Aggregates Manager May 2015 by Sandy Turner Jr

Control Your

Operating

Costs

May 2015

www.AggMan.com

Reduce settling pond requirements

Provide a steady feed for your primary

What does MSHAâ&#x20AC;&#x2122;s RTLB calculator mean for you?

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On Our Cover: Equipment insights can help lower operating costs. Cover photo by Elena M. Tarasova.

30 13

Because a feeder cushions the primary from the impact of large dump loads, it’s important to inspect it regularly and ensure proper maintenance. John Deere rolls out new dozers that meet Tier 4 Final emissions standards and offer fuel savings of approximately 20 percent.

CONTENTS MAY 2015 VOLUME 20, NUMBER 5

COLUMNS & DEPARTMENTS

FEATURE ARTICLES

30 37

Controlling Equipment Ownership Costs

It’s all about production — and production is a lot more profitable when equipment owning and operating costs are kept down with these eight guidelines.

Feed the Beast

A vibrating grizzly feeder not only absorbs the shock of large dump loads, it also improves the efficiency of the primary crusher.

Just Roll with It

Conveyor components keep aggregates rolling smoothly throughout your operation.

3 5

EDITORIAL Are you ready for a media close-up? AGGMAN ONLINE Catch up on the latest news from our web site and social media channels.

MINING The latest stock and fuel price 7 DATA trends impacting the industry. AND PROVINCE NEWS A roundup of 8 STATE the latest news in North America. KCMA Corp.’s new 957Z and 115Z7 wheel loaders, and other new equip13 ROLLOUTS ment for the aggregate market. LAW MSHA’s new ‘Rules to Live By’ calculator provides information to aid com40 ROCK pliance, but raises concerns of heightened enforcement.

INDEX See who’s who and where to find their products. 42 ADVERTISER

OPERATIONS ILLUSTRATED Squeeze Play

ADS Aggregates industry classifieds. 43 CLASSIFIED

Filter presses have gained popularity among aggregate producers looking to shrink or eliminate settling ponds from their sites.

IN STONE In the 1830s, teamsters got an early lesson on the economics of 44 CARVED transporting granite during the construction

of Vermont’s second state house.

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

May 2015

Vol. 20, No. 5

aggman.com /AggregatesManager @AggMan_editor

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

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

Construction Media VP of Sales, Construction Media: Joe Donald sales@randallreillyconstruction.com

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

Corporate Chairman/CEO: Mike Reilly President: Brent Reilly Chief Process Officer: Shane Elmore Chief Administration Officer: David Wright Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Vice President of Events: 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 2015. 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.

Is Your Crisis Communication

PLAN IN PLACE?

f your operation was suddenly in the spotlight and the news media showed up on your doorstep, could you handle an interview? Do you know who would serve as spokesman for your operation? Would you know what key points to communicate to neighbors, community, and local leaders? If not, it’s time to compile a crisis communication plan. In the past, it was much easier to avoid newspaper or television journalists. Media requests often came through phone calls to a general number or — can you imagine — a fax request for an interview. Now, cell phones, emails, social media tags, and personal messages all mean greater access; whether or not you want it. Typically, the media doesn’t show up unless something has gone wrong, and you need to be prepared. So what does that mean? 1) Anticipate what could happen. Consider the most likely scenarios to draw the media to your door and develop talking points. 2) Respond promptly and truthfully. Keep messages clear, concise, and on point. Be calm and cooperative. 3) Consider all forms of communication. While many are accustomed to traditional media channels, don’t forget social media channels. Unhappy community members certainly won’t. 4) Follow up as needed. Sometimes, you need additional information before you can answer a question. It’s okay to tell a media representative you don’t have the information they need, but you will get it to them. Just be sure to follow through. 5) Evaluate the results. Learn from the experience, and adjust plans for future communications accordingly. As you develop a crisis communication plan, also look to your peers. For example, when a blast at a British Columbia operation disturbed neighbors, the operator quickly issued a letter of apology to neighbors. According to The News, the letter cited unforeseen weather changes in the weather and air pressure after the blast was loaded. “We noticed the changes in conditions,” the letter noted, “but since we had already started loading the blast, it is best practice (safety wise) to let the blast go instead of letting mixed explosives sit overnight.” The letter also noted that the resulting air pressure was outside the acceptable tolerances for company standards, but explained that its standards are more stringent than the provincial government standards. Finally, it outlined a number of ways it had modified its operations to create less impact for neighbors. So, let’s review. They proactively apologized. They outlined the scientific conditions behind the air pressure. They explained that safety concerns caused them to proceed with the blast. They highlighted that they go beyond legal requirements. And, they noted numerous ways in which they strive to be a good neighbor. If your crisis communication plan is as effective as this one, you’ll be well prepared when the media comes knocking. AGGREGATES MANAGER May 2015

Magna Tough

Baldor•Dodge® MagnaGear XTR™ speed reducers are designed and manufactured to be the most rugged and reliable reducers in the world for high torque applications. Available in parallel shaft or right angle with torque capacities from 100,000 to 2,100,000 in-lbs. and capable of accommodating 4,500 Hp or more, the MagnaGear XTR is ideal for bulk material handling in dirty, dusty, harsh environments.

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Catch up on top news and content from our web site and social media channels.

TOP POST OF THE MONTH

Tweets Therese Dunphy ‪ @AggManEditor

Mar 18 Why are you here? @csluck4 outlines his perspective #NSSGA strategic plan for upcoming year.

Photos from Bluegrass Material Co.’s Texas Quarry

Participants at the National Stone, Sand and Gravel Association’s (NSSGA) annual convention had the opportunity to tour Bluegrass Material Co.’s Texas Quarry, which Bluegrass President Ted Baker describes as the company’s flagship quarry. “This is our biggest quarry both sales and production wise,” he adds.

Mar 18 It’s everyone’s job to work as advocates for our industry says Grassroots CEO of the Year Bob Weldon III #NSSGA

TOP READS Caterpillar: Modern Earthmoving Marvels traces equipment evolution

Whether or not you’re a fan of yellow iron, there is a lot to be learned from the newly released Caterpillar: Modern Earthmoving Marvels. The book, written by Frank Raczon (along with equipment historian Keith Haddock), highlights the manufacturer’s journey from developing motor graders pulled by animals to hybrid excavators. Strategic introductions and acquisitions are highlighted and put into context.

Trinity Materials’ Indian Village Plant runs a sand dredging operation in southwest Louisiana

Trinity Materials’ Indian Village Plant stays busy dredging and processing sand from a small lake in southwest Louisiana where the recent oil and gas boom has brought new life to the construction industry.

MSHA fatalgram report

The Mine Safety and Health Administration (MSHA) sent out a fatalgram last week (March 16) providing details about a fatal accident that occurred at a limestone quarry in Ohio on Dec. 1, 2014. A 46-year-old contract truck driver with 26 years of experience was killed when the articulating haul truck he was operating traveled over a berm and into a large pond. Dive teams were required to extract the victim from the truck.

Aggregates Manager magazine

Aggregates Manager magazine Posted by Therese Dunphy · March 17 at 11:18pm ·

Share this picture and link with your elected officials as you tell them about the need for a long-term highway bill.

MSHA issues citations to five metal/non-metal mines during impact inspections in February

The Mine Safety and Health Administration (MSHA) announced that federal inspectors issued 195 citations and 15 orders during special impact inspections conducted at 12 coal mines and five metal/non-metal (MNM) mines during the month of February. One of the five MNM mines, a U.S. Silica Co. sand mine in Illinois, was issued 25 citations, two of which were S&S. Two of the mines belonged to Essroc Cement Corp., one in Pennsylvania and one in West Virginia. The Pennsylvania mine was issued a total of 12 citations, five of which were S&S, and the West Virginia mine was issued five citations, two of which were S&S. AGGREGATES MANAGER May 2015

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Data Stock Report Company Cemex, S.A.B. de C.V.

U.S. On-Highway Diesel Fuel Prices Ticker CX

CRH plc

CRG

Eagle Materials Inc. Granite Construction Inc.

Current Value $9.79 q

52-Week 52-Week High Low $13.66

$8.72

One Week

One Year

$2.754

-0.030 q

-1.198 q

East Coast

$2.916

-0.034 q

-1.152 q

$26.51 q

$27.49

$16.30

EXP

$83.85 q

$105.69

$68.54

New England

$3.076

-0.038 q

-1.144 q

GVA

$36.18 q

$39.34

$30.44

Central Atlantic

$3.080

-0.042 q

-1.113 q

$51.64

Lower Atlantic

$2.759

-0.027 q

-1.188 q

Midwest

$2.633

-0.042 q

-1.299 q

Gulf Coast

$2.620

-0.023 q

-1.170 q

$20.01

Rocky Mountain

$2.703

-0.022 q

-1.239 q

$53.01

West Coast

$2.914

-0.004 q

-1.067 q

Heidelberg Cement AG

HEI

Holcim Ltd.

HOLN

$77.12 q

$85.45

$58.13

Martin Marietta Materials, Inc.

MLM

$138.00 q

$146.21

$103.09

MDU Resources Group, Inc.

4/13/2015

United States

MDU

$81.62 q

$22.41 q

$81.85

$36.05

United States Lime & Minerals, Inc. USLM

$66.84 q

$76.98

U.S. Concrete

USCR

$33.31 q

$35.75

$21.48

West Coast less California

$2.720

-0.022 q

-1.173 q

Vulcan Materials Co.

VMC

$82.60 q

$86.25

$54.10

California

$3.071

+0.010 p

-0.985 q

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 4/13/2015.

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

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AGGREGATES MANAGER May 2015

State & Province

NEWS

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

Connecticut

A 51-year-old man is accused of embezzling more than $1.1 million from his former employer, Kobyluck LLC. According to The Bulletin, Todd Francis was arrested for first-degree larceny. He served as operations manager for Kobyluck LLC in Waterford for a decade and handled production and distribution of sand, gravel, and ready-mixed concrete. When he was off work last year, his employer discovered missing paperwork for deliveries and contacted local law enforcement. Francis had been pocketing payments for deliveries by taking cash orders from customers at a discount, then destroying delivery records or not creating a delivery record at all. From 2005 to 2014, the company lost $1.14 million as a result of his activities.

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

California

Vulcan Materials Co. is in the process of transforming all of the original 30- to 50-foot benches at its Azusa operation into 1- and 2-foot microbenches that match the contours of the natural hillside. According to the San Gabriel Valley Tribune, the operator has an Aug. 19 deadline to finish the first phase of its reclamation work. At the same time, preparation has begun on the quarry’s western side, as overburden is removed to provide access to more than 100 million tons of granite reserves. That development has been the source of numerous legal challenges from the neighboring community of Duarte. Both biologists and air quality specialists regularly visit the site to monitor progress. Jeff Cameron, Vulcan’s special projects manager, told the newspaper that the company is taking a number of steps, including setting up sprinkler systems on the hillside, to minimize air pollution.

California

An $18 million campaign is underway to reopen UC Santa Cruz’s outdoor Quarry Amphitheater, the Santa Cruz Sentinel reports. The quarry was operated from 1860 to 1946 and provided much of the limestone used in San Francisco construction during that time period. The amphitheater opened in 1967 and served as the heart of the campus prior to being closed in 2006 due to safety reasons. Its restoration is a top priority for Alison Galloway, campus provost and executive vice chancellor. Students voted to direct $6.38 million of its student fee reserves toward the project, but nearly $8 million is needed to break ground on the first phase of construction. If enough funds can be raised by the summer, construction will begin in the spring, and the theater will reopen in early 2017.

AGGREGATES MANAGER May 2015

Georgia

As Bluegrass Materials expands the surface area of its quarry in Forsyth County, it held a meeting with neighbors to discuss blasting. The Forsyth County News reports that some meeting attendees reported feeling stronger vibrations during recent blasts. Donnie Walker, operations manager, told the newspaper that the operation has been expanding its pit since last November. He told attendees that another shot would likely be required as the operation strips overburden to open up the pit. A blasting consultant for the company noted that it is well within the regulations and uses the latest technology to minimize impact, including more expensive blast caps for quick detonation.

Kentucky

Simpson County Judge-Executive Jim Henderson was dismissed as a defendant in a lawsuit brought by Drakes Creek Holding Co., which sued him, the Franklin-Simpson County Planning and Zoning Commission, and the Franklin-Simpson County Board of Zoning Adjustment. According to the Bowling Green Daily News, the operator sued the parties last year for $13 million, claiming they had engaged in a pattern of behavior designed to interfere with its effort — along with sister company, Charles Deweese Construction — to operate a quarry. Its permit application was denied last year by the board of adjustment. The operator appealed the decision. Five lawsuits related to the quarry have been filed in Simpson Circuit Court.

Maine

An operator and the Maine Department of Environmental Protection (MDEP) are having a difference of opinion on whether a Mount Desert quarry should be grandfathered from current regulations. The Mount Desert Islander reports that Harold MacQuinn Inc. applied for a license to resume operations in Mount Desert after the town adopted a licensing ordinance in 2014. An attorney for the operator said that permit requirements do not apply to quarries smaller than one acre and there is an exemption for quarries that existed before 1970. The operator argues that it is operating within a 1.1-acre footprint and, as long as it stays within that footprint, it is not subject to DEP regulations. The mining coordinator for MDEP’s Bureau of Land & Water Quality said that, based on the operation’s long-term plan to expand the site to 4.3 acres, it must file a Notice of Intent to Comply with MDEP rules.

New York

Tilcon New York is developing a plan to address dust at its Haverstraw Quarry. The state Department of Environmental Conservation issued a consent order and $125,000 fine in January. “The company has been cooperative and is currently in compliance with the consent order,” DEC spokesman Wendy Rosenbach told The Journal News. The DEC issued seven violations against the operation for issues such as over-excavation, erosion from material stockpiles, and failure of dust control. A spokesman for the company told the newspaper that it is working closely with DEC and has begun to remove material from the stockpile while developing a remediation plan.

Pennsylvania

Five Amish miners at Russell Stone Products operation had to be moved to other roles. According to CNBC, the issue stems from the Mine Safety and Health Administration’s requirement that workers wear hardhats on the site. The safety requirement conflicts with Amish religion, which requires them to wear black felt or straw hats. A senior fellow at the Young Center told The Morning Call that the Amish view the hat as a religious symbol and don’t want the loss of the hat in construction areas to lead to an erosion of wearing it elsewhere.

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Pennsylvania

A tenant at H&K’s operation in Douglassville has put it in the spotlight — and not in a favorable way. Frontier Mulch Products leases land at the quarry for its business, but it has experienced nearly a dozen mulch fires since last November. According to 69 News, the most recent fire kept dozens of fire companies busy on Easter Sunday. More than 1 million gallons of water and nearly 200 firefighters were needed to control the blaze that day. A spokesman for Amity Fire & Rescue said the fire depleted the Pottstown borough’s water supply. The mulch company referred the news crew to H&K spokesman Tony Jeremias, who said the matter is being taken very seriously, and fire prevention is a top priority.

Pennsylvania

Dingman Township Supervisors renewed a conditional-use permit that will allow Springbook Enterprises’ quarry to continue operations for another decade. According to The Pike County Courier, brothers Keith and Roger Mitschele Jr. appeared before the supervisors to present their case, but no other members of the public attended. The town’s roadmaster was directed to keep supervisors updated on the status of the access road used by the operation and to alert them to any changes, as well as whether reimbursement issues arise. The company pays 10 cents per ton when material is removed from the site.

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STATE & PROVINCE NEWS

Rhode Island

Michelle Buck, town manager of Westerly, resigned in early April, citing an ongoing dispute over a quarry. The Westerly Sun reports that Buck said matters regarding Copar quarry interfered with her and the town council’s work. Prior to her resignation, Buck met in a closed-door session with council to respond to accusations of unethical conduct, dishonesty, and participation in a cover up regarding the quarry case.

Wyoming

The County Planning and Zoning Commission approved a permit application from John E. Rice and Sons, Inc. to mine stone, sand, and gravel from a 40-acre tract to make crushed base and hot-mix asphalt for Wyoming Department of Transportation projects near Sheridan. The DOT project is expected to require 30,000 tons of base and 37,000 tons of asphalt, according to The Sheridan Press. The operator was given a four-year permit, and the operation will be permitted to work around the clock from Monday through Saturday. Several other conditions apply.

Wisconsin

The Town of Deerfield Board held a special meeting to consider several ordinances governing non-metallic mining. The Cambridge News reports that it considered three resolutions: Non-Metallic Mine Operator’s Licenses, Town of Deerfield Blasting Ordinance, and A Resolution Establishing Fees for Non-Metallic Mining and Blasting Licenses in the Town of Deerfield. During discussion of the proposed ordinances, Jon Halverson, who owns and operates Oak Park Quarry; legal counsel; and a blasting consultant explained the technical aspects of blasting. At the end of the meeting, the board tabled the first ordinance and planned to re-write it to separate fracking from quarry mining. The proposed fee schedule was tabled to allow the operator to review it. The blasting ordinance was adopted by the full board.

Wisconsin

If Yahara Materials wins a bid to supply materials for the Interstate 39-90 construction project, the state Department of Transportation will allow the new quarry to open on Highway 73 in Albion. According to the Wisconsin State Journal, a DOT state access committee required the operator to pay for an extra lane on the far side of the quarry entrance so traffic can pass trucks turning left into the quarry. DOT Access Manager Scott Hinkle also wanted the quarry to add a full lane for trucks turning right out of the quarry driveway and onto the highway. He initially turned down the operator’s request to access the highway from the quarry, but was overruled by the committee. Yahara Materials president Tim Geoghegan told the newspaper that the highway will be widened for better egress, but it won’t be a full lane. He also pointed out that plans for the quarry entrance are the same as similar entrances on Highway 73.

15-MCL-0588_MayJune_AggregatesMgr_AD.indd 1 Untitled-5 1

mclanahan.com

AGGREGATES MANAGER May 2014

4/6/15 4/13/15 12:26 9:51 PM AM

Performance, Value and Technology are just a few of the things we deliver.

www.BKT-tires.com

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

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

Loaders boast bucketheaping ability KCMA Corp. rolls out the 95Z7 and 115Z7 XTreme wheel loaders. It says the units reflect recent demand for the short boom, load and carry, or two-pass configuration loaders. Both machines were tested in various applications and environments. KCMA says the results exceeded expectations for fuel economy and breakout force, but also notes that bucket-heaping ability stood out. The 9.0-cubic-yard 95Z7XT bucket weighed in at more than 15 tons with sand and 13 tons with gravel. That unit is also available with a 9.8-cubic-yard bucket, while the 115Z7XT is available with a 9.15-cubic-yard bucket. To accommodate the weight demands, the boom arms are shorter, thicker, and stronger. The bucket hydraulic cylinder bore is larger. The chassis was reinforced to handle additional torque and load, while the counterweight was also increased. KCMA Corp. | www.kawaskiloaders.com

Fuel-efficient Tier 4 dozers John Deereâ&#x20AC;&#x2122;s 550K, 650K, and 700K Crawler Dozers meet Tier 4 Final emission standards and offer features such as Eco Mode, which can offer fuel savings of approximately 20 percent without any loss of productivity. A new push-button throttle controls engine rpm, as opposed to a rotary dial. The 550K and 650K incorporate a PowerTech 4.5L diesel engine with 92 horsepower and 104 horsepower, respectively. The 700K boasts a PowerTech 6.8L diesel engine with 130 horsepower. DPF cleaning occurs automatically, with up to 15,000 hours before ash removal. Additional customer favorite features include blade shake and courtesy lighting. John Deere | www.JohnDeere.com

Crusher duty motor Baldor Electric says its new line of crusher duty motors feature improved reliability, performance, and energy efficiency to help lower the total cost of ownership. Baldor-Reliance crusher duty motors are engineered for the demanding high-torque applications and harsh environments of the aggregate, cement, and mining industries. It is available in frame sizes 180T to 449T and power range of 5 to 350 horsepower. The rugged cast-iron design is said to minimize vibration and bearing temperature. With higher breakdown and locked rotor torque performance, the manufacturer says Baldor-Reliance crusher duty motors meet the demands of the toughest crushing applications. Baldor Electric | www.baldor.com AGGREGATES MANAGER May 2015

ROLLOUTS

Robust portable jaw crusher Terex Finlay’s Finlay J-1170AS mobile jaw crusher is built around the Terex 44-inch by 28-inch jaw crusher. The jaw chamber is available with optional hydraulic release with an automatic overload protection system to prevent damage by uncrushable items in the feed material. An onboard after-screen delivers a single-sized product, removing the need for a second machine. It can also be removed quickly to allow the operator to use a standard unit. An automatic variable-speed VGF ensures continuous choke feeding of the crushing chamber, while the hydraulic-assisted closed-side setting adjustment is said to minimize downtime and allow for quick adjustments.

New series of artic trucks Cat 735C, 740C EJ, and 745C articulated trucks include engines that meet Tier 4 Final emission standards, as well as new transmissions with expanded electronic control, automatic traction control, automatic retarder control, hill assist and waiting brake systems, and an optional payload weighing system. The upgrades are aimed at delivering lower cost per ton by reducing cycle times, saving fuel, and easing operator workload. The rated capacities for the new models are 36, 42, and 45.2 tons, respectively. The new 745C’s 1.7-ton capacity increase, compared to the 740B’s capacity, combines with its faster cycle times for significant production gains. Caterpillar | www.cat.com

Terex Finlay | www.terexfinlay.com

Efficient dust control Soilworks introduces a patent-pending gas-to-liquid technology with its Durosoil dust control product, which, it says, results in the most efficient dust control product in the world. Rather than using petroleum-based dust suppressants or synthetic fluid derivatives made from crude oil, its dust control fluid is produced from natural gas. The manufacturer says Durasoil’s synthetic fluid properties control dust on a micron level by “wetting out” any soil or aggregate to create a long-term, reworkable, self-healing solution. Soilworks | www.soilworks.com

Parallel blasthole drilling Atlas Copco’s BenchRemote remote operator station allows drillers to operate more than 100 yards from the drill, which can be more than 30 yards below them, as long as they maintain line-of-sight radio communications. The increased distance from highwalls and machines on steep or rough terrain can improve worker safety. The device installs on a vehicle, trailer, or container. Its controls and displays mirror those of the working rig, giving the operator the same capabilities as working from the rig itself. A closed WiFi network communicates operator inputs and machine feedback independent of the local network infrastructure. If the network is lost for any reason, the rig automatically shuts down as an additional safety precaution. Atlas Copco Mining and Rock Excavation | www.atlascopco.us

AGGREGATES MANAGER May 2015

GAME CHANGER NEW Terex® Cedarapids “V” Screens Deliver UNMATCHED Production The revolutionary design of our new LJ-TSV screen combines the legendary El-JayTM oval stroke with the unique ability to vary the screen slope to increase production and handle applications that are not possible with traditional horizontal screens.

Features of the NEW LJ-TSV Horizontal Screens: *Screen installs from 0° up to 10° in 2.5° increments to best fit the application for increased capabilities *Variable slope allows screen to handle larger deck loads and bigger screen openings for increased production More steel in “rock zone” for industry leading durability High G-force, El-JayTM oval stroke design for high efficiency *Optional bottom deck deflector plates boost efficiency Easy to maintain — new maintenance reducing features *Patent Pending

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

ROLLOUTS

Tier 4 Final excavator Komatsu America Corp. introduces the PC390LC-11 hydraulic excavator. With a net 257 horsepower, it is powered by a Komatsu SAA6D114E-6 engine. With operating weights ranging between 87,388 and 89,248 pounds, the upgraded cab features and enhanced power mode are said to offer greater productivity and a lower cost per ton. The unit features a one-size-classlarger heavy-duty undercarriage components for high lift capacity and lateral stability. The larger undercarriage has a 6-percent wider track gauge and offers up to 18 percent greater over-the-side capacity than the PC360LC-11. It is equipped with the latest Komtrax technology, and a new Operator Identification System reports key operating information for multiple operators. A new Auto Idle Shutdown function helps reduce idle time and operating costs. Komatsu America Corp. | www.komatsuamerica.com

Vibration analysis service program

SCALE

ISO CERTIFIED

W.S. Tyler, the processing arm of Haver & Boecker, introduces the Pulse vibration analysis program. Designed to monitor the health of vibrating screens to ensure performance and durability, it detects irregularities that could diminish performance, decrease efficiency, or increase operating costs of the vibrating screen. Reporting and historical tracking provide the operator with equipment insights. The system consists of both hardware and software to record vibrations. Data is transmitted to the manufacturer, where engineers can analyze it. The system consists of an industrial grade tablet with wireless technology to connect with eight tri-axial sensors. The sensors are placed in key places on the equipment and send 24 channels of data to illustrate the machineâ&#x20AC;&#x2122;s orbit, acceleration, deviations, and more. W.S. Tyler | www.wstyler.ca

AGGREGATES MANAGER May 2015

“With the roller bearing crushers, we don’t pour that steady stream of money into the crusher.”

Kevin Storedahl J.L. Storedahl & Sons

Kodiak® Plus roller bearings reduce operating expenses by up to 50%. Patented Tramp Iron Relief System significantly reduces stress. Patented internal counterweights maintain true balance. Anti-spin cone brake extends manganese wear life.

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Tier 4 Final motor grader Komatsu America Corp. rolls out the GD655-6 motor grader. Featuring 218 net horsepower, the unit is said to deliver a high-performance, more environmentally friendly engine that burns less fuel and costs less to operate. Standard features include a Turbo II precleaner, independent blade lift float, frontmounted work lights, and a toolbox with lock. Also standard on the grader are 10 control valves, leaving two extra valves with linkage for additional attachments. Komatsu America Corp. | www.komatsuamerica.com

Portable counting scales Cardinal Scale’s new C series digital counting scales can be used for QA/ QC samples. The C series scales are available in 6-pound, 30-pound, and 65-pound capacities and feature a built-in rechargeable battery pack (standard), up to 99 stored product look ups, sturdy stainless-steel platform, backlit LCD, preset weight and quantity limits with audible beep alerts, and weight accumulator mode. Cardinal Scale | www.cardinalscale.com

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Mining & Aggregates

Topcon’s new GLS-2000 is equipped with ultra high speed scanning that provides time saving benefits without compromising accuracy. With a scan range of over 350 meters, a full-dome 360° x 270° field-of-view, and a simple one-touch operation, the GLS-2000 is a rugged and versatile tool that enables you to capture accurate 3D data in all your challenging work environments, across all your applications. The GLS-2000 is an industry-leading scanner that no serious practitioner should be without. topconpositioning.com

AGGREGATES Untitled-34 1 MANAGER May 2015

12/18/14 10:56 AM

ROLLOUTS

App offers on-the-go insights GivenHansco introduced its Keystone On-Demand Mobile App. An extension of its Keystone Dispatch, Truck Tracking, and Financials suite, the app provides live business intelligence to ready-mix sales personnel, plant managers, and owners. Written for and compatible with most iPad and Android devices, its features include a drill-down schedule of data from plant overview to ticket detail, tracks truck on-job times and offers a view of a live GPS map, shows customer account balances and ticket history, and provides sales with job site awareness to solve problems on site. GivenHansco | www.givenhansco.com

Medium-duty dump truck Curry Supply Co. expanded is commercial service truck product line with the introduction of a medium-duty dump truck. It features a 5- to 6-cubic-yard fill capacity, 7 gauge ASTM steel construction, continuous welds, formed side walls, hydraulic 18-ton hoist with a 50-degree dump angle, and pintle hitch plate with 25-ton capacity. The dump bed can be installed on all makes and models of chassis. Curry Supply Co. | www.currysupply.com

As the only synthetic screen media producer to use injection molding exclusively, we can produce premium quality screen panels faster than anyone. • Many popular screen panel designs kept in stock; • Non-stock screen panel orders shipped in 2 to 3 weeks; • Emergency service available. Can 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 or dealer in your area.

AGGREGATES MANAGER May 2015

Cubee the AggMan helping educate children about the importance of aggregate since 1998 “The Story of Cubee the Aggregate” helps teach children at the youngest ages about the important role aggregate plays in their daily lives. Geared for students in grades K-3, Cubee and his aggregate friends will take children on a magical journey from Cubee’s birthplace in the neighborhood quarry to his new home in the schools, roads and other structures that enrich our communities and our lives.

The “You’re on Rock” Workbook presents basic earth science information while emphasizing the vital role of the industry in our world. An aggregate activity book for junior geologists, mining engineers and earth scientists. Geared for students in grades 4-6.

Cubee the AggMan T-Shirts are available. To learn more about these great tools for community outreach, adopt-a-school programs, and receive sample copies of the coloring/workbooks,

Call 800-430-4540 e-mail: cubee@aggman.com

or visit www.AggMan.com

PULL-OUT GUIDE By Kerry Clines, Contributing Editor

OPERATIONS ILLUSTRATED ri Take

ifferent D A : y a l P e z S q u ee Filter press turns slurry into dried cakes

Filter press requires minimal space

Dried cakes drop from filter press

Filter presses create no open water hazards

Dried material is easily removed by wheel loader

on Dewate ng

OPERAT 1

Out with the old settling pond

Solving Fines Problems

ilter presses have been used in aggregate operations in Europe for some time, but they were most commonly found in waste water treatment plants in the United States…until recently. Now that the technology has been introduced to the aggregates industry in North America, things have been changing. “Over the past three or four years, filter presses have really taken off in the United States,” says Cory Jenson, general manager – Environmental Division, McLanahan Corp. “We think the trend here in the U.S. is moving the same way it happened in Europe,” he says, “and for us, it’s growing very fast. There are more and more people considering filter presses and putting them in.” Though there are several factors that have helped filter presses gain interest in the aggregates industry, many producers see them as a way to reduce the number of settling ponds they have at their operation or eliminate them altogether. This might be due to a lack of space, difficulty in acquiring a settling pond permit, or the extra expense and time spent cleaning out a settling pond. “We don’t have an abundance of room for multiple settling ponds, and we don’t have an abundance of room to clean out the settling ponds and lay the clay material out to dry,” says AGGREGATES MANAGER

Jason Voss, quarry operations manager at Stevens Creek Quarry, which had a filter press installed on site two and a half years ago. Though the name suggests that water is pressed out of the fines slurry, that’s not what actually happens. A filter press consists of a series of recessed plates that are hollowed out on each side. When the plates are put together, they form a chamber between the plates. Each chamber is lined with filter media so that, when the plates are put together and the fines material is fed into the chamber, the pressure from the slurry does the dewatering. Once the chambers are full of solids, they open, and the dry material falls out in cakes. “The dry cakes that come out of the filter press look like a big thick mud flap, like what you’d find on a truck,” says Bryan Pfohl, current president and chairman of Carolina Sunrock LLC and Sunrock Group Holdings Corp. “What comes out of the press is a clean, finished product, so to speak, and has the possibility to be used for other purposes.” Jenson agrees. “Sometimes, depending on the material, the location, and the market, the cakes can become a saleable product for an operation,” he says. “Everybody’s tailings are different, so it depends on what it consists of as to what it can potentially be sold for.”

Over the past three or four years, the filter press has gained interest among aggregate producers who see it as a way to reduce the number of settling ponds they have at their operations or to eliminate them altogether. The desire might arise from a lack of space for a pond, difficulty in acquiring a settling pond permit, or the expense and time involved in cleaning out the pond, not to mention plant downtime during the clean out process.

Water is recirculated

The filter press system is a closed-loop system that recycles the water. As the solids are removed from the slurry, the water is sent back to water tanks for storage and reused in the processing plant, as needed. Settling ponds lose a lot of water to evaporation because of their openness, as well as when they are cleaned out. Only a small amount of water is lost through the filter press’ closed-loop system, which is what is left on the finished products.

TIONS ILLUSTRATED Squeeze Play: A Different Take on Dewatering 2

In with the new filter press

Usable/saleable product

Many aggregate producers are foregoing the traditional settling pond and replacing it with a filter press system. A filter press consists of a series of recessed plates that are hollowed out on each side. When placed together, the plates form a chamber, which is lined with filter media. When the slurry material is pumped into the chamber, the water is forced out, leaving behind only solids. The chambers then open up, and the dry material drops out.

The dry cake material that comes out of the filter press is a clean, finished product that resembles the mud flap on a truck. The material can be used for reclamation by mixing it with stripping material to backfill areas of the quarry where mining has been completed. Depending on the type of deposit, the location, and the market in the area, the material might also become a saleable product that can be used for a variety of purposes.

Easy to handle material

In most cases, the dried cakes of material are dropped onto the ground beneath the filter press. A wheel loader can then scoop them up and load them into a haul truck for easy removal. One quarry operator took the process a step farther by installing the filter press over a set of bins with hoppers, so the cakes of material fall out of the filter press directly into the hoppers. A haul truck can then drive beneath the bins, load up the material, and remove it.

Easy setup and operation

The modular construction of the filter press system and its design allow for quick, easy setup and start up. The system is automated, easy to use, and requires very little maintenance. One employee can run both the processing plant and the filter press, so no additional manpower is required. While the filter press turns fines into a manageable product, the processing plant can continue operating, which means no unnecessary downtime.

OUR EXPERTS Bryan Pfohl is president and chairman of Carolina Sunrock LLC and Sunrock Group Holdings Corp., which supplies construction aggregates, ready-mixed concrete, hotmix asphalt, and contracting services in the Raleigh/ Durham metropolitan area of North Carolina. He has been actively involved in the 66-year-old, family-owned business for his entire adult life. He has also been involved in the business and construction materials communities.

Cory Jenson is the general manager â&#x20AC;&#x201C; Environmental Division for McLanahan Corp. He graduated cum laude with a degree in finance and chemistry from Utah State University. Jenson has designed and developed water management systems around the world, and led the design and development of McLanahanâ&#x20AC;&#x2122;s filter presses. His main areas of expertise are fines recovery, thickening, water recovery, and filtration.

Jason Voss is the quarry operations manager at Stevens Creek Quarry, a small, family-owned quarry in the Silicon Valley area of California. He is the fourth generation to work at the quarry, which was started by his great-grandfather in 1936. Voss handles all the day-to-day operations at the quarry, as well as at the companyâ&#x20AC;&#x2122;s recycle crushing operations.

May 2015

Voices of Experience Bryan Pfohl

North Carolina company recently installed a Matec filter press at one of its quarries that mines trap rock. “Trap rock fines are more difficult to work with because they have a completely different nature in the settling pond environment,” says Bryan Pfohl, president and chairman of Carolina Sunrock LLC and Sunrock Group Holdings Corp. “Where most rock types will settle easily on their own, trap rock requires flocculants to get the fines to settle, and if you disturb them, they re-suspend themselves and won’t settle.” Pfohl says they tried a variety of solutions at the 31-year-old quarry. The conventional wet settling ponds were messy and difficult to clean out. The dry collection system that separated the fines during the manufacturing process was only moderately successful. He knew he had to find a better way. “We studied the filter press system and elected to go with it for a variety of reasons,” Pfohl says. “It offered more of a batch-type nature, had the resiliency to give us some flexibility of growth in our system, and we felt it was easier to operate for our personnel, by its nature.” Pfohl says where most operations allow the filter press to drop the dried cakes of material on the ground, his operation installed it over a set of bins. When the cakes fall out of the filter press, they go right into a series of hoppers. A dump truck can drive beneath the bins, load up, and carry the material away to a disposal area or use it for other industrial purposes. “The filter press was a large capital investment, so the capital payback is slower,” Pfohl says. “Now that we’ve operated it for a while, we’ve been quite satisfied with it, but people have to make a personal judgement based on their personnel and their material to determine what’s best for them.”

AGGREGATES MANAGER

Cory Jenson

ilter presses have only recently found a place in the aggregates industry in the United States, according to Cory Jenson, general manager – Environmental Division, McLanahan Corp. “There’s now a pretty wide acceptance of the technology,” he says. “When we first introduced it here, the early adopters were ready to jump on board, but a lot of other companies wanted to wait and see how it went. Now, people are a lot more comfortable with it.” Jenson says there are several factors that make filter presses of interest to aggregate producers. Some operations are running out of space for settling ponds. In some cases, it may be too expensive for the operation to put in and maintain a pond. At first glance, it may seem cheap to dump processing water into a settling pond, but cleaning it out can be very expensive. Environmental regulations can be another factor, as well as the lack of water in some areas of the country. “We’re putting in filter press systems where people can’t get a permit for a new settling pond or are uncertain of getting a permit,” Jenson explains, adding that some prefer the closed-loop filter press system so they don’t need complicated permits. “Where water is a constraint or costly, it’s definitely an advantage to recycle as much water as possible. If they do it right, they can use it for good public relations. They can show that they’re trying to do everything in the most environmentally friendly way possible.” Safety is another reason some aggregate operations are looking to replace settling ponds with filter presses, according to Jenson. Most operations are concerned about the possibility of a child or someone else falling into a settling pond full of mud. Equipment operators have died in the past when the equipment they were driving broke through a berm or toppled over into a settling pond.

Jason Voss

small family-owned quarry in California has been using a McLanahan filter press, along with a deep cone thickener, for two and a half years. “We pretty much operate on the side of a mountain, so we don’t have a lot of real estate,” says Jason Voss, quarry operations manager at Stevens Creek Quarry. By installing a filter press on site, the company was able to put a concrete pad where the settling pond was and turn it into a stockpile area for finished product. Voss says he wasn’t sorry to see the settling pond go. Cleaning it out was very expensive and time consuming, and the material had to be handled several times. The material that comes out of the filter press is a much drier product than they were ever able to get from the settling pond, and it’s much easier to handle. “Now, we handle the material once when we load it right out from underneath the filter press and put it into the truck,” he says. “Then we haul it up to the reclamated fill to compact it in, and we never have to touch it again.” The lack of space to have more than one settling pond created another problem for the quarry. “We had to build up a large inventory and then shut the plant down for a week to clean the settling pond,” Voss says, explaining that this caused a big fluctuation in inventory. “Now we’re able to keep a steady inventory and press mud while we’re operating, so there’s no downtime.” The fact that the filter press offered automation was also a big deal for the quarry. “We wanted to make sure that a certain part of the filter press was automated so we wouldn’t have to put more manpower in the plant,” Voss explains. “The same operator who runs the processing plant is able to run the filter press.”

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Educating operators and maintenance personnel on Tier 4 engine requirements will help ensure machines are operated efficiently while achieving the greatest amount of productivity.

Controlling Equipment

Ownership Costs It’s all about production — and production is more profitable when equipment owning and operating costs are kept down with these eight guidelines. by Brad Stemper

AGGREGATES MANAGER May 2015

ggregates operations are all about production. Everything relates to how quickly (and safely) overburden can be stripped, and the material below be recovered and processed. Speed has a big effect on production costs, as does general equipment owning and operating costs. Labor efficiency also plays a role. This article looks at ways that aggregate producers can keep the total cost of ownership for their equipment down and maximize profits on production.

Cutting down on idle time with telematics

Telematics provides a lot of data — what you do with that data is what gives you an advantage. One of the more simple pieces of data is engine idle time. Engines aren’t built to idle — it is a cause of unnecessary wear to

the engine and its related components, and a complete waste of fuel. Engine idling most often signifies one of two things. The first is simple operator inactivity, which can be addressed/corrected through coaching. The second is…

Right-sizing equipment/ workflow synchronization

Idle time can also be a symptom of equipment that is not optimally matched to the application. A wheel loader with a 6-cubic-yard bucket may be matched with a hopper that can’t handle that much material at once. That loader may be completing a simple cycle and then sitting and waiting for the material to cycle through before it can dump the next bucket. This idling is not an efficient use of the machine and may indicate any number of possible improvements to the operation.

MINE MANAGEMENT

Do you need that large wheel loader with a 6-cubic-yard or would a smaller wheel loader with a 3-cubic-yard bucket be more efficient (and ultimately offer a lower owning/operating cost)? Are there improvements to the plant to allow it to process material faster? Identifying a piece of equipment not operating to its full potential can expose other efficiencies that can be implemented upstream or downstream of that machine.

Incorporating pre- and post-shift walk-arounds

The “preflight check” is critically important in production environments because there is no downtime throughout the day to be outside of the machine and identify something visually wrong with the machine (or the working surroundings). Each operator should perform a routine machine walk-around before and after each shift looking for leaks, structural damage, irregularities, etc. Identifying these proactively may cut down on future downtime.

Optimally scheduling maintenance Aggregate production works like clockwork. If it’s a 10-hour shift, that machine is operational for 10 hours. If a facility works multiple shifts, maintenance can only happen between shifts. Telematics automates machine hour tracking so the fleet manager can schedule service during planned downtime without affecting productivity. Similarly, telematics can alert the fleet manager to operating factors outside of acceptable parameters, which may be a symptom of something wrong with the machine — allowing them to get ahead of potential downtime.

Managing equipment utilization For large fleets and decentralized operations — possibly with multiple locations spread out across a region — it may be easy to overlook underutilized pieces of equipment. You might need a wheel loader in Quarry A, but you may not know that a wheel loader in Quarry B is only used 20 percent of the time. Getting a better understanding of equipment utilization through telematics can help you better deploy equipment and reduce unnecessary equipment rental/purchases when you think you are in need of another machine, but actually have the assets sitting elsewhere, ready to go.

A simple metric such as engine hours tracked via a telematics program can be very important in keeping ahead of preventive maintenance.

Other equipment options/upgrades (telematics, machine control, special guarding, or auxiliary systems) also affect total cost of ownership less when worked into the initial purchase price. It may seem like a minor detail, but take into consideration the costs involved with taking that machine out of service (downtime), and the costs associated with adding that feature or technology at an aftermarket price. Is it better to spend $1 now or $2 later? Working those added features and capabilities into the initial purchase price establishes one cost up front with standard/consistent payments. Factory fit features generally offer/equate to factory quality and warranty. Aftermarket features/components may not be covered under warranty, and the installation of such components by non-certified technicians can lead to further operating issues or a warranty impact.

Properly outfitting equipment at time of purchase

Plan ahead for whatever options or auxiliary items may be useful on the machine rather than waiting to add at a later time. It’s important to outfit each machine with the optimal cutting edges/teeth to match the type of material it will be working in. Efficiency can decrease considerably if the right teeth aren’t used, or simply are worn.

Depending on the part and the machine, a remanufactured part can cost up to 40 percent less than a comparable new part. AGGREGATES MANAGER May 2015

MINE MANAGEMENT

controlling track spinning. Identifying and curtailing “rowdy” or unsafe operating practices is also important to reduce possible damage to the machine and the jobsite. For instance, an operator may be reckless in a loading application and damage the sideboard of the truck he’s loading. That results in unplanned out-of-pocket expenses and potential downtime.

Using remanufactured parts The practice of OEMs remanufacturing parts has grown in recent years and has evolved to include thousands of parts and components in stock that can be shipped to equipment dealers upon request. This can be a significant advantage for fleet managers as they On tracked machines, the undercarriage accounts for a majority of maintenance costs over the race against the clock to get equipment life of a machine. Keeping it in optimal operating condition will help keep costs down. back up and running. That’s the first advantage: Rather than having a machine “down” while a major component is rebuilt, or having to rent a replacement machine in its place, Ensuring operator training the customer can purchase a remanufactured part and have How a machine is operated can have a significant effect on it installed immediately upon receipt. Remanufactured parts its bottom line. Operators can be coached in ways to reduce come ready to install and can significantly lower downtime equipment costs, including methods to reduce idle time, opand repair costs. erating the machine in a manner that puts the least amount Another advantage of a remanufactured part is purchase of wear and stress on an undercarriage, and proper use of price. Depending on the part and the machine, a remanufacmachine controls and functions to optimize fuel efficiency. tured part can cost up to 40 percent less than a comparable This can be as simple as educating an operator on how new part — all without sacrificing quality. Quality is as good different controls affect fuel efficiency: a wheel loader, for as a new part and better than a rebuilt part, and remanufacinstance, may be able to perform the same loading cycle in tured parts can provide an apples-to-apples cost savings in an eco/fuel efficiency mode as it would operating at full rpm many cases. in a standard or power boost setting. In this case, there’s no Remanufactured parts can also feature warranties that practical reason to run at the less efficient setting. are better than what a rebuilt part can offer and may meet or Educating operators on how features such as return-to-travel, exceed other OEM warranties. This provides fleet managers return-to-dig, and height control work will help make their with peace of mind and protection against additional costs cycling more efficient and, ultimately, optimize the power during the life of the warranty. being put into the machine to complete the task. These are just a few recommendations for lowering the Operator practices can have even greater effect on tracked total cost of equipment ownership — and the suggestions are machines — and can be more costly because a greater perrelatively universal, whether working with wheel loaders, centage of the machine’s costs are wrapped up in mainexcavators, or skid steers. What may seem like relatively tenance and upkeep of that undercarriage. Higher speeds minor changes may significantly lower equipment costs, can affect the wear rate on pins, bushings, and sprockets; which will ultimately improve overall profits on the produced counter-rotation, or pivot turns, can cause accelerated wear product. AM on the undercarriage; constant operation on hills in one direction can accelerate wear to idlers, rollers, and guide lugs Brad Stemper is the solutions marketing manager for CASE by placing greater force on one side. Some other key pracConstruction Equipment. tices for operators include alternating turning directions and

AGGREGATES MANAGER May 2015

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To learn more about an NSSGA membership that is a perfect fit for your business, go to www.nssga.org/eProducer today.

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A vibrating grizzly feeder absorbs the shock of dump loads and provides a regular feed to the crusher.

AGGREGATES MANAGER May 2015

EQUIPMENT MANAGEMENT

Feed the Beast A vibrating grizzly feeder not only absorbs the shock of large dump loads, it also improves the efficiency of the primary crusher. by Dave Anderson

n the world of aggregate crushing, the word “feeder” can apply to many different devices. There are roller belt feeders, apron feeders, electromagnetic feeders, pan feeders, and others. This article focuses on a feeder type that plays a critical role in the efficient operation of primary crushers — the vibrating grizzly feeder or VGF.

The purpose of a VGF is twofold: to absorb the shock of large dump loads and to maximize the pri-

mary crusher efficiency. It makes the primary crusher more efficient by supplying a constant, metered rate of feed to the crusher and by pulling fines from the feed material to keep it out of the crushing chamber. VGFs handle a variety of material types from large shotrock to sand and gravel; from highclay aggregate to recycled concrete; from iron slag to gold-laced shale ore. The VGF also helps to clean and separate sticky or conglomerate type materials prior to entering the crushing chamber. The VGF takes a beating in most primary applications, allowing the rest of the circuit downstream to operate at an optimum level. For this reason, the VGF should be a point of focus for regular inspections and preventive maintenance. Like all discussions on aggregate processing equipment, the starting point is to talk about safety. Always follow the OEM guidelines and your company’s lock-out/tag-out procedures prior to starting maintenance or repair work on a VGF. Always use the correct lifting devices that have been inspected and calibrated for your requirements, and don’t lift with your back. Since most VGFs operate on the basis of unbalanced weight rotation, make sure all stored energy has been relieved prior to working on the machine. Work smart and stay healthy!

Use the right settings for the application Vibrating grizzly feeders use medium speed rotating eccentric shafts to “throw” material down the feeder and into the crushing chamber. Even though most feeders operate at a lower rotations per minute (rpm) than typical material sizing devices (screens) — typically in the 500 to 800 rpm range — the bearings on the feeder shafts are still subject to the stresses of friction at a medium speed over long time periods. Friction leads to high heat generation, the enemy of bearings in any situation. This is one of the many forces acting to wear down your vibratory equipment. Maintenance personnel are charged not only with keeping equipment in good shape and running smoothly, but also attaining the most uptime from every piece of equipment and making it last as many years as possible. There are several

AGGREGATES MANAGER May 2015

stroke angle will feed the material at a slower feed rate and allow the crusher to more efficiently process the aggregate without overfilling the crusher feed hopper. The VGF feed rate can also be controlled by varying the feeder rpm, preferably with a variable frequency drive controller on the feeder drive. Make sure that the variable speed controller is tuned to the OEM minimum and maximum allowable speeds. A lower angle VGF stroke angle, on the Know the meaning of all safety emblems on the vibrating grizzly feeder and respect their message.

other hand, will concentrate the agitation toward the discharge or grizzly end of the

feeder. Imparting a more lively action to the grizzly can lessen the chances of material wedging between the grizzly bars, maintain a thinner bed depth of material, and move it more quickly down the feeder and into the crusher. Again, in combination with a variable frequency controller, the operator can tailor a horizontal stroke angle to move material more quickly into a crusher to keep it properly fed. By ensuring the feeder is set to the correct operating angle, both feeder and crusher efficiencies will improve. Always refer to the OEM manual for correct stroke angle for the application and keep a magnetic stroke gauge handy to accurately check the feeder’s performance. Anyone connected with the maintenance or repair of aggregate equipment knows that the old adage “speed kills” is Always follow both your company’s lock-out/tag-out procedures and those included in the OEM guidelines.

applicable to all vibratory equipment, including vibrating grizzly feeders. Simply running a VGF faster will not always equate to more material into the crusher, but it will lead to more frequent

factors involved with operating and maintaining a VGF feeder to

bearing changes and possible costly failures. The faster a bear-

ensure optimum daily operation, as well as maximum longevity.

ing turns, the sooner it will wear out or fail, so it’s important to

These include the following:

understand the “sweet spot” of speed vs. production. Consult

• Stroke angle of the feeder,

your OEM guidelines for the rpm range for the feeder and the

• RPM of the driven shaft, and

nominal operating temperatures of the feeder bearings. Set

• Maintenance schedules.

up the feeder drive according to their specifications, and keep

Let’s look at these factors in closer detail. Most vibrating

a good log of the feeder bearing operating temperatures as

grizzly feeders in our industry have adjustable throw capability,

compared to the OEM temperature limits. This will allow you to

which allows the angle of eccentricity to be changed.

recognize a bearing problem early on and have time to address

A more vertical throw will concentrate the agitation toward

it before a major failure. Maintaining the correct feeder rpms is

the intake end of the feeder. This can assist in loosening sticky

sound advice to reduce labor costs and down time — and it may

material and allow more fines to work down to the bottom of

save your new equipment warranty!

the material bed for removal at the grizzly. Applications with this setting by retarding material flow and keeping it on the

Implement the appropriate preventive maintenance routines

feeder longer. In applications where material is at the top end

All of the above information goes out the window if the vibrat-

of allowable feed size to a jaw crusher, the more vertical VGF

ing grizzly feeder is not being regularly and correctly main-

a high percentage of fines or sticky material may benefit from

AGGREGATES MANAGER May 2015

EQUIPMENT MANAGEMENT

MIND-BLOWING EFFICIENCY A more vertical stroke angle feeds material at a slower rate, which allows for efficient crushing without overfilling the crusher feed hopper.

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By adjusting the throw, the operator can achieve different goals. For example, a more vertical throw concentrates agitation toward the intake end of the feeder, which works well with sticky materials. A lower angle concentrates agitation toward the discharge end, which is appropriate if the operator is concerned with material becoming wedged in the grizzly bars.

Call today. 1-800-2 MR COOL or go online at www.hammondac.com and order your system and parts today.

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081-135A Equip World 4.5x4.5.indd 1

AGGREGATES MANAGER May 2015

2015-03-17 12:12 PM

www.AGGMan.com Aggregates Manager Magazine is proud to announce the launch of the new mobile version of AGGMan.com. Stay up-to-date while you are on the go, with the latest news in the aggregates industry along with insight from our award-winning editorial team.

EQUIPMENT MANAGEMENT

tained. Most OEMs will require the completion of a delivery in-

important to understand the lubricants that are required. All

spection form upon receipt of a new feeder at the dealer/customer.

manufacturers provide recommended lubrication for their equip-

This is a critical document which will be required by a transport

ment in the operations and maintenance manuals, so be sure

company should alleged damage occur during transit. Both the

to keep that manual nearby. It’s important to follow lubrication

operator and the OEM benefit from the time taken to accurately

recommendations for brands, number designation, temperature,

complete and submit this form. Some OEMs require this docu-

viscosity, and synthetic or natural type oils.

ment to be completed and submitted in order to initiate the new

Keep your vibrating grizzly feeder running at peak efficiency,

machine warranty period. Along with this form, some manufactur-

and it will serve the rest of the crushing circuit well and provide

ers will also specify a new equipment start-up procedure to help

years of dependable operation. AM

ensure the new machine is started up correctly. Again, following and completing these documents are the best way to protect the

Dave Anderson is an applications specialist with Terex Minerals

operator, dealer, and OEM when processing new equipment.

Processing Systems.

Once a new feeder has been properly processed and all forms completed and submitted, a regular maintenance schedule needs to be in place. Most OEMs will outline required maintenance items in the VGF operations and maintenance manuals. These regular maintenance checks are typically broken down into daily (before, during, and after operation), weekly, and special instructions for extended shut down and storage. Here are some examples of these checks:

Vibrating grizzly feeders are also available for portable operations.

Daily maintenance checks: Before start up:

CONVEYING PERFORMANCE

 Check all lubrication fluid levels  V-belt tension During operation:  Abnormal movement of feed box  Unusual noises

IDLERS | PULLEYS | IMPACT BEDS | ACCESSORIES

 Unusual vibrations  Smell of overheated or smoking lubricant Luff offers a complete line of conveyor components to fit your application needs.

 RPM of feeder  Grizzly bar plugging After operation:  Bearing temperature check  Driven sheave and bushing tightness  Feeder hopper and base hardware

All products come with a

 Grizzly bar damage

FULL YEAR WARRANTY

Weekly maintenance checks:  V-belt condition  Springs equal height and not worn, cracked, or broken  Inspect liners for wear, cracks  Smooth grizzly bar worn, sharp edges  Change lubricating oil (per manual)  Check all electrical connections Luff Industries Ltd.

When topping off or changing oil in any vibratory unit, it’s

tf: 1.888.349.LUFF (5833)

w: www.luffindustries.com

e: info@luffindustries.com

AGGREGATES MANAGER May 2015

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

JUST ROLL WITH IT Conveyor components keep aggregates rolling smoothly throughout your operation.

Severe-duty conveyor pulleys Its Dodge CEMA conveyor pulleys have been operating the world’s most demanding material handling applications for more than 100 years, says Baldor Electric Co. An extensive range of pulleys can be provided with high-quality lagging designed to ensure maximum belt and pulley life in severe duty applications. Standard Dodge Heavy-Duty Drum pulleys meet or exceed CEMA application standards for use with conveyor belts rated to 800 pounds per inch of belt width. Baldor Electric Co. | www.baldor.com

New design lowers belt cleaner cost Martin Engineering says its new conveyor belt cleaner was engineered to contain a smaller total volume of urethane, while maximizing the useable area. By minimizing the non-consumable portion of the blade, the heavy-duty primary belt cleaner is said to deliver the same performance and durability of its predecessor, but at a lower purchase price. It is manufactured with the company’s Constant Angle Radial Pressure technology to maintain an efficient cleaning angle throughout its service life. It also features a no-tool replacement process that can be safely performed by one person in less than 5 minutes. Martin Engineering | www.martin-eng.com

Wobbler keeps belts on track The wobbler from Hewitt-Robins is a training idler designed to solve common conveyor belt training problems. Its unique design, a steel roll centered on a 2.36-inch ball bearing, pivots when the conveyor belt moves off-center and guides it back to allow for efficient conveyor operation. The wobbler is available with a steel roll or with a 1/4-inch urethane cover for sticky material or adverse weather conditions. With the urethane cover, the trainer is said to eliminate material build-up on the idler’s surface. Wobblers are stabilized by two simple brackets and have no framework on which material can build up. Motion Industries | www.motionindustries.com

AGGREGATES MANAGER May 2015

Belt scale offers spill-proof suspension Heavy-duty gear design The Falk Quadrive, from Rexnord, is said to deliver heavy-duty gear design for aggregate applications. It features grease-purged Viton seals to prevent leakage and trap abrasives before they can groove the shaft or enter the gear drive. The TA bushing design cuts installation and removal time, the manufacturer says, and is positioned on the conveyor side of the gear unit, which positions the sheave closer to the bearings to reduce overhung load and increase bearing life. Rexnord | www.rexnord.com

According to Thayer Scale, its single idler â&#x20AC;&#x2DC;Quarry Kingâ&#x20AC;&#x2122; Conveyor Belt Scale was designed for outdoor conveyor weighing of aggregates and fines where rugged construction and spill-proof suspension design are the most important attributes. The new pipestem single idler suspension system incorporates built-in storage means for its calibration weight (no test chains are required). Thayer Scale says the combination of its rocking flexure fulcrums and suspension system provides an important advantage for operations concerned about dust build-up and spillage. The idlers can be used on troughed belt idlers ranging from 18 to 48 inches in width, operating at speeds up to 600 feet per minute and inclines of up to 18 degrees. Thayer Scale | www.thayerscale.com

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SUPPLY LINES

Ceramic pulley lagging Quick fix for problem areas Superior Industries, Inc. says its flexible guard panels are a speedy solution for regions of conveying equipment that require protection. The safety yellow rolls are UV-resistant and prepackaged with selftapping screws and washers for quick installation. They are available in two sizes; a 50-foot by 4-foot roll in 3/4-inch mesh and a CIM_CIM 1/2 HORIZONTAL- 7 x 4.875 1/20/15 8:37 AM Page 1 100-foot by 4-foot roll in 1/4-inch mesh. Superior says the rolls easily cut to any size or shape with shears or a comparable cutting tool. Superior Industries, Inc. | www.superior-ind.com

Flexcoâ&#x20AC;&#x2122;s Flex-Lag Medium Ceramic Pulley Lagging can be used in dry, wet, or muddy applications where slippage can occur. It features 39-percent tile coverage. Horizontal grooves in the lagging trap and deflect water and debris, while ceramic buttons grip the beltâ&#x20AC;&#x2122;s underside for positive traction and no slippage. The lagging comes in strip widths from 35 to 101 inches to match pulley face widths or 18 to 84 inches to match belt widths. It works with pulley diameters of more than 12.6 inches. Flexco | www.flexco.com

RULMECA MADE BY RULMECA. We strongly believe in continually challenging the status-quo. All of us at Rulmeca are driven to find new and better ways to extend conveyor life and decrease down times. We believe all conveyors can and should run much safer and quieter than they do today. www.rulmeca.ca

Moving ahead. Rulmeca_AGrm0515_Pg.indd 1

4/20/15 3:34 PM AGGREGATES MANAGER May 2015

Rock by Arthur Wolfson

MSHA’s new ‘Rules to Live By’ calculator provides information to aid in compliance, but raises concerns of heightened enforcement.

COMPLIANCE TOOL May Come With a Price

Arthur Wolfson is a member of Jackson Kelly, PLLC’s Pittsburgh practice. His practice is focused on occupational safety and health and mine safety and health. He can be reached at 412-434-8055 or via email at awolfson@ jacksonkelly.com.

AGGREGATES MANAGER May 2015

uring a stakeholder meeting on Feb. 25, 2015, the Mine Safety and Health Administration (MSHA) unveiled a new online web tool to provide information on a mine site’s compliance with the ‘Rules to Live By’ standards. ‘Rules to Live By’ standards are those that MSHA has identified as being most commonly associated with fatal accidents. In the metal/non-metal sector, the ‘Rules to Live By’ standards include the following: § 56.9101: Operating speeds and control of equipment; § 56.12017: Work on power circuits; § 56.14101(a): Brake performance; § 56.14105: Procedures during repairs or maintenance; § 56.14130(g): Seat belt worn by equipment operators; § 56.14131(a): Seat belts provided and worn in haul trucks; § 56.14205: Machinery, equipment, and tools used beyond design capacity; § 56.14207: Parking procedures for unattended equipment; § 56.15005: Safety belts and lines; § 56.16002(c): Bins, hoppers, silos, tanks, and surge piles; § 56.16009: Persons shall stay clear of suspended loads; § 56.20011: Barricades and warning signs; § 57.3360: Ground support;

§ 46.7(a): New task training; § 56.3130: Wall, bank, and slope stability; § 56.3200: Correction of hazardous ground conditions; § 56/57.14100(b): Safety defects; examination, correction, and records; and § 56.15020: Life jackets and belts. The new ‘Rules to Live By’ calculator shows the mine’s compliance with those standards in comparison to the national average of mines of the same type and sector (i.e., underground, surface or facility, and metal/non-metal or coal). Similar to the Pattern of Violations calculator, the ‘Rules to Live By’ calculator allows date-specific searches to be conducted using a mine’s identification number and provides a rate of violations issued under the ‘Rules to Live By’ standards per mine. The rate is calculated by dividing the number of citations/orders issued by inspection hours, multiplied by 100. If the rate is below the national average, the percentage will be shown in green. If the number is above the national average, the number will be shown in red. If the mine received fewer than three citations under ‘Rules to Live By’ standards,” the rate will be reported in black and not compared with the national average. The calculator will also show which of the ‘Rules to Live By’ standards the mine violated during the given date range. The ‘Rules to Live

ROCKLAW

McCarthy June 2014), MSHA alleged, and the Administrative By’ calculator can be accessed at http://www.msha.gov/drs/rlbLaw Judge upheld, the high negligence finding of a ‘Rules to violations-calculator.asp. Live By’ violation due, in part, to the notice to the operator and The unveiling of the ‘Rules to Live By’ calculator is in keepenhanced emphasis by MSHA provided by the ‘Rules to Live ing with MSHA’s recent emphasis on fatality and near-miss By’ program [36 FMSHRC at 1694]. prevention in the metal/non-metal sector. During the Feb. 25 To prepare themselves for the possibility of such enhanced stakeholder meeting, MSHA also highlighted training, examinaenforcement, operators should redouble their efforts to docution of work areas, pre-operational checks, and maintenance of mobile equipment as areas of focus to improve prevention of ment all steps taken to comply with these standards. Records of training sessions should be developed and maintained, serious accidents. and should include the date, topic, list of attendees, and subThe ‘Rules to Live By’ calculator provides operators with stance of the training. Records of workplace examinations and useful information in its efforts in these areas. Mine operators preoperational checks should document that, when hazards should make use of this tool and keep track of how their sites and conditions are discovered, they are corrected. Despite an are performing with respect to these standards. If the mine’s operator’s best efforts, if violations do occur, such evidence ‘Rules to Live By’ rate indicates a trend of increased violations, steps to reverse that trend should be taken. Additionally, train- may provide mitigation against heightened negligence and increased penalties. AM ing and examinations should be tailored to prevent violations of these standards and immediate correction of conditions that may lead to such violations. MSHA’s continued emphasis on ‘Rules to Live By’ standards and the implementation of the calculator does raise concerns with respect to enforcement. Under the ‘Rules to Live By’ program, all citations and orders alleging violations of the enumerated standards shall be reLower costs for parts and service viewed for potential special assessment will pay back your investment under 30 C.F.R. § 100.5. Under that fast with Beka-Max automatic provision, MSHA may elect to waive the lubrication systems... and there’s use of its regular penalty assessment no extra charge for the added formula under § 100.3 and, instead, isproductivity from your equipment! sue a substantially higher “special” assessment. Specially assessed penalties • More production, less unscheduled downtime may be as high as five times as much • Longer life for critical components as the penalty that would have been as• Expert factory support with dealers nationwide sessed as a regular assessment. Additionally, it is foreseeable that MSHA may attempt to justify high negligence or unwarrantable failure designations for violations of such standards 1. 888. 862. 7461 based on the notice provided to operawww.b e ka -l ub e .c om tors by “Rules to Live By.” For example, B E K A - 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 in Big Ridge Inc., 36 FMSHRC 1677 (ALJ

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026-033A EW 4.5x4.5 4C.indd 1

2014-01-24 5:39 PM

AGGREGATES MANAGER May 2015

Advertising COMPANY

WEB

PAGE #

Aggregates Manager Community Outreach

www.aggman.com/community-outreach

20 33

Atlas Copco Construction Mining Technology

www.atlascopco.us

Baldor Electric Co.

www.baldor.com

Beka-Max of America, Inc.

www.beka-lube.com

Bill Langer - Research Geologist

www.researchgeologist.com

BKT Tires

www.bkt-tires.com

C.L. Dews & Sons Foundry

www.dewsfoundry.com

Cardinal Scale Manufacturing Co.

www.cardinalscale.com

Columbia Steel

www.columbiasteel.com

Elrus Aggregate System

www.elrus.com

IBC

Great American Truck Show

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Hammond Air Conditioning, Ltd

www.hammondac.com

John Deere Construction Equipment

www.johndeere.com/loaders

KPI-JCI and Astec Mobile Screens

www.kpijci.com

Kruse Integration

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Linear Rubber Products

www.belting4conveyors.com

43 35

Luff Industries, Ltd

www.luffindustries.com

Martin Sprocket & Gear, Inc.

www.martinsprocket.com

McLanahan Corp.

www.mclanahan.com

Motion Industries, Inc.

www.motionindustries.com

IFC

NSSGA Membership

www.nssga.org

Polydeck Screen Corp.

www.polydeckscreen.com

Progressive Commercial Insurance

www.progressivecommercial.com

Pugmill Systems, Inc.

www.pugmillsystems.com

43 39

6 11

Rulmeca Group

www.rulmeca.ca

Sandvik Construction Mobile Crushers & Screens USA

www.construction.sandvik.com

SDLG North America

www.sdlgna.com

Sweet Manufacturing

www.sweetmfg.com

Terex Minerals Processing Systems

www.terexmps.com

Topcon Positioning Systems

www.topconpositioning.com

Walz Scale

www.walzscale.com

Worldwide Electric Corp.

www.worldwideelectric.net

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

AGGREGATES MANAGER May 2015

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3/31/15 Sweet_AGRM0910.indd 2:24 PM 1

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WEBSITE!

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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

Services Offered: Applied geology and geological research for construction rocks and minerals, with an emphasis on aggregates. • Resource evaluation • Expert testimony

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Bill-Langer@researchgeologist.com www.researchgeologist.com AggregAtes MAnAger May 2015 BillLanger_AGRM0115.indd 1

12/16/14 1:21 PM

In Stone

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.

The

VERMONT STATE HOUSE Teamsters get an early lesson on the economics of transporting granite during the construction of Vermont’s second state house.

“The walls of the exterior are of [Barre dark] granite, which shews the architectural details to great advantage.” — Zaddock Thompson, 1842, History of Vermont, Part Second, p. 132 Barre Granite, the topic of this series of articles, had achieved recognition as an attractive building material by the 1830s, and quarries had been established to provide large quantities of the beautiful granite. A committee in Montpelier was established to prepare a plan to build a new state house. The committee solicited bids to furnish 23,000 cubic feet of Barre dark granite for the walls of the state house. Construction on the state house took place between 1833 and 1836. The pillars, foundation, window caps, sills, and cornices for the second Vermont State House were extracted from a quarry on Cobble Hill, and the ashlars for the walls came from Millstone Hill. But the granite had to be transported from Barre to Montpielier, and that was no easy task. My great grandmother’s family was in the drayage business, and my mother would regale my siblings and me with many a tale about hauling freight by horse-drawn wagon. But nothing we heard compares with the demanding struggle to move large granite blocks from the quarries to the state house. The contract to haul Barre granite to Montpelier for use in the state house was undertaken, not by granite men, but by teamsters. Their workday began before the 5 a.m. breakfast with the feeding and harnessing of the horses. After breakfast, sleds were hitched to the horses, taken to the quarries, and loaded. Although some of the more advanced quarries had crude derricks operated by men or by horses, most blocks were loaded by pushing and pulling them on rollers. After the sleds were loaded, workers returned home for mid-day dinner and fed the horses. After dinner, they left for Montpelier with their load of granite, unloaded it, and returned to Barre. By the time they had supper and tended to their horses, it would be 9 p.m. The heavier blocks were left for winter when they could be drawn over the snow on sleds. Special strong sleds were built especially for the task at hand. Each sled runner would be ‘clogged’ with a chain in front. As many as 30 or more oxen and horse teams would sometimes be required to transport large blocks down the hill. Three or four teams of horses might be harnessed to the rear of the sled to hold back the load. The workers could breathe a sigh of relief when they arrived safely at the foot of the hill. Unfortunately, the teamsters lost money on the contract to haul the granite for the state house. They had a cubic foot of granite cut and weighed and bid for the contract based on the weight of that cubic foot. They expected to be paid the bid price for every cubic foot of granite they drew to Montpelier. However, the granite at the quarry was in blocks of different sizes. Each block had the size it would be after it was cut and trimmed at the job site. Consequently, the teamsters drew hundreds of cubic feet of granite for which they received no pay. But their hard labor contributed to the construction of a building with lasting value. “When in 1837 the Capitol was completed, it was pronounced the finest in the United States and called forth loud praise for the high grade of granite used in its construction.” — A.W. Brayley, 1913, History of the Granite Industry of New England, Vol. II, p. 31

AGGREGATES MANAGER May 2015

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