Aggregates Manager July 2015

Check Out Our

Award-Winning

Reclamation Projects

July 2015

www.AggMan.com

10

Dolese Bros.’ Davis Quarry leverages its location

26

Five factors affecting fuel efficiency

35

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26

When it comes to mine set up, material location has the largest fuel and operational efficiency impact.

On Our Cover: Community-focused reclamation projects create a winning combination.

Cover photo courtesy of RCP Block & Brick, Inc.

9

Case Construction Equipment rolls out five new crawler excavators that meet Tier 4 Final emission standards and provide operational gains over previous models.

CONTENTS JULY 2015 VOLUME 20, NUMBER 7

FEATURE ARTICLES

10

26 35 38

Location is Key

When Interstate 35 was completed in 1970, Dolese Bros.’ Davis Quarry opened the next year to take advantage of the quick and easy route to its market in Oklahoma City.

Five Factors of Fuel Efficiency

By looking at all five factors — idle time, operator technique, mine set-up, equipment selection and configuration, and technology — operators can better control fuel costs.

Get the Most (Water) Out of Your Dewatering Screen

By paying attention to items such as initial setup, finetuning of settings, and maintenance, your screen can put the squeeze to both coarse and fine feeds.

Portable Plant Options

An expanding array of choices allow operators to select plants with features that best match their specific needs.

OPERATIONS ILLUSTRATED Rethinking Reclamation

21

Entries into our second annual photo contest showcase cooperation between aggregate operations and local communities.

COLUMNS & DEPARTMENTS

3

EDITORIAL Stories worth sharing.

MINING The latest stock and fuel price 5 DATA trends impacting the industry.

AND PROVINCE NEWS A roundup 6 STATE of the latest news in North America.

Polydeck’s new heavy-duty dewatering screen panels, and other new 8 ROLLOUTS equipment for the aggregate market.

LAW Supreme Court Justices criticize the disregard for formal rulemaking and 40 ROCK note ‘constitutional concerns’ about the

ability of agencies to change the meaning of regulations at their discretion.

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

42 ADVERTISER ADS Aggregate industry classifieds.

43 CLASSIFIED IN STONE The combination of granite’s weathering characteristics and 44 CARVED mechanization of the industry led to the rapid growth of Barre’s mining.

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

July 2015

Vol. 20, No. 7

aggman.com /AggregatesManager @AggMan_editor

Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Online Managing Editor: Bobby Atkinson

Stories

WORTH SHARING

editorial@aggman.com

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

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Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2015. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406.

Subscription rates: $24 annually, Non-domestic $125 annually.

Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

E

arlier this year, I announced Aggregates Manager’s reclamation photo contest on this very page. The contest, which was also promoted on our website, drew more than a dozen entries from operators across North America and created stiff competition for those featured in this issue.

The entries were striking because so many operators go above and beyond what is legally required for reclamation. For example, Vulcan Materials Co.’s River Rock operation voluntarily revised its mining and reclamation plan to preserve some of the last remaining, old growth stands of mixed riparian forest along its portion of the San Joaquin River. It even went so far as to develop a nursery on the site for the more than 20 species of native plants used for reclamation.

At Graniterock’s Santa Cruz Sand Plant, the company worked with local biologists and the Fish and Wildlife Service to develop Santa Cruz County’s first Habitat Conservation Plan for the California red-legged frog — which is listed as a threatened species. Its plan focuses on how to operate the facility with minimal impact and to provide a habitat conservation area to be held in perpetuity. The site has been used to train local, state, and federal biologists on handling and maintaining red-legged frogs.

In addition to protecting the red-legged frog, the operation uses holistic management techniques for its reclamation areas. As part of this practice, it used a seed mix in the late 1990s that contained non-native invasive grasses. To encourage the growth of native plants, Graniterock allowed 90 goats to graze the property. As the goats fed, native plant seed was spread over the property and fertilized by the goats. A year later, more native plants, including purple lupine (pictured on page 21), are growing on the property.

And, featured on this month’s cover, RCP Block and Brick transformed channels created through sand mining into part of a river walk trail that is a segment of a larger community project. By working cooperatively with local government officials, the operator reclaimed the site into an attractive setting, and the city followed up by creating the public trail along the site. Even though this operator is in California, land of the NIMBY, the city went so far as to install placards along the trail that explain how the river provided sand for many local projects. Sweet!

After you read more about these projects in Operations Illustrated, be sure to visit www.aggman.com to see a photo gallery of all the projects. But don’t stop there. These projects showcase how an aggregates operation can be an excellent member of any community. Use these materials to educate local officials when you kick off your next permitting project.

AGGREGATES MANAGER July 2015

3

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

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

CRH plc

CRG

Eagle Materials Inc. Granite Construction Inc.

Current Value $9.30 q

52-Week 52-Week High Low $13.13

$8.38

One Year

-0.025 q

-1.008 q

East Coast

$2.980

-0.021 q

-1.003 q

$30.21

$17.18

EXP

$80.98 q

$105.69

$68.54

New England

$3.076

-0.016 q

-1.016 q

GVA

$36.61 p

$39.09

$30.44

Central Atlantic

$3.122

-0.021 q

-0.957 q

$54.48

Lower Atlantic

$2.853

-0.021 q

-1.033 q

Midwest

$2.774

-0.030 q

-1.071 q

Gulf Coast

$2.783

-0.016 q

-0.986 q

Rocky Mountain

$2.825

-0.010 q

-1.084 q

West Coast

$3.121

-0.042 q

-0.874 q

HEI

Holcim Ltd.

HOLN

$76.62 q

$89.19

$60.67

Martin Marietta Materials, Inc.

MLM

$148.67 p

$155.98

$103.09

Summit Materials

One Week

$2.884

$27.97 p

Heidelberg Cement AG

MDU Resources Group, Inc.

6/8/2015

United States

MDU SUM

$80.04 q

$20.31 q 26.54 (new)

$87.02

$35.41

$19.88

29.00

19.65

United States Lime & Minerals, Inc. USLM

$59.88 q

$76.98

$55.35

West Coast less California

$3.001

-0.054 q

-0.898 q

U.S. Concrete

USCR

$37.43 p

$40.50

$21.48

California

$3.217

-0.032 q

-0.857 q

Vulcan Materials Co.

VMC

$88.55 p

$93.07

$54.10

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 6/8/2015.

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

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AGGREGATES MANAGER July 2015

5

State & Province

NEWS

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

Indiana

In early June, Judge Randy Williams ruled against Rogers Group Inc. in a case it brought against Tippecanoe County. The Lafayette Journal & Courier reports that the lawsuit involved the county commissioners, the Board of Zoning Appeals, the Area Plan Commission, and the Tippecanoe County building commissioner. In 2014, commissioners passed an ordinance prohibiting new quarry operations when 100 residences are within a 2-mile radius. The lawsuit alleges that commissioners don’t have power to pass an ordinance banning the quarry, that commissioners violated the operator’s mineral rights by passing the ordinance, and that the county had taken its land without just compensation.

The judge’s ruling states, “The Board of Commissioners of Tippecanoe County properly passed the Ordinance as an exercise of its broad home rule authority to regulate conduct, or use or possession of property that might endanger the public health, safety, or welfare.” Essentially, the judge says that the ordinance is a safety ordinance rather than a zoning one.

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

Massachusetts

Representatives for West Roxbury Crushed Stone outlined their plans to fill in the quarry during a recent community meeting. Wickedlocal.com reports that key points to the operator’s plan include ending blasting no later than 12 years after the reclamation process begins; filling the quarry with clean, S-1 soil that the state DEP considers to be acceptable for use in sensitive locations; instituting a cap on the amount of trucks entering and leaving the facility; holding truck drivers accountable for their driving; and having qualified environmental professionals at both the site where soil is being taken from and where it is being transported. Earlier this year, a city councilor said that he was concerned about the soil that would be used to fill the quarry and authored a zoning code amendment “to provide for a robust community process before the acceptance of any soil or dirt.”

Missouri

Winter Brothers Material Co. faces another round of community opposition in its 14-year-long effort to permit a new quarry. According to the St. Louis Post-Dispatch, it withdrew a petition for a special-use permit to allow mining on 363 acres in Eureka several months ago. Now, it hopes to permit a 537-acre property in unincorporated St. Louis County that it says is better suited for mining.

While community members acknowledge that the operator has committed to “high-tech mining processes,” they continue to be concerned about the impact of truck traffic. A study by the Missouri Department of Transportation shows that new access roads commissioned by the operator will result in an increase of traffic on area thoroughfares of only 0.6 percent. The operator has also agreed to address truck access near the local highway.

New Jersey Kentucky

New leaders of the Kentucky Crushed Stone Association (KCSA) were recently announced. According to The Advocate Messenger, John Albright, of Caldwell Stone, was elected to a three-year term as a director of the association. Phil Crump, of Mercer Stone Co., was re-elected. In 2014, the state reportedly produced more than 40 million tons of aggregates valued at more than $350 million.

6

AGGREGATES MANAGER July 2015

Millington Quarry Inc. received a renewal of its annual operating license in a 3-2 Township Committee vote, The Bernardsville News reports. Operators said they have an estimated five years of mining remaining at the operation until it would transition to residential use. Tainted soil brought into the site in previous years has been an ongoing issue for the operator and its former tenant. Community residents opposed to the mine encouraged local officials to reject the license based on “Section 1” of the general licensing ordinance, which allows a license to be rejected if the applicant’s “character, ability, or business responsibility is unsatisfactory.”

New York

At Aggregates Manager’s press time, the Lockport County Council was expected to hear Lafarge’s proposal to expand its existing operation by using a parcel it purchased that is located within the city limits. According to The Buffalo News, the expansion of the Redlands Quarry received approval by the city’s planning board in January 2014, but was never presented to the county council for official action. One concern about the request was that blasting at the site might damage underground pipes that carry the area’s drinking water. The county’s legal representative said he had received materials from Lafarge that had not yet been reviewed.

The operator’s response to that concern may have been addressed in those materials.

Pennsylvania

A proposal for a quarry in Lower Milford Township is set to get its long-awaited public hearing before the state Department of Environmental Protection. The Morning Call reports that the DEP will hear testimony regarding Geryville Materials Inc.’s proposal for a 127.6-acre quarry. Previously, the township’s Planning Commission rejected its zoning application, but a Commonwealth Court decision overturned that decision and allowed the project to move forward.

To date, the township is estimated to have spent more than $1 million fighting the operation.

Rhode Island

Police identified a 28-year-old man from Westerly who died after falling 80 to 100 feet in an area quarry as Jack Daniels. According to abc6.com, Daniels and three others had been riding motorcycles on the quarry property at the time of the incident.

Daniels was not on a motorcycle when he fell, however, during the May 24 incident.

Officers found him at the base of the quarry in serious condition. He was treated at the scene, but died a short time later. Police are continuing their investigation.

Virginia

The Loudon County Planning Commission recently received a presentation on Waterside development, a plan that would create a 54-acre lake and nearly 2,600 multifamily residential units. The site would be created by filling Loudoun Quarries to create the lake and by building the residential units, as well as retail, commercial, and educational development. The project developers committed to making more than $40 million in road improvements, according to Leesburg Today. The project is expected to generate more than $160 million in local taxes over 25 to 30 years.

SOLVING ISSUES ALONG THE BELT LINE

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Utah

The Hanksville-Burpee Dinosaur Quarry in Salt Lake City recently offered free public tours.

Deseret News reports that the educational staff from Burpee Museum led daily tours and talked about current and past excavations. Three 45-minute tours were offered each day. They were made available through a partnership between the Bureau of Land Management’s Utah Henry Mountains Field Station and the Burpee Museum of Rockford, Ill. To date, the quarry has yielded long-necked sauropods and carnivorous dinosaurs, as well as a rare Jurassic armored dinosaur, Mymoorapelta.

Washington

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Neighbors of Yacolt Mountain Quarry voiced safety concerns about conditions around the operation, particularly regarding trucks, The Columbian reports. In response, Columbian County is restriping an intersection near the operation to improve turning, clearing vegetation to improve stopping and sighting distance, putting up warning signs, and working with the local operator to improve road conditions, including turning radius.

Tel: +1-630-971-0150 Email: info@flexco.com

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AD224_enUS_224_HPvert_Aggman_0615.indd 1 Untitled-4 1

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AGGREGATES MANAGER 6/10/15 July 20157:20 AM

6/15/15 1:32 PM

by Bobby Atkinson, Online Managing Editor: BobbyAtkinson@randallreilly.com

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

Tier 4 Final artic truck Komatsu America Corp. has a new HM400-5 articulated dump truck with a net 469-horsepower SAA6D140E-7 engine that is EPA Tier 4 Final emissions-certified. The dump truck has a 44.1ton payload, weighs 165,633 pounds, and has a loading height of just 10 feet, 5 inches. Komatsu’s new trucks come equipped with the K-ATOMiCS system, which offers a six-speed, automatic transmission that is said to improve efficiency by eliminating shift shock and torque cutoff with an advanced electronic system. On the inside of the cab, the dump truck has a 7-inch LCD monitor that allows the operator to modify settings for auto idle shutdown or the auto-reversing fan, check the operational records such as driving history and fuel consumption, monitor the KDPF, or check to see how long before the next maintenance interval. In addition, the monitor can offer tips on how to reduce fuel consumption.

Komatsu | www.komatsuamerica.com

Heavy-duty dewatering panel The new 1-foot by 1-foot polyurethane heavyduty dewatering screen panel from Polydeck can carry the same weight of thick bed depths, but at a much thinner size. The screen panel doesn’t need an additional substructure to get the job done. It has openings as small as 0.1 mm by 15 mm and multiple PolySnap or pin-style fastening options. It also has the ability to integrate surface features like dams into panel construction.

Polydeck Screen Corp. | www.polydeckscreen.com

New load scanner Walz Scale has introduced a new non-contact measurement instrument to measure the volume of loads in open-top vehicles with eye-safe laser scanners and new algorithms. The scanner is capable of accurately determining the amount of material being carried by using the laser scanners to measure the 3D profile of the load and the algorithms to find out the size. After the load is scanned, the system sends back the actual load volume and a graphical image. The system allows users to more accurately manage materials, stock inventories in real time, and monitor cycle time.

The system also allows users to view and manage inventories and production on a smart phone or tablet.

Walz Scale | www.walzscale.com

8

AGGREGATES MANAGER July 2015

ROLLOUTS

Tier 4 Final wheel loaders Volvo’s new L60H, L70H, and L90H wheel loaders come standard with a new efficient Tier 4 Final engine. Combined with the new Torque Parallell linkage, the machines are said to have improved fuel efficiency without any drop in performance. The wheel loaders also are equipped with a counter shaft transmission that can withstand high stress levels.

Each of Volvo’s new machines has the Human Machine Interface system inside that keeps the operator up-to-date on machine information.

Volvo’s online telematics monitoring system, CareTrack, lets the fleet manager get a real-time look at important machine information.

Volvo | www.Volvoce.com

Fuel-efficient excavators Case Construction Equipment rolls out five new crawler excavators that provide operational gains over previous models and meet the EPA’s Tier 4 Final emissions standards. The CX210D, CX250D, CX250D Long Reach, CX300D, and CX350D all have cycle times up to 12 percent faster, improved responsiveness and multifunctional control, up to 14 percent greater fuel efficiency, and increased breakout forces of as much as 6 percent. The arm and boom of the new excavators are stronger and more durable than previous models to support the new power. Case’s new machines also come with the Case Intelligent Hydraulic System that’s made up of four systems: Boom Economy Control, Auto Economy Control, Swing Relief Control, and Spool Stroke Control.

Case Construction | www.CaseCE.com

Large cone module Terex Minerals Processing Systems launched a new MC450X cone module designed to increase tonnage, application capabilities, and crushing efficiency.

Terex says the new product is its largest cone crusher module yet. The MC450X comes with a new Cedarapids MVP 450X cone crusher. New features include high speed clearing of jammed materials, faster crusher separation capabilities, and user-friendly computer controls. It also comes complete with a heavy-duty I-beam frame, a galvanized steel structure of walkways, stairs, and guard rails.

Terex MPS | www.terexmps.com

Updated skid-steer loader Caterpillar’s 272D2 Skid Steer Loader comes with new features such as an advanced display and a new engine-compartment sealing system for enhanced airflow debris control. The loader has a Cat C3.8 98-horsepower engine that meets the EPA Tier 4 Final emissions standards. The 272D2 has a rated operating capacity (ROC) of 3,400 pounds, and the more powerful XHP model has a ROC of 3,650 pounds. The new model comes standard with sealing around the rear engine enclosure and cooling package to provide more protection against material ingestion when used with a high volume of airborne debris.

Caterpillar | www.cat.com AGGREGATES MANAGER July 2015

9

Location is Key

When Interstate 35 was completed in 1970, Davis Quarry opened the next year to take advantage of the quick and easy route to its market in Oklahoma City.

I

n the late 1800s, four brothers started

Dolese operations are almost exclusively in

a public works construction company in

Oklahoma now, except for a few in Louisiana.

the Chicago area, Dolese Bros. Co. When the oldest brother left the company, the

Dolese had several quarries located along the

pany’s focus to supplying railroad ballast and

rail lines in Oklahoma, but when Interstate 35

followed the main rail lines south into Kansas,

opened up in 1970, the company wanted to

Oklahoma, and New Mexico.

take advantage of the easy transportation the

Dolese had several active quarries in Oklaho-

10

AGGREGATES MANAGER July 2015

new interstate highway offered, so it opened

ma when it became a state in 1907, so it pro-

a greenfield quarry in Davis. The quarry was

vided thousands of tons of crushed stone and

located just a few miles from the interstate and

sand for building the state’s roads. As the towns

only 70 miles from Oklahoma City.

and cities in Oklahoma grew, Dolese grew with

by Kerry Clines, Contributing Editor

Choosing the location

remaining three brothers changed the com-

“We’re the closest quarry to I-35,” says Earl

them, expanding its business to include ready-

Coll, general superintendent at Davis Quarry.

mixed concrete in 1927. The company eventu-

“I-35 is the corridor that takes this material to

ally made Oklahoma City its corporate home.

Oklahoma City, and the Oklahoma City area is

PLANT PROFILE

The processing plant at Dolese Bros.’ Davis Quarry is a copy of the company’s Richards Spur Quarry located near Lawton. The plant was designed by Roger Dolese with future growth in mind.

probably 75 percent of our business.

from now,” Coll says. “It’s a good design.

mobile structure for the crusher system

That’s the reason we built this quarry.”

We’ve made some improvements to it

that enables it to be moved throughout

since it was put in, but it’s still the same

the quarry.

Plant construction began in January of 1971 and was completed approximately

design. We only use half of our crusher

six months later. The operation originally

building. There are four crushers on one

crusher,” Coll says, explaining that it

had a small outside plant, but improve-

side along with all the extra equipment

doesn’t matter whether it’s moved just

ments and additions were made over the

that goes with them, but there’s room for

100 feet or a mile. “It takes a day to dig

years until a new fractionated blending

another four-crusher set up on the other

it out, a day to move it and set it up, and

plant was built in 2006. The new plant is

side. We’d have to build another mill to

another day to get it all tuned up and

a copy of Dolese’s Richards Spur Quarry

handle the extra load, though.”

running again. We used to move it every

located near Lawton, which was built in

The plant includes a 42-inch gyratory

“It only takes three days to move the

three months to keep it within 300 feet

1951. Roger Dolese, the son of one of the

crusher, which was used at a couple of

of the shot rock and fed it with 992 Cat

founding brothers, designed the plant

Dolese’s other quarries before coming to

loaders from the sides. Two years ago,

with an eye towards future growth.

Davis. The gyratory crusher is one of a

we parked it and now feed it with Kom-

few in the country that is designed to be

atsu end-dump trucks. That has been

portable. Dolese engineers designed a

more efficient.”

“Roger Dolese didn’t think about tomorrow, he thought about 100 years

AGGREGATES MANAGER July 2015

11

PLANT PROFILE

started at the beginning with the drilling and blasting and went all the way through the primary crushing process.

By doing that, we increased productivity by almost 50 percent. Now Earl and the team are looking at the mill process — the screening process, screen media, and deck media.”

Daily operations Blasting takes place once a week, depending on the weather, and it’s always a large shot. “We shoot down 40,000 to 50,000 tons and sometimes more,” Dumont says. “We are working on about four different faces right now and try to keep one or two shots laid out ahead of The primary plant boasts a 42-inch gyratory crusher that was used in two other Dolese quarries prior to being installed at Davis Quarry.

time to optimize productivity.”

In the pit, the material is run through the gyratory crusher and then conveyed via an overland conveyor to the fractionated plant. There, it is sent through a system of crushers and screens, which separates it into various finished sizes. At this point, the crushed stone is sent through the blending system to be combined into various finished products.

The blending plant, or mill, is completely enclosed inside a large 140-foot-tall building, which helps control dust and noise. The material is carried via conveyor to the top of the mill where it goes through hoppers and

Material is conveyed up from the pit to the fractionated plant where it is sent through a system of crushers and screens to separate it into various finished sizes.

is separated into various sizes and then combined again to make the different products. Each product has a special

Coll explains that the dump wall is

bit,” says George Dumont, general man-

formula, which is created by running

made of concrete sections that bolt to-

ager of Dolese Aggregate Operations.

the conveyor belts under the hoppers

gether so it can be moved along with

“We’ve used the lean process to work

at different speeds.

the crusher. As the working face of the

through different stages and have even

According to Coll, each batch is spe-

quarry moves away, the crusher and

optimized the quarry. We looked at the

cially crafted to ensure the perfect blend.

dump wall will be moved also, but only

original set up, looked at how we could

“Our blending plant isn’t automated;

once every six to seven years.

remove all the wasted steps, and came

we use dials to set our blend specs,” he

up with a more efficient process. We

explains. “We know what speeds the

“We’ve optimized the plant quite a

12

AGGREGATES MANAGER July 2015

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After the blending process is complete, the materials are then transferred into a set of lower hopper bins that, in turn, dump the material into commercial trucks and haul trucks. Two sets of scales under the bins ensure accurate and safe delivery. The loadout clerk controls the amount of material being loaded via computer and a closed-circuit television screen to make sure the right tonnage is loaded into each truck. Tickets are generated at the mill, and the drivers pick them up at the scalehouse before leaving the quarry.

Surplus materials are stored in stockAt the blending plant, or mill, materials are blended together and transferred into a set of lower hopper bins where customer trucks and haul trucks can load.

piles away from the mill to provide quick access and delivery for future needs.

“When the hoppers get full, we stockpile

conveyors need to run to get the blend

don’t have to change screens. All we

the material and then load the trucks

we want. In 30 minutes, we can change

have to do to change specs is empty the

with stockpile loaders,” Coll says. “The

course to make a different material. We

bin and reset the dials.”

loaders have bucket scales to make sure

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AGGREGATES MANAGER July 2015

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PLANT PROFILE

the trucks aren’t overloaded. These tickets are generated from the scales at the scalehouse.”

All sales from the Davis quarry are by truck. An average of 400 customer trucks per day go across the scales.

Dolese maximizes the shipping hours at the facility to accommodate its customers. They currently open at 2 a.m.

Monday through Friday and continue shipping until 8 p.m. Additionally, the quarry is open from 4 a.m. until noon on Saturdays.

The hours of operation for the processing plant vary, depending on the time of year. Normal hours are 6 a.m. to 2 p.m., but when business increases,

The loadout clerk controls the amount of material being loaded into each truck via computer and a closed-circuit television screen.

the quarry changes to 12-hour shifts that run from 5 a.m. to 5 p.m. The option in the OG&E (Oklahoma General and CIM_CIM 1/2 HORIZONTAL- 7 x 4.875 1/20/15 8:37 AM Page 1

quarry stops running its big electric mo-

erating hours change again during the

Electric) peak use program. From June

tors at 2 p.m., so the processing plant

summer due to the quarry’s participa-

1 through the end of September, the

shuts down.

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15

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

just the usual safety personnel and managers, the company sent a handful of hourly employees.

“We were one of the few, if not the only one, that did that,” Dumont says.

“Normally, an hourly person’s only experience with MSHA is when they see an inspector come on site. By involving them in the conference, they can see the other side and see what MSHA is trying to accomplish. The feedback was tremendous.”

Keeping it green As a company, Dolese prides itself on being proactive about the environment.

Customer trucks loaded from the stockpiles make their way across the scales at the scalehouse and receive their tickets.

“We’re in full compliance, and our internal requirements go way beyond the regulations,” Dumont says. “We’re big

“That’s one reason we went to

foremost on everyone’s mind. “There’s

supporters of the Nature Conservancy,

12-hour shifts starting in April, so we

always constant communication on safe-

which has some big projects going on

could build up our inventory to sustain

ty,” Coll says. “It’s the initiative we push

in the state, restoring lands back to

us from June to October,” Coll explains.

to really emphasize its importance. The

their native environments.”

“We can work 24 hours a day on Sat-

catwalk talks are just one form of that.”

urday and Sunday, if necessary, but we don’t like to do that.”

Dolese is in the process of reclaiming a piece of property several hundred

ous improvement teams made up of

acres in size to return it back to a wild-

Planned maintenance is performed

hourly employees who look at specific

life habitat. “It’s south of here and was

after the plant shuts down. “We have a

issues. “We asked our first continuous

purchased as reserves for future mining,

large maintenance shop and have well-

improvement team what we could do

but we didn’t mine it,” Dumont says.

trained, full-time mechanics and weld-

to improve our safety performance, and

“We’ve built ponds, planted trees, and

ers,” Coll says. “Our guys have laptops

they came up with the catwalk talks,”

fenced it off to keep livestock off of it.

to diagnose problems with the newer

Dumont says. “Another continuous im-

We want to get it back to as natural a

equipment. We do still have some of

provement team is looking at workplace

state as we can and keep it that way.”

the old equipment, and it’s not spare

exams, hazard reporting, and near-

equipment, so they keep it running. If it

misses to develop a system to make us

to the east of Davis Quarry, so concrete

breaks down, they can fix it.”

more proficient. Because these teams

retaining ponds were built to catch all

are made up of the people who are out

the water flowing out of the process-

Making it safe

16

Dolese has also developed continu-

A large underground aquifer lies just

there in the quarry, it’s very effective

ing plant. “We let it settle out and then

Davis Quarry is one of the largest em-

and gets great buy-in from the whole

pump the water back into our lake, so

ployers in the area. With 56 hourly

company.”

the process water doesn’t leave our

employees and five salaried employees,

A group from Dolese attended the

site,” Coll says. “We have filter berms in

safety has to be a daily priority. Person-

Mine Safety and Health Administration

several locations to stop sediment from

nel have “catwalk talks” where they talk

(MSHA) safety conference that was held

leaving the property and have three bag

about safety every day and try to keep it

in Fort Worth in April. Rather than send

houses on our secondary crushing plant

AGGREGATES MANAGER July 2015

PLANT PROFILE

to keep fugitive dust from going into the atmosphere.”

and safety glasses during the visit.

“We start out in our clock house,

in the quarry,” Coll explains. “Then we tour the quarry and plant in a bus.

Although Davis Quarry is still years

show a company video, and have safe-

We take them out to see the gyratory

away from reclamation, there is a rec-

ty talks about what we want to do and

crusher in operation. That’s a big hit

lamation plan in place. “We’ve only

what we don’t want to do while we’re

for the kids and the adults.”

been here for 44 years,” Coll says. “We lease most of this property and only own a small bit of it, but the pit will be a large lake for the landowner’s grandchildren one of these days.”

Davis Quarry has a very large fleet of equipment, but it has made the decision to replace all of its old equipment with new Tier 4 final equipment.

“We’re heavily investing in that,” Coll says. “The new equipment is more fuel efficient and better for the environment. We have four nearly brand new Komatsu haul trucks and three loaders that were bought last year.” The plan is to phase in the new equipment based on life cycle, replacing four or five pieces per year.

Being a good neighbor Davis Quarry’s nearest neighbor is a mile and a half away, so there are no problems with production and blasting noise, but the quarry still works at maintaining good relations with the people in town. “We do a lot of things quietly that we don’t want to brag about,” Coll says. “We donated both materials and funds for a new fire station in Davis several years ago, and donate materials and other things to schools.”

One outreach activity that Davis Quarry is extremely proud of is being the showcase quarry for Dolese’s Kids ROCK Tour program. This program involves bringing 30 to 60 school children, along with teachers and sponsors, into the

mclanahan.com

quarry. Each child receives a t-shirt in safety neon yellow, a hard hat, earbuds,

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

17

AGGREGATES MANAGER July 2015 4/6/15 4/13/15 12:26 9:51 PM AM

PLANT PROFILE

love crawling around and honking the

It’s fun for us, too. We take lots of

tion point overlooking the quarry, which

horns on the equipment. They have

pictures and show them to the school

was built specifically for the Kids ROCK

fun and always want to come again.

afterwards.” AM

The school tour ends at an observa-

program. A variety of quarry equipment is parked at the overlook, and the employees talk to the kids about the equipment and allow them to explore.

“We talk a bit about geology and fun facts, such as how long a conveyor is, how many thousands of pounds a haul truck can hold, and how many thousands of pounds a loader can pick up in its bucket,” Coll says. “We do all the talking, and then at the end, we start asking questions to see who listened. There’s candy involved in that part. It’s very hands-on and interactive, and the kids

18

AGGREGATES MANAGER July 2015

Major equipment List • • • • • • • • • • • •

Komatsu HD605-7E0) trucks (4) Komatsu WA500-7 wheel loaders (3) Caterpillar 773B water truck Caterpillar 773D haul truck Caterpillar 773E haul truck Caterpillar 775E haul truck Caterpillar 924G loader Caterpillar 980C loader Caterpillar 988F loader Caterpillar 980G loader Caterpillar 990H wheel loader (2) Caterpillar 990 Series II wheel loader • Caterpillar 320L excavator • Caterpillar 14H grader • Grove RT500D crane

• • • • • • • • • •

42-inch Traylor gyratory crusher 7-foot Symons standard crusher (2) 7-foot Symons short head crusher (2) Impact Service Corp VSI crusher Telsmith 8x20 screen units (2) Metso 8x20 screen units (4) Metso 8x24 screen units (4) Diester 8x20 screen unit Diester 8x24 screen unit McLanahan VD21S dewatering screen • McLanahan VD9 ultra-fine recovery sand screen • UniBridge 220x18 scales (2) • UniBridge 10x80 scales (2)

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OPERATIONS ILLUSTRATED i g R c a ti t Re hink n

e l m a on

Consider the operation’s location and needs of the surrounding community.

Use plants that will foster animal habitats and breeding grounds.

Consider how the project coordinates with other goals, including community relations and permitting.

Develop a diverse mix of plantings that support wildlife.

OPERAT 1

Consider traditional projects

New projects target community needs

M

any of the most successful reclamation projects are ones that enhance the community surrounding the site, as well as ties between the operator and the community. An end use that suits the needs of the community offers a win-win for both the operator and the community.

According to Gary O’Toole, director of environmental services for Lehigh Hanson, it tries to complete its reclamation obligations with careful thought to both local and regional needs. At its Fairmount Quarry, in Fairmount, Ill., the result was a cooperative effort that showed how native warm grasses could not only be grown in low-nutrient soil, but could actually improve the soil quality in a way that could lead to additional future uses of the property.

The operation also worked with local farmers by setting up a fully automated water station. “It was done in the spirit of working with the local farmers,” O’Toole says. “Water isn’t always accessible in some of those areas. We pump it out of our pits. A farmer tanker can pull up and take a full load. It saves a lot of travel time and reduces diesel fuel costs.”

Young community members were at the heart of Cemex’s reclamation plans at its Clermont, Fla., sand mine. In a single week, hundreds of students planted 2,500 live oak, laurel oak, and long-leaf pine trees.

“Involve your students. They get to learn about plant species and what AGGREGATES MANAGER

animals are attracted to them, and why wetlands are important,” advises Jenna Emerson, Cemex’s legislative and public affairs manager, Florida/Carolinas. “Then, they are the ones who go home to their parents, their Cub Scout groups, and their churches and share what they’ve learned.”

A good rapport with local government officials led to the city’s involvement with a reclamation project. “We’ve had a great working relationship with the city (Santee),” says Kathy Olsen, CFO of RCP Block & Brick, Inc. and daughter of the founder. “We’ve done what they asked us to do, so they have trust in us.”

In fact, once the company was done contouring and vegetating the channel of its sand mine, the city built the trail. It even posted signs along the trail that explain how sand from the site was necessary for the concrete blocks used in many local homes and schools. “A lot of the sand that came out of this project built Petco Park, where the San Diego Padres play. It’s in the San Diego Convention Center and the Southern California military bases,” Olsen adds. “The sand that has come out of this river has been integral to San Diego.”

By working with various local constituencies, each of these operators stands out for going beyond the requirements and enhancing the community in which the operation was located.

Historically, aggregate operations have been reclaimed for use in residential and commercial construction, as well as golf courses. Here, Chaney Enterprises reclaimed its Mardis Mine facility as an 18-hole public golf course in Davidsonville, Md. In 2004, the company was selected as a recipient of the Maryland Department of Environmental Reclamation Award, as well as the Interstate Mining Compact Commission national reclamation award (non-coal category) for this project.

4

Work with the community

RCP Block & Brick tied reclamation activities at one of its Santee Sand Pits to a greater community development project along the San Diego River. As mining was completed in areas along the river, slopes were graded and native vegetation was planted. The city of Santee installed a public trail along these slopes. The trail includes placards explaining how the river once provided the sand needed for concrete blocks used in local homes, schools, and other projects. Both city and county officials were on hand to celebrate the dedication of the trail.

TIONS ILLUSTRATED Rethinking Reclamation 2

Involve future leaders

Reclamation kicked off in a big way with Cemex’s Engstrom Lake Project at its 474 Sand Mine in Clermont, Fla., when more than 500 elementary students spent a week there. Students planted 2,500 trees to help restore and enhance a mined and reclaimed upland.

Once plantings were complete, the operation added an outdoor learning center and project learning area that includes 20 acres divided into four habitat areas. The operation hosts field trips throughout the school year, with nearly 3,000 students visiting the site each year.

5

Grow institutional knowledge

Lehigh Hanson’s Fairmount Quarry in Westchester, Ill., used non-traditional farming equipment to plant native seeds selected for their vigor and ability to grown in low-nutrient soils, they were able to quickly establish the necessary ground cover. The operation won the Illinois Department of Natural Resources’ 2014 Illinois Mined Land Reclamation Award, the Noncoal Reclamation Award from the National Association of State Land Reclamationists, and an Honorable Mention for the Kenes C. Bowling National Mine Reclamation Award from the Interstate Mining Compact Commission.

3

Go beyond requirements

While the original mining permit for Vulcan Materials Co.’s River Rock operation in Fresno, Calif., allowed it to mine all of Rank Island, it recognized that the site contains one of the last remaining, old growth stands of native mixed riparian forest along that section of the San Joaquin River. It voluntarily revised its mining and reclamation plan to preserve undisturbed portions of the property. A native plant nursery was developed on the site for the natural plants used for reclamation. The site received the Excellence in Reclamation award from the California Department of Conservation.

6

OUR EXPERTS

Don’t overlook entertainment options

Rogers Group Inc.’s former Louisville Crushed Stone operation, in Louisville, Ky., was mined until the 1970s, when its reserves were depleted. The surface property is now home to a K-Mart, the Louisville Zoo, and several industrial-use properties, but the underground project is truly the star. One portion of the cavern is leased as manufacturing and commercial warehousing. There, Warner Brothers stores old film archives. Another portion is an entertainment center that features the nation’s largest underground zipline facility, a ropes course, bike trails, a Christmas lights show, and event and meeting space for up to 100.

Gary O’Toole is the director of environmental services for Lehigh Hanson, Inc. He has a bachelor of science degree in environmental biology from Eastern Illinois University.

He began his career with Material Services Corp. and has more than 35 years of experience. He has served on NSSGA’s environmental committee and sustainability task force. He is also a past chair of the Illinois Association of Aggregates Producers environmental committee.

Tom Phelps is currently reclamation manager for RCP Block & Brick. He previously served as sand plant manager for the family-owned company. Phelps has been involved in the aggregates industry for nearly 40 years and has worked at the current pit since 1992.

Jenna Emerson is the legislative and public affairs manager, Florida/Carolinas, for Cemex USA. She studied interpersonal and organizational communications at Florida State University and the University of Central Florida. Emerson is a member of the National Stone, Sand & Gravel Association’s Young Leader Council and serves on the Wildlife Habitat Council’s wetlands committee.

July 2015

Voices of Experience Gary O’Toole

A

s it planned reclamation at its Fairmount Quarry, in Fairmount, Ill., Lehigh Hanson sought not only a better way to meet challenging reclamation requirements at its site, but also a way of doing so which provided local and regional benefits.

Gary O’Toole, director of environmental services for Lehigh Hanson, credits Kelly O’Brien, plant manager, with having a vision for the site’s reclamation process.

“Kelly was looking for a better way to do his reclamation,” O’Toole says. “He wanted it to be more efficient and longer lasting.”

O’Brien reached out to a local farmer, John Miller, and University of Illinois Professor DoKyoung Lee. The operation used non-traditional farming equipment to plant native seeds, chosen for their vigor and ability to grow in low-nutrient soils. The planting program used native warm season grasses to quickly establish necessary ground cover, while testing methods of biomass production, options for carbon sequestration, and developing local agribusiness opportunities.

Within one year, some areas performed so well they were released from bond. O’Toole says that under normal circumstances, it would have taken multiple years, several plantings, and many more man hours to achieve reclamation requirements. “Typically, it would take two to three years to get areas released from a reclamation bond,” O’Toole explains, noting that it depends on variables such as planting season, plant type, rainfall, etc.

Another positive outcome from the project is that the reclamation techniques used offer the potential to significantly improve soil reformation processes, allowing the area to have even more diverse uses in the future.

While the techniques used at the Fairmount Quarry are unique, some of the principals may be applied at other sites in the future. “We’ve done some tests on similar soils at another quarry, but it’s not something that we’ve rolled out completely,” O’Toole says.

AGGREGATES MANAGER

Tom Phelps

W

hen Lemon Grove, Calif.-based RPC Block & Brick began to mine portions of the Walker River in 1970s, it had previously been mined by a number of sand and gravel producers and was a bit of a patchwork of sand and gravel channels.

Since then, the operator has developed a concurrent reclamation plan that ties mined-out portions of the site into a trail system that feeds into a broader project — the San Diego River Trail.

Company founder Marvin Finch and his daughter, Kathy Olsen, spearheaded permitting for the project and received approval on the reclamation plan in 1991. Shortly after, Finch’s nephew, Tom Phelps, became plant manager and managed both the extraction and concurrent reclamation processes.

The multi-stage reclamation plan began with the construction of a streambed stabilizer at the eastern end of the property. The dam-like structure was designed to protect upstream properties on the San Diego River from erosion and scouring. “The property was pretty chopped up and had been mined in several places,” Phelps recalls. “In some of the areas, slopes needed to be reworked. Mining was complete in those areas when we got to them, so we went to work right away on those and re-vegetated them. Once the plan was approved, we began work on reclamation in areas where we could, and we stayed ahead of it.”

Phelps says that the company has paid particular attention to ensuring that the slopes look natural. Rather than having one even slope, they’ve created outcroppings and variations in the slopes. Because sand mining also took place below the water table, the site also has some man-made lakes, which are somewhat unusual in that part of California.

The result has been well received.

In fact, Phelps says that many of the people who regularly hike the trail don’t even realize it had been a sand mining property.

Jenna Emerson

W

hen reclaiming portions of its sand mine in Clermont, Fla., Cemex USA turned to a unique crew to help them with the project — approximately 500 students from a local elementary school, as well as students from the nearby Valencia Community College.

“We wanted to unite the community,” says Jenna Emerson, Cemex’s legislative and public affairs manager, Florida/ Carolinas. “This was an opportunity to do so and provide a hands-on learning experience for students.”

During a single week, students planted 2,500 live oak, laurel oak, and long-leaf pine trees to restore and enhance the site. More than a decade later, the 20-acre property is home to many animal and bird species, and the Engstrom Environmental Education Center welcomes between 2,500 and 3,000 students each year to its classroom. In fact, the Wildlife Habitat Council has certified the site as Corporate Lands for Learning and as a Wildlife at Work site.

Before students visit the center, teachers share a Power Point presentation that describes the basics of mining and talks about some of the uses of the sand produced at the site. When they arrive, students see the equipment in action and get to participate in a number of environmental activities, including cane pole fishing. One of the company’s three local geologists gives students a lesson that ties into state indicators, including not only the sand and limestone being mined on the site, but also other common minerals throughout the state.

As part of its community relations program, Cemex foots the bill for bus transportation for students and will even reimburse the school district for a substitute teacher.

“It’s basically a free field trip,” Emerson says. While school recently ended, she says she’s already received more than a dozen emails from teachers who want to be part of the program for the 2015-16 school year.

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Five

Factors of

Fuel

Efficiency By looking at all five factors, operators can better control fuel costs.

by Jason R. Hurdis

26

AGGREGATES MANAGER July 2015

F

uel expense in owning and operating aggregates equipment is a constant and will account for about 50 percent of total machine operating costs. Fuel prices have recently been on the decline, but based on history, this trend will soon reverse. In a recent article, the International Energy Agency warned “oil prices have dropped by 30 percent in the past four months…the low prices could deter investment in production, which will eventually hurt supply.”

With the unpredictable nature of fuel prices and fuel’s absolute necessity for business operations, most aggregate producers have simply looked at how much fuel they are burning and paid the bill. Recently, technology has changed,

and now with the addition of production data, producers can look at their fuel efficiency (how they are using fuel) and know its impact to the bottom line.

Fuel efficiency does incorporate the amount of fuel burned, but its final value is dependent on several factors. These factors, or fuel efficiency influencers, can be categorized as follow:

1. Idle time, 2. Operator technique, 3. Mine set-up, 4. Equipment selection and configuration, and 5. Technology.

MINE MANAGEMENT

In truck loading applications, an experienced equipment operator has more than a 30-percent fuel efficiency advantage over a novice.

Fuel efficiency Fuel efficiency is defined as material moved (work) in a time period over the amount of fuel consumed to move the material in the same time period. The fuel efficiency formula for aggregates equipment appears as: Fuel efficiency =

This article will explore each of these influencers in detail, explaining the parameters and overall interaction of these on fuel efficiency.

Material moved per unit of time Fuel consumed per unit of time

To put this formula into plain terms from an application point of view, material moved, also known as productivity, is measured in tons or cubic yards. Fuel consumed is measured in gallons used to move the material. The unit of time for fuel efficiency is an hourly measurement, which results in units of tons per gallon or cubic yards per gallon.

Based on this, improvements in fuel efficiency are achieved

AGGREGATES MANAGER July 2015

27

by either increasing the productivity while retaining the same amount of fuel consumed, or reducing the fuel consumed while retaining the same productivity level.

1. Idle time Equipment idle time is one of the largest and generally the most misunderstood influences to fuel efficiency. Idle time is defined as fuel being consumed with no work or productivity.

Idle time in aggregates applications is impossible to avoid considering equipment warm-up and shutdown requirements.

Industry studies show equipment idle time can be as much as 40 to 50 percent of total operation time. Idle time results in a direct expense to companies’ profit margins. Chart 1 is a simple example of idle time cost.

Chart 1

It is obvious idle time has a direct impact on fuel consumption. In fact, when idle time is reduced, hourly fuel consumption is actually increased. This relationship is often confusing to users as the general thought is if the equipment is idling less, the hourly fuel consumption should decrease, not increase.

This phenomenon is best explained by understanding the relationship between idle time, working time, productivity, fuel consumption, and fuel efficiency.

equipment, overall operation, environmental stewardship, and company profits.

2. Limit warm-up time – Equipment warm-up time at start of shift varies by ambient conditions, but a rule of thumb from the Environmental Protection Agency (EPA) indicates warmup times can be limited to 3 to 5 minutes.

3. Implement a 5-minute idle rule – If equipment idles for more than 5 minutes, shut it down to save fuel. Restarting equipment uses less fuel than idling, considering most aggregates equipment consumes an average of one gallon per hour at idle. Most aggregates equipment manufacturers offer as standard or option attachments shutdown timers that automatically shut off machines after 5 minutes or other user-defined time periods.

4. Limit cool-down time – Equipment should be idled at end of shift to allow turbochargers and emission systems to cool and purge. As another general rule, idling for 2 minutes at the end of the shift will allow most equipment to reach optimum shutdown temperatures. Newer aggregates equipment has automatic shutdown features that control this time and process for the user.

5. Idle management systems – Some equipment is equipped with ‘auto-idle’ or ‘engine idle management’ systems. These systems monitor equipment parameters and automatically reduce engine rpm to idle rpm or below normal machine idle rpm. Using these systems can reduce idle fuel consumption to less than 1 gallon per hour.

6. Breaks and lunch – Studies and observations indicate equipment is left idling over breaks or lunch periods. The most frequent reason stated by equipment operators for doing this is to keep cab environment at temperature, whether warm or cool. Systems such as engine off cab heaters and coolers can reduce the “need” to idle over breaks and lunch.

Operator education and layout of break/lunch areas to production areas can be helpful as well.

7. Monitoring asset utilization – Best practice today includes using telematics for monitoring equipment and utilization to benchmark and identify opportunities to reduce idling time and enhance the fleet utilization.

2. Operator technique

While some equipment idle time is unavoidable, it can still be controlled or minimized. The following are effective methods to reduce idle time.

1. Education – Reviewing fuel consumption data and fuel costs with employees helps educate them on idling effects to the

28

AGGREGATES MANAGER July 2015

The equipment operator’s experience, operating technique, and application knowledge all equally influence fuel consumption, productivity, and resulting fuel efficiency. One study indicates efficiency can vary up to 40 percent between different operators on the same equipment in the same application. Caterpillar recently conducted a study using eight operators of various experience and skill levels on the same machine in the same application. A summary of the test results appear in Chart 3.

MINE MANAGEMENT

Chart 3 – Operator Impact Study

Chart 4 shows results from studies conducted with various operator experience/skill levels with different sized wheel loaders and track-type machines in the same application.

Chart 4

a. On-the-job training – One method of on-the-job training is mentoring, using an experienced operator to train a less skilled or inexperienced operator. Mentoring allows training on site with site machines and using site conditions while maintaining production, even if at a reduced level, during the mentoring period. A potential risk of mentoring is the progression of ‘bad habits’ from the trainer to the trainee.

Another method of on-the-job training is using manufacturer equipment training services. Equipment manufacturer training can be completed either in a controlled event such as a demonstration and training center or on the customer’s site and machines in the customer’s applications. Like mentoring, this type of training incorporates environmental conditions, job site conditions such as gradients, maneuvering restrictions, and other equipment interactions the operator may encounter during daily work periods to be experienced.

Either method of on-the-job training requires an investment in time and expense, but the rewards can be quickly realized via improved production, equipment care, and fuel efficiency. b. Training simulators – The use of simulators allows operators to develop basic control familiarity in a controlled environment without fear of mistakes, equipment hour accumulation, production interruption, or fuel consumption. However, equipment simulators lack the feel, stability, visibility, and environmental conditions that a real

The variables in these studies are derived from material engagement with loading device, equipment movement, interaction with equipment controls and engine-transmission-traction management, and experience with particular machine platforms.

As shown in these studies, fuel efficiency can also be dramatically affected by an operator’s experience, skill level, and familiarity with a specific piece of equipment. Time frames for an operator to become comfortable with a particular piece of equipment can vary from a few hours to several weeks based on experience and skill levels with similar types of aggregates equipment.

While operator proficiency levels vary, the impact to fuel efficiency can be reduced with aggregates equipment in any application. The following methods can be used to improve operator technique and achieve fuel efficiency improvements.

Mentor drivers can help new operators to learn on the job, but can also lead to transfer of 1. Training – operator training can be bad habits from one driver to another. Equipment manufacturer training is another option for operator training. separated into two basic types.

AGGREGATES MANAGER July 2015

29

Material location has the largest fuel and operational efficiency impact. Improper stockpile location requires operators to travel greater distances to load the truck, which increases fuel consumption, causes additional equipment wear, and leads to operator fatigue.

machine in a real application can provide. Nonetheless, simulators can be valuable in a new operator or continuous training programs.

The training duration and resulting fuel efficiency improvements of either on-the-job or training simulators will vary based on the operator’s initial experience and skill level, commitment to improve, and ability to retain techniques learned during training.

2. Equipment features – Some equipment has built-in features and systems that automate control systems, traction aid devices, transmission shift points, and engine-hydraulic interactions, all of which the operator can select to enhance their performance and improve fuel efficiency. Recent features added to equipment include performance modes which adjust engine horsepower, hydraulic power, hydraulic speed, and rimpull to improve fuel efficiency. As mentioned previously, systems like auto idle, engine idle management, and others are rendered useless if an operator does not know how to engage or effectively use them.

3. Mine set up How the quarry is planned and set up is another fuel efficiency influencer. Typically, it is planned far in advance, taking into consideration land acquisition, right of ways, material deposits, permitting, and the production volumes required to make the site profitable. If there is not an effective and systematic

30

AGGREGATES MANAGER July 2015

approach to the initial job site planning, cost overruns, time delays, and manpower expenses mount rapidly.

Mine site fuel efficiency influencers include the following: 1. Material location – Material location has the largest fuel and operational efficiency impact. Improper stockpile location requires load out equipment to traverse the site to load customer trucks, which results in additional fuel consumption, additional equipment wear, and operator fatigue. Safety issues such as blind spots can also arise from poorly planned stockpile placement.

2. Inadequate space – Where space is limited on the site, stockpiled materials can blend together which causes additional equipment cycling times and increased fuel consumption. Space constraints can also increase equipment transport distances, or ‘roading,’ which consumes additional fuel and limits productivity.

3. Site roads – These can significantly affect aggregates equipment fuel consumption, productivity, and fuel efficiency.

4. Equipment selection Equipment selection is simply defined as having the right machine for the right application at the right time. If the machine is too large for the application, fuel efficiency can be reduced as the machine can potentially exceed production requirements, which may lead to additional material re-handling, extended idle time, and operator inefficiency. If the machine is too small

MINE MANAGEMENT

for the application, fuel efficiency is impacted as the machine will consume more fuel while trying to achieve production requirements.

To ensure the right equipment is selected for the application, consider the following: 1. Work tools – The work tool size and type affects the digging or excavating performance, stability, cycle times, and fuel consumption. If the work tool is too large for the machine, additional engine rpm, hydraulic power, digging times, and digging forces will result in higher fuel consumption. If the work tool is too small, productivity will suffer and, as such, additional cycles and fuel will be required to meet production requirements.

As a subset of work tools, ground engaging tools are an important selection. Using the incorrect edge or tooth configuration can affect production, cycle times, operator technique, production, fuel consumption, and fuel efficiency.

2. Application – Machines are designed for specific applications, such as loose material truck loading, load and carry, face material truck loading, below ground excavation, or utility work.

While a single machine may be able to complete each of these applications, additional job set up or support machines might be required.

3. Tire selection – Studies conducted by tire manufacturers indicate radial tires result in up to 10 percent less fuel consumption. Tire pressures also play an important part for fuel efficiency. Underinflated tires increase rolling resistance, which increases fuel consumption and can also affect stability, which impacts productivity. Overinflated tires can change ride characteristics of a machine impacting fuel efficiency via production losses from lost material during transport.

4. Machines features – Most equipment manufacturers offer fuel saving and production improving features such as variable work modes, fuel management systems, traction aids, lock up

clutch torque convertors, load sensing hydraulic systems, and on-demand fans. These features can be adjusted or applied by the operator or automatically based on application and environmental conditions.

5. Fleet or system match – Loading and hauling units need

AGGREGATES MANAGER July 2015

31

to be sized correctly in order to be most the fuel-efficient system. As a rule of thumb, loading units should be able to load hauling units within four to six passes.

Equipment dealers are valuable resources and should be consulted to assist in machine selection.

5. Technology

Simulators can familiarize operators with basic controls but lack the feel, stability, visibility, and environmental conditions of a real machine in a real application.

Technology can also influence fuel efficiency. Technology in this article encompasses both telematics and equipment technologies. Each is equally important to equipment fuel efficiency.

1. Telematics – Telematics can be broken down into two sections: off-board and on-board. Off-board telematics are equipment manufacturer or third-party services which provide individual machine or fleet information to site personnel. They provide site personnel with fuel information without additional labor to obtain the data via on-site measurement. This information allows site personnel to better understand their operations and analyze individual machines, operators, and mine site set up to improve and sustain fuel efficiency.

Operations Manager Lyman Richey Sand & Gravel, located in Waterloo, NE is currently seeking a high quality individual to fill our Operations Manager position.

Essential Duties and Responsibilities:  

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

• Technical writing and review • Lecturer

Contact me at:

Bill-Langer@researchgeologist.com www.researchgeologist.com

32

BillLanger_AGRM0115.indd 1

AGGREGATES MANAGER July 2015

    

Supervises plant employees in all aspects of aggregate production.

Carries out supervisory responsibilities in accordance with the organization’s policies and applicable laws.

Communicates with General Manager on issues affecting business including: personnel, safety, quality and maintenance.

Works with Safety Department to ensure compliance with State and Federal regulations.

Oversees and maintains appropriate inventory levels.

Ensures that equipment and facilities are properly maintained.

Works with the Quality Control Department to ensure products meet specifications.

Education and Experience Required:

Bachelor’s degree (B. A.) from four-year college or university and at least 5 years related experience and/or training in the Aggregate/Mining industry; or equivalent combination of education and experience.

APPLY ONLINE at www.lymanrichey.com and click the “employment” tab Equal Opportunity Employer

12/16/14 1:21 LymanRichey_AGRM0715pg32.indd PM 1

6/18/15 2:46 PM

MINE MANAGEMENT

On-board or on-machine telematics are machine monitoring systems and displays providing the operator with real-time information such as productivity, fuel consumption, idle time, and fuel efficiency. This information allows the operator to make adjustments to the operating technique or machine to improve fuel efficiency in real time. The operator can also use this information with site management to assist in mine site improvements or identify issues that may be affecting fuel efficiency.

2. Machine technology – Advancements in equipment design and development have been rapid in the last five years.

Several engines and machine platforms are now designed to deliver full power at lower rpms, which reduces fuel consumption and emission packages.

3. Advanced technologies - Common in the automotive market, advanced technologies such as hybrids, electric drive, hydrostatic, or continuously variable transmissions have been introduced in recent years. These machine technologies are creating double-digit fuel consumption reduction with productivity levels equal to or greater than standard configured models in the same size and machine class.

Several of these technologies also improve the operator technique by automatically adjusting performance or transmission settings.

4. “Add-on” technologies - “add-on” technologies such as grade technologies and payload technologies can improve fuel efficiency. Grade technologies improve operator efficiencies and reduce unnecessary idle and fuel consumption. Payload control systems improve production, reduce idle time, reduce fuel consumption, and improve operator efficiencies.

Conclusion Idle time, operator technique, mine site setup, equipment selection and configuration, and technology all influence fuel efficiency. While one may be more visible or easier to control than another, all five must be understood, investigated, and acted upon conjointly to maximize fuel efficiency.

Jason R. Hurdis is senior market professional, Quarry and Aggregate Industry, for Caterpillar.

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Get the Most

(Water)

Out of Your

Dewatering

Screen

Consider the material type, feed rate, and percent of solids in the feed before the initial start-up of your dewatering screen.

By paying attention to items such as initial setup, fine-tuning of settings, and maintenance, your screen can put the squeeze to both coarse and fine feeds.

by Michelle Cwach

D

ewatering screens are common

your dewatering screen is mint from the

tools used to dewater fine aggre-

manufacturer, there are common operating

gates (typically, minus-3/8-inch

and maintenance missteps that can prevent

or smaller) prior to stockpiling.

you from achieving optimal performance from

Feed to a dewatering screen can come from a

your dewatering screen, according to Carson

variety of sources, including cyclones, density

Schott, sales engineer for KPI-JCI and Astec

classifiers, fine material washers, and even di-

Mobile Screens.

rectly from classifying tanks. Depending on the gradation of the product to be produced, dewa-

Start-up and daily maintenance

tering screens will typically produce a finished

One of the first steps to take at set-up is to

product with moisture content as low as 8 to

ensure the vibrating motors are turning op-

15 percent by weight.

posite of one another, Schott says. All motor

But whether you’re a seasoned professional who’s been operating for years or

counterweights should be set equal to one another, and the switchgear must be installed to

AGGREGATES MANAGER July 2015

35

ensure both motors run together and in the proper direction.

“Many of the dewatering screens manufactured use vibrating motors, although some use exciter drives,” Schott says. “If you have a dewatering screen that uses vibrating motors, you should verify the motors are turning opposite of one another. The motor connections can easily be wired incorrectly, so customers should check to make sure the switchgear is installed to ensure both motors run together and in the proper directions to create the

By fine-tuning variables such as raising the discharge dam or amount of feed material larger than the media opening, an operator can find the sweet spot for a particular application.

screen’s linear motion.”

When conducting this visual inspection, producers should also take note of available clearance room, keeping all adjacent equipment and structures a minimum of 3 inches away

isolated or on one side, troubleshoot the cause. Many times, it may be due to uneven feed or motor settings.”

from the screen. When a screen starts up or shuts down, it

Adjusting for optimal performance

hits a natural frequency and goes through an extra lung-

It’s critical to first evaluate what type of material you are

ing motion, especially when powering down, Schott says.

working with, the feed rate, and the feed percent solids to

By maintaining the proper clearance, it ensures feed boxes,

determine how you should initially start the dewatering

chutes, and other structures are kept far enough away to

screen, Schott says. Coarser material, such as concrete sand,

ensure the screen doesn’t cause damage or become dam-

is composed of bigger particles, which do not carry and hold

aged itself.

as much water. Smaller particles, like those involved in fines

Producers should focus on how the material is being fed to

recovery, have more surface area on which to hold water,

the screen. Feed slurry should be centered and evenly distrib-

which leads to a higher moisture content. Dewatering coarse

uted across as much of the feed end of the screen as possible.

material is easier, and the screen can handle more tonnage.

Like other screens, the dewatering screens need to be fed

As the feed becomes finer, the capacity of the dewatering

evenly so it’s not loaded to one side. If feeding evenly isn’t

screen is reduced.

possible, Schott says producers should at least try to have the material centered on the screen as much as possible.

Next, producers should perform weekly checks to verify

Although dewatering screens are designed with simplicity in mind and do not typically offer many options for adjustments, producers can not only adjust the stroke, but also

screen media, side wear liners, springs or buffers, and

manually adjust the discharge dam (or weir) to help control

all bolts and fasteners are in proper operating condition,

product moisture, bed depth, and rate of travel.

Schott says.

It’s a balancing act, Schott says, and one that often takes

“Producers should confirm the screen media is secure and

a couple of adjustments to obtain the “sweet spot” needed

not worn,” Schott says. “At the same time, you should check

for a particular application to achieve the desired moisture

the coil springs or rubber buffers and confirm they are not

content.

worn or damaged. If you notice excessive wear, it’s time to order replacement parts as soon as possible. If the wear is

36

AGGREGATES MANAGER July 2015

“Raising the discharge dam will help build a bed of material on the media, which will naturally help squeeze that

EQUIPMENT MANAGEMENT

water out of the fine aggregate,” Schott says. “Another way to

must be considered, including product gradation, feed rate,

help build a material bed is to ensure at least 10 percent of

and the percent solids of the slurry feed. Generally speaking,

your feed material is larger than the media opening. Features

a finer product reduces the capacity of the unit.

such as dams can also be integrated in the media panels to help improve the material flow and moisture content.

But just as important as the correct size and capabilities of a screen is the quality of the screen media and the manufac-

“At the same time, you don’t want to overload the screen to the point of dampening the stroke or damaging the deck,”

turing involved in building the structure, Schott says.

“Screens can receive a lot of abuse,” he says. “Producers

he adds. “You want to find that sweet spot between feed rate,

should ask themselves, ‘Are they built to endure? Does the

the throw of the motors which controls rate of travel, and how

manufacturer offer a satisfactory warranty provision? Is there

much of the dam you have raised.”

dealer support? Can you build a complete system customized

The angle of operation can also be adjusted, though Schott

to your needs?’ By asking yourself these questions, you will

says adjusting this is less common amongst producers. Typi-

be able to avoid incurring additional expenses associated with

cally, dewatering screens function at an angle of 5 degrees,

piecing together inferior commodity equipment or purchasing

but can be lowered down to zero degrees if desired. The

a system designed to do more than what you need.” AM

lower the angle of operation, the more water will carry with the material versus having the uphill slope to naturally hold it back.

Michelle Cwach is the media relations manager for KPI-JCI and

To find the optimal balance of settings, Schott encourages

Astec Mobile Screens.

producers to only change one variable at a time.

“If you need extra capacity, you can increase the throw of the motor to move material a little faster,” Schott says. “Then analyze whether the dam needs to be raised or lowered to maintain an optimum bed depth or moisture content.”

“Just be aware that every adjustment affects one of the other variables in the process. For example, if you raise the discharge dam (weir) to increase the bed of material and improve the moisture content, you risk reducing capacity,” he explains. “If you adjust the counterweights to reduce the rate of material travel on the screen, you also may risk reducing capacity. Larger media openings or more open area allows more water to pass through the deck, but you risk losing desired fine material.”

YOUR UPTIME INSURANCE Your safety and productivity are in good hands with Atlas Copco CARE Agreements. Extended warranties, flexible ways to pay and various tailored plans are just some of the ways we CARE. 800-732-6762 www.atlascopco.us

Replacing equipment When it comes time to replace your dewatering screen, several important elements

AGGREGATES MANAGER July 2015

37

Supply

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

PORTABLE PLANT OPTIONS An expanding array of choices allow operators to select plants with features that best match their specific needs.

Diesel-powered sidewinder IROCK Crushers says customer demand led to its introduction of a diesel option for its line of Sidewinder crushers. It offers the Sidewinder-15 with a 350-horsepower Caterpillar C-9 diesel engine, which powers a 134-horsepower generator for full on-board power. The power system is an alternative to the standard electric option. The crusher is V-belt driven and features a P.T. Tech clutch, which is said to decrease power loss and increase fuel efficiency. The machine incorporates a 5-foot-by-16-foot Cedarapids horizontal screen box with a triple-shaft design for long life.

The manufacturer also equipped the unit with four hydraulic outriggers for quick plant set up.

IROCK Crushers | www.irockcrushers.com

Secondary and tertiary crushing Kleemann’s Mobicone MCO 9i EVO/MCO 9i S EVO mobile cone crusher offers aggregate producers high-productivity secondary or tertiary crushing in a fuel-efficient, Tier 4 Final compliant machine. The S-version provides a discharge conveyor-mounted final classifying screen with oversized aggregate return conveyor to allow a closed material cycle and production of final particle sizes without a standalone screen. Optionally, oversize material can be discharged via the swivel-mounted return conveyor. The unit’s diesel-electrical drive provides low fuel consumption. Its power plant generates 332 horsepower at 1,500 rpm, and the unit can crush up to 287 tons per hour.

Kleemann | www.wirtgenamerica.com

Efficient portable jaw McLanahan Corp. says its 3264 Portable Jaw Crusher helps producers do more with their resources by allowing them to become more efficient, more productive, and more profitable.

The plant features a 3264 Universal Jaw Crusher, which can handle from 100 to more than 1,000 tons per hour of material.

The jaw offers a compressive stroke that is nearly equal at the top and bottom of the chamber, producing more spec material at a lower cost per ton. Both hydraulic and shim adjustment are available on this crusher. It also comes fully equipped with a 62-inch by 25-foot Severe-Duty Vibrating Grizzly Feeder.

McLanahan Corp. | www.mclanahan.com

38

AGGREGATES MANAGER July 2015

Crusher and screen The Lokotrack LT220D combines a crusher and screen on the same chassis. It can be equipped with either the Nordberg GP220 or HP200 cone crusher. A large 10 square-yard screen is said to provide high capacity, as well as excellent screening efficiency. By combining this unit with a LT106 primary jaw crushing plant, operators can produce up to three calibrated end products using just two plants. The Intelligent Metso IC process control system also ensures safe and reliable control of the crushing process. A single Cat C13 diesel engine runs both crusher and screen.

Metso | www.metso.com

Combined crushing and screening The UH450E is a compact track-mounted crusher and screener, which combines the Sandvik CH440 cone crusher with a loop-feed conveyor and a screening system. With the means to operate via electrical mains or an onboard diesel generator and the ability to work either as a secondary or tertiary unit, the plant is said to offer one of the most versatile, cost-effective and environmentally friendly mobile solutions on the market. Both the cone and screen come with a choice of crushing chambers and screening media, respectively, as well as with a wide range of options.

Sandvik | www.construction.sandvik.com

High production portable crushing The Terex Cedarapids CRJ3750 plant combines a large 37- by 50-inch JS Series jaw crusher with a high stroke, 52-inch by 20-foot vibrating grizzly feeder resulting in a high production portable crushing machine. The mobile plant is said to be easy to operate and maintain. It features improvements such as wedge release jaw dies and hydraulic assist jaw crusher settings. Multiple options are available, allowing customers to configure the plant to meet specific needs. Options include a rock breaker, folding hopper wings, hydraulic jacks, hydraulic deployed switchgear, and quad or 3+1 axle configurations.

Terex Minerals Processing Systems | www.terexmps.com

Fuel-efficient jaw crusher Powerscreen’s Premiertrak 300 jaw crusher is said to excel at higher fuel efficiency and lower transportation costs. The unit uses a 40-inch by 24-inch jaw chamber and is capable of producing up to 308 tons per hour of crushed material.

Options include a vibrating grizzly feeder or a large fully independent hydraulically driven pre-screen. An optional hydraulically folding extended side conveyor, with a stockpile height of 10 feet, 2 inches, is available with the pre-screen feature. The crusher is powered by a 275-horsepower Tier 3-compliant Cat C9 ACERT engine or a 272-horsepower Tier 4 Final-compliant Scania DC9 engine.

Powerscreen | www.powerscreen.com

AGGREGATES MANAGER July 2015

39

Rock

by Patrick W. Dennison

Supreme Court Justices criticize the disregard for formal rulemaking and note ‘constitutional concerns’ about the ability of agencies to change the meaning of regulations at their discretion.

ANDoctrine ENDofTO THE Deference?

I

Patrick W. Dennison is an associate in Jackson Kelly PLLC’s Pittsburgh office, practicing in the Occupational Safety and Health Practice Group and the Coal and Oil and Gas Industry Groups. He can be reached at 412-4348815 or pwdennison@ jacksonkelly.com.

40

AGGREGATES MANAGER July 2015

n the October 2011 edition of Aggregates Manager, I wrote an article entitled “No Notice Required: MSHA’s disregard for rulemaking authority makes its way to the Review Commission” that detailed the Mine Safety and Health Administration’s (MSHA) substantive change to the standard, 30 C.F.R. § 56.12028 without formal rulemaking. Since that article, the Federal Mine Safety and Health Review Commission affirmed the ALJ’s decision in Tilden Mining, Co., 36 FMSHRC 1965 (Review Commission, August 2014), and found that MSHA’s application of Section 56.12028 to extension and power cords was interpretive rather than substantive, and that it was entitled to deference. Because of the Commission’s characterization of the change in the standard as interpretive, they also found that the Secretary did not need to undertake rulemaking.

MSHA’s about-face application of Section 56.12028 is a prime example of an administrative agency regulating by fiat where, through the guise of “interpretation,” it creates new laws without subjecting them to the scrutiny of formal rulemaking. The Commission’s decision in Tilden illustrates the deference courts provide to agencies, even where current positions contradict prior ones. But are the days of agency deference numbered? In a recent Supreme Court decision, three Justices criticized the disregard of formal rulemaking and called to end the doctrine of deference.

On March 9, 2015, the Supreme Court is-

sued a decision in Perez v. Mortgage Bankers Assoc., et al., 135 S. Ct. 1199, 575 U.S. ___ (2015), invalidating a legal doctrine that subjected interpretive rules that significantly deviate from a previously adopted interpretation to notice and comment rulemaking. The opinion, written by Justice Sonya Sotomayor, found that, because notice and comment procedures are not required when agencies enact interpretive rules, they should not be required to make subsequent interpretations.

But Justices Alito, Scalia, and Thomas focused their concurring opinions on a critique of agency power, ambiguous regulations, and deference. Justice Alito wrote that, “The creation of the doctrine may have been based on the aggrandizement of the power of administrative agencies as a result of the combined effect of (1) the effective delegation to agencies by Congress of huge swaths of lawmaking authority, (2) the exploitation by agencies of the uncertain boundary between legislative and interpretive rules, and (3) this Court’s cases holding that courts must ordinarily defer to an agency’s interpretation of its own ambiguous regulations.”

Justice Scalia proposes abandoning deference. He notes that agencies, “may not use interpretive rules to bind the public by making law, because it remains the responsibility of the court to decide whether the law means what the agency says it means.” But because of deference to an agency’s interpretation of its own

ROCKLAW

regulations, according to Justice Scalia, courts have allowed agencies “to control the extent of its notice-and-commentfree domain” — a domain they expand by writing “substantive rules more broadly and vaguely, leaving plenty of gaps to be filled in later, using interpretive rules unchecked by notice and comment.”

Justice Thomas, like Justice Scalia, criticizes “a doctrine of deference that has taken on a life of its own.” Deference, according to Justice Thomas, gives “legal effect to the interpretations rather than the regulations themselves.” This raises “constitutional concerns” as it transfers “the judicial power to an executive agency.” Thus, deference allows agencies to change the meaning of regulations at their discretion and without any advance notice to the parties, which undermines the “obligation to provide a judicial check on the other branches.”

While the decision in Mortgage Bankers answered the question of whether changes in interpretative rules require notice and comment rulemaking, the decision did not ad-

dress what constitutes an interpretive rule versus a legislative rule and whether a change in a rule is legislative, if it has the effect of amending a prior legislative rule. In fact, as Justice Sotomayor recognized, the parties in Mortgage Bankers litigated the suit on the understanding that the rule at issue was interpretive, not legislative. 135 S. Ct. 1199, 575 U.S. ___, 14 (2015).

Which brings us back to the October 2011 article mentioned above: the Commission’s decision in Tilden Mining, Co., 36 FMSHRC 1965 (Review Commission, August 2014), is currently pending appeal before the United States Court of Appeals for the District of Columbia Circuit. MSHA’s current application of Section 56.12028 contradicts its prior position, and Tilden has argued before both the ALJ and Commission that the change is legislative, not interpretive. Thus, in light of the Mortgage Bankers decision, it will be interesting to see whether the D.C. Circuit provides a judicial check on MSHA’s rulemaking authority and attempt to change the law without formal procedures. Stay tuned. AM

Deference gives “legal effect to the interpretations rather than the regulations themselves,” – Justice Thomas

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AGGREGATES MANAGER July 2015

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Terex Minerals Processing Systems

www.terexmps.com

IFC

Terramac

www.terramac.com

20

Worldwide Electric Corp.

www.worldwideelectric.net

5

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

42

AGGREGATES MANAGER July 2015

PAGE #

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43

In Stone

by Bill Langer

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

He can be reached at Bill_Langer@hotmail.com

From the Quarry

TO THE CEMETERY

The combination of granite’s weathering characteristics and mechanization of the industry led to rapid growth of Barre’s mining.

‘When our forefathers crossed the ocean and settled in this country, it was not long before the tombstone cutter made his appearance, and with his wagon load of slate and marble slabs, he journeyed through the towns, and when he sold one, he put up his horses and proceeded to letter the stone on the spot; and when he had finished and set the job, he started on in quest of another victim.’

(Arthur W. Brayley, 1913, History of Granite, p. 118 Way back when I was in graduate school, one of my geology professors The completion of the ‘Sky Route’ railroad led to took our class on a field trip to a cemetery to study gravestones, which, explosive growth in Barre’s granite industry. at first, seemed like a pretty creepy thing to do. But we were there to observe how rock weathered, and what better place than an outdoor laboratory with slabs of various types of rocks, all nicely showing the date they were originally put out to weather.

The red and brown sandstone monuments, when standing upright, had almost always crumbled or scaled off, sometimes showing only a ghost of the original inscription. Most of the crisp inscriptions originally carved into the marble gravestones had been severely softened by acid rain. We also noticed sugaring, which is a gradual disintegration of the surface of the marble creating a rough granular, crystalline appearance. What was striking was how well the granite monuments had survived the elements.

My graduate school class was not the first group of people to notice the differences in deterioration of gravestones. By the end of the 19th century, granite, by virtue of its superior weathering characteristics, had become the favorite rock for use in the construction of large and costly monuments and mausoleums, particularly in northern climates of the United States.

This shift in preference for granite monuments gave a huge boost to the Barre granite industry. About $60,000 of granite was produced in Vermont during 1880. By 1886, Vermont’s granite production had doubled, and during 1895 exceeded $1 million. Most of the production was for monuments and mausoleums.

One might wonder how the granite industry was able to grow at such a fast rate. Increased production was enabled by the mechanization of the granite industry. The boom derricks that utilized oxen or horses for hoisting and man power for pulling the loads around were being supplanted by those powered by steam. That led to structures capable of lifting blocks weighing scores of tons from deep-hole quarries. Likewise, stone shed machinery was changing from hand operation and horse sweeps to powered drives. And stone sheds were redesigned for more efficient handling of stone.

Also notable was the evolution of the work force. The pioneers of the industry had been young, practical, skilled workmen, but lacking in business training. By the late 1800s, business owners had acquired significant business acumen.

Finally, in 1889, the completion of the ‘Sky Route’ railroad from the stone sheds in Barre to the quarries filled a desperate need of the granite industry. Previously, the rough granite had a slow, tedious trip to the finishing sheds on wagons or sleds drawn by ox teams and horses. Before the Sky Route was constructed, Barre was home to six stone-cutting firms employing about 50 stonecutters. Four years after the railroad went into service, there were more than 100 firms operating stone sheds that employed about 1,500 stonecutters.

Barre had entered its own Stone Age.

44

AGGREGATES MANAGER July 2015

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