Y o u r
g u i d e
t o
p r o f i t a b l e
p r o d u c t i o n
May 2016 | www.AggMan.com
Bristol Sand & Gravel's Unique
Approach to
Overburden 21
Consider the opportunities and obstacles of whole-plant automation
26 39
Learn the best practices for your portable crushing plant Review Commission finds MSHA inspector abused his discretionary authority
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Knowledge of four key points — structural, mechanical, hydraulic and electrical, and application — will allow operators to better operate their portable crushers.
PAGE 26
On Our Cover: Lehigh Hanson’s Bristol Sand & Gravel Plant serves the Dallas and Fort Worth areas of Texas. Cover photo by Kerry Clines.
McLanahan’s Max Series Vibrating Screen features independent cross members for individual replacement of worn sections of screen.
PAGE 9
TABLE OF CONTENTS MAY 2016 |
VOLUME 21, NUMBER 5
FEATURE ARTICLES
12
Making the Climb to Excellence
26
Prime Portable Crushing Practices
35
Which ADT is the Right Fit?
Bristol Sand & Gravel found a way of doing things that has led to increased operational efficiency and environmental excellence.
Get optimal performance and longevity from your portable plant through best practices.
Articulated dump trucks focus on payload, performance, and operating costs.
COLUMNS & DEPARTMENTS 3 Editorial Community opposition takes a new tactic. 4 Data Mining The latest financial analysis of issues impacting the industry and Aggregates Manager’s exclusive aggregates industry outlook. 6 State and Province News A roundup of the latest news in North America. 9 RollOuts Caterpillar’s new medium wheel loaders, and other new equipment for the aggregate market. 39 Rock Law Review Commission finds MSHA inspector abused his discretion with abatement timeline and citations.
OPERATIONS ILLUSTRATED Absolute Automation
21
Whole-plant automation helps improve plant efficiency and maximize productivity through real-time monitoring.
42 Advertiser Index See who’s who and where to find their products. 43 Classified Ads Aggregate industry classifieds. 44 Carved in Stone Through the Loess Hills, road cuts and cliff faces expose Loess Kindchen, also known as the Children of Loess.
Industry Focus. Powerful Results.
Where Vision Meets Value.
Select Assets of Eastern Industries, Inc. a division of New Enterprise Stone & Lime Co., Inc.
a subsidiary of
New Enterprise Stone & Lime Co., Inc.
have been acquired by
a portfolio company of BMC Enterprises, Inc.
a division of
has acquired select aggregate assets from
has been acquired by
has been acquired by
a division of Oldcastle, Inc. *Represented by FMI Capital Advisors
FMI Capital Advisors, a subsidiary of FMI Corporation, is the leading investment banking firm serving the Construction Materials industry. With over 100 completed transactions in Construction Materials, our industry focus enables us to provide our clients with valuable insight and advice. Clients gain access to our unparalleled network of industry contacts and relationships, deep market knowledge and technical expertise, based on decades of experience.
George Reddin | 919.785.9286 | GReddin@fminet.com
Scott Duncan | 713.936.4930 | SDuncan@fminet.com
WWW.FMINET.COM
May 2016
EDITORIAL
Vol. 21, No. 5
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
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 Vice President, Construction Media: Joe Donald sales@randallreillyconstruction.com
3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com
Corporate Chairman: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Russell McEwen Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Vice President of Events: Stacy McCants Vice President, Audience Development: Prescott Shibles Vice President, Digital Services: Nick Reid Vice President, Marketing: Julie Arsenault For change of address and other subscription inquiries, please contact: aggregatesmanager@halldata.com.
Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2016. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.
Community Opposition
Takes a New Tactic
I
t’s interesting to see how far communities are willing to go when fighting a quarry greenfield development or expansion, or, occasionally, each other. If you are looking for an indicator of economic recovery, look no further than the nearest permitting effort. In recent months, numerous operators have encountered resistance to permitting efforts. - In Rapid City, S.D., Croell Redi-Mix Inc. encountered opposition to its effort to expand its Perli Quarry. - More than 100 people attended a public hearing to oppose Frontier Stone’s proposed quarry in Batavia, N.Y. - In Statesville, N.C., city council members faced dozens of residents wearing “Elmwood Strong” t-shirts when they heard about an annexation petition that would pave the way for a quarry. - Opponents of Little River LLC developed a website with photos of both onand off-road trucks involved in accidents to generate opposition to a proposed Little River, N.C., operation. At about the same time, the Board of Trustees of Sister Bay, Wis., passed a resolution to allow the village staff to purchase land that had been operated as a quarry by Sister Bay Properties LLC (see State and Province News, page 6). Last fall, the quarry owner tried to expand the operation, but the village board would not approve a zoning code amendment that would have allowed the expansion. This year, they unanimously passed the resolution to purchase the property and shut down the quarry. To cover the cost, the village is refinancing bonds, seeking a developer for the site, and will use “debt smoothing” to make minimum payments if the property isn’t sold. It’s taking quite a gamble to put an end to mining in the area. And, while many communities are willing to spend thousands to fight quarries, one of the most interesting community battles I’ve ever seen was the one between two cities — Duarte and Azusa, Calif. When Vulcan Materials made changes to its operation there, including a progressive approach to mining a mountain using microbenches for more natural looking reclamation, the city of Duarte fought the plan tooth and nail. In the end, it spent an estimated $600,000 contesting Vulcan’s environmental impact report and going after the neighboring community. Fortunately, Duarte’s efforts were ineffective, but when communities invest tens or hundreds of thousands of dollars to fight a responsible operator who would run a good operation, create local jobs, and increase the tax base, these communities themselves are the ultimate losers.
AGGREGATES MANAGER / May 2016
3
q
DATAMINING Stock Report Company
Ticker
Cemex, S.A.B. de C.V. CRH plc Eagle Materials Inc. Granite Construction Inc. Heidelberg Cement AG LafargeHolcim Ltd. ADR Martin Marietta Materials, Inc. MDU Resources Group, Inc. Summit Materials United States Lime & Minerals, Inc. U.S. Concrete Vulcan Materials Co.
CX CRG EXP GVA HEI HCMLY MLM MDU SUM USLM USCR VMC
Current Value
$7.06 p $28.78 p $69.96 p $45.37 p $84.57 p $9.55 p $164.10 p $19.31 p $19.86 p $58.70 p $60.89 p $106.54 p
52-Week High
52-Week Low
$10.48 $32.25 $88.81 $48.59 $87.83 $15.49 $178.67 $23.12 $28.57 $69.02 $63.67 $109.63
$3.64 $20.81 $45.03 $28.45 $66.20 $6.92 $108.31 $15.58 $13.12 $45.56 $33.04 $78.83
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 4/11/16.
U.S. On-Highway Diesel Fuel Prices 4/11/16
One Week
United States
$2.128
+0.013 p
-0.626 q
East Coast
$2.187
+0.008 p
-0.729 q
New England
$2.237
-0.006 q
-0.839 q
Central Atlantic
$2.301
+0.005 p
-0.779 q
Lower Atlantic
$2.090
+0.013 p
-0.669 q
Midwest
$2.082
+0.017 p
-0.551 q
Gulf Coast
$1.992
+0.009 p
-0.628 q
Rocky Mountain
$2.142
+0.019 p
-0.561 q
West Coast
$2.332
+0.015 p
-0.582 q
West Coast less California
$2.200
+0.021 p
-0.520 q
California
$2.437
+0.011 p
-0.634 q
Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
4
AGGREGATES MANAGER / May 2016
One Year
Aggregates Industry Outlook 150 140
130.00
129.05
131.68
130.99
128.42
125.60
130
127.51
128.61
128.99
122.49
120 110 100
July 2015
August 2015
September 2015
October 2015
November December 2015 2015
January 2016
February 2016
March 2016
In April, the Aggregates Industry Outlook (AIO) fell slightly, decreasing 2.04 percent from March, to an overall score of 128.99. While overall market sentiment is strong, concerns about state and federal budgets — as well as the potential impact of regulatory decisions — seems to have dampened optimism somewhat.
May 2016
Comments: We’re very confident for the next 12 months. The government and commercial work outlook is fairly strong, and the private sector outlook is holding its own. Low energy costs are helping spur development in all sectors. — Rick Gerroll, Sales Executive, County Materials Corp. While we are pleased with the passage of the FAST Act and the state DOT’s effort to address the infrastructure, we are worried about how these programs will be paid for. — Bill Schmitz, Vice President, Quality Control and Sales, Gernatt Asphalt Product, Inc.
Activity and backlogs are strong through mid year. The fall period presents some risk given state budgets in some regions. — Damian Murphy, Regional President, Summit Materials.
We’re very interested in the ramifications of the government’s rollout of the silica final rule. Enforcement of the stipulations has the potential to negatively affect the aggregate industry, especially the small operator with fewer resources for compliance. It would have the same negative effect on aggregate end-users in a wide variety of trades. — Robert L. Stone, Manager of Sales and Compliance, Hunter Sand & Gravel, LLC Our opinions are based on where we are currently engaged in exploration and permitting activities, which includes North Carolina, South Carolina, Georgia, and Texas. We continue to see more greenfield activity in Texas, North Carolina, and Georgia. — O.F. “Russ” Patterson, III, Chief Geologist, Patterson Exploration Services All of our Florida clients are seeing demand surge in 2016, and they are accordingly making notable investments in fixed and mobile equipment in order to keep up. — Gregory Dayko, Principal, Inlet Capital Group, LLC As a geologic consultant to the aggregate industry, I see a very positive attitude with my clients as to the 2016 production year. Those aggregate clients located near larger markets such as Dallas-Fort Worth, Atlanta, and New York City, as well as other metropolitan areas seem to be doing well and most expect a positive year. — Mark J. Zdunczyk, Consulting Geologist, Mark J. Zdunczyk, LLC AGGREGATES MANAGER / May 2016
5
STATE & PROVINCE
NEWS
To keep up to date with news from the United States and Canada, visit www.AggMan.com for daily updates.
ILLINOIS
by Therese Dunphy | Editor-in-Chief tdunphy@randallreilly.com
CALIFORNIA After more than six hours of presentations about the proposed expansion of Syar Industry’s 497-acre basalt quarry, Napa County supervisor continued discussion on the matter until their April 26 meeting. According to the Napa Valley Register, the county planning commission approved the operator’s bid to expand its quarry by 106 acres in a 3-2 vote. Two grassroots groups, Stop Syar Expansion and Skyline Park Citizens Association, then appealed the issue to the board of supervisors. County staff and consultants defended the environmental impact report while opponents voiced concerns about air pollution and the environmental impact of the operation on local headwaters and creeks. Syar Industries will be able to address the appeals presentations at a later date.
CONNECTICUT Area residents seem to be in favor of plans to develop a clean water reservoir at the Tilcon quarry in New Britain. The community’s plan is to lease Tilcon a 131-acre quarry site for mining while also producing 239 acres of watershed property and 327 acres of open space through the 40-year agreement. The New Britain Herald reports that neighbors are responding well to the plans, which would move blasting further away from nearby homes. Local officials, concerned by intermittent periods of drought, are looking to tap the potential of an additional 4.75 billion gallons of water reserves.
At the beginning of April, Lake County officials said that commercial stone production at Singleton Stone LLC’s quarry in Eagle Creek Township was imminent. According to The Chicago Tribune, the company had submitted as-built drawings for the project and needed only to resolve “some more or less housekeeping things on the drawings.” While some residents had expressed concerns that stone was already being shipped from the site, the county official clarified that the operator was allowed to mine stone to calibrate machinery and construct the site. A scale had not yet been built on the quarry site.
IOWA An employee at Martin Marietta’s Earlham Quarry was killed in an accident on March 22. The Newton Daily News reports that 42-yearold Tracy Hockmeier was apparently struck by debris following a routine blast at the site and pronounced dead at the scene.
KANSAS Demand for aggregates for local construction projects was among the topics of discussion at a recent Neosho County Commissioners meeting. According to the Chanute Tribune, quarry foreman Chris Hoagland requested authority and funding to blast at the county’s Neely quarry. The operation had last blasted in November 2015. The foreman told commissioners he had enough rock for 50 miles of roadwork, but anticipated high demand for rock on a gravel road that would serve as a detour around bridge construction on K-39 this summer.
GEORGIA In early April, blasting began the Bellwood Quarry as the city begins to redevelop the site as a water storage facility. According to the Atlanta Business Chronicle, construction will begin with a five-mile, 10-foot diameter tunnel system that will link the quarry to the Chattahoochee River. One tunnel will run from the quarry to the city’s water treatment plant, while the second will connect the plant with the city’s water intake on the river. The $280 million project is expected to extend Atlanta’s water supply reserves from three to more than 30 days.
ILLINOIS Mode, Ill.-based Brush Creek Quarry was recognized for its commitment to safety by the Illinois Association of Aggregate Producers (IAAP), the Effingham Daily News reports. The quarry received the Rock Solid Safety Gold award from the association. “By rewarding our industry’s health and safety leaders, these programs encourage other IAAP members to adopt more proactive safety practices and systems designed to prevent job-related injuries or illnesses,” IAAP’s Shawn McKinney said in a press release.
6
AGGREGATES MANAGER / May 2016
NEW YORK Frontier Stone media consultants sat down with The Daily News to explain how its proposed Shelby quarry would operate, as well as how it would benefit the community. The proposed operation would involve mining dolomite on 215 acres of a 269-acre property, in four phases over 75 years. When addressing the issue of blasting, the consultant made a savvy comparison between the sound level of a permitted blast (133 decibels) and that of a .357 revolver (172 decibels) or a .22 caliber rifle (144 decibels). Both guns are commonly used during the hunting season in the same area.
OHIO Miami County Commissioners approved a truck haul route for a proposed quarry. According to the Daily Call, Piqua Materials purchased a 93-acre property and has submitted a proposal for a surface mine there. The county engineer is required by law to devise a route for ingress, egress, and hauling to the proposed operation. The company told the county it anticipates annual sales of 500,000 tons of material. Several neighbors spoke against the proposed operation, but commissioners noted that approval of mining will go before the Board of Zoning Appeals.
MAINE
UTAH
The Maine Aggregates Association (MAA) partnered with the Mine Safety and Health Administration’s Education Field and Small Mine Services and the National Mine Health & Safety Academy to produce a new training DVD titled “Aggregate Safety Series, Small Mines.” According to Chip Laite, president of MAA, “This DVD will provide high-quality and up-to-date training materials for gravel mining operations throughut the country and assist operators in providing state-of-the-art training to their employees.” The DVD was first presented at the MAA’s annual safety conference in March.
Tourists are visiting U-Dig Fossils, located in a Delta quarry. The Columbus Dispatch reports that the quarry provides rock hammers, buckets, and a guide to visitors. A backhoe pulls piles of shale into the quarry, where tourists are encouraged to search for tribolite fossils. According to a website for the quarry, a typical visitor discovers 10 to 20 tribolites in a standard four-hour hunt.
TEXAS According to the San Antonio Express-News, executives at Capitol Aggregates hope to begin operations at their 510-acre property in Hondo by the end of the year. The company applied for an air permit from the Texas Commission on Environmental Quality in January. The newspaper says that local officials and company leaders discussed making road improvements to support increased truck traffic, but no commitments have been made. Vulcan Materials has a 1,710-acre property under development near the site, and Simpson Crushed Stone opened another operation nearby last summer. A local opposition group, Medina County Environmental Action Association, has expressed concerns about the effect of operations on air and groundwater, as well as road quality.
WiSCONSIN
A letter to the editor of The Cambridge News laments the lack of enforcement of the town of Deerfield’s non-metallic mining ordinances. While the town board says that citations are to be handled by the Circuit Court, the clerk of the Circuit Court has said that the court cannot handle the citations. The letter claims that 11 violations of the ground vibration limit, 14 of the low frequency limit, and seven of the air blast limit have occurred.
WISCONSIN In late March, the village of Sister Bay purchased two lots that have been operating as Sister Bay Quarry. According to the Green Bay Press-Gazette, the village purchased the 123-acre property from Sister Bay Properties LLC for $650,000. The owner had been operating the site as a legal non-conforming use, but the site will no longer function as a quarry. Rather, it will be brought into compliance with the village’s comprehensive development plan. Previously, the village had spent more than $30,000 on legal fees fighting the quarry.
AGGREGATES MANAGER / May 2016 Untitled-2 1
3/8/16 1:26 PM
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Aggregate Drones
Automatically calculate aggregate stockpile volumes...
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ROLLOUTS
Your complete guide to new and updated equipment and supplies in the aggregates industry.
by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Screen features independent cross members Based on customer requests, McLanahan developed its new MAX Series Vibrating Screen. Capable of separating coarse feed materials from finer materials, the screen is available in a range of sizes from 6- by 16-feet to 8- by 24-feet. The screens feature a low-headroom design to fit into existing structures and operations without rework. The screens are built with maximum steel strength so they can withstand heavy loads. Sideplates are fully bolted construction to avoid crack propagation and feature cross beam inspection ports for easier operator inspection. Independent cross members allow for individual replacement of worn screen sections. A direct drive system eliminates the requirements for a pivoting motor base to keep belt tension at startup.
McLanahan Corp. | www.mclanahan.com
Medium wheel loaders get an update Caterpillar’s move toward more frequent machine updates is reflected in updates to its M Series medium wheel loaders (including 950M, 962M, 966M, 966M XE, 972M, 972M XSE, 980M, and 982M). Improvements focus on technology, safety, and reduction of operating costs. The new Product Link Elite system, which provides faster cellular and satellite connection abilities, is now standard equipment. New cab steps increase durability and improve boot contact for increased safety in and out of the cab. The XE models feature a new Economy Mode that is said to provide up to 4 percent improved fuel economy.
Caterpillar | www.cat.com
Secondary belt cleaner offers ease of serviceability Martin Engineering introduces the Pin Latch Secondary Belt Cleaner, a tungsten carbide-tipped secondary cleaner that slides in and out for service without requiring any tools. The design features a square, tabbed mainframe with segmented blades connected by a simple pin mechanism, allowing easy access and quick blade replacement by semi-skilled personnel. The pin latch design provides adjustable tension for varying conditions such as belt speed, material being conveyed, and belt cleaner position relative to the head pulley. It will handle belt speeds of up to 1,000 feet per minute, and the unit accommodates belt rollback. The carbide tip is acid- and abrasionresistant, and the assembly is said to be well suited for use on belts with mechanical splices.
Martin Engineering | www.martin-eng.com
AGGREGATES MANAGER / May 2016
9
ROLLOUTS
Aluminum replacement pump upgrade Wilden releases new aluminum versions of its 420/430 Advanced FIT AODD pumps. Featuring bolted product containment, easier maintenance, and more efficient operation, the pumps were specifically designed to be direct replacements for existing 1 1/2- through 3-inch sizes with either aluminum or stainless-steel wetted options. The pumps are said to offer an easy, cost-effective way to enhance and upgrade existing pump performance with improved bolted product containment.
Wilden | www.wildenpump.com
New line of breaker attachments Paladin Attachments adds the Strike Force Breaker Series to its line of attachments. Available in a range of sizes for various machines, the larger sizes in the line feature an efficient piston and cylinder designed to transfer the highest shock wave into breaking objects. They have only two moving parts for easy service and maintenance and are backed by a two-year warranty.
Paladin www.paladinattachments.com
Plug-in GPS tracking system protects against tampering DPL Telematics offers the next generation of Trackall OBDII Vehicle Tracking System, which features an internal backup battery and anti-tamper features. The system is an advanced solution for wireless monitoring and remote tracking of vehicles. The GPS unit has no external wiring or antenna and plugs into the existing OBDII port of most vehicles for quick installation. New antitamper features include a backup battery, which delivers immediate disconnection notifications with location, as well as GPS jamming detection.
DPL Telematics | www.dpltel.com
Cone offers optimal production McLanahan introduces its McLanahan Symons Principle (MSP) Cone Crusher, which is said to deliver minimal downtime processing optimal amounts of material, ultimately leading to a faster return on investment. Using improved factors of performance such as balanced eccentric, higher speeds, fulcrum point position, and stroke to enhance the Symons Principle, the MSP creates torque and resultant crushing forces that McLanahan says are as effective as any cone crusher on the market. The eccentric stroke is designed to work with the eccentric speed and fulcrum position to produce higher yields and minimize recirculating loads.
McLanahan Corp. | www.mclanahan.com
10
AGGREGATES MANAGER / May 2016
ROLLOUTS
Intuitive telematics interface John Deere rolls out the JDLink Dashboard, a new telematics interface that provides intuitive, easy-to-use tools for operators to manage equipment that has active JDLink Ultimate, Express, or Locate subscriptions. The manufacturer says customers will see the most important metrics — such as red alerts, machines over zero hours, machines with the highest idle, and machines that are being over- or under-utilized — up front. A new tool, called Maintenance Manager, allows users to set up factory or custom plans using either engine-hour or calendar-based service intervals. The system can be accessed using web browsers, tablets, or smart phones.
John Deere | www.johndeere.com
Switch box for service trucks Coxreels introduces its Switch Box, which is available in open and closed variations. It is said to contain all of the necessary parts and components to make the motorized reel function in most service truck or trailer installations. The unit mounts to the motor and contains a relay, circuit breaker, and switch. The relay activates the motor, and the circuit breaker protects the vehicle from overload. It is available in 12-V DC (open) and 12-V DC or 24-V DC (closed).
Coxreels | www.coxreels.com
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11
PLANT PROFILE by Kerry Clines | Contributing Editor
Making the Climb to Excellence
Bristol Sand & Gravel found a way of doing things that has led to increased operational efficiency and environmental excellence.
L
ehigh Hanson’s Bristol Sand & Gravel Plant is located approximately an hour’s drive southeast of Dallas, near the small town of Ennis, Texas. Although the plant is less than seven years old, it has become one of the company’s largest sand and gravel producers and suppliers of construction material for the Dallas/Fort Worth and surrounding areas of North Texas. Along the way, the plant developed a unique way of stripping overburden
12
AGGREGATES MANAGER / May 2016
and reclaiming mined out areas at the same time, helping it to earn recognition from the National Stone, Sand & Gravel Association for environmental excellence. The operation has received several safety awards, both internally and from the Texas Aggregates and Concrete Association. It has also had five zero-citation inspections by the Mine Safety and Health Administration since it opened, and three of them were consecutive, which is quite an accomplishment these days.
Starting out Bristol Sand & Gravel opened in August 2009 as a replacement for the company’s nearby Ferris plant that closed in 2007. In the beginning, it was nothing but a greenfield site, one that had been used for farming. The farmer had been adding special enzymes to the top soil for years to help it retain water and never dry out, which helped with raising good crops, but has been anything but helpful for mining. If a little bit of water is intro-
duced to the soil, it gets very challenging to drive in. “We keep a pump running in the pit to pull the water out so we can mine, otherwise there would be 3 to 4 feet of water in it,” says Tim Soule, area sand and gravel manager for Hanson. “Drier material is a lot easier to put on the conveyor.” Because of all the moisture in the soil, the operation started out with draglines. “It was a dragline operation that we later converted to excavators
and trucks,” Soule says. “Right now, we’re running one internal pit and have a separate satellite mining operation off site. The off-site operation is unique to this plant. We have contract load and haul at that site, so two contractors do the excavating and hauling for us.” One contractor does all the excavating at the site and places the material into a stockpile. The other contractor loads it into belly-dump trucks and hauls it to the Bristol plant for process-
ing. The trucks dump into a pivoting clamshell feeder at a separate location near the processing plant. The clamshell opens out flat for dumping. Once the material is dumped, one side of the clamshell raises up and then pivots so that the other side raises up to force all of the material through the grizzly, into the hopper, and onto a 42-inch-wide conveyor that carries it to a telescoping, radial stacker for stockpiling. If necessary, the material can even be
AGGREGATES MANAGER / May 2016
13
PLANT PROFILE
Bristol Sand & Gravel has developed a unique way of stripping overburden and reclaiming mined-out areas at the same time. The pit is mined in long slots. Dozers remove overburden to uncover material in one strip and push the overburden straight across to backfill the old mined-out strip.
Once the overburden is removed, an excavator digs up the material and loads it into articulated haul trucks.
fed directly into the primary processing plant. The material from the off-site plant is processed at the same time as the material that is mined onsite. This process helps the plant operate more efficiently and meet the ever increasing demand for construction aggregates in the local market area.
14
AGGREGATES MANAGER / May 2016
Operations The deposit is mostly fine sand with just a bit of gravel mixed in. Due to the high price and demand for sand these days, the plant plans to install a crusher to produce manufactured sand to blend in with the fine sand that is currently being mined. This would allow the plant
to get more tonnage per acre. Overburden has been a problem for the operation. “We have 3.5:1 to 5:1 overburden ratio,” Soule says, adding that the plant has actually found a good way to deal with it. “We’ve evolved a program where, as we strip an area to be mined, we also reclaim the old area at the same time. We basically cut long slots and use dozers to remove overburden and uncover material in one strip. Then the dozers push the overburden straight across and backfill the old mined-out strip. The reclaimed area isn’t perfectly flat, but once we get through with an area, we level it off and let Mother Nature take it from there. It has reduced our cost pretty dramatically. It’s very successful and very easy to manage.” The simultaneous strip and reclaim program has not only helped with the environmental side of the operation, it has actually provided more precise control over excavations. This has allowed the operation to go back in and reassess the reserves that had been written off, potentially opening up a lot more life expectancy for the operation. Once the overburden is removed and the material is uncovered by dozers, an excavator takes over in the pit. The excavator loads the material into articulated haul trucks. The trucks then go to a drive-over grizzly where the material is dumped into a hopper that feeds a conveyor system. The overland conveyors then carry the material up to the processing plant. At the processing plant, the material is fed through a four-deck screen. Gravel is sent to a rock plant with a log washer and a double-deck screen for processing. Anything an inch and a half or larger is sent to a waste pile. The sand goes through a classifier and a set of twin screws. Yet another screw is used for producing cushion sand. “We hope to have our crusher in soon,” Soule says. “We have the plans drawn up and are using repurposed assets from other locations. We will insert the crusher into the rock plant area, so, basically, the material will
CUTTING DOWN ON EXPLOSIVES INTEREST IN SURFACE MINING MACHINES FOR QUARRIES GROWS ALONG WITH DRILL AND BLAST REGULATIONS
IF YOU ASK PEOPLE WHO RUN QUARRIES WHAT THEIR BIGGEST PAIN POINT IS, THEY’RE LIKELY TO SAY TRANSPORTING THEIR PRODUCT. IT’S EXPENSIVE AND LOGISTICALLY CHALLENGING.
Because those products are mostly used as building materials, the goal usually is to locate quarries near where road and other construction projects occur. This is typically in urban areas. And that is becoming an even bigger pain for mining companies because a major trend in the industry worldwide is increasing regulations on drilling and blasting methods due to environmental and safety concerns, especially in populated areas.
a 600-horsepower (447 kW) engine and can cut a swath up to 27 inches (68.6 cm) deep and 12 feet (3.7 m) wide in a single pass.
More and more quarries are turning to surface excavation machines as a solution. They have numerous advantages over drilling and blasting:
Mining companies are benefitting from these features. There’s a Vermeer customer that chose not to use a primary crusher because its Terrain Leveler SEM could consistently produce a 6-inch (15.2 cm) minus particle size.
• THEY can be used in parts of surface mines that explosives cannot. • THEY cause less noise, dust and vibration. • THEY cut more precisely. • THEY produce a smaller, more consistent particle size. • THEY can take steps and equipment out of the mining process. • THEY can also be used for site preparation and haul road construction. As a surface excavation machine moves on its tracks, its cutting drum rotates and the teeth on the drum mechanically excavate material. To give an example, the Vermeer T1255 Terrain Leveler® surface excavation machine (SEM) has
It can be equipped with an optional GPS for precision cutting, allowing an operator to use the full length of the drum and minimize the overlap with each pass. Additionally, a survey can be taken of a quarry to create a flitch plan, which can be uploaded to a computer on the machine.
Another customer had a million tons of mineable product but could no longer drill and blast because of nearby pipelines, powerlines and roads. “The surface excavation machine is getting that last remaining bit of aggregate,” says Patrick Robinson, senior commercialization manager for mining at Vermeer. “The site is already permitted, but if not for the surface excavation machine, it would probably be abandoned because drill and blast is no longer an option.” It may go without saying, but surface excavation machines are quieter and create less vibration than explosives. As for dust suppression, the
Vermeer Terrain Leveler SEM offers an optional traditional water spray bar or an optional dust-collection system that uses vacuum technology instead of spraying. The smaller, consistently sized product wastes less space than the larger material from drilling and blasting, which may allow more material to fit into haul trucks and loaders or possibly allow for the downsizing of equipment, which in turn can lower expenses. A surface excavation machine also could potentially let a quarry get to market faster. The infrastructure and planning needed for drill and blast — conveyer systems, purchasing and setting up large pieces of equipment like primary crushers, permits — can take years. “Many of the mining companies interested in surface excavation machines usually are forward-thinking in terms of how they adopt technology, their processes and their process control,” Robinson says.
Visit Vermeer at Booth #8401 at MINExpo.
Vermeer, the Vermeer logo, Equipped to Do More and Terrain Leveler are trademarks of Vermeer Manufacturing Company in the U.S. and/or other countries. © 2016 Vermeer Corporation. All Rights Reserved.
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PLANT PROFILE
Material from the off-site pit is transported by bottom-dump trucks. The trucks dump into a pivoting clamshell feeder near the processing plant. The clamshell opens out flat for dumping, then raises up on one side, pivots, and raises up on the other side, ensuring that all of the material goes through the grizzly feeder and onto a 42-inch-wide conveyor.
come out of the log washer and go to the crusher. An underflow conveyor will bring it back up from the crusher to the screen, which will act as a recirculating mode. We should get a very significant reduction ratio right off the bat. That will go straight to sand, and the rest will recirculate. It’s fairly efficient and simple to install.” All the material that leaves the plant is shipped by truck. Most mornings, employees will find a line of trucks waiting to get into the plant to pick up their first load of the day. The plant is preparing to open a new area for mining. A back-up-and-dump hopper has been installed to feed the new conveyor system that has been set up to transport the material from the new area to the processing plant. Some upgrades to the plant are in the planning stages. “We’re looking at getting a remote printer,” Soule says. “We’re also looking at Smart Loader, where the loader has an iPad in it.” The RFID reader at the scalehouse would read a truck’s RFID tag when it arrives and send information to the loader operator about what type of material that truck wants and how many tons to load into it.
Crew members The operation runs 16 hours a day with two shifts and is manned by approximately 30 crew members. Production
takes place five days a week with maintenance performed on Saturdays. “The night crew is fairly new people, but we have an older, experienced lead man running it,” Soule says, explaining that there’s a mix of older and newer employees. “The two shifts overlap by about an hour to allow for a smooth transition. You don’t want them to step into something they’re not aware of.” Most of the maintenance is done inhouse, but vendors come in to provide on-site services for the heavy equipment. Everybody is on the maintenance team, which Soule says encourages good preventive maintenance during the week on such things as maintaining good lubrication levels. Soule says that, when the employees do their own maintenance, they take ownership of it and take pride in what they do. “One of the challenges of the industry as a whole is trying to find the next generation of employees,” Soule comments. “We look at the employees that are in-house. We have some people that really stand out as far as work ethics, enthusiasm, and questions. People who ask questions are great. We try to identify the stand outs. They may be ready to take on a little more responsibility or be put in a lead man role. Then we start sending them to some training, like Agg Academy or Train the Trainer, to prepare them for that future role. It’s huge. You
Family Safety Days Bristol Sand & Gravel opens up its operation to the families of its employees once a year for Family Safety Day, giving everyone a chance to see what their family member does at work and what aggregate mining is all about. It also provides a chance for the company to talk about safety. “We design Family Safety Day around the children. We have bounce houses and haul in a big pile of sand for the kids, but the kids spend all their time using their imaginations in the sand pile,” says Allen Lathem, plant manager. “We let the kids put their hands in paint and put it on the side of the tank on our water truck. We had just bought several pieces of equipment and didn’t run them until after the event, so we could show them off.” Everyone is fed at the event, and there are drawings for prizes for the employees, but safety is an important part of it. “We have a quick safety meeting with the employees and their families,” Lathem explains. “We talk about what we do every day and how we have to be safe, and discuss some of the steps we take to be safe. The kids usually get hard hats, a high-visibility vest, and safety glasses so they can dress up like daddy.”
AGGREGATES MANAGER / May 2016
17
PLANT PROFILE
All sand at the operation is screened and sent through a classifier. Once separated, fine sand goes through a set of twin screws and cushion sand goes through a separate single screw.
do better by growing your own than by buying somebody else’s.”
Environmental excellence In addition to stripping and reclaiming at the same time, Bristol Sand & Gravel has an excellent environmental program that begins, and ends, with its employees. Soule says that without their buy-in and participation, there would be no program. “At the end of the day, methods don’t work unless the employees are engaged,” Soule explains. “All the tools in the world won’t be successful, if the employees don’t use them. Employee engagement here is spot on. They pay attention to the equipment. If one starts leaking, they report it. They don’t throw trash on the ground. If a fuel hose starts developing a leak, they speak up. They pay attention to what they’re doing and don’t allow things to get away.” The operation retains all of its water onsite, so that nothing escapes into the nearby Trinity River. After the recent five-year drought that affected most of Texas, the plant has started collecting and storing all of its process water.
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AGGREGATES MANAGER / May 2016
There are several settling ponds and water storage areas onsite, as well as a clean pond that holds groundwater and rainwater. Many birds, as well as different species of wildlife, have made their homes near the water.
Safety “Safety goes back to employee engagement,” Soule says. “The industry operates around safety. We have good leadership, an open-door policy, honesty, and transparency. We talk about safety at the plant all the time, but our employees say they also have near misses at home. So, the company kind of extended that to Safe at Work, Safe at Home, because if our guys get hurt at home, it affects work.” Soule says he believes that communication plays a key role. Weekly safety meetings are held to cover issues, but daily meetings are held when deemed necessary. Near misses are discussed and shared with other sites because, whether the experiences are good or bad, they can be used to help others. “We do something nice for our employees when they do a good job,”
Soule says. “If we have a great safety inspection, we do something for them, like feed them lunch. We’re going to say thank you, though. To me, that’s more important. I think that’s why we have such long-term employees. Thank you goes a long way.” Bristol Sand & Gravel was one of the first plants to get involved in the company’s CLIMB program, which is a continuous improvement program that helps to improve operational efficiencies. “CLIMB pushes that cross-functional working of operations, quality, and sales to make sure everything is a consistent experience, whether it’s the person working at the plant or the customer getting the product that they want,” Soule explains. “We’ve been doing CLIMB for five years or more here and have come a long way since we started. Productivity is high, safety is high, and environmental excellence is high. This plant has been an extremely consistent performer over the last few years with all the changes that have come into play.” AM
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PULL-OUT GUIDE By Mary McCaig-Foster, Contributing Editor
May 2016
Absolute Automation
Whole-plant automation has vastly improved over the years.
Take decisions out of the operator’s hands for better efficiency.
Retrofits bring capability to existing plants.
Control of the feed is key.
Improve tons per man-hour.
OPERAT 1
Old school: Manual controls
Master the Balance Between Man and Machine
M
ore and more producers are adding automation to their operations — not only with new plants, but also as part of retrofitting existing operations. Automation can provide anything from basic machine control to a high level of process control to maintenance and service control. Moving beyond single-machine control, a wholeplant system automates the entire plant so that all of the equipment, from the primary to the final conveyor, communicates well with each other — essentially acting together as one machine. Total plant automation includes feed control, startups and shutdowns in the proper sequence, and automatic plant monitoring for problems and data collection. Running the plant manually can be difficult. The operator must pay close attention to plant flow and monitor everything manually because he doesn’t have all of the data that is available. In comparison, an automated system monitors all equipment and catches issues quicker than an operator can, and it can stop the plant — in the proper sequence — before any catastrophic damage occurs and without the risk of messes and cleanups. Whole-plant automation packages help improve plant efficiency through real-time monitoring that maximizes productivity and reduces downtime. It does this by helping identify bottlenecks, tracking equipment performance, and troubleAGGREGATES MANAGER
shooting problems. From a proactive maintenance standpoint, an automated system helps schedule and plan preventive maintenance. From a service standpoint, data trending helps operators troubleshoot and then plan a plant shutdown and order parts before a failure occurs. A whole-plant automation system can certainly be specified and built into a new plant, but a retrofit on any plant is possible. Most existing operations that choose to automate their plants discover the automation package can be installed with little or no modification to the existing equipment. “‘Why should I automate?’ used to be the main question received by producers when we would meet about potential projects,” says Matt Etheridge, president of Etheridge Automation. “We used to have to sell the concept more. But most producers, at this point, know it is better to have it — from the standpoints of efficiency, production, safety, and maintenance.” According to Arnold Connelly, Jr., area manager of aggregates for Tilcon New Jersey, “With the old school way of operating equipment manually, the operator would use amp draw in combination with ‘slugging crushers’ in deciding whether to tighten the crusher to maximize key products. But it’s not a reliable or efficient operating method, and it often requires longer operating hours. A totally automated plant will usually lower your operating hours and increase throughput.”
Plants that start, stop, and run manually almost always run at less than optimal production. The only real control an operator has after starting the plant is the speed of the feeders. Segregation occurs often within surge piles, creating fluctuations in material to crushers and constant gradation changes. To ensure that the plant doesn’t have problems, the operator will run the feed at an “operator comfort zone” speed to handle the variables.
4
Improve safety and maintenance
An automated plant will run at the optimal speed without overloading equipment. Because an automated plant is interlocked between all equipment, if there is an issue, it can shut itself down quickly in the proper sequence. Most stages can run unmanned, reducing the overall amount of manpower required and taking the plant from two or three operators down to a single operator. The system can also see maintenance issues and alert the operator before the plant breaks down.
TIONS ILLUSTRATED Absolute Automation
2
New school: Whole-plant automation
A plant that is totally automated runs with information from every component — including screens, bins, crushers, and conveyors. The automation software has more information than the operator and makes decisions on the fly about how much to alter speeds of specific components as needed to increase production. With interlocked components, the automated plant has the ability to shut down quickly, in proper sequence, providing greater safety.
5
Track data
Automation allows operators to track productive and unproductive time. Managers on a regional or national basis can see the entire system remotely, allowing them to ask questions of the operator. By tracking data trends, operators and managers alike can adjust the plant for better performance. Historical data tracking ultimately improves the bottom line for better production and lower costs.
3
EXPERTS
Defining total plant automation
Just because a plant might have a PLC or a single component that is automated, such as a crusher, it is not actually a fully automated plant. If a plant can operate with decisions being handled automatically for every piece of equipment, adjusting the speed of all components from the primary feed to the final conveyor without input from the operator — that is total automation. Based on plant modes, the system will increase production of key products.
6
OUR
Automation challenges
Unlike automobile manufacturing or food processing, which are automated with uniform input and output, automation within the aggregates industry must be built to handle a large number of variables. In the automotive world, automation is sold as a package, with robots that handle production of uniform machines. In comparison, with aggregates operations, total plant automation requires vast knowledge of the process and understanding of each unique quarry’s variables.
Matt Etheridge is president of Etheridge Automation, based in Powhatan, Va. He is considered an expert in the field of aggregates automation with more than 20 years of experience and hundreds of successful projects across the U.S. and Canada. Etheridge is active in NSSGA and is an experienced speaker on the topic of automation, having given talks at NSSGA, as well as various state associations. He is also a master electrician and resides in Powhatan, Va., with his wife and five daughters.
Arnold Connelly, area manager of aggregates for Tilcon New Jersey, has been with the company for almost seven years. With Tilcon, an Oldcastle Materials Co., he was a plant manager for the Riverdale and Mt. Hope quarries before taking his position as area manager. Connelly’s plant management experience in aggregates goes back to 1996. He has a bachelor’s degree in mining and mineral engineering from the University of Kentucky and an M.B.A. in general business administration and management from Centenary College.
For the past four years, Mark Cohen has been the electrical maintenance manager for Tilcon New Jersey, an Oldcastle Materials Group Co. Prior to that, he was head electrician at the Mt. Hope quarry for a total of 20 years. Initially, the quarry was known as Mt. Hope Rock Products until 2001, when it was sold to Tilcon. Cohen was electrician helper at Mt. Hope from 1989 to 1992. He has worked at the Mt. Hope Quarry a total of 27 years.
May 2016
Voices of Experience Arnold Connelly and Mark Cohen
A
t
ccording to Arnold Connelly, area manager of aggregates, and Mark Cohen, electrical maintenance manager — both employees of Tilcon New Jersey, it is better to have total automation in a plant versus automating individual pieces of equipment. “Single machine automation is good, but it’s like having a limb missing,” says Connelly. “You’re not getting all of the information you need, and it’s difficult to make good management decisions.” Total plant automation gets the operator and management the accurate data they need from throughout the plant. “The whole quarry is one big electrical system. It monitors amp draw from every piece of equipment, and helps the operator in determining problems. It tracks the scales, the tons-per-hour — anything you want,” Cohen says. “You can see problems before something breaks down. For instance, if the conveyor belts are slipping or the screen is running outside of the correct amp parameters, you can schedule preventive maintenance, rather than running into unexpected downtime for a repair.” For historical information, a total plant automation system will track and record data from every piece of equipment, so that decisions can be made for running the plant more efficiently. Scheduled maintenance is much more accurate because the operator has true knowledge of tonnage history and amp draw. “The ability to track history tells the truth about everything that has happened in the plant. Before automation, we had to rely on information from the operator, who didn’t have all of the information. It’s a lie detector, so to speak, because you have accurate data to review,” Connelly says. “The ability to monitor the plant remotely through the boardroom allows area and upper management to see the entire plant from a remote office at any time, and ask questions of the operator.” Tilcon New Jersey is in the process of automating all of the plants in the area. And Cohen says the learning curve for using the automation system is typically quick because the system on the monitor looks graphically like the plant the operator has been running all along. Similarly, gaining buy-in from operators has been fairly easy. “A 20- or 30-year plant veteran might be a bit nervous about it. Younger guys who grew up using computers adapt quicker,” Cohen says. “After the system is installed, the manufacturer stays behind and works with the operators until they are comfortable with running the plant through the system. The manufacturer also gives great phone support and helps online if there are questions. Once the operators actually start using it, they love it. It makes their jobs easier and takes
Matt Etheridge
“A
t
lmost all manufacturing processes in the U.S. are fully automated. Think of automotive manufacturing, food processing, etc.,” says Matt Etheridge, president of Etheridge automation. “Our industry (the aggregates industry) is the only one that has lagged in the ability to be fully automated.” Why is this so? Etheridge explains that other industries that automate rely on uniform input into a process. The automotive industry purchases its automation systems in packages. The philosophy is that the robots handling welding and other tasks are handling uniform tasks for identical automobiles that advance along the assembly line. “It’s easy to automate because the controls all repeat,” Etheridge says. “Compared to our industry, it would be the same as trying to build a compact car, followed by an SUV, followed by a van coming down the line. The robots can’t work with these variations because the parameters are constantly changing. There’s no uniformity.” Etheridge says the number-one reason all quarries are not automated is that simple process automation doesn’t work for them. When automating a quarry, the automation provider must be intimately familiar with the industry and the processes. “There are so many variables you have to work with when automating an aggregates operation,” he says. “There are variables with blasting — how the material fractures, moisture content, gradations, etc. We have to write our own unique control loops into the PID (proportional integral derivative) every time. The automated system has to adapt to all variables and be flexible because no two quarries are alike. It must drive the process variables to a set-point value and then control the output. “In a typical retrofit, we build the PLC (programmable logic controller) in the shop with all the relays and terminals. This is mounted in the MCC (motor control center). A wire goes to each starter for each piece of equipment,” Etheridge says. “All wiring is in the MCC. We add some sensors out in the plant for bins, maximizer probes, levels in the crusher. We are able to use fewer of these than we did in the early years.” Etheridge adds that automation packages today can monitor what is going on in the plant without a lot of outside sensors, which are easily damaged by the harsh conditions. The PLC runs the plant and also talks to the computer, where the operator can see everything that is going on in the plant with one or more monitors. “The system has to be hard-wired so that every piece of equipment communicates between the PLC in the MCCs. We also can build systems that communicate with fiber optics or even wirelessly,” Etheridge says, adding “Wireless has gotten better and better and better.” AGGREGATES MANAGER
CELEBRATING 20 YEARS OF KNOWLEDGE THAT RUNS DEEP Aggregates Manager celebrates two decades of amplifying the successes of every strata of the aggregates industry from crushed stone, sand & gravel operators to equipment manufacturers and dealers, and providers of services and supplies. Aggregates Manager has provided knowledgable support to the aggregates industry through key editorial coverage, timely expert analysis, and fostering a constantly active online community. We, at Aggregates Manager, look forward to delivering the vital information that streamlines your operations in 2016 and beyond.
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EQUIPMENT MANAGEMENT by Michelle Cwach
Prime
Portable Crushing Practices Get optimal performance and longevity from your portable plant through best practices.
M
aintaining portable crushing equipment can be challenging for producers unless organized and well-managed programs are developed and followed. But before a maintenance program can be structured, it is important
26
AGGREGATES MANAGER / May 2016
to first understand how portable equipment is built, according to Wade Lippert, field service representative with KPI-JCI and Astec Mobile Screens. Typically, stationary equipment is designed to be heavier, with a fixed foundation or permanent cribbing,
whereas portable equipment is built lighter for road portability and is often equipped with hydraulic jacks for portable cribbing or is mounted on tracks, which requires additional maintenance points. Stationary equipment also uses platforms, such as catwalks, to provide
are followed and accomplished.” Lippert recommends focusing on the following three key maintenance points when developing a program: 1. Lubrication schedule: Lubrication is often the only maintenance definition offered when asked if one maintains their equipment. It is certainly an extremely important component of a maintenance program and deserves its own focus, Lippert says. A lubrication schedule should include suggested intervals, grease and oil types, along with the location and desired quantity of the lubricants. A checklist provides completion accountability. Having a checklist also provides structure so that anyone tasked with the job can easily accomplish it, although ideally everyone receives the same task training. Lippert reminds producers that it is vital to use only manufacturer-recommended lubricants. “Using a less-than-quality lubricant could cause catastrophic failure and can result in a voided warranty,” he cautions.
To understand proper care of a portable crusher, the operator must first understand how it is built.
access for greasing and maintenance of the plant. Portable equipment uses additional remote grease lines, is more compact, and typically does not provide for platform access, which can present unique challenges in accessing key areas for maintenance.
“Once producers understand how the equipment is built and where the key maintenance points are, it is simple to create a maintenance program that is precise and easy to follow,” Lippert says. “Developing a structured program ensures proper maintenance protocols
2. Maintenance repair log: Daily maintenance should include lubrication, but it should also include walk-around inspections, which will serve as a time to assess risks and identify necessary adjustments due to wear. When performing a plant walk-around throughout the day, producers should look for anything out of the ordinary, such as broken or missing bolts, cracked welds, and material build-up. Nothing should be considered too small or ignored. By developing a repair log, producers can identify issues, identify what parts are needed, estimate a time to repair the issues, and determine whether the equipment is in need of immediate attention or if it can wait for scheduled downtime. Once finished, there should be a provision for a completion date. AGGREGATES MANAGER / May 2016
27
EQUIPMENT MANAGEMENT
lubrication schedule, maintenance repair log, and wear parts replacement is a great way to develop proper maintenance practices, Lippert reminds producers that, unless they understand the equipment function and limitations, equipment failure is imminent. “It is vital that producers become educated on each piece of equipment so they know how to properly maintain it and operate it to its fullest potential,” he says. “Producers should focus on four key points — structural, mechanical, hydraulic and electrical, and application. These points are important to creating a maintenance program that fits the needs of your equipment.” 1. Structural: Knowing what is needed for ground support and plant levelness is key to properly supporting the equipment, Lippert says. Understanding structure is vital to application throughput and equipment efficiency
Three key maintenance considerations include the lubrication schedule, the repair log, and the record of wear parts.
“These items provide a proactive approach to maintenance and are helpful in identifying trends that can lead to improved procedures and better methods to operating and maintaining equipment, and hopefully preventing issues from reoccurring in the future,” Lippert says. 3. Identifying wear parts needs. Wear parts are an important part of crushing maintenance and can add cost to the final product. Identifying wear parts and how often they are needed is the best way to plan for wear parts replacement. This is referred to as historical data. “Historical data can greatly benefit the producer by identifying possible ways to improve his throughput, helping him to plan for wear parts replacement downtime, and reducing expensive shipping costs associated with delivering emergency wear parts,” Lippert says.
Understanding the equipment While paying special attention to the
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29
RISING RISING STAR? STAR?
2016 2016 NSSGA NSSGA Young Young Leaders Leaders Annual Annual Meeting Meeting | | JW JW Marriott Marriott | | Austin, Austin, Texas Texas 2016 NSSGA Young Leaders Annual Meeting | JW Marriott | Austin, Texas
The 2016 NSSGA Young Leaders Annual Meeting in Austin, Texas The 2016 NSSGA Young Leaders Annual Meeting in Austin, Texas will shine with a Young lineup of the industry’s stars: in Austin, Texas The 2016 NSSGA Annual Meeting will shine with a lineup Leaders of the industry’s stars: F. Williford Jr., President & CEO, Memphis Sand & Gravel Co. will Hal shine with a lineup of the industry’s stars: Hal F. Williford Jr., President & CEO, Memphis Sand & Gravel Co. Karl Watson Jr., President, CEMEX USA Hal F. Williford Jr., President & CEO, Memphis Sand & Gravel Co. Karl Watson Jr., President, CEMEX USA Mark Helm, President, Dolese Bros.USA Co. Karl Watson Jr., President, CEMEX Mark Helm, President, Dolese Bros. Co. Jon Morrish, President Dolese & CEO, Lehigh Inc. Mark Helm, President, Co.Hanson, Jon Morrish, President & CEO, Bros. Lehigh Hanson, Inc. Richard Szecsy, President, TACA Jon Morrish, President & CEO, Lehigh Hanson, Inc. Richard Szecsy, President, TACA Michael W. Johnson, President & CEO, NSSGA Richard President, TACA& CEO, NSSGA Michael Szecsy, W. Johnson, President Michael W. Johnson, President & CEO, NSSGA Young Leaders in the industry will have the opportunity to tour one of Young Leaders in the industry will have the opportunity to tour one of the first quarries theindustry state of Texas to implement a dry dust-suppression Young inin have the opportunity to tour one of the firstLeaders quarries inthe the state of will Texas to implement a dry dust-suppression system, reducing water usage by 80%. Industrial Asphalt’s KBDJ Conservation the first quarries in the state of Texas to implement a dry dust-suppression system, reducing water usage by 80%. Industrial Asphalt’s KBDJ Conservation Land & Quarry (Summit Materials) is an Austin, Texas-based mining company system, reducing water usage by 80%. Industrial Asphalt’s KBDJ Conservation Land & Quarry (Summit Materials) is an Austin, Texas-based mining company committed to protecting the environment. Land & Quarry (Summit Materials) is an Austin, Texas-based mining company committed to protecting the environment. committed to protecting the environment. This is one event every rising star in your organization should attend. This is one event every rising star in your organization should attend. For more to register, visitorganization nssga.org or contact This is oneinformation event everyand rising star in your attend. For more information and to register, visit nssga.org orshould contact Shannon Grace at 800-342-1415 ext. 1072 or email sgrace@nssga.org. For more Grace information and to register, visit or contact Shannon at 800-342-1415 ext. 1072 ornssga.org email sgrace@nssga.org. Shannon Grace at 800-342-1415 ext. 1072 or email sgrace@nssga.org.
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EQUIPMENT MANAGEMENT 3. Hydraulic and electrical: These two functions are associated with equipment control and require maintenance attention of their own. These usually coincide with other housekeeping items. Filter maintenance and oil changes should be a part of any lubrication schedule, which should also include hose and wiring inspections. Simple items overlooked at this stage will halt production and are not always easy to diagnose. Understanding these control functions will make troubleshooting easier and will help provide safer equipment. “Remember, the most unsafe piece of equipment is one that is misunderstood,” Lippert cautions. “Ignorance is dangerous. Most operations will have a specialized person tending to these functions — like an electrician, for example. However, we still advise that everyone understands the control functions, even if they are not required to work on them. Educated
Operators must also understand the equipment and its functions. Otherwise, Lippert says, “Equipment failure is imminent.”
and should never be overlooked or underestimated. The levelness of the equipment helps keep material evenly distributed. This prevents material side loading, which creates improper bed depths that affect product throughput, as well as bearing side loading, which will shorten bearing life. A level structure also protects equipment longevity, as a properly supported frame helps prevent frame cracking that arises from energy releases from improperly supported moving components.
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2. Mechanical: Understanding the mechanics means understanding how each particular component — such as the shaft, bearings, etc. — works mechanically. This helps producers understand equipment limitations as they relate to function. This also improves the safety of the equipment. Equipment operated and maintained according to its designed parameters and factory recommendation will provide optimal performance while limiting unnecessary downtime.
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1 9 2 7
AGGREGATES MANAGER / May 2016 Untitled-18 1
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1/20/16 9:47 AM
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
EQUIPMENT MANAGEMENT
Operators should understand structural, mechanical, and hydraulic and electrical parameters as well as appropriate applications.
employees will be better suited to identify problems while still manageable and can report to their maintenance protocol before a catastrophic event happens.” 4. Application: Once the producer understands equipment function, they can then focus on the application. The first questions usually asked by the service technician are related to application. This is key to identifying the problem and is often the reason an issue exists. Proper application is also critical for optimizing output. For example, consider a typical portable crushing application. Producers should start by properly sizing feed material prior to feeding a crushing plant to ensure consistent feed and eliminate the possibility of misusing a piece of equipment. After sizing the feed, the producer needs to identify the desired output gradation. Controlling factors include closed-side-settings, crusher speeds, fines removal, and maximum feed limitations. Most portable equipment uses a closed-circuit configuration, which also needs to be considered, as producers should avoid bringing back unnecessary material to re-crush, which takes up valuable space, slows down production, and creates excessive loads on a crusher, which affects performance. This can usually be resolved by using the correct screen cloth media, which allows producers to use the entire screen, maximizing throughput.
“When we understand how the equipment is designed to operate, efficiency and production issues can often be avoided,” Lippert says. “This is key to optimizing an operation and ensuring equipment operates as it was intended.”
Investment in personnel By regularly attending factory training
and consulting factory experts, producers can make the right choices to improve their operations. Taking time to invest in education will always help producers save money and improve the efficiency of their operations by eliminating the downtime associated with uninformed choices, Lippert says. “The investment in training always pays off,” he adds. “Training will help producers develop a simple-to-follow but precise maintenance program and will help their crew members understand the importance of a regular, consistent maintenance and prevention program. “Remember, everything ignored at some point will require your attention,” Lippert says. “The amount of time you choose to spend on an issue is always less if handled sooner than later.” AM
Michelle Cwach is the media relations manager for KPI-JCI and Astec Mobile Screens.
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2015-03-17 12:12 PM
AGGREGATES MANAGER / May 2016
NEW VIRTUAL MEMBERSHIP
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Designed for U.S. producers operating a single location with less than 10 non-office staff, your eProducer membership is an excellent value at a cost of less than $1 per day.* As an NSSGA eProducer member, you will have access to the members’ only section of the NSSGA website, including: • Legislative and regulatory updates • Health & safety information • Environmental issues • And much, much more! Other valuable benefits include: • Subscription to Digital Aggregate, NSSGA’s instant newsfeed • Subscription to the online version of NSSGA’s bi-monthly magazine, Stone, Sand & Gravel REVIEW
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SUPPLYLINES by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Which ADT is the Right Fit? Articulated dump trucks focus on payload, performance, and operating costs.
NEW
More power and bigger payload The new CAT 730C2 is a 367-horsepower truck with a 31-ton payload capacity. Standard automatic traction control ensures efficient operation of the artic, which advances the design of the predecessor model with increased productivity, lower operating costs, and added rimpull/retarding capability. The Tier 4 Final machine is also available with an ejector-type body. The Cat 6F/R powershift transmission electronically modulates clutch engagement pressures for smooth, positive shifts, while an engine-compression brake provides 60 percent more retarding force than the previous model. An optional Cat Production Measurement system calculates payload values using sensors located on the walking beam suspension and shows when the target weight is reached. Caterpillar | www.cat.com
Excellent traction in rough terrain The DA40-5, from Doosan, offers excellent driving stability, equal weight distribution, and superior traction. Doosan also says it is among the most fuel-efficient off-road trucks in the industry. The 490-horsepower, Tier 4 Interim machine has a rated payload of just over 44 tons. The unit’s turning ring is located in front of the articulation point to ensure equal weight distribution to the front wheels in all situations. Two state-of-the-art, limited slip differentials ensure excellent traction. A free-swinging rear tandem gear-driven bogie keeps the rear wheels in contact with the ground for a smoother ride in rough terrain. Doosan | www.doosanequipment.com
Cab updates may improve operator efficiency The largest of John Deere’s Tier 4 Final articulated dump trucks is the 460E. It features 481 horsepower and is said to deliver impressive power and torque with an excellent power-to-weight ratio and cycle time. A ZF transmission includes eight forward gears and four reverse gears, as well as a high-capacity retarder to increase service brake life. An updated cab is sealed and pressurized to keep out dust and noise. Other cab features include push-button start, low-effort push-button controls, air-suspension heated high-back seat, and optional premium radio with Bluetooth auxiliary input and satellite radio capacity. An optional weighing system uses mirror-mounted LED load indicator lights to indicate capacity. John Deere | www.johndeere.com
AGGREGATES MANAGER / May 2016
35
SUPPLYLINES
Increased body capacity and payload Komatsu America Corp.’s HM300-5 articulated dump truck boasts 324 net horsepower and is powered by a Tier 4 Final Komatsu SAA6D125E-7 engine. The truck is said to deliver high levels of performance while reducing fuel and operating costs. It has a 30.9-ton payload and a gross vehicle weight of 117,892 pounds. Through body design optimization, the truck has increased body capacity and payload. The low 9-foot, 2-inch loading height matches with 30- to 60-ton excavators or 5- to 7.5-cubic-yard wheel loaders. Economy and Power modes allow the operator to tailor machine performance to work conditions. Komatsu Advanced Transmission with Optimum Modulation Control System (K-ATOMiCS) uses an advanced electronic system to shift shock and torque cutoff to improve operator and engine efficiency. Komatsu | www.komatsuamerica.com
Like 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
AGGREGATES MANAGER / May 2016
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NEW First unit upgraded in renewal program At Bauma, Terex Trucks unveiled an upgrade to its flagship TA400 truck, the first of a new generation of machines going through a product renewal program. The Tier 4 Final 444-horsepower unit has a maximum payload of 41.9 tons. The manufacturer focused on increased performance and lower operating costs while revamping the truck, which features upgraded hydraulic hoses, electrical interfaces, transmission mountings, and brake pipes. Terex also introduced magnetic pressure filters to reduce the risk of contaminants entering the system and to improve the cleanliness of the hydraulic oil. Force-cooled multi-disc brakes enhance safety. Supported by an electronic activated exhaust brake and a six-stage modulating transmission retarder, brake component lifecycles should be extended. Terex Trucks | www.terextrucks.com
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It’s only $35 US in the USA and Canada, $45 US all others. To join, call us at 419-352-5616, or mail a check or money order to HCEA, 16623 Liberty Hi Road, Bowling Green, Ohio 43402. Join online and learn more about us at www.hcea.net.
AGGREGATES MANAGER10/22/15 / May 1:27 2016PM
37
Need to navigate your way around the industry? Get the the most current information with the Atlas on CD While the printed version of the Aggregates Manager 2015 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more. The Atlas on CD contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2015 Aggregates Industry Atlas in pdf format. Order additional copies of the Aggregates Manager 2015 Aggregates Industry Atlas on CD or the printed version of the Atlas today!
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by Arthur Wolfson
ROCKLAW Preventing Abuse of Authority Review Commission finds MSHA inspector abused his discretion with abatement timeline and citations.
W
Arthur Wolfson is a member in Jackson Kelly PLLC’s Pittsburgh office, practicing in the Occupational Safety and Health Practice Group. He can be reached at 412-434-8055 or awolfson@ jacksonkelly.com.
hen does an MSHA inspector abuse his or her discretion in setting an abatement deadline? A recent Federal Mine Safety and Health Review Commission (Commission) decision answered that question when it found that an inspector “failed to set abatement times that were…reasonably required for abatement” and subsequently issued § 104(b) orders when those times were not met. In Hibbing Taconite Co., Docket No. LAKE 2013-231, et al. (Rev. Comm. March 3, 2016), the Commission reversed an administrative law judge and vacated four § 104(b) orders for that reason. An operator who has been issued a citation during an MSHA inspection must fix the cited condition to abate the alleged violation and terminate the citation. That requirement is found in the Mine Act, where § 104(b) requires an operator who has been issued a citation to abate the “violation described in [the] citation issued pursuant to [Section 104(a)].” 30 U.S.C. § 814(b). In setting the abatement time, the issuing inspector must “describe with particularity the nature of the violation” and “fix a reasonable time for the abatement of the violation.” 30 U.S.C. § 814(a). An operator must complete abatement within the time set by the inspector or request (and
be granted) an extension of time to complete abatement. Section 104(b) provides that an inspector shall issue a failure to abate order when the cited violation has not been “totally abated” within the abatement time originally fixed or as subsequently extended and if he determines “that the period of time should not be further extended.” 30 U.S.C. § 814(b). In determining what amount of time is reasonably required for abatement, the inspector should consider factors such as the extent of the violative condition, the availability of miners to undertake the corrective work, and competing safety concerns. Importantly, the inspector must consider the particular factors of the cited condition when setting an abatement time for that condition. Similarly, the inspector should also consider these factors when deciding whether or not to grant a request for an extension of time. Should a resulting § 104(b) order be issued, the operator may challenge the reasonableness of the time set for abatement or the inspector’s refusal to extend that time. Hibbing Taconite involved four § 104(b) orders issued to the mine operator after three § 104(a) citations were issued on Friday, Dec. 14, 2012. In addition, there was a previously issued § 104(a) citation for which abatement had been extended to Friday. On
AGGREGATES MANAGER / May 2016
39
You have to see it to believe it. Where trucking comes home. Due to popular demand, we opened registration earlier than ever before! Kick off your GATS 2016 experience now with free online registration and we’ll keep you posted on everything to look forward to this year. See you in Dallas! #GATS #TruckShow
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Friday, the inspector set the abatement deadline for the following day, Saturday, Dec. 15, at 8 a.m. The inspector indicated that he had a personal policy of setting the abatement deadline for 8 a.m. on the day following issuance of a citation and that the operator could expect such abatement deadlines for all citations he issued. When the inspector returned to the mine on Saturday, Dec. 15, the cited conditions had not been abated. The operator explained that it was in the process of cleaning the plant top to bottom and this cleaning delayed its ability to address the cited conditions. The inspector disregarded this explanation, refused to extend the abatement times, and issued four § 104(b) orders. The operator challenged the validity of the § 104(b) orders. The administrative law judge upheld the orders, and the operator appealed her decision. The operator argued that the inspector arbitrarily set abatement times and his refusal to extend the abatement deadline was unreasonable, given the particular circumstances of the cited conditions. On appeal, the Review Commission reversed the administrative law judge’s decision, finding that the inspector’s policy of uniformly setting an abatement deadline for 8 a.m. the following day was contrary to the requirements that he fix an abatement time based upon “the time reasonably required for abatement of the specific conditions.” The Commission found the inspector’s deadline to be arbitrary and not based on the specifics of the condition. As a result, the Commission vacated the § 104(b) orders. The decision is significant be-
cause it reinforces that inspectors must set abatement times that are both “reasonable” and based upon the specifics of the cited conditions. It also reinforces why the company escort must play an active role in the inspection process. When a citation is issued, the company escort should ask the inspector about the time allotted for abatement. The company escort should point out to the inspector particularities about the cited condition that may cause abatement to be delayed. It is best for this conversation to occur when the citation is being issued. Most inspectors will work with an operator who demonstrates a good faith effort to abate the condition as quickly as it can. However, if the inspector is inflexible about abatement time, as in Hibbing Taconite, the company escort should document the conversation with the inspector in case a challenge becomes necessary. If abatement time has already been set and an operator is faced with a deadline that it believes to be unreasonable, it should explain to the inspector why it believes the deadline to be unrealistic and what amount of time would be required to correct the condition. If an operator has attempted to abate a citation and finds that it needs more time, it should ask the inspector for additional time and explain the basis for the request. It should document all efforts it has made to abate the condition. Here, too, the inspector must consider the specifics of the condition in considering a request for more time. Should the inspector fail to consider these specifics and refuse to grant an extension for abatement time, the resulting § 104(b) order may be vacated. AM AGGREGATES MANAGER / May 2016
41
ADINDEX May 2016
Advertiser
Web
Aggregates Manager Atlas Data/CD Products
www.aggmanatlas.com
38
Aggregates Manager Community Outreach
www.aggman.com/community-outreach
32
Beka-Max of America, Inc.
www.beka-lube.com
31
Bill Langer - Research Geologist
www.researchgeologist.com
36
C.L. Dews & Sons Foundry
www.dewsfoundry.com
43
Elrus Aggregate System
www.elrus.com
FMI Corp.
www.fminet.com
Gilson Company, Inc.
www.globalgilson.com
Great American Truck Show
www.gatsonline.com
Hammond Air Conditioning, Ltd
www.hammondac.com
33
HCEA
www.hcea.net
37
Kespry, Inc.
www.kespry.com/aggregates
Kleemann, A Wirtgen Group Co.
www.wirtgenamerica.com
19
KPI-JCI and Astec Mobile Screens
www.kpijci.com
BC
Kruse Integration
www.kruseintegration.com
43
Linear Rubber Products
www.belting4conveyors.com
43
Minexpo 2016 International
www.minexpo.com
16
NSSGA Membership
www.nssga.org
34
NSSGA Young Leaders
www.nssga.org
30
Progressive Commercial Insurance
www.progressivecommercial.com
11
Pugmill Systems, Inc.
www.pugmillsystems.com
43
Sandvik Construction Mobile Crushers & Screens USA
www.construction.sandvik.com
IFC
Stedman Machine Co.
www.stedman-machine.com/save
43
Sweet Manufacturing
www.sweetmfg.com
43
Top Bid
www.topbid.com
28
Vermeer
www.vermeer.com
15
Vertex Railcar Corp.
www.vertexrail.com
This index is provided as a service. The publisher does not assume any liability for errors or omissions.
42
AGGREGATES MANAGER / May 2016
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CARVED IN STONE
Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at Bill_Langer@hotmail.com
Children of Loess
Through the Loess Hills, road cuts and cliff faces expose Loess Kindchen.
S
hortly after the Great Midwestern Flood of 1993, I undertook a project to map the surficial geologic materials - the sediments left by glaciers, water, and wind - near St. Joseph, Mo. During the Ice Age, the area around St. Joe was covered by a massive glacier extending down from Canada. The ice deposited many tens of feet of black clayey deposits called till. Rivers in the valley bottoms reworked that till, mixed it with other sediment washed to the rivers from the adjacent uplands, and deposited it as alluvium. But the most conspicuous material in the area is loess (rhymes with fuss); a fine soil created by the glacier and deposited by the wind. The glacier ground some rock into silt, tiny particles no bigger than the diameter of a hair. Meltwater from the glacier carried the silt downstream Road cuts expose loess kindchen, or Children of Loess. and deposited it on floodplains. Wind picked up the silt and deposited it Copyright Amy Lilienfeld as dunes along the ancient waterway that became today’s Missouri River. The prevailing winds were from the northwest so most of the deposits ended up on the east (Iowa and Missouri) side of the river. Those windblown deposits are referred to as loess. The end result of this geologic activity was a unique landscape called the Loess Hills. The hills form a 200-mile-long band up to 15 miles wide running north-south along the Missouri River extending from north of Sioux City, Iowa, southward to near St. Joseph, Mo. Although loess is quite common, the Loess Hills are unusual because the loess is extraordinarily thick; as much as 200 feet in some places. Nowhere else in the world, except near Shaanxi, China, is loess thicker than it is in the Loess Hills. Loess has a natural tendency to slump on steep slopes. Over tens of The existence of loess kindchen depends on local groundwater and soil conditions. Courtesy Hungarian Natural History thousands of years, erosion created a landscape of narrow undulating Museum ridges flanked by steep slopes and numerous side spurs. The intricately carved terrain of the Loess Hills makes them a rare geologic wonder that can be experienced via the Loess Hills National Scenic Byway. If you are in that neck of the woods, it certainly is worth a ride along the byway. As you ride through the Loess Hills, you are apt to see deep road cuts where the loess stands in near vertical faces on either side of the road. You can also see steep cliff faces of loess in some places along the Missouri River, like in St Joe. This brings us to the tiny subject of this article. Some of the road cuts or cliff faces expose Loess Kindchen, which is German for ‘Children of the Loess.’ As rainfall or snowmelt percolates through the loess, it dissolves the calcium carbonate in the soil. When the calcium-rich water reaches a nucleus, such as a snail shell fragment, the calcium carbonate precipitates out, forming a concretion around the nucleus. The concretions commonly are irregularly shaped nodules of calcium carbonate, many of which resemble tiny dolls, hence their name. The existence of loess kindchen is dependent on local groundwater and soil conditions. When present, sometimes you can find them peeking out of near-vertical road cuts and bluffs. Over time, they may erode out of the bluffs where they collect in streams at the base of the bluffs. While the Loess Hills is a true geologic wonder, the tiny loess kindchen make the area all that more fascinating.
44
AGGREGATES MANAGER / May 2016
• • • •
TM
To learn more visit: www.elrus.com, email: info@elrus.com or call 888-535-7877
Stroke and flywheel size doesn’t matter.
WE DISAGREE.
The 3055 Jaw Crusher offers up to 25% more capacity than competitive models. Large, dynamically-balanced flywheels reduce peak horsepower requirements. Class-leading, 1-1/2” stroke offers faster throughput for higher capacity. Dual wedge adjust eliminates manual shims and enhances operator safety.
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