Aggregates Manager May 2019

Industry outlook PG4

|

Challenging citations PG27

Your guide to profitable production

River Aggregate’s

new Rye Plant

Partnership with landowner creates dredge operation along Trinity River

10 Tips for bucket selection 15

Optimize the crushing circuit

|

Seismic awareness PG32

May 2019 | www.AggMan.com

MAXIMUM FINES RECOVERYIT TAKES MORE THAN A PIECE OF EQUIPMENT

With a McLanahan Ultra Fines Recovery System you can keep 30,000 tons or more from going to the pond, giving you more usable product. The Ultra Fines Recovery System includes dewatering screens, cyclones, sumps, pumps and a structure all engineered to your specifications by McLanahan. With McLanahan, you get years of experienced process engineering coupled with an analytical lab, all supported by a dealer network to provide local parts and service.

mclanahan.com

Keestrack debuts its new flagship, the B7e jaw crusher, at bauma.

PAGE 6

On Our Cover: Carl Davis, managing partner at River Aggregates, designed and built its new Rye plant.

Cover photo by Kerry Clines.

Make sure to select the size and type of bucket that best matches its use.

PAGE 10

TABLE OF CONTENTS MAY 2019 |

VOLUME 24, NUMBER 5

FEATURE ARTICLES

COLUMNS & DEPARTMENTS

10 The Anatomy of a Wheel Loader Bucket

3 Editorial Partner with a park.

20 Dredging in the River Bottoms

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

Understand how the various parts of the bucket support its health and productivity as a whole.

River Aggregates works with a landowner to turn pastureland near the Trinity River into a dredging operation.

22 A Bit of Texas History

With visitors ranging from Jim Bowie and Davy Crockett to John Wayne and Loretta Lynn, River Aggregates’ new Rye Plant sits on a site rich with Texas history.

6 RollOuts McLanahan Corp.’s UltraWASH modular wash plant, and other new equipment for the aggregates market.

27 Rock Law Strict liability puts the responsibility for violations at the operator’s door, but proper training and record-keeping can lower negligence 30 Advertiser Index See who’s who and where to find their products.

OPERATIONS ILLUSTRATED

15

Control Your Crushing

Use of control points throughout your operation helps even out material flow and increase efficiency.

31 Classified Ads Aggregates industry classifieds.

32 Carved in Stone Take steps to ensure operational capabilities following seismic events.

COMMON

LEVEL

DESIGN

• • • •

Smaller Footprint No Excess Conveyors Faster Set-Up More Product....Less Equipment

®

May 2019

EDITORIAL

Vol. 24, No. 5

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

aggman.com /AggregatesManager /AggManEditor

Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle

Partner with a Park

Senior Editor: Kerry Clines Online Editor: Wayne Grayson editorial@aggman.com

Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Leah Boyd 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 Emeritus: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Kim Fieldbinder Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Senior Vice President, Acquisitions & Business Development: Robert Lake 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 2019. 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.

E

ducating the public about the importance of aggregates to their everyday life is an important mission for many aggregate producers. From open houses to school visits, explaining why aggregates operations exist and how they improve communities is a long-term investment.

For years, the Minerals Education Coalition has communicated this message via the Mineral Baby graphic, which shows each American uses 1.28 million pounds of stone, sand, and gravel throughout his or her life. This message certainly has had an impact; most middle and high school earth science teachers are familiar with the graph, and it is used in many classrooms. It’s a great initiative. That said, we need more ways to meet people where they live and via formats where the message resonates.

On an afternoon hike through a local metro park, I noticed graphics that explained the local geology, including descriptions of the various shale and sandstone commonly found in northeast Ohio. The graphics were well done and pointed out examples of the various types of stone, but I found myself wishing they had gone one step farther and explained how local mineral deposits were used in everyday life. It’s the perfect opportunity to bring focus to how minerals are used to not only create homes, schools, hospitals, and roads, but also less obvious products such as makeup, toothpaste, and light bulbs.

The timing for a partnership with a park seems right. According to the National Park Service, those parks have been averaging more than 330 million recreational visits per year over the last couple of years. In 2017, more than 15 percent of parks set new records for visitation and more than 20 percent of the parks enjoyed more than 1 million visits.

In fact, parks are being so well loved, that there are real concerns about preserving the natural aspects of our parks as visitors create an increasing burden on infrastructure maintenance and cleaning. At the same time, proposed federal budget cuts could leave parks with fewer resources than ever before.

So, here’s a thought: private partnerships with parks could be mutually beneficial for both aggregate producers and the parks themselves. Aggregate producers are in a unique position to help with issues such as road maintenance and could also serve as an educational resource on the site’s geology and its importance on everyday life.

Industry experts could share insights into local geologic formations while stressing the importance of protecting natural resources — both parks and future reserves.

One way to begin would be with reclamation projects being developed as parks for local communities. This could help operators build their credibility with local, state, and national park services. Think about partnering with a park — and show outdoor enthusiasts that mining and nature are not mutually exclusive. AM

AGGREGATES MANAGER / May 2019

3

mining

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

Diesel Fuel

Prices 4/8/19

United States $3.093 One Week +0.015  One Year +0.050

Central Atlantic $3.324 One Week +0.015  One Year +0.092 

Lower Atlantic $2.998 One Week +0.007  One Year +0.059 

Midwest $2.993 One Week +0.009  One Year +0.036 

Gulf Coast $2.879 One Week +0.007  One Year +0.035 

Rocky Mountain $3.028 One Week +0.021  One Year +0.058 

West Coast $3.591 One Week +0.050  One Year +0.091 

West Coast less California $3.189 One Week +0.036  One Year -0.037 

California $3.910 One Week +0.061  One Year +0.193  Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).

$4.47

$7.60

$32.53 

$25.04

$37.05

EXP

$84.47 

$57.00

$115.75

Granite Construction Inc.

GVA

$42.81 

$38.55

$60.11

HEI

$77.61 

$58.39

$96.03

HCMLY

$10.12 

$7.80

$11.39

Martin Marietta Materials, Inc.

MLM

$204.98 

$150.75

$232.89

MDU Resources Group, Inc.

MDU

$25.74 

$22.73

$29.62

Summit Materials

SUM

$14.80 

$11.25

$31.36

United States Lime & Minerals, Inc.

USLM

$78.55 

$68.20

$85.95

U.S. Concrete

USCR

$43.01 

$27.68

$65.85

Vulcan Materials Co.

VMC

$119.70 

$82.52

$133.59

Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 4/9/19.

East Coast $3.137

One Week -0.003  One Year +0.077 

$4.97 

52-Week High

CRG

COMPANY SPOTLIGHT

One Week +0.010  One Year +0.071 

New England $3.193

52-Week Low

Eagle Materials Inc. HeidelbergCement AG

U.S.

CX

Current Value

CRH plc

LafargeHolcim Ltd. ADR

On-Highway

Ticker

H

eidelbergCement (HEI) reported 2018 revenues of $20.4 billion, compared to $19.5 billion in 2017, an increase of $0.9 million or 5 percent. Adjusted for currency and consolidation effects, revenues increased by 8 percent.

In contrast, results from current operations decreased by 2 percent to $2.5 billion on a comparable basis, which is in line with the company’s revised October 2018 outlook. The decrease was attributed to adverse weather conditions, particularly in core North American markets, as well as higher-than-anticipated increases in energy and electricity costs and lower-than-planned proceeds from the sale of depleted quarries.

“In 2018, HeidelbergCement achieved most of its goals in an operationally challenging environment,” said Dr. Bernd HeidelbergCement (HEI) Scheifele, chairman of the managing board of HeidelbergCement, in a press release. “In its 145-year history, our group has never sold more cement, concrete, sand, and gravel than in 2018. With more than 18 billion Euros ($20.4 billion), a new record figure was also achieved in revenue.”

The company’s financial result improved significantly by $59 million to $413 million, due primarily to lower interest expenses thanks to more favorable refinancing of maturities. HeidelbergCement also generated enough cash to pay a full dividend, reduce liabilities by $369 million, and strengthen market positions by means of substantial investments in growth. It purchased Cementir Italia in Italy and Alex Fraser Group in Australia.

On the safety front, the company reported a 12-percent decrease in its accident frequency rate across the group. It also sponsored the fourth edition of the Quarry Life Award, which supports innovative approaches to the exploration and promotion of biodiversity in quarries and pits. More than 300 project proposals were submitted from 25 companies.

“Considering the overall positive outlook for the global economy, we are confident about the future,” Scheifele said. “In 2019, we will focus on our action plan in order to accelerate our portfolio optimization and increase cash flow and margins. In addition, we will press ahead with the digitalization of our entire value chain in order to improve our operation excellence… We believe we are well equipped for the opportunities and challenges of 2019.”

Source: Market Watch

Data

STOCK REPORT

AGGREGATES INDUSTRY OUTLOOK Building on modest improvement last month, the April Aggregates Industry Outlook increased by 4.6 percent.

The most significant increase was reported among positive responses for monthly sales, which were up 14.1 percent from March. While the shortterm outlook received positive feedback, the month’s biggest decrease was registered among responses concerning annual sales. The April responses in this category marked a 7.2-percent decline from March.

Aggregates Industry Outlook 150 138.10

145

134.94

140

132.22

130.86

130.68

135 130 125

127.22 134.72

132.73

132.64

136.65

120

125.00

115

120.20

110 105 100 May 2018

June 2018

July 2018

Aug. 2018

The backlog for work in 2019 still appears strong in our markets, however, there just seems to be a hesitation on getting the work started. Hopefully, April is the month we see things really open up.

— Ray Mack, Sales Manager, Carmeuse Lime & Stone

Sept.

2018

Oct. 2018

Nov. 2018

Dec. 2018

Jan. 2019

Feb. 2019

Mar. 2019

Apr. 2019

Coming out of winter and seeing signs from all segments — aggregates, cement, and sand — of strong backlogs and ramping up production rates. Several producers are increasing production of asphalt and road base materials. If Illinois roads are reflective of other areas, there are lots of patching and re-paving needs!

— Jason Hurdis, Senior Market Profesional, Caterpillar

Most of my clients are optimistic about 2019 production, which started slowly because of weather for several areas in the United States. The Northeast and upper Midwest construction seasons are just getting started as winter slowly disappears. The Dallas-Fort Worth area, as well as other metropolitan cities, seems to be doing very well for producers. Acquisitions continue.

— Mark J. Zdunczyk, Consulting Geologist, Mark J. Zdunczyk LLC

Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.

QUARTERLY CRUSHED STONE & SAND AND GRAVEL REPORT Quantity Crushed Stone 4th qtr. 2018

Percent change

New England

10,500

3.9

7,380

-7.9

Middle Atlantic

42,700

15.8

12,600

8.6

East North Central

56,300

7.4

29,100

2.3

West North Central

29,100

-11.3

29,700

3.1

South Atlantic

79,900

3.3

16,500

4.4

East South Central

37,000

6.1

6,970

3.9

West South Central

58,500

4.1

31,600

8

Mountain

13,800

Pacific

23,700

6.6

415,300

7

TOTAL

359,000

5.1

241,000

4.4

Region/Division Northeast:

Midwest:

South:

West:

Quantity sand and gravel 4th qtr. 2018

-4.1 metric tons * thousand

Percent change

45,700Source: U.S. Geological 1.9 Survey

* thousand metric tons Source: U.S. Geological Survey

ROLLOUTS

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

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

Modular wash plant McLanahan Corp. launched its UltraWASH modular wash plant at bauma 2019. Available in three sizes, the plant can produce up to three aggregate products and two sand products. Thanks to the company’s acquisition of Anaconda Equipment, the plant’s feed hopper and conveyor can be upgraded to come with tracks for easier conveyor maintenance. The UltraWASH is available with several configurations and options, including feed preparation (log washers, blade mills, and screw washers), attritioning, organics removal, and water treatment (filter presses and thickeners). Material can also be sized to meet specific requirements using the line of UltraCRUSH equipment, which includes a modular cone crusher.

McLanahan Corp. | www.mclanahan.com

Hybrid jaw crushing plant Keestrack featured the Keestrack B7e jaw crusher, its new 700 ton-per-hour flagship. The plant is built around the CJ 412 jaw, with a 47- by 32-inch inlet for feed sizes up to 27 inches and a hydraulically adjustable closed-side setting of 3 to 10 inches.

Available only as a plug-in hybrid, the crusher is driven by a 177-horsepower electric motor. Another 73-horsepower motor powers the hydraulic system for the tracks, lifting cylinders, vibrating feeder with two-deck pre-screen, and all conveyors. The diesel-electric power is delivered by the on-board Volvo diesel engine and the on-board generator. The engine house is available in a detachable drop-off module, to be positioned away from the crusher in a dust- and vibration-free environment. According to Keestrack, energy savings of up to 80 percent can be obtained in emission-free, plug-in operation from mains or external gen sets.

Keestrack | www.keestrack.com

Cost-efficient materials transportation At bauma, Bell Equipment added the 40-ton B45E 4x4 to its lineup of trucks. The front half of the truck is essentially the same as its 6x6 counterpart and designed to serve as an efficient and cost-effective transport solution. The truck is powered by a 523-horsepower sixcylinder engine from Mercedes Benz, optimized for off-highway use by MTU. This, combined with the Allison seven-speed automatic transmission, contributes to the truck’s performance and low fuel consumption.

Wet brakes on both axles ensure safe deceleration and work with the Jacobs Engine Brake to provide multi-stage programmable automatic retardation. The standard cab is said to be spacious and offer great visibility. Productivity is enhanced based on collection of real-time data by the truck’s sensors.

Bell Equipment | www.bellequipment.com

6

AGGREGATES MANAGER / May 2019

Hauler offers comfort and safety Volvo Construction Equipment unveiled its updated G-Series articulated hauler range. The G-Series focuses on the correlation between operator comfort and productivity. The trucks boast hill assist, load and dump brake, and Volvo Engine Brake, as well as new features such as cruise control and downhill speed control.

Volvo says the new features enhance safety, comfort, and productivity. The ergonomic cab and controls are designed to suit all operators. Automatic functions, including the new OptiShift, improve fuel efficiency and speed cycle times.

Volvo Construction Equipment | www.volvoce.com

Solar-powered stacker With an eye to the future, Keestrack featured its Keestrack S5e Solar tracked stacker. Believed to be the world’s first solar-driven processing plant, the stacker is powered by photovoltaic battery packs mounted above the 75-foot long conveyor, which feed the battery installed in the chassis. The battery powers all electric driving, lifting, and conveying functions. In case of bad weather or intensive, continuous operation, the system can also be powered or recharged via external sources, such as upstream diesel-electric crushers and screens or via mains plug-in.

Keestrack | www.keestrack.com

Sensor-based sorting Binder+Co introduced the MINEXX sorting system. The modular system uses a series of various sensors, including VIS, UV, NIR, and XRT, that work in combination. Sensor data are linked to specially developed evaluation algorithms to allow simultaneous sorting based on criteria such as color and type of material. The modular design allows for simple retrofitting to existing systems.

Binder+Co | www.binder-co.at

Impact plant offers improved product shape Kleemann’s MR 130 Zi EVO2 impact plant features a new inlet geometry, which increases penetration of the material into the range of the rotor. The wear behavior of the new C-form impact ledges has been improved so the edges remain sharper longer, leading to improved material shape.

The rotor ledges are held secure by a new, user-friendly clamping system for quicker changeouts and higher plant uptime. The machines are equipped with direct drive. The diesel engine transmits power directly to the crusher’s flywheel via a fluid coupling and V-belts. Rotor speed can be adjusted in four stages for various processing applications.

Kleemann | www.wirtgen-group.com/america AGGREGATES MANAGER / May 2019

7

ROLLOUTS Positive seal tailgate Philippi-Hagenbuch Inc. invented a new version of its Autogate Tailgate, specifically for off-highway trucks and roll-off containers that require a 100-percent positive seal. The new design can be paired with Phil’s proprietary fluidic seal material to create a water-tight seal that contains liquid materials within an off-highway truck body or roll-off container when environmental regulations or local laws make even slight spillage undesirable. The tailgate can be designed for nearly any off-highway truck or roll-off container.

Philippi-Hagenbuch Inc. | www.philsystems.com

VR immersive safety training Caterpillar Safety Services rolls out Cat Safety VR, a new virtual reality safety training module. The initial training module is customized for paving applications and immerses the trainee into a virtual four-lane rural highway construction site. It allows the employee to interact with co-workers and identify hazards in a safe and controlled environment. The kit comes with a gaming laptop preloaded to run the program, HTC VIVE virtual reality headset system, mount stand kit, and transport case. The training segments last 20 to 30 minutes, and the program can be adapted to meet the needs of specific industries and applications.

Caterpillar | www.cat.com

Mixed service tire extends useful life Cooper Tire adds the Roadmaster RM351 HD tire to its commercial tire lineup. Engineered for mixed-service applications, including mining, the tire is designed for both on- and off-road driving. It is available in two sizes: 11R22.5 and 11R24.5, in load range H. The tire is a full inch wider than its predecessor, the RM300 HH, and has a 20-percent larger footprint. With a 32/32nds tread depth, the tire is said to provide up to 25 percent more miles to removal, depending on application.

The tire features five lugs that have an open pattern to minimize stone holding while enhancing traction. Stone ejector edges, coupled with angled grooves, also help prevent stone drilling.

Cooper Tire | www.coopertire.com

Software update expands analyticse TrendMiner NV’s newest release, TrendMiner 2019.R1, includes a new visual representation of time-series data, as well as a number of usability enhancements to further improve views of available data. The software enables operators to analyze, monitor, and predict operational performance through trend analysis of time-series data. The new Stacked Trend View enables display of trend data within separate lanes, vertically stacked and aligned. The interface allows the user to move trend lines from one lane to another by dragging and dropping tags to combine similar measurements. Other new features include date pickers for the double slider, custom time spans for focus chars, and a keyword filter.

TrendMiner NV | www.trendminer.com

8

AGGREGATES MANAGER / May 2019

A WIRTGEN GROUP COMPANY

FLEXIBILITY MEETS PRECISION. THE NEW MOBISCREEN EVO SCREENING PLANTS

HIGH-LEVEL FLEXIBILITY AND THE BEST SCREENING RESULTS. The new MOBISCREEN MS EVO screening plants stand out with their broad application versatility, ideal transport properties and fast set-up times. With the plant’s state-of-the-art control system, operating conditions can always be viewed conveniently and all machine functions can be controlled easily and intuitively. The efficient MOBISCREEN EVO plants deliver the best possible performance values combined with low fuel consumption and guarantee precise results with a wide range of application materials. This is where flexibility meets precision. www.wirtgen-group.com/america

WIRTGEN AMERICA, INC. · 6030 Dana Way · Antioch, TN 37013 · Telephone: (615) 501-0600

EQUIPMENT MANAGEMENT

by Perry Girard

The

Anatomy

of a Wheel Loader

Bucket

The selection of both the bucket and its optional features impacts the overall performance of the wheel loader.

Understand how the various parts of the bucket support its health and productivity as a whole.

A

wheel loader’s bucket is a pretty straightforward attachment — but it’s also arguably the most important component on the machine, as it has a significant effect on productivity, machine uptime, and performance in aggregates operations. While there are a number of selections, features, and variables that go into choosing the right wheel loader bucket type, teeth, and

10

AGGREGATES MANAGER / May 2019

cutting edges, the decision can be made simple by knowing and understanding your operation and the materials you work with each day.

Material density matters There are four essential styles of wheel loader buckets: light material, general purpose, 4-in-1, and rock buckets. In addition, there are pin-on and coupler

configurations to consider with each of those styles.

Determining the bucket style that is best for your needs starts with your machine size and primary material density. Some operations may be moving a combination of sand, stone, dirt, or gravel, while machines in other pits are focused on just one of those materials.

Bucket choice should be a reflection

of the heaviest material density being handled the majority of the time, as well as by the abrasiveness of the material being moved.

One consideration to keep in mind is that in damp or rainy climates, sand may be your heaviest material due to its ability to retain water. In more arid climates, that is likely not the case, so it is uniquely dependent on your geographic location and climate.

Sizing considerations One of the first core decisions to make about a wheel loader bucket is its size. It may seem intuitive to default to “bigger is better,” but, ultimately, the decision needs to evaluate the size and power of the wheel loader, the production expectations of the operation, the abrasiveness of the material, and then the size of the trucks and hoppers the wheel loader will fill. Keep in mind the following: • Bucket capacity is important, but

the weight of the bucket will change based on what type of bucket it is. A rock bucket is going to be heavier than other bucket styles and, as such, may have a greater effect on operating speeds/ performance than a lighter bucket.

• A smaller, heavier, stronger bucket may be best for standing up to work in really abrasive environments. The more abrasive the soil or material, the stronger the bucket is recommended to be to maximize bucket life or reduce bucket replacement costs.

• Optimal bucket capacity is decided not only by the machine, but by the size and types of containers it loads. If, for instance, you know your operation runs at optimal performance when trucks can be loaded in three passes, pick the best combination of bucket to truck capacity (within the operating parameters of the loader).

• As long as it’s within the operating capacity of the loader, it may be better to err on the side of a larger bucket, as a smaller bucket may result in it taking too many additional passes to fill trucks or hoppers and, therefore, slow other downstream activities.

Aligning applications A light material bucket is a great solution for operations moving materials like wood pulp, dry dirt, or even waste.

Agricultural operations could also be a fit for a light material bucket. These buckets give the user the greatest amount of capacity and volume — but may not ultimately be the best for working in aggregates operations.

A general-purpose bucket, on the other hand, is a good middle-ground solution if you’re working with a variety of materials and conditions. It is stronger and more durable than light material buckets. It can be used for moving

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11

EQUIPMENT MANAGEMENT If a wheel loader is dedicated to one function, a pin-on connection is the best option. If, however, it will need to switch between bucket types, a quick coupler option may be more suitable.

light materials, aggregates, and sand. While the flexibility of a general-purpose bucket makes sense for many organizations, you will sacrifice some of the bucket capacity available with light material options — but it will stand up better when working in abrasive conditions.

The next option is the 4-in-1 multi-use bucket. This bucket gives you the option to bulldoze, clam, pick up, dump, and load, all in one attachment. It also adds a unique level of flexibility on construction job sites, but added hardware that provides the moving parts adds weight, which

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AGGREGATES MANAGER / May 2019

3/28/19 9:51 AM

translates to generally smaller bucket options than what the general purpose buckets offer. This hydraulically operated bucket provides major versatility — but is not generally practical in aggregates operations.

Finally, the rock bucket has a number of varieties, but is designed for the most rugged applications and rock handling.

The rock bucket comes equipped with heavy-duty lips to protect against scalloping, and is often available with specialized rock teeth, cutting edges, or segments that can provide even more protection to the lips of the bucket.

These attachments are going to be found most in quarries and other severe applications.

Operators moving heavy, high-density materials such as granite — a much more abrasive material than limestone, for example — will want to consider heavy-duty rock buckets with additional protective elements. Those come in both bolt-on or weld-on varieties.

To couple or not to couple When considering the type of connection you want for the implement, there is really one main consideration: will the bucket remain on a dedicated machine, or will you need to switch between bucket types?

If using the attachment on a dedicated piece of equipment, the pin-on connection is the best option.

Other quick coupler connections, predominantly JRB- or ACS-style connectors, allow operators to switch quickly between multiple buckets and attachments. This is a great feature for operators working in diverse situations that may include a variety of aggregate or material types.

Accessorizing to maximize profitability

to adjust a base model bucket to the particular needs at that time. This makes the attachment more versatile and, by virtue, profitable.

For example, say a loader is fracturing ground one month and moving sand the next. It would be a great fit for a bolt-on system featuring teeth that can be used during the first month and replaced with a cutting blade for the next month.

These best practices not only make the equipment more effective, but prolong its lifecycle by minimizing wear to the bucket lip.

In addition to using cutting edges, aftermarket wear protectors are available to help minimize wear and tear on both the bucket’s main lip and sidewalls.

These relatively small additions can make a big impact on the lifespan of a wheel loader’s bucket. AM

There are additional options to consider that can increase the profitability of the bucket. For most buckets, bolt-on teeth and cutting edges may be added

LET'S BUILD

Perry Girard is product manager, CASE Construction Equipment.

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13

P A R T N E R S O L U T I O N S / H I TA C H I

New flagship wheel loader shows Hitachi at the top of its game

T

he team behind the new generation of Hitachi Wheel Loaders felt they have something to say to America’s most demanding buyers of heavy equipment. With the release of the ZW550-6 loader, the statement comes through loud and clear.

Tough, sleek, nimble and productive, the ZW550-6 is Hitachi’s announcement that there’s a new player at the table when earthmoving contractors and quarry operators are dealing for a big, dependable machine.

Stepping up for heavy-duty applications The ZW550-6 is the flagship of the new Dash-6 series of Georgia-based Hitachi Wheel Loaders. Weighing in at 104,000 pounds and 512 gross hp, it targets the heaviest applications with a choice of 8.2 cubic yard or 9 cubic yard buckets. With its standard Dual Z-Bar linkage, high tipping load, and high breakout force, Hitachi sees a place for the new machine in tough rock handling, aggregate operations and among high-volume material producers.

Also included is a full suite of new-generation features that Hitachi premium users have come to expect. The ZW550-6 sports smart technology such as traction control, ride control, auto power-up, and an operator-friendly LCD color monitor. Hitachi’s “Global e-Service” combines with its ConSite telematics program to give service managers 24/7 remote monitoring, maintenance data and daily operational reports. Dash-6 machines also take the lead in Tier 4 Final power, dispensing with the aggravation of plugged diesel particulate filters and regeneration downtime with its move to clean selective catalytic reduction technology using a simple DEF system.

A solid foundation To develop the new loader, Hitachi started with a solid foundation. The ZW550-6’s heavy-duty box frame is built for the long haul in tough environments. The durable frame is matched with a low-mount lift arm that minimizes twisting on the front frame, especially in uneven environments. The cooling package is equally suited for long duty cycles in hot, dusty applications. A reversible cooling fan comes as standard, and can be activated automatically or manually.

Aluminum cooling cores ensure high cooling efficiency as well as extending service life free of corrosion. A protective rear grille also helps to prevent dust and raw material from entering the radiator compartment.

Power Mode boosts productivity With Hitachi’s new Power Mode feature, the ZW550-6 raises the bar for high-performance productivity and efficient duty cycles. At the flick of a switch, operators can instantly boost power with a 10% burst in engine rpm. Conveniently mounted on the steering joystick, Power Mode provides immediate access to added rim-pull and breakout force for digging into heavy piles or for climbing grades with a full load onboard.

Power Mode also provides a faster hydraulic speed to allow quicker bucket lifts. Switching to Power Mode does not compromise the loader’s top speed. It gives you the same top end speed; you just get there quicker with more payload in every cycle.

Loading tasks are further simplified with the ZW550-6’s responsive lift/bucket prioritization. Its Parallel Tilt & Lift movement smooths out digging operations while the tandem function prioritizes the bucket while dumping; then the automatic return-to-dig function resets the bucket for the next load.

The best visibility in the business Hitachi claims the best visibility in the business for loader operators, with clean lines of sight in all directions. Joystick steering removes the steering wheel as an obstacle to the operator’s view of the work zone. The ZW550-6 also opens up the view to the rear by relocating the exhaust stack to the far end of the rear cowling and by designing the roll-over protective structure with frame struts forward, out from the corners of the cab. A rear safety camera is standard equipment, along with proximity detection providing audible and visual alerts for stationary and moving objects up to 20 feet from the loader.

If this describes what you are looking for in your next machine, talk to your Hitachi dealer.

OPERATIONS ILLUSTRATED

By Therese Dunphy, Editor-in-Chief

Control your Crushing

Observe operations daily.

Understand the mineralogy and gradation goals.

Watch for bottlenecks.

OUR EXPERTS

Test materials as the geology of the deposit changes.

Kelly Graves is Kleemann’s director of sales for crushing in North America. He has more than 30 years of experience in crushing and screening, both from the producer and manufacturer side. Graves has a bachelor’s degree in business from Pellisippi State.

Matt Wolverton is plant manager for Aggregate Industries’ Fulks and Hayfield Sand and Gravel sites, as well as interim plant manager at its Accokeek Sand and Gravel operation. He began his career interning with the company and returned two years after receiving his bachelor’s degree in mining and minerals from Virginia Tech.

Jamie Gauger is Metso’s applications and systems manager, aggregates, U.S. and Canada. He has been in the aggregates industry for 19 years. He has a bachelor’s degree in international business from the University of Wisconsin-Whitewater. He also holds a certificate in international quarry operations from the University of Derby.

AGGREGATES MANAGER / May 2019

15

Focus on material characteristics and desired gradations

T

he axiom ‘knowledge is power’ applies to all segments of an aggregates operation, but is particularly true when it comes to crushing.

That knowledge comes from an understanding of the entire production process, however, not just the crushing circuit. “Some people request us to look at one machine,” says Jamie Gauger, Metso’s applications and systems manager, aggregates, U.S. and Canada. “We like to take a step back and look at what’s going on in the system. Just putting in a new machine, whether it’s the same physical size or horsepower class, does not always get to the root of the problem.”

When visiting high-performing plants, Gauger says he sees plant managers who walk the plant on a regular basis, listening to its cadence and observing operations, so they know what is happening.

“They are constantly looking for signs that something is going wrong or something is about to go wrong,” he says. “It’s all about having people on a team who really understand what’s going on. Having detailed knowledge of their process and their system is one of the best practices I’ve seen in my time.”

Kelly Graves, Kleemann’s director of sales for crushing in North America, adds that operators who know their material characteristics and the intended gradations are a step ahead when it comes to making changes to optimize their crushing circuit.

1

“There are a number of producers who may not have the right information to determine the type of process that’s required,” he says. For example, material type, moisture content, and contaminants all play a role in crushing decisions.

State laboratories, quality control labs, and some manufacturers can provide the analysis necessary to understand the impact of these variables, but they are not all static. As a crushing operation moves deeper into a deposit, material composition and hardness may change. “It’s something producers need to monitor,” Graves says, noting that changes in final product gradation and production capacities are clues that may indicate adjustments are needed.

In the Mid-Atlantic Region of Aggregate Industries, a LafargeHolcim company, a careful eye on material coming out of the pit helps it keep its crushing operation running smoothly. “We always look to maximize our crushing performance based on the pit material,” says Matt Wolverton, plant manager for its Fulks and Hayfield Sand and Gravel sites, as well as interim plant manager at its Accokeek Sand and Gravel operation. “If we are going to make gravel, we make sure we do so while running the heavy gravel portions of our deposit. This allows our crushing circuits to stay maxed out while still maintaining the hourly production target.”

Know your material

Start with a thorough understanding of your material and its characteristics. Material testing can highlight factors such as particle density, L.A. abrasion value, resistance to wear by attrition, impurities, and more.

An understanding of these characteristics, which may change throughout the deposit, helps operators make better decisions about crushing options.

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AGGREGATES MANAGER / May 2019

2

Add control points

Add control points such as surge bins, surge hoppers, and surge piles to even the flow of material throughout the plant. While control points do create additional costs, they also can allow the plant to produce additional tonnage and lower operating costs.

3

Leverage technology

With technology options now available on crushers, information on items such as power consumption, wear rates, and incident rates is more easily tracked. This can allow producers to optimize the life of wear liners and lower costs, while also enabling manufacturers and dealers to remotely diagnose and troubleshoot problems.

4

Stock essential wear parts

Be sure to stock major wear components essential to keeping the crusher up and running. Electrical components, as well as feed belts, crusher sheaves, blow bars, filters, breakers, and other common wear parts should be on hand. Standardization throughout regions allows larger producers to more easily stock parts.

AGGREGATES MANAGER / May 2019

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Voices of Experience Kelly Graves

W

hen trying to optimize a crushing circuit, it’s important to understand the material being processed and the gradations an operator wants to produce, advises Kelly Graves, Kleemann’s director of sales for crushing in North America.

“I’ll start from the very beginning: from how they blast material, how they carry the material at the plant, what their scalping capability is, and how they clean material to the primary, secondary, tertiary, and quaternary crushing,” Graves says. “You have to take into account all of the operation in order to achieve one production goal.”

Each application is unique and must be tailored appropriately. “The type of material plays a big part in how you’re going to process the material,” he explains. For an abrasive material, a jaw/ cone set up works well, while impact and cone crushers work well for softer materials.

At the same time, the planned product mix also has to be factored into that analysis. For example, impactors work well with limestone, but if the operator wants to avoid generation of fines, a cone crusher may be more suitable.

“Typically, an aggregate producer wants less fines; they want to produce the minimum amount possible,” he says. “If it’s a sand and gravel operation, on the other hand, it wants more sand, therefore more fines.”

Another factor to be considered is matching the anticipated throughput to the capacity of the crusher. Operators often try to push a crusher to exceed the manufacturer’s recommended production capacity on crushing and screening equipment. “If a cone crusher is rated for 300 tons per hour, they will want to push it and try for 350 to 400 tons and produce more than the capabilities for that specific piece of equipment,” Graves says. “In a nutshell, they’re trying to ask more of the machine than what it’s capable of doing.”

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AGGREGATES MANAGER / May 2019

Matt Wolverton

Jamie Gauger

S

O

izing abrasive material for concrete sand keeps Aggregate Industries’ Accokeek plant, part of LafargeHolcim, attentive to its crushing circuit. Abrasive material is hard on manganese, requiring vigilance toward maintenance and frequent wear materials changeouts, says Matt Wolverton, interim plant manager for the site.

“We go through wear liners in three months,” he says, explaining that under other crushing conditions, those same liners might last two years. The site uses an MVP 450 cone, as well as a Texas Impactor to reduce 1¼-inch plus material.

“We’re not worried about particle shape,” Wolverton notes. “We are focused on particle size.” To achieve the reduction necessary, a significant amount of material recirculates through the crushing setup. This means a high power draw, but has an upside as well. “We aren’t putting material on the ground that we can’t sell,” he says.

Frequent liner wear translates to frequent quality inspections. Wolverton says the operation keeps wear materials for the impact crusher on hand and works with the local dealer for wear parts for the cone crushers. Standardization between sites also helps ensure the necessary stock is on hand.

Maintaining the proper closed-side setting on the crusher and keeping a consistent material feed through the use of overhead bins keeps the crushers choke fed and improves crushing efficiency. Occasionally, the operation may make #57s or pea gravel. When that happens, the operation opens up the closed-side setting as needed, but proper communication is also necessary.

“You have to forecast ahead enough to order wear liners one to two months in advance,” Wolverton says, noting that there is a delicate balance between appropriate manganese content and the desired product. “It’s a hard thing to manage. It requires solid communication between sales and production.”

ne way to improve production is through the use of control points, such as surge bins, surge hoppers, and surge piles with variable speed feeders throughout the operation.

“The more control points you have in that process, the easier it is to iron out all the peaks and valleys in operation,” says Jamie Gauger, Metso’s applications and systems manager, aggregates, U.S. and Canada. “Control points improve your efficiency and improve your profitability.”

When visiting a site where an operator has a complaint about production, he begins by walking through the entire circuit and looking at conveyors, transfer points, screens, and feeding practices.

Often, inefficiencies in other areas can impact production from the crusher. For example, screens are a common bottleneck. “The screen is the cash register.

It’s making the actual gradations that the operator is putting on the ground,” Gauger says. “If those can be improved and made more efficient, the operator could get more recoverable product.

That is hugely beneficial; it can improve operator profit, and it can lower operating costs.” Conversely, when a screen becomes inefficient, it may produce a contaminated or unsellable product or push that inefficiency to the crusher and generate excess fines. Primary plant feeding is another common problem area. As it becomes inefficient, it affects everything downstream.

That’s where control points come in, but while they ensure smooth flow of material, they do so at a cost. “Any time you have extra material transfer points of material, it’s been proven to increase operating costs due to the extra piece of equipment, extra power required, and extra maintenance,” Gauger says.

“It’s not always physically or financially viable, but operators need to understand what type of benefits those types of implements would give them, both in terms of production and overall system operating costs.”

Get the the most current information with the 2018 Aggregates Industry Atlas and the Atlas Download.

While the printed version of the Aggregates Manager 2018 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas Download to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more.

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Quarries and property values Equipment investment continues to climb The final Workplace Exam Rule

PLANT PROFILE

by Kerry Clines | Senior Editor

Dredging in the River Aggregates works with a landowner to turn pastureland near the Trinity River into a dredging operation.

R

iver Aggregates has been supplying aggregate products to customers in the Houston, Beaumont, and East Texas markets since 2011. It has two sand and gravel operations in Texas — one in Conroe, and a new one in Rye. The Houston area is growing at a rapid pace, creating a huge demand for building materials.

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AGGREGATES MANAGER / May 2019

“There’s a lot of activity coming out in this direction,” says Rob Van Til, managing partner of River Aggregates, speaking of the market for the new Rye plant. “We think over the next 10 years, we’ll not only get into the north and east side of Houston, but we’ll also get into Baytown and the Port of Houston area, as well as Beaumont and a little bit of east Texas, with our material.”

As reserves at its old Romayor operation neared depletion, River Aggregates began the hunt for a new location. It found the perfect spot, just 4 miles from its Romayor operation near the small town of Rye, northeast of Houston. The location includes 1,300 acres of coarse sand and gravel and is expected to have a lifespan of 20 years. It is expected to yield 60 percent concrete sand and 40

River Aggregates’ new Rye Plant dredging operation sits on Trinity River bottom lands that are part of the historic Plantation Ranch in Texas.

River Bottoms Photo credit: River Aggregates.

percent fine sand after removing 5 to 8 percent gravel.

Let’s make a deal The new Rye dredging operation is located on bottom lands near the Trinity River that once served as a pasture, but it didn’t happen overnight. Just a couple of years ago, River Aggregates’ Rye Plant was simply an idea being discussed with the landowner, Will Daniel, who envisions the land as one day being the location of his family’s dream home.

Daniel spent a lot of time working out the details with River Aggregates before reaching an agreement.

Daniel wished to capitalize on the land before turning it into a homestead.

He was focused on timber production and cattle grazing leases, but knew there were several aggregate companies in the area, so he believed there might also be usable aggregate on his property.

However, it was only a few years earlier that a major aggregate producer cored part of Daniel’s land and passed on the

opportunity to open a mine there. Despite the prior rejection, he spoke with several other mining companies in the region, and ultimately pursued a deal with River Aggregates, which was willing to mine all the materials on the site, not just concrete sand, and was willing to work with him on a timeline for completion of mining.

“The process took about a year of conversations, talking, dreaming, and sharing concerns, hopes, and future ideas,” Daniel notes. “As a result, we’ve AGGREGATES MANAGER / May 2019

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PLANT PROFILE

A bit of Texas history River Aggregates is leasing a bit of Texas history for its new Rye Plant. The parcel of land is a part of Plantation Ranch, which has a long history dating back before Texas won its independence from Mexico.

After the American Revolution, Pvt. Aaron Cherry and his family left Virginia, eventually making their way to Texas in 1818. They settled on a bluff overlooking the east bank of the Trinity River and built a plantation. From there, Cherry traded with the Indians and the infamous pirate Jean Lafitte, who had a settlement on Galveston Island. In 1835, the Mexican government granted one league (4,428 acres) of land to Cherry.

Cherry played host to some of Texas’ greatest heroes in its fight for independence from Mexico, including Jim Bowie, William Travis, Davy Crockett, and Sam Houston. In 1936, the Texas Centennial Committee named the Cherry plantation the oldest permanent Anglo settlement in Texas. So, by the time William Partlow “Bill” Daniel and his wife, Vara Faye Martin Daniel, purchased the plantation in 1948 and named it Plantation Ranch, it already had a rich heritage.

“In Texas’ long history, the ranch has not changed hands much,” says Will Daniel, grandson of Bill Daniel and current landowner of the parcel of land being leased by River Aggregates. “Aaron Cherry sold it to the Ellis family, who sold it to the Cruse family, and the Cruse family sold it to the Daniel family. It’s worth noting that President Sam Houston appointed Ellis as ambassador to the Alabama-Coushatta Indians on behalf of the Republic of Texas. One can only imagine what the ranch has witnessed over its long history.”

Daniel says his grandfather discovered the plantation in the late 1940s while campaigning to be county attorney. Due to fuel rationing during World War II, his grandfather traveled the county in a horse-drawn wagon, which required him to stay overnight in the far reaches of Liberty County. On at least one occasion, he stayed with the Cruse family at their historic plantation.

“Poppa fell in love with it and set his mind on acquiring it someday,” Daniel says.

Even though his older brother, Price Daniel, made a career out of politics, serving as Texas’s attorney general, United States senator, three-term Texas governor, and justice on the Texas Supreme Court, Bill made his living off the land and as a country lawyer. Occasionally, he answered the call to serve, first as Liberty County’s county attorney, next in the U.S. Army, then in the Texas House of Representatives, and later as governor of Guam after being appointed by President John F. Kennedy in 1961, thus earning the enduring nickname ‘Governor Bill.’

After purchasing the plantation property from the Cruse family, Governor Bill continued to buy adjoining tracts of land, eventually making up nearly 3,000 acres of contiguous pastureland. At times, he ran up to 1,100 head of cattle on the ranch, which required a lot of help, especially when he was in Guam.

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AGGREGATES MANAGER / May 2019

During the Liberty County Bicentennial Observance in 1956, a marker was placed at Plantation Ranch to denote its rich heritage in Texas history.

“Through the years, Poppa hired a lot of staff,” Daniel says, explaining that there were numerous buildings and houses on the ranch with several families living there. “It was a large cattle ranch, practically a small town itself, continuing its history as the ‘oldest permanent Anglo settlement in Texas.’”

Over the years, Governor Bill’s Plantation Ranch hosted many famous people, including Roy Rogers, Dale Evans, Loretta Lynn, Fess Parker, Roy Acuff, Kitty Wells, and a young Hank Williams Jr. It also hosted a retreat for United States astronauts and Russian cosmonauts during the Cold War. Partial planning for the original movie, The Alamo, took place there as well.

John Wayne had his own bedroom in the “Big House,” and a longer runway was built so he could fly in and out. Governor Bill also provided and/or secured hundreds of longhorns and horses for the movie and appeared in three parts — a Tennessean, a Mexican, and the speaking part of Colonel Neill.

“The Ranch hosted annual Crippled Children’s Parties for many years to provide the children a day of fun, fresh air, shows, and a historical atmosphere — all free from my grandparents,” Daniel notes. “Another of the ‘big four’ family charity projects was the annual Easter Egg Hunt, to which everyone ‘young at heart’ in east Texas and west Louisiana was invited.

School children would also come to the ranch as part of an elementary school field trip to learn about cattle operations and ranch management. The point is, this land has so much history behind it that was important not just to the family, but to the entire region.”

The Daniel family has been a big supporter of Baylor University in Waco. Governor Bill, and his father M.P. Daniel, made significant monetary and other donations that have been providing scholarships for students from Liberty and Montgomery counties who attend the university. In 1985, buildings from Plantation Ranch, along with thousands of artifacts from life in the late 1800s, were donated to Baylor by the family.

The buildings include a cotton gin, blacksmith shop, hotel, livery stable, school-house, barbershop, dance hall, saloon, and town hall, as well as 25 horse-drawn wagons. Many of the historical items are now on display at the Governor Bill and Vara Daniel Historic Village, which is part of the Mayborn Museum Complex located along the Brazos River beside Baylor Law School.

got a really good reclamation plan that supports our long-term objectives. Kudos to them for doing their homework. While other larger companies had the money to do so and chose not to, River Aggregates drilled my entire property, identifying a large source of reserves that extended beyond the area drilled by a bigger, well-known company that said it would be a “geological anomaly” for there to be reserves in the area where River Aggregates found them.”

In the end, it was a win-win scenario for both parties.

When it came time to set up the operation, Carl Davis, managing partner at River Aggregates, took on the job of designing and building the plant, but it wasn’t easy. There were setbacks.

“We had already made the agreement and had leased this place and were in the process of coming out here, but Hurricane Harvey slowed us down in getting everything ready to go,” he explains.

The company bought all new equipment for the operation, including a new DSC Dredge and a new McLanahan processing plant. When the land was leased, however, the type of processing plant had not yet been determined.

“The old processing plant at the Romayor location was what is considered a conventional sand processing plant consisting of a sand classifying tank and sand screws,” Davis explains. “But, we knew that hydrosizer technology was out there that would make a better quality product. McLanahan had the equipment we needed to make the sharp and consistent cuts required to make quality concrete sand.”

There was already a small pond on site, but it was enlarged and filled with water. The dredge was then put in, and the processing work began.

From the dredge, slurry is pumped through a large pipeline at approximately 6,000 gallons per minute to the primary plant, where it is pre-processed. It first passes through a velocity box, where the water settles before it proceeds to the primary screen. The primary plant kicks out the oversize and gravel, and

The small pond on site was enlarged and filled with water before a new DSC dredge was brought in to begin working.

Photo credit: River Aggregates.

Setting up the plant

River Aggregates bought all new equipment for the operation, including a McLanahan Hydrosizer Plant and Ultra Fine Sand Plant. Hydrosizer technology allows for a better, cleaner cut between coarse and fine sand.

the balance of the sand and water goes into the sump tank below, where it is pumped to a density separator.

“Basically, the density separator is a big round tank sitting at the top of the structure,” Davis notes. “All of the sand is pumped into two large cyclones, where the water and silts are separated to waste, and the sand slurry is fed into the hydrosizer. In the hydrosizer, a fluid bed of water about half way down allows the heavier sand to fall through, while the lighter sand spills out over a weir into the next section and goes on to the fine sand plant.”

The fluid bed is created by spray bars in the tank, which are fed by a large pipeline that brings in water from the pond at approximately 2,400 gallons per minute to provide a constant water pressure. The feed and water pressure have to be consistent.

“This is a new technology for us, but it’s not really new in the industry,” Van Til explains. “That [hydrosizer] technology lets you make a better, cleaner cut than you would with a classifier tank.

It’s becoming more and more desirable, because it does a better job of making a more consistent grade of sand. We think AGGREGATES MANAGER / May 2019

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PLANT PROFILE Safety first “At River Aggregates, safety is, and has to always be, our number one priority,” Davis says. “Since we are regulated by MSHA, we tailor our safety training and documentation to those requirements.”

The Rye Plant crew consists of the plant manager and eight employees.

Everyone who works at the plant, or its sister plant, is involved in regular safety meetings and refresher training. At each plant, at least one 15-minute safety meeting is held every week first thing in the morning to cover current safety issues.

Safety meetings are also held once a month and are designed to be interactive, Davis says. At the meetings, they cover refresher subjects and discuss new issues encountered at any of the company’s operations. The company also uses Westward Environment safety trainer to help with the monthly meetings. The net result is a successful safety program.

we’ve probably increased our yield by 4 or 5 percent.”

“We knew that moving to the new hydrosizer technology was going to be a learning curve for us,” Davis adds.

“McLanahan has done a great job of understanding what we want to do and helping us design and develop the plant that we know will do what we want in making concrete sand. We are able to offer a better quality product to our customers.”

Davis explains that both the concrete sand and fine sand circuits use McLanahan dewatering screens.

He says sand that has been through a sand screw has 18 to 20 percent moisture, while sand that goes through a dewatering screen has only 10 to 12 percent moisture. The drier sand makes it easier to stockpile the sand and to load trucks more consistently.

“While concrete sand is our primary product, the Ultra Fine Sand

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Plant allows us to keep the fine sand particles out of the settling ponds and produce a fine sand we can sell,” Davis notes, adding that the sand plant features four separators that pull the water out of the slurry and send it back to the pond.

The control room or control center is located right next to the processing plant, so the plant operator can keep a close eye on everything without the need for cameras and monitors.

The control room is also raised, so the operator can easily see the tops of the tanks.

“What I like about this plant is, today, I can walk in here, turn on the plant, and it runs,” Davis says. “It makes quality sand every day.”

“We spent a lot of time from an equipment and technology standpoint,” Van Til notes. “Carl has done a great job of building and designing a state-ofthe-art plant.” AM

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AGGREGATES MANAGER / May 2019

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by Karen L. Johnston

ROCKLAW Know Your Options for Challenging a Citation Strict liability puts the responsibility for violations at the operator’s door, but proper training and record-keeping can lower negligence.

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Karen L. Johnston is a member in Jackson Kelly PLLC’s Denver, Colo., office where she practices in the Construction and Manufacturing industry groups, focusing primarily on workplace health and safety litigation. She can be reached at 303-390-0008 or kjohnston@jacksonkelly.com.

ver since the passage of the Federal Mine Safety and Health Act of 1977 (the Mine Act), the mine operator has had the duty to provide a safe and healthy working environment for all miners. Additionally, the Mine Act imposes upon the mine operator the primary responsibility to prevent the existence of unsafe conditions at the mine site. And, the mine operator and its agents are required to exercise reasonable care in carrying out these obligations.

So, what happens when the mine operator exercises reasonable care, yet a violation still exists on the mine site due to the conduct of an hourly miner? Or, what happens when a violation exists on the mine site and mine management had no knowledge of the condition nor could it have known? If it is not the mine operator’s fault, how can the Mine Safety and Health Administration (MSHA) issue a citation to the mine operator under these circumstances?

The answer to these questions lies in a legal premise known as “strict liability.” The Mine Act is unique among the laws that govern workplace safety and health in that it imposes liability without regard to fault or negligence on the mine operator. This means that when a violation of an MSHA standard exists on the mine site, MSHA has the statutory authority to issue a citation to

the mine operator, regardless of who caused or created the violation.

All hope is not lost, however, when it comes to violations caused by the conduct of an hourly miner. The mine operator can lower the negligence on a citation by showing evidence of due diligence.

For example, on a citation alleging a violation of §§ 56/57.15005 (requiring the use of safety belts and lines when working where there is a danger of falling), the mine operator can try to reduce the negligence by showing evidence of the following: • Mine operator’s written policy requiring that all miners must wear fall protection when working where there is a danger of falling; • Training on when and how to use fall protection (e.g., task training and annual refresher training); • Having fall protection gear available for the miner to use as needed; • Company policy stating that a violation of the fall protection policy is subject to disciplinary action, up to and including termination; and • Disciplinary records showing the policy is enforced.

In addition, during the inspection, the mine operator’s representative should ask the miner

AGGREGATES MANAGER / May 2019

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if he or she knew about the safety rule and whether they The Secretary of Labor appealed both decisions, and the had been trained on it. If the miner denies training, providing Federal Mine Safety and Health Review Commission (Review the MSHA inspector with training records (as noted above) Commission) issued its decisions on July 19, 2016. Lewisand documentation of safety meetings where the topic of fall Goetz and Co., 38 FMSHRC 1663 (July 19, 2016); Nally & protection was discussed can be helpful. (Author’s note: This Hamilton Enterprises, 38 FMSHRC 1644 (July 19, 2016). The is a good reason for mine operators to keep a record of safety Review Commission reversed both ALJ decisions on similar meetings for a few years. The records should include when the grounds and concluded that the mine operator “is strictly meeting was held and the topics covered, as well as a sign-in liable for such violation without regard to the diligence with sheet to show who attended the meeting.) which it has trained and required miners” to use fall protecFrom 2013 to 2016, mine operators could have reasonably tion. Nally & Hamilton Enterprises, 38 FMSHRC at 1647. believed that strict liability under the Mine Act was being Bottom line for mine operators: having a safety policy in chipped away. Two decisions by two different administrative place, communicating the policy to your miners, and enforcing law judges (ALJs) gave mine operators hope that, if the opethe policy is the best way to strive for compliance with MSHA rator was diligent in requiring that safety rules be followed, standards. And, where employees fail to comply with the that would be sufficient. Lewis-Goetz and Co., 35 FMSHRC MSHA standard, having documentary evidence of these actions 2192 (ALJ Rae) (July 22, 2013); Nally & Hamilton Enterprises, can give you the grounds to argue for lower negligence. AM 35 FMSHRC 2198 (ALJ Moran) (July 24, 2014). The fall protection standard was at issue in Lewis-Goetz, and Nally & Hamilton addressed an equipment operator’s failure to wear a seat belt. In both cases, the ALJ held that the mine operator’s duty was to require the miner to wear a seat belt or to require the miner to use fall protection, and that was sufficient for compliance with the MSHA standard. The conclusions were based on the plain language of the standards With over 1,200 different kits engineered at issue. For example, the cited fall and developed and over 7,000 line items in protection standard stated, in relevant stock, count on Arctic Wolf TM for integrated part, that employees “shall be required air conditioning systems. If your equipment to wear” safety belts and lines when has an engine and a cab on it, we can put there is a danger of falling. 30 C.F.R. § cool air into it.

77.1710(g). Similarly, the cited seat belt Contact us at 1-800-2 MR COOL or standard stated employees “shall be online at www.hammondac.com. required to wear” seat belts in a vehicle Order your systems and parts today. where there is a danger of overturning.

30 C.F.R. § 77.1710(i). Both of these are coal standards, not metal/non-metal standards. The language of the analogous metal/non-metal standards differs slightly and required that the protective 1-800-267-2665 • sales@hammondac.com • www.hammondac.com device “shall be worn.”

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Earthquakes, Aggregates, and Seismic Awareness Take steps to ensure operational capabilities following seismic events.

L

ast month, this column described, among other things, some of the damage from the 1906 San Francisco earthquake. I closed the article by writing, “[T]he more seismic-aware society becomes, the better prepared people will be to minimize the effects of an earthquake.”

With that in mind, this article looks at a few ways that aggregate producers might become more seismic aware. The article is based on the ShakeOut Scenario, a wide-ranging exercise conducted to identify the physical, social, and economic consequences of a magnitude 7.8 earthquake on the San Andreas Fault in southern California. My conclusions for the ShakeOut were extrapolated from the observations of an experienced aggregate operator of the impacts caused by the magnitude 6.7 Northridge earthquake of 1994.

Some, but not all, aggregate, concrete, and asphalt companies in earthquake-prone areas design and construct their facilities to withstand earthquakes and conduct regular inspections to ensure their facilities remain in sound operating condition. Facilities that take these precautions may suffer little or no damage during an earthquake. In contrast, poorly constructed or The San Andreas Fault follows the line of trees maintained operations could be severely damaged; some beyond repair. through this photograph.

Large earthquakes can cause significant damage to buildings and infrastructure. Emergency repairs and long-term reconstruction may require large amounts of aggregate, asphalt, and concrete.

Being seismic-aware helps reduce the response time for emergency repairs. For example, following the Nov. 30, 2018, magnitude 7.0 earthquake in Anchorage, Alaska, all eight major transportation corridors that had been severely damaged by the quake were re-opened within five days, in spite of frigid weather and numerous aftershocks. Bringing damaged facilities back online after a major earthquake depends heavily on spare parts and new equipment, some of which may not be immediately available. For example, new crushers and screens may be in demand by both the aggregates industry and the recycling industry.

Making concrete and asphalt requires materials from upstream cement manufacturers and refineries. Damage to those industries could limit the ability of local producers to meet demand. Similarly, outages of electrical power, water, gas, and fuel will affect production. Equally important, many of the skilled workers needed to operate aggregates and related facilities would likely be impacted by the earthquake and tending to personal needs. For example, following Hurricane Katrina (Sept. 6, 2005) aggregate operations in the Gulf Coast area took as long as two weeks to assemble sufficient skilled personnel from the grieving workforce.

There are a number of things that aggregate producers can do to be better prepared for an earthquake.

• Individual facilities might benefit from a seismic safety audit by engineering professionals, which could identify weaknesses and recommend modifications in advance of an earthquake.

• Spare parts, especially for vulnerable equipment, can be positioned at plants themselves, or at central locations.

• Standby sources of electrical power generating equipment, cranes, and portable processing facilities can be identified and advance lease or purchase agreements could be made.

• Large producers with multiple plants can make advanced plans for intracompany transfer of product, personnel, and equipment following an earthquake.

• Intercompany mutual aid agreements similar to those commonly used by police and fire fighting agencies can be made in advance by aggregate, asphalt, and concrete producers.

A plausible estimate of damage to the aggregate, concrete, and asphalt industries following an earthquake in your area, combined with prudent advanced preparations, should facilitate a timely response by the construction materials industries. AM

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