregates Plant in DuPont, Wash.

“Our sand and gravel deposit is a very good mix of coarse aggregate and sand that’s very stable and well-draining.”

Though berms offer some resistance, they should never be relied on to stop a vehicle. They should only serve as a guide to warn the operator that the vehicle is too close to a dropoff or edge.

“I always felt like, if you have a berm that’s at least half the height of the axle of your largest machine, it would take a pretty big machine to plow through it,” says Bill Page, project manager at Huntsville, Ohiobased Duff Quarry. “But, according to MSHA’s reports online, a berm like that can be pierced by a runaway machine fairly easily.”

To help operations understand proper berm construction, MSHA offers a 15-minute video, Good Berms Save Lives, on its website, www.msha. org. The video shows the results of one mining company’s study on berms using various materials and different heights. It shows how the size and speed of mining equipment, weather conditions, and grades all play a role in proper berm construction.

When constructing a berm, be sure to choose a material that allows for drainage and won’t compact too much or support weed growth.

A well-constructed earthen berm can be as much as three times wider than it is high. When planning for a new roadway, be sure to allow enough room for the berm in addition to the space necessary for traffic.

4

Allow for drainage

Drainage can be an issue for some quarries, so proper drainage must be engineered into the berms when they are built.

Some put a break in the berm, but it must be located in such a manner that it doesn’t create a hazard for vehicles driving on the roadway. Others create an area in the berm that has larger aggregate to allow water to drain through easily.

TIONS ILLUSTRATED Building Better Berms 2

Exceed height requirements

3

Do not use berms as a stop

MSHA policy requires berms to be at least mid-axle high of the largest piece of equipment that uses the road. However, weather conditions can cause a berm to settle, and material spillage can cause the roadway to become higher, so it’s a good idea to build a more substantial berm, initially, that exceeds requirements and doesn’t require constant touch up or repair.

When approaching a berm, especially at a dump point, do so with care. A berm is not meant to stop a vehicle or keep it from going over the edge of a roadway or drop-off. It is only meant to be used like a curb on a city street to let the operator know when the vehicle is near the edge of the roadway or a drop off.

5

6

Be vigilant about maintenance

OUR EXPERTS

Bill Page, project manager at Huntsville, Ohio-based Duff Quarry, began working full-time at the quarry when he was 18. He spent a year at the Nashville auto diesel college and continued his education with night courses. Page oversees maintenance and electro-mechanical changes at the quarry. He enjoys the automation and improvements that come from new ideas in the industry and has patented one of his own inventions, the Screen Cleaner (www.thescreencleaner.com).

Alternative berms offer flexibility

Jim Tweedy is plant superintendent at CalPortland’s Pioneer Aggregates Plant in DuPont, Wash. After owning his own small operation for a number of years, he went to work for CalPortland in 2002.

One of the things he most enjoys is working with the staff and crew whose commitment and dedication really show at the facility.

Berm maintenance should be ongoing. It’s up to equipment operators and other employees to monitor the berms every day as a part of the work area exam. If a problem is noted, repairs should be made as soon as possible. A minor repair, such as a low area in the berm, can easily be handled by a loader operator. Anything requiring a major repair should be reported to a supervisor or foreman.

Though berms built out of aggregate are the norm at most quarries, some operations build concrete berms or barriers out of retained concrete from ready-mix plants. The concrete berms offer the same strength as aggregate berms without taking up as much space and offer a way to recycle material that would normally be a waste product. These berms work especially well on ramps where loaders feed hoppers.

May 2014

OPERATIONS ILLUSTRATED Voices of Experience Bill Page

“O

t

Jim Tweedy

t

ne thing I think about when constructing a berm is what type of material to use,” says Bill Page, project manager at Duff Quarry in Huntsville, Ohio. “If you build a berm with too much fines in it or cover it with fines, within a year or so you’re looking at big weeds growing up alongside your roadway or project. We generally try to choose a material that will slow or stop a machine, but won’t support agriculture. You want it to look good five years after it is built and, hopefully, still be in place. If you use a material that’s stable, you don’t have to do much to maintain it. You just need to keep an eye on it. If you use a material that’s not very stable, rain and time will cause the berm to settle, and you may have to touch it up more often. If you use a larger, coarse aggregate, it will still be there. It’s not going to change much.”

At Duff Quarry, wheel loader operators generally take care of building and maintaining the berms. They are constantly on the move in the quarry loading trucks, so they can easily transport a bucket of aggregate to repair a berm. Haul trucks are sometimes necessary to transport large amounts of material, if a berm is being constructed or a repair is extensive.

Prior to constructing a berm, it is important for the plant manager or person in charge to do a site survey. “He needs to look at the condition of the area where the berm will be constructed,” Page says. “Is it solid? Is there a weakness? Are there cracks in the wall? Every area is different. He needs to work with the loader operator building the berm or the haul truck driver bringing in the material to make sure it’s placed on solid ground.”

The sale of material continues at Duff Quarry during the winter months, but production shuts down due to the harsh weather. Prior to starting back up in the spring, every berm is inspected to determine where repairs should be made. Some repairs may be needed on perimeter and roadway berms, but, according to Page, some of the biggest areas of concern are the stockpile berms. Material is drawn from the stockpiles during the winter months, which can undercut the berms.

“There may have been a berm to start with, but it may have dissolved or rolled over the top as the material was extracted below,” Page explains. “Once activity gets underway at the quarry, we look for those situations and make sure those berms are put back in place.”

A

s the plant superintendent at CalPortland’s Pioneer Aggregates Plant in DuPont, Wash., Jim Tweedy says berms are an important part of the planning process. “When considering where to place a roadway, we make sure to design it wide enough to accommodate the stable base of a well-constructed berm,” he says. “We need at least a traffic-width road plus room for a berm. At a minimum, the base of the berm will be three times as wide as it is high.”

MSHA requires that berms be mid-axle high of the largest piece of equipment operating in the area, but Tweedy looks at that as a minimum requirement. “If you aim at just mid-axle height of your largest equipment, within a month, the berm will be a bit lower than that,” he explains. “Over a period of time, that berm will settle due to rain and freeze-thaw, so it needs to be pretty substantial to begin with. We try to build that berm higher than what it needs to be, initially, and then monitor its height.”

It isn’t always the berm that settles, sometimes the roadway elevation changes due to material spillage. “We see that a lot at feeders where material spills as the equipment pulls away,” Tweedy says. “Over time, that will increase the height of a ramp or roadway, and, pretty soon, the berm is no longer high enough. So we cut it back down with a grader or wheel loader.”

Berm maintenance is ongoing at the quarry. It’s part of the work area exam for equipment operators. They are expected to monitor berms on a daily basis and either repair them or report the conditions to their supervisor. Because the Northwest receives so much precipitation, drainage areas are designed into the berm to allow water to pass through. These may be small breaks in the berm or an area filled with larger material.

Not all berms are built out of aggregate, however. “We took a jersey barrier form and modified it to be more than mid-axle high on the largest piece of equipment feeding batch plants and ramps where loaders are feeding hoppers,” Tweedy says. “We use retained concrete from our ready-mix plants to build them. The new barriers don’t take up nearly as much room, yet provide stability and strength, and they can be pinned together to form a longer barrier.

“We are also using some large concrete and steel pilings for berms,” Tweedy adds. “They are substantial in size, and allow water to drain freely beneath. Each end of the piling is buried in a pile of aggregate for stability. These also make good backstops at dump sites.”

AGGREGATES MANAGER

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

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High-production portable plant Terex Minerals Processing Systems introduces the Terex Cedarapids CFJ3750 plant, which combines a JS Series jaw crusher with a high-stroke, 52-inch by 20-foot vibrating grizzlyfeeder to create a high-production portable crushing machine. The system boasts a new hopper design to handle severe primary applications, while the jaw crusher features improvements such as wedge-release jaw dies and hydraulic-assist crusher settings. Isolation of the jaw reduces plant vibration, while the tail of the product conveyor lowers for operation, maximizing clearance under the crusher. The conveyor discharge adjusts to reduce material impact on the receiving conveyor.

Terex Minerals Processing Systems | www.terex.com

Updated wheel dozer The Cat 834K builds on the machine’s nearly 50-year history with a completely new cab, drive train refinement, new monitoring and diagnostic features, new safety features, and structural enhancements. Available blade types include straight, universal, semi-universal, and coal, ranging in capacity from 10.3 to 29.0 cubic yards. The 496-horsepower Cat C18 engine is available in three configurations, including Tier 4 Final, Tier 3 equivalent without aftertreatment, and Tier 2 equivalent without after-treatment. The Cat 4F/3R planetary power-shift transmission features a new Advanced Productivity Electronic Control Shifting system, which is designed to provide greater momentum through shift points, enhancing performance and saving fuel.

Caterpillar | www.cat.com

DEF handling kits For customer convenience in using Diesel Exhaust Fluid (DEF) and other fluids in its Tier 4 Final equipment, John Deere offers a full range of fluids and handling equipment. The company now offers a line of pump kits and portable dispensing units for handling larger volumes of DEF. The 110V and 12V pump kits come fully assembled and include everything needed to dispense DEF, including 4-foot suction hose with closed system dry break coupler and 20-foot discharge hose with stainless steel automatic shutoff nozzle. It also offers 20- and 60-gallon portable dispensing units, which consist of a DEF compliant tank, removable 12V pump with 20-foot dispensing hose, and stainless steel auto shutoff nozzle with swivel. These units are designed to fit in a pickup truck or on a fuel trailer for easier transport.

John Deere | www.johndeere.com

24

AGGREGATES MANAGER May 2014

Roller bed conveyors Lake Erie Portable Screeners adds three roller bed conveyors — ground, stacking, and radial stacking — to its line of screening equipment. The manufacturer says roller bed conveyors excel in applications that require consistent and continuous transfer of materials and move heavier loads faster and with less power than slider bed conveyors, which typically have smaller drive pulleys that require more torque to operate. The ground conveyor is mounted on a steel frame that rests directly on the ground, with a large footprint for enhanced stability. The stacking and radial stacking models move from 5 to 11 feet high and feed material directly into a loading vehicle or to create stockpiles. The units can be used with the company’s Pitbull 2300 screening plant to produce three grades of material at once.

Lake Erie Portable Stackers | www.pitbullscreeners.com

Easy-to-clear crushing chamber The new Terex Cedarapids MVP380X cone crusher, from Terex Minerals Processing Systems, includes enhancements that increase the unit’s productivity and ease of use. The 300-horsepower crusher incorporates pinned cylinder ends that remove quickly to allow fast cone separation for quicker manganese changes and less downtime. At the press of a button, fully guided dual-action, tramp relief cylinders provide a 6-inch lift for easy clearing of jammed material to reduce downtime and increase productivity. The hydro-pneumatic tramp iron relief system instantly resets the crusher setting after passing uncrushable material without having to activate valves and pumps. Computeroptimized main frame components are all-cast construction, while a more rugged cone head is designed for abrasive, hard rock crushing applications.

Terex Minerals Processing Systems | www.terex.com

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Text INFO to 205-289-3782, or visit aggman.com/info.

McLanahan_AGRM0514_PG25.indd

1

AGGREGATES MANAGER May 2014

25

4/21/14 8:41 AM

Heavy-duty hydraulic hammer

High G-force screen Terex Minerals Processing Systems introduces the Terex Cedarapids V Series horizontal screens, which combine the efficient, high G-force ElJay oval stroke motion with variable slope operation to handle larger deck loads. The new design features more steel in the ‘rock zone’ to improve durability. The LJ-TSV screens have multiple new patent-pending features to boost production, including a variable slope that handles larger deck loads and bigger screen openings to increase production. The screens install up to 10 degrees in 2.5-degree increments to suit the application. A patent-pending vibration damper system offers low maintenance, while a patent-pending optional bottom deck deflector boosts efficiency.

Terex Mineral Processing System | www.terex.com

Montabert introduces its V46SHD heavy-range hydraulic breaker, which features an automatic speed variation system, adjusting its impact energy and striking rate to match material hardness in demolition, excavation, and quarrying applications. Designed for use on excavators weighing between 59,500 and 88,200 pounds, the 5,616-pound hydraulic breaker delivers between 510 and 1,160 blows per minute. For optimal breaking power, the V46SHD requires a hydraulic flow rate of between 47-1/2 and 70 gallons per minute and is rated within the 7,500 foot-pound impact energy class. Standard features include a progressive start system that prevents the breaker from slipping, a blankfire protection system that reduces harmful metal-to-metal contact, and an energy recovery system that recycles recoil energy to increase strike power. The fully hydraulic breaker’s enclosed energy chamber provides maximum and constant energy with every blow.

Montabert | www.montabert.com

Tier 4 Final motor graders The new Cat M Series motor graders —12M3, 140M3, 160M3, and their all-wheel-drive counterparts — meet Tier 4 Final emission standards. The graders use Cat’s after-treatment solution, with the addition of Selective Catalytic Reduction (SCR). A new standard economy mode can be used to help save fuel by reducing engine speed so the machine works in a more efficient range. The average fuel savings is up to 10 percent, depending on application. Product Link tracks location, hours, fuel usage, productivity, idle time, and diagnostic codes through the online VisionLink interface. In the cab, two electronic joysticks reduce arm movement by up to 78 percent to lessen operator fatigue and increase productivity.

Specifications Engine Model Base Power - Net VHP Plus Range - Net AWD Range - Net Moldboard – Blade Width Operating Weight Operating Weight AWD Caterpillar | www.cat.com

26

AGGREGATES MANAGER May 2014

12M3/12M3 AWD Cat C9.3 ACERT 179 horsepower 179-231 horsepower 189-252 horsepower 12 feet 42,647 pounds 44,614 pounds

140M3/140M3 AWD Cat C9.3 ACERT 200 horsepower 200-252 horsepower 210-272 horsepower 12 feet 43,950 pounds 45,917 pounds

160M3/160M3 AWD Cat C9.3 ACERT 221 horsepower 221-272 horsepower 231-293 horsepower 14 feet 45,547 pounds 47,514 pounds

TAILOR MADE Customized Terex® Simplicity Inclined Screens Deliver.

Drop-fit a customized Terex® Simplicity Inclined Screen into your existing structure and boost your productivity. We will build a screen to fit your current envelope, providing an exceptionally cost effective solution for your screening needs. Known for their rugged construction, Terex® Simplicity Inclined Screens deliver dependability.

Terex® Simplicity Inclined Screen Benefits: Versatile... Terex® Simplicity inclined screens are applicable in virtually all types of screening operations.

Dependable... our screens have been performing reliably since 1921. All units are tested prior to shipment.

Serviceable... components are designed for quick, easy access and repair to increase uptime.

Available... a multi-million dollar inventory of parts is maintained for fast, off-the-shelf availability.

Visit www.terexmps.com to find your local distributor and learn how we can work for you.

Terex® Minerals Processing Systems Durand, Michigan | Tel +1 (989) 288-3121 | Toll Free +1 (888) 571-8352 Cedar Rapids, Iowa | Tel +1 (319) 363-3511 | Toll Free +1 (800) 821-5600

TOPS2.0 Reduces Costs The TOPS2.0 Terex Oil Purification System is a light weight, highly portable oil filtering system designed to reduce the labor and material costs of maintaining lubricants in vibrating screens and a variety of other equipment.

Simple 3-step process: connect–pump–disconnect Convenient and light weight A QuickLube kit is available to retrofit Terex® Simplicity and Terex® Cedarapids screens Easy to use oil sampling port to determine oil condition

Learn more at www.terexmps.com

Text INFO to 205-289-3782 or visit www.aggman.com/info

Terex, the Terex Crown design, Works For You, Simplicity and Cedarapids are trademarks of Terex Corporation or its subsidiaries. Copyright 2014 Terex Corporation.

Double-locking quick coupler

Artics feature turbocharged engines Volvo’s new G-Series articulated haul trucks — including the A35G, 135G FS, 140G, and A40G FS — feature new turbocharged six-cylinder Volvo engines that meet Tier 4 Final emission regulations. The drivetrain and inline dropbox are designed for high ground clearance, while the drivetrain delivers high rimpull, lowers fuel consumption, and provides reliability in heavy-duty applications. Oil-cooled wet multiple disc brakes are said to reduce maintenance costs and increase uptime, even on muddy or dusty sites. A retardation system controls downhill haul speeds using wheel brakes and the engine brake. Automatic traction control and differential locks are standard, while an onboard weighing system allows the equipment operator to optimize payload. The machines are also fitted with CareTrack, Volvo’s telematics system.

Volvo | www.volvoce.com

The new Geith Generation 3 hydraulic quick coupler is said to provide operators with a safe, simple, and durable design that allows quick changes of attachments. Featuring four independent safety components, the double locking, fully automatic quick coupler configuration complies with the impending safety standards set forth by ISO/ FDIS 13031:2013(E). The front safety lock retains the attachment in the event of improper link/rear pin connection, while the front safety lock and the mechanical secondary rear safety system independently retain the attachment in a working position should a loss of hydraulic power occur. It also features a hydraulic cylinder check valve, as well as a patented “curl to release” control system for safe attachment engagement and release.

Geith | www.geith.com

One crusher One screen One Lokotrack®

Lokotrack® LT220D™ The revolutionary Lokotrack® LT220D™ is an efficient and easy-to-transport unit that combines a screen with a crusher. This combination helps you eliminate the need to move multiple machines and saves on your fuel costs. Provide your customers with high quality aggregates with the new Lokotrack LT220D.

www.metso.com/lokotrack Text INFO to 205-289-3782 or visit www.aggman.com/info

28

AGGREGATES MANAGER May 2014

Text INFO to 205-289-3782 or visit www.aggman.com/info

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Everett Quarries has acquired certain assets of

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FMI Capital Advisors is a leading Investment Bank serving the Engineering and Construction industry. Our unique industry focus, serving a broad range of industry sub-sectors, enables us to provide our clients with valuable insight and advice. With over 600 completed transactions, FMI combines advisory expertise with industry-focused knowledge and relationships in order to achieve value for clients.

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Data Stock Report Company

U.S. On-Highway Diesel Fuel Prices Ticker

Current Value

52-Week 52-Week High Low

4/7/2014

One Week

United States

$3.959

-0.016 q

-0.018 q

East Coast

$4.057

-0.019 q

+0.066 p

New England

$4.240

-0.015 q

+0.106 p

Central Atlantic

$4.205

-0.036 q

+0.143 p

$3.946

-0.009 q

0.000 p

Midwest

$3.942

-0.017 q

-0.014 q

Gulf Coast

$3.793

-0.011 q

-0.095 q

Rocky Mountain

$3.955

-0.020 q

+0.056 p

West Coast

$3.982

-0.008 q

-0.135 q

Cemex, S.A.B. de C.V.

CX

$13.24 p

$14.37

$9.13

CRH plc

CRG

$29.40 p

$30.32

$20.35

Eagle Materials Inc.

EXP

$88.73 q

$94.25

$61.59

Granite Construction Inc.

GVA

$38.18 q

$40.55

$26.07

Heidelberg Cement AG

HEI

$88.83 p

$95.18

$68.47

Holcim Ltd.

HOLN

$92.77 p

$97.95

$71.37

Lower Atlantic

Martin Marietta Materials, Inc.

MLM

$126.50 p

$130.00

$93.03

MDU Resources Group, Inc.

MDU

$34.98 p

$35.60

$23.40

Texas Industries Inc.

TXI

One Year

$88.66 p

$90.74

$53.23

United States Lime & Minerals, Inc. USLM

$56.38 q

$62.50

$45.00

U.S. Concrete

$24.07 q

$28.64

$13.13

West Coast less California

$3.894

-0.014 q

-0.129 q

$45.42

California

$4.056

-0.004 q

-0.140 q

Vulcan Materials Co.

USCR VMC

$65.11 q

$69.50

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 4/9/14.

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

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Text INFO to 205-289-3782 or visit www.aggman.com/info AGGREGATES MANAGER May 2014

31

LEVEL DESIGN

Text INFO to 205-289-3782 or visit www.aggman.com/info

by Dana M. Svendsen

Rock

ROCKLAW

Administrative law judges take different viewpoints on pre-shift examinations and MSHA inspections.

Differing

PERSPECTIVES D

Dana M. Svendsen is an associate in Jackson Kelly PLLC’s Denver office, where she practices with the Occupational Safety and Health Practice Group. She can be reached at 303-390-0011 or via email at mailto:dmsvendsen@ jacksonkelly.com.

uring Mine Safety and Health Administration (MSHA) inspections, disputes between operators and inspectors can arise over whether an observed condition is a defect or whether a piece of equipment is ready for use. Under the Mine Safety and Health regulations, an operator must conduct a pre-shift examination of all mobile equipment prior to using the equipment during a shift (see, e.g., 30 C.F.R. §§ 56/57.14100, 77.1606). Any defects observed must be corrected in a timely manner, and defective equipment must be removed from service. Several decisions have reached differing conclusions on the validity of issued citations when the existence of a defect is acknowledged, and the operator argues that the defect would have been identified and corrected during the pre-shift exam — but no such exam had yet taken place. Some administrative law judges (ALJs) have adopted MSHA’s strict liability approach that the existence of a defect merits a citation unless the equipment has been tagged out. Other ALJs have found that the operator must have an opportunity to conduct a pre-shift exam.

Whether a violation has occurred often turns on what it means to assume continued normal mining operations. Typically, MSHA argues this means the equipment would be put into use, while operators argue that the normal course would be to first inspect the machinery. MSHA’s view is problematic for operators because it assumes the existence of a separate violation, i.e., failure to perform an adequate exam — an exam

that has yet to be conducted — to show that the violation has occurred. This effectively shortcuts the government’s burden to prove that the operator knew or should have known about the alleged defect and did nothing to correct it.

In a recent decision, ALJ Rae rejected this approach by MSHA and vacated a citation issued to Martin Marietta for inoperable headlights on a steer skid loader [see Martin Marietta Materials, Inc., Docket No. CENT 2013-332-M (Feb. 18, 2014) (ALJ Rae)]. It was undisputed that the lights had been working when the loader was operated the day before, but on the day of the inspection, the lights did not function. It was also undisputed that, at the time of the inspection, the operator had not yet conducted a pre-shift examination, and the loader was not in use. At the time of the inspection, the skid steer loader was parked in an equipment shop, though it was not tagged out. ALJ Rae rejected MSHA’s argument that the operator either violated 30 C.F.R. § 56.14100 (b) (failure to correct defects in a timely manner) or 30 C.F.R. § 56.14100(c) (failure to tag out equipment not immediately corrected). She found there was no evidence that the operator would have failed to identify the headlight defect prior to putting the skid steer loader into operation.

There was no reason to assume that the operator would not have inspected, identified, and corrected the defect prior to putting the equipment back into use, and because there was no evidence of “continued operation,” there was no violation.

In a similar case, ALJ Moran vacated a citation AGGREGATES MANAGER May 2014

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issued under 30 C.F.R. § 56.14100(b) for allegedly failing to adequately inspect a front-end loader with a defective brake light [see Beverly Materials, LLC, 35 FMSHRC 88 ( Jan. 14, 2013) (ALJ Moran)]. The inspector issued the citation after initially observing the front-end loader in one location and then observing it at a new location about an hour and 20 minutes later. The operator explained the reason for the change in location was that the front-end loader had to be moved to the location of the steepest grade the machine would travel to test the parking brake during the pre-shift exam. Based upon this explanation, the ALJ found the front-end loader was not in service, and the “only credible conclusion” was that the loader was moved to facilitate the pre-shift exam. The citation was vacated because the loader had not yet been put into operation with the defective brake light. The decision in Beverly Materials is on appeal to the Federal Mine Safety and Health Review Commission (Commission), and there will continue to be uncertainty around this issue until the Commission issues its ruling on ALJ Moran’s decision.

The Federal Mine Safety and Health Act of 1977 (Mine Act) could have easily declared equipment be maintained defect free “at all times.” The regulations could have taken the same approach. Neither one has such a draconian rule. Instead, the regulations require an inspection be conducted prior to use and that defects be addressed in a reasonable time [see Giant Cement Co., 13 FMSHRC 286 (Feb. 25, 1991) (ALJ Merlin) (§ 56.14100(b) does not prohibit defects, but requires only that defects be corrected in a timely manner)].

MSHA’s aggressive stance effectively requires all equipment to remain free from defects at all times unless tagged

out of service. This view should be rejected by the Commission. By assuming miners will not follow the most basic of safety precautions, MSHA unreasonably burdens operators with alleged violations that may never come about. AM

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Experience: Retired November 2011 following 41 years with the U.S. Geological Survey • USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present

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VISIT

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Terex Minerals Processing Systems. . . . . . . . . . . . . . . . . . . .www.terexmps.com . . . . . . . . . . . . . . . . . . . . . . . 27 Topcon Positioning Systems . . . . . . . . . . . . . . . . . . . . . . . . .www.topconpositioning.com . . . . . . . . . . . . . . . . . 16 Volvo Penta. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.volvopenta.com/us . . . . . . . . . . . . . . . . . . . BC Worldwide Electric Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . .www.worldwideelectric.net . . . . . . . . . . . . . . . . . . . 5 This index is provided as a service. The publisher does not assume any liability for errors or omissions.

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by Bill Langer

Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business.

He can be reached at Bill_Langer@hotmail.com

T

In Stone

This Must

BE THE PLACE The trek along Route 66 travels through the small towns of Oklahoma.

oday, we depart Quapaw, Okla., and continue our westbound journey along old Route 66. We drive by several mountainous piles of waste rock (referred to as chat) from the past mining activities; sad reminders of poor mining practices of days past when people did not know any better.

The landscape noticeably changes as we transition from the hilly Ozark Plateau to the Osage Plains of Oklahoma. The plains are relatively flat, but there is enough relief to allow for the occasional road cut, which helps break the monotony.

Along with the change in the landscape comes a change in geology. No longer are the local towns the products of lead zinc mining. Many of the Oklahoma towns west of here were shaped by another natural resource...oil.

Oil was discovered near Chelsea, Okla., in 1889, and that discovery shaped the entire state.

During 1901, oil was discovered near Tulsa. Four years later an even larger oil discovery gave Tulsa its title as the “Oil Capital of the World.” In 1928, oil was discovered in Oklahoma City making that city the state’s newest boomtown.

But during the 1930s, Oklahoma was dealt a triple blow. The oil boom was dying down, and the loss of jobs greatly impacted the small towns. The Great Depression dealt a second punch.

In previous depressions, farmers could feed themselves, but drought, horrendous dust storms, In 1889, oil was discovered in Oklahoma and led to rapid growth. and failed crops of the Dust Bowl provided the third blow. During the 1930s, approximately By the 1930s, however, declining 60,000 people, from city and countryside alike, left Oklahoma. Many headed west to California. oil demand, the Great Depression, Their stories were immortalized in John Steinbeck’s book The Grapes of Wrath. and the failed crops of the Dust Bowl led thousands to leave the area and It is ironic that while farmers left the land, factories shut down, and businesses closed their move west. doors along the Mother Road, there were people producing aggregate for the workers paving the road, and new tourist camps, cafes, and gas stations were opening up all along the improved highway. In Route 66 – The Highway and its People, author Susan Croce Kelly quotes Leon Little, who operated a service station and restaurant on Route 66 in western Oklahoma. “We thought mighty hard about [moving along with others], but we were eating regular, and we had a stoop over our head, and the people that worked for us…were about as well off as we were. We were all living, see?”

We have been dawdling, so we hop on I-44 to Oklahoma City. There we follow to I-40 where we bypass all the small Route 66 towns. As we wiz past those towns, we play a little trivia about famous people from Oklahoma towns along old Route 66. Commerce is the hometown of the legendary baseball player Mickey Mantle. Claremore is the hometown of humorist Will Rogers and singer Patti Page. In Chelsea, Will Rogers discovered Gene Autry. Yukon is home to Garth Brooks. And Erick was home to two Country music performers: Sheb Wooley, who recorded the “one-eyed one-horned flying purple people eater,” and Roger Miller, Mr. “King of the Road” himself.

Just before we leave Oklahoma, we exit the interstate and drive through Texola, the westernmost town in the state. Texola is nearly a ghost town, but on its western edge an interesting old bar has a proclamation on the side of its building: “There’s no other place like this place anywhere near this place so this must be the place.”

Perhaps it was. AM

40

AGGREGATES MANAGER May 2014

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