New equipment PG7
|
One MSHA PG28
|
The future of automation PG32
July 2019 | www.AggMan.com
Your guide to profitable production
Hoover
Materials
transforms greenfield into an active quarry 17
Access additional reserves through dredging
22
11 ways to extend excavator life
Komatsu rolls out the GD655-7 motor grader with low-effort control levers.
PAGE 7
On Our Cover: Tom House, quarry manager for Hoover Materials, transformed a greenfield site into one of Nashville’s newest quarries. Cover photo by Kerry Clines.
Make sure to select the size and type of bucket that best matches its use.
PAGE 22
TABLE OF CONTENTS JULY 2019 |
VOLUME 24, NUMBER 7
FEATURE ARTICLES
COLUMNS & DEPARTMENTS
10 From Greenfield to Active Quarry
3 Editorial What’s next for infrastructure?
14 Hoover Materials Tackles Safety
4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook.
Hoover Materials turns an overgrown field in Tennessee into a robust limestone quarry.
Operation focuses on developing a culture that prevents unsafe acts.
22 11 Tips to Extend Excavator Life
From reviewing the tracks and bucket to maintaining the cab, these tips will lead to a more reliable and productive machine.
7 RollOuts Bridgestone’s VersaBuilt All Traction radial, and other new equipment for the aggregates market. 28 Rock Law MSHA undertakes Phase Two of the ‘One MSHA’ initiative, implements additional transitions to modernize the agency. 30 Advertiser Index See who’s who and where to find their products.
OPERATIONS ILLUSTRATED
17
Digging Deep with Clamshell Dredges
Prolong the life of a site by converting from dry processing to dredging.
31 Classified Ads Aggregates industry classifieds. 32 Carved in Stone The 2019 First Robotics World Championship highlights how today’s youth may shape the future of automation.
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July 2019
EDITORIAL
Vol. 24, No. 7
by Therese Dunphy, Editor-in-Chief, tdunphy@randallreilly.com
aggman.com /AggregatesManager /AggManEditor
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Senior Editor: Kerry Clines
What’s next for infrastructure?
Online Editor: Wayne Grayson editorial@aggman.com
Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Leah Boyd production@aggman.com
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Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2019. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.
I
t’s been a Dickensian month in my world. At my most recent village council meeting, the treasurer informed council that — as a result of Ohio’s fuel tax increase — the village’s infrastructure revenues would increase by 62 percent for 2020; definitely the best of times. Sadly, however, national leaders have once again allowed partisan bickering to prevent them from meeting the infrastructure needs of their constituents. The President’s promise of an infrastructure plan has devolved from having one in the first 100 days of his presidency to a scant chance of having one during his first term. An initial meeting between President Donald Trump, House Speaker Nancy Pelosi, and Senate Minority Leader Chuck Schumer appeared promising, with both parties speaking about a $2 trillion infrastructure plan. Hopes for such a package were quickly dashed as discussions of Russia, Mueller, and investigations sent leaders to opposite corners. Frankly, the national leaders need to stop acting like they belong at the children’s table rather than in our government’s hallowed halls. There is clear, compelling need for an infrastructure plan. • The World Economic Forum ranks infrastructure as one of the pillars of competitiveness. In this competition, the U.S. is increasingly falling behind and is now ranked ninth in the world, receiving its lowest scores based on its railroads and roads. • Michael McGarry, chairman and CEO of PPG, and Jay Timmons, president and CEO of the National Association of Manufacturers (NAM), penned an editorial in The Hill noting that manufacturers are becoming increasingly concerned about rising transportation costs and insufficient infrastructure. NAM released a plan, Building to Win, that outlines ways to finance infrastructure investment. • By the U.S. Department of Transportation’s own evaluation, 65 percent of major U.S. roads are rated as being in “less than good condition.” • A report from the National League of Cities (NLC) shows that more than half of mayors (57 percent) discussed infrastructure at length during their annual State of the City addresses this year; up 26 percent from only two years ago. Perhaps our national leaders should take a lesson from Massachusetts Governor Charlie Baker (Republican) and Boston Mayor Marty Walsh (Democrat). The two traveled together to Washington, D.C. for Infrastructure Week and were able to put aside party politics to address the greater good. “If you are a farmer in rural America, you need infrastructure. If you’re working in a factory in the Midwest, you need infrastructure. If you’re in an urban area, you need infrastructure,” Walsh said, according to an NLC report. “Infrastructure shouldn’t be a partisan issue,” Baker agreed. “It should be something everyone should agree on.” Perhaps we should send a transcript of their comments to our national leaders. AM
AGGREGATES MANAGER / July 2019
3
Data mining
STOCK REPORT Company Cemex, S.A.B. de C.V.
Diesel Fuel
Prices 6/3/19
52-Week Low
$4.29
$3.94
52-Week High $7.60
CRG
$32.37
$24.62
$38.46
Eagle Materials Inc.
EXP
$90.95
$57.00
$115.75
Granite Construction Inc.
GVA
$42.52
$38.55
$59.28
HEI
$75.10
$58.33
$89.70
HCMLY
$9.61
$7.96
$10.66
LafargeHolcim Ltd. ADR
U.S.
CX
Current Value
CRH plc
HeidelbergCement AG
On-Highway
Ticker
Martin Marietta Materials, Inc.
MLM
$223.66
$150.75
$232.89
MDU Resources Group, Inc.
MDU
$25.41
$22.73
$29.62
Summit Materials
SUM
$15.15
$11.25
$28.34
United States Lime & Minerals, Inc.
USLM
$82.20
$68.20
$85.95
U.S. Concrete
USCR
$49.81
$27.68
$65.85
Vulcan Materials Co.
VMC
$131.87
$82.52
$133.59
Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 6/3/19.
United States $3.136 One Week -0.015 One Year -0.149 One Week -0.011 One Year -0.129
New England $3.219 One Week -0.006 One Year -0.083
Central Atlantic $3.344 One Week -0.016 One Year -0.098
Lower Atlantic $3.011 One Week -0.009 One Year -0.155
Midwest $3.026 One Week -0.012 One Year -0.198
Gulf Coast $2.875 One Week -0.018 One Year -0.180
Rocky Mountain $3.163 One Week -0.018 One Year -0.196
West Coast $3.760 One Week -0.022 One Year -0.188
California $4.109 One Week -0.025 One Year +0.106 Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
C
EMEX, S.A.B. de C.V. (CX) reported that, on a like-to-like basis for ongoing operations and adjusting for foreign exchange fluctuations, consolidated net sales increased by 1 percent in the first quarter of 2019 to $3.2 billion. The increase was attributed to higher prices for the company’s products, as well as higher volumes in three core products in Europe, as well as in ready-mix and aggregates in the United States. “We are pleased with the 1 percent top-line growth we achieved during the first quarter, despite important volume declines in our two most important markets: Mexico and the U.S.,” said Fernando A. Gonzalez, CEO, in a press release. “During the quarter, we enjoyed improved pricing performance in all our regions with favorable volume dynamics in Europe. In the U.S., ready-mix and aggregates volumes also grew despite CEMEX, S.A.B. de C.V. (CX) adverse weather in part of our footprint.” In the United States, CEMEX operations reported net sales of $878 million in the first quarter, an increase of 3 percent from the same period in 2018. Aggregates volumes jumped by 7 percent, while ready-mix volumes grew by 3 percent. Domestic gray cement volumes declined by 2 percent. In a year-over-year basis, prices increased by 1 percent for aggregates, 2 percent for ready-mix, and 4 percent for gray cement. For comparison, volumes for aggregates, ready-mix, and gray cement decreased by 6 percent, 11 percent, and 15 percent, respectively, in Mexico during the first quarter. Cement and aggregates prices in Mexico increased by 3 percent during the quarter, while ready-mix prices rose by 4 percent. At the same time, operating EBITDA decreased 3 percent on a like-to-like basis during the first quarter on a year-over-year basis to $562 million. Free cash flow after maintenance capital expenditures for the quarter was negative $337 million. “Our EBITDA generation during the quarter was impacted by lower volumes in our other regions, higher energy costs, and purchased cement, as well as increased raw material costs in our readymix business,” Gonzalez noted. “We expect EBITDA to improve in the following quarters and end 2019 at a higher level than in 2018.” Source: Market Watch
East Coast $3.153
COMPANY SPOTLIGHT
AGGREGATES INDUSTRY OUTLOOK The June Aggregates Industry Outlook fell by just over 6 percent to 134.72, after being temporarily buoyed in May by the short-lived prospect of progress on a federal infrastructure bill. Despite seemingly dim prospects for such a bill prior to 2020 presidential elections, existing backlogs of projects seem to be fairly common among respondents. Depending on the region, weather has helped or hurt producers throughout the nation with their expectations for monthly aggregate shipments.
Aggregates Industry Outlook 150 145
138.10 134.94
140
134.72 130.68
130.86
135 130 125
143.33
127.22 136.65 132.73
132.64
120
125.00
115
120.20
110 105 100 July 2018
Aug. 2018
Sept. 2018
Oct. 2018
Nov. 2018
Dec. 2018
Jan. 2019
Feb. 2019
Mar. 2019
Apr. 2019
May 2019
June 2019
Business is good. Dryer weather along the Gulf Coast region has certainly helped the construction industry. — Van Stockstill, President, Consolidated Aggregates
Feedback from within our markets indicates that there are still strong backlogs of construction work that will be completed. Seeing as it’s June already, it appears the fall will be busy, as well as potential carryover into 2020. We have not seen any particular weakness in public or private work. Both seem to be balanced. — Ray Mack, Sales Manager, Carmeuse Lime & Stone
We, like the rest of the country, have had a lot of rain. It has led to a slow start in certain industry segments but, in all, I believe it will be a good year.
Weather has slowed shipments and projects, but backlogs and sold material orders are strong and predicted to be strong through the third quarter.
— Jon Thompson, President, Letart Corp.
— Jason Hurdis, Senior Market Professional, Caterpillar
Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.
VALUE OF CONSTRUCTION PUT IN PLACE, SEASONALLY ADJUSTED ANNUAL RATE 4/1/2019
3/1/2019
% change Apr. 2019 - Mar. 2019
% change Apr. 2019 - Apr. 2018
Residential
505,904
508,669
-0.5
-11.2
Non-residential
792,643
790,492
0.3
6.4
78,217
77,662
0.7
9.5
Commercial
85,573
88,894
-3.7
-6.7
Health Care
43,098
43,138
-0.1
3.2
Type of Construction (Private)
Office
Educational
99,765
98,810
1.0
6.8
Transportation
55,476
53,388
3.9
10.0
Power
100,179
101,618
-1.4
-2.2
Highway and Street
114,682
107,399
6.8
21.4
Sewage and Waste Disposal
25,901
25,453
1.8
19.0
Manufacturing
68,479
73,752
-7.1
5.0
Seasonally adjusted annual rate. (Millions of dollars. Not all sub-categories of non-residential construction are included.) Source: U.S. Census Bureau.
Get the the most current information with the 2019 Aggregates Industry Atlas and the Atlas Download. While the printed version of the Aggregates Manager 2019 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas Download to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more. The Atlas Download contains compete information on nearly 11,000 operations in the United States in a data file as well as the entire 2019 Aggregates Industry Atlas in pdf format. Order additional copies of the Aggregates Manager 2019 Aggregates Industry Atlas Download or the printed version of the Atlas today! Purchase in Print
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Plus $4.50/Atlas shipping and $8 handling fee
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ROLLOUTS
Your complete guide to new and updated equipment and supplies in the aggregates industry.
by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Excavator improves fuel-efficiency, reliability Hitachi introduces the EX1200-7 excavator, the third machine in its EX7 series lineup. Available in backhoe or shovel configuration, the machine is Hitachi’s smallest mining excavator and serves as a crossover machine for the construction market. Leveraging Hitachi’s Fuel Consumption Optimization technologies, the EX1200-7 offers a 6-percent reduction in fuel consumption compared to the previous model. The unit is powered by a Cummins Tier 4 Final engine with DEF. When in neutral, auto-idle reduces engine speed to save on fuel consumption. The excavator also boasts a 4.5-percent increase in bucket capacity with a 9.2-cubic-yard bucket. Equipped with optimized swing control, the EX1220-7 has an improved hydraulic flow with a flow regeneration valve to reduce power requirements from the hydraulic system and engine, lowering fuel consumption and improving pump life. Optional is Aerial Angle, which offers 360-degree vision via cameras positioned at different locations around the machine.
Hitachi Construction Machinery Co. www.hitachiconstruction.com
Emissions-free stacker Keestrack rolls out the semi-mobile electric Feeder/Stacker S1e. It is equipped with a diesel-electric plug-in drive and is said to offer an emissions-free stockpile handling option. The unit is installed on a height-adjustable pedestal with lifting and 180-degree swivel hydraulics. The 33.5-foot belt feeder conveys up to 280 tons per hour of sand or gravel, with a maximum size just under 8 inches. It creates kidney-shaped stockpiles up to 2,900 tons.
Keestrack | www.keestrack.com
Expanded size for all-traction tire Bridgestone Americas, Inc. announces the expansion of its Firestone VersaBuilt All Traction radial tire line to include the 14.00R24. Designed primarily for loaders and graders, the tire is engineered to provide improved traction, versatility, and dependable performance in a variety of environments. All sizes feature heavy-duty steel casing and a SideArmor sidewall that deflects stone and debris to help protect against cuts and punctures. Additionally, a self-cleaning tread pattern allows for improved traction in soft and muddy surfaces. The non-directional pattern also promotes even wear over time.
Bridgestone Americas, Inc. | www.bridgestoneamericas.com
AGGREGATES MANAGER / July 2019
7
ROLLOUTS Cloud-based platform connects drivers, producers TRUX, a dump truck logistics platform, continues to expand its market footprint with services in Chicago. Now available in 12 states, the company says it will expand to 20 states by the end of the year. Its logistics platform provides truckers, contractors, and material producers with key features such as automated dispatching, tracking, driver notification, paperless ticketing, and driver payment. The open marketplace allows independent dump truck drivers to have access to a greater number of jobs and determine their own schedules.
TRUX | www.truxnow.com
Low-effort control levers Komatsu America Corp. introduces the GD655-7 motor grader. Equipped with a Tier 4 Final engine, the latest edition will be sold concurrently with the GD655-6. New standard features include a smaller steering wheel that provides more visibility and operator room in the cab, a steering lever, multi-position adjustable arm rests, and LH/RH consoles have power raise and lower; air-suspension seats, stop-at-center articulation, and an operator presence monitoring system that alerts the operator if they leave the seat and controls are not properly locked out. A new transmission shift lever with finger-operated forward-neutral-reverse switch simplifies operation and reduces hand movement.
Komatsu America Corp. | www.komatsuna.com
Improved tipping load, bucket capacity Hyundai’s HL975 wheel loader is powered by a Cummins QSG12 engine producing 331 net horsepower and is equipped with a standard 6.3-cubic-yard bucket. It has an operating weight of 58,420 pounds and a rated tipping capacity of 44,090 pounds, providing an affordable alternative for quarry operations.
Hyundai Construction Equipment Americas, Inc. | www.hceamericas.com
Electronic initiation for underground perimeter blasting Dyno Nobel launches EZshot, which is said to offer accurate electronic timing combined with the ease of use of NONEL shock tube. The EZshot detonator series, designed exclusively for underground perimeter blasting, gives operators the ability to use electronic timing for improved perimeter control. It uses the same J-Hook hookup as NONEL to eliminate the need for new training and has a high-strength detonator in a heavy-walled copper shell with an electronic circuit board timing chip to provide precision and accuracy.
Dyno Nobel | www.dynonobel.com
8
AGGREGATES MANAGER / July 2019
ROLLOUTS Digital weight indicator Cardinal Scale offers the 185 Rival weight indicator with bright green LCD for easy viewing. The molded ABS enclosure is built for durability in harsh outdoor weighing applications. Also available with rechargeable battery power, the indicator is powered by six standard AA alkaline or rechargeable Ni-Cad or NiMH batteries. It can be used for remote display for long-range viewing when connected to another weight display, and the watertight power connector meets washdown requirements.
Cardinal Scale Mfg. Co. | www.cardinalscale.com
Factory-integrated grade guidance Hitachi introduces Hitachi Grade Guidance for precision excavation. Integrated and developed in cooperation with Topcon, the new option is available on the several Dash-6 models, including the ZX210-6, ZX210LC-6, and ZX350LC-6, and is expected to be available on additional models in the future. Grade Guidance is installed and calibrated at the factory. Full integration into the machine’s cab and structures helps shield key components and damage. Operators can choose 2D or 3D Grade Guidance. The 2D guidance, with an optional laser receiver, displays the elevation of the cutting edge in relation to a reference plane while the 3D guidance with Global Navigation Satellite System displays position and elevation with respect to a global preference.
Hitachi Construction Machinery Co. | www.hitachiconstruction.com
OKADA. ON THE JOB. DOING THE JOB. Carriers prefer demolition attachments made by Okada America, Inc. Okada’s demolition attachments expand the versatility of the excavator, mini-excavator, loader/ backhoe, skid-steer and track loader carriers. Okada has a wide variety of attachments. Breakers. Demolition Shears. Crushers. Pulverizers. Processors. Grapples. Compactors. Screening Buckets. These attachments are precision-engineered, productive and dependable. For the name of the Okada Distributor nearest you, call 1-800-270-0600. Okada. On the job. Doing the job. www.okadaamerica.com
12950 SE Highway 212 Clackamas, Oregon 97015
904 Medina Road Medina, Ohio 44256
115 Commerce Boulevard Cleburne, Texas 76033
AGGREGATES MANAGER / July 2019
9
PLANT PROFILE by Kerry Clines | Senior Editor
From Greenfield
to Active Quarry Hoover Materials turns an overgrown field in Tennessee into a robust limestone quarry.
O
n the outskirts of Nashville, in the little town of Old Hickory, a fairly new quarry is making its mark. The quarry has only been in operation for a short while, having started out as a greenfield site just a few years ago, but its presence is
10
AGGREGATES MANAGER / May 2019
being felt in the local aggregates market. The site was just a grass-covered field when Hoover Materials made the decision to open a quarry. It wasn’t all smooth sailing, however, there were a few bumps along the way. It took several years to get the quarry up and running,
but the company has now been crushing material at the site for close to three years.
Getting started Hoover Materials was established by Tommy Hoover in 2014. He had been
and it’s likely the last. Hoover says it’s difficult and almost impossible to meet new regulations in Davidson County. After the permit was approved, legislation was introduced to eliminate any new quarries. Hoover needed a good quarry manager, so he contacted Tom House, who had just left another aggregate company a week earlier. “Tommy called me and said, ‘I got something in the works, and I’d like you to do it,’” House notes, adding that they had never met. “He said he had a son, and he wanted me to teach him what I knew about crushing rock. He said, ‘I want you to run it like it’s your own.’ House was there through all the permitting and is now overseeing all the production. He says he only talks to or sees Hoover a few times a year. There are cameras in the quarry that allow Hoover to keep an eye on what’s going on in the quarry, but he has confidence in House to run the operation. Hoover’s son, Tom, comes to the quarry for an hour or so every two or three days, but he has other business, so he stays busy elsewhere. “It’s a really good relationship,” House says. “I couldn’t ask for any better people than the Hoover family. He has faith in what I have to say and provides whatever financial support I need to run it.”
Opening the quarry
Hoover Materials started out as a greenfield site just a few years ago, but its presence is being felt in the local aggregates market.
a part of Hoover Inc., which owned quarries in Tennessee, Mississippi, and Alabama, but the company sold to Blue Water Industries, a part of Bluegrass Materials Co. LLC. Hoover decided he wasn’t ready to retire and wanted to stay in the aggregates business, so he bought
the greenfield site near the Cumberland River and began the process to open up a new Nashville quarry. This new quarry was the first permitted quarry in metro Davidson County under 50 years of zoning ordinances for metropolitan Nashville and Davidson County (COMZO),
Taking the property from a greenfield site to a quarry had its challenges. Local residents weren’t thrilled about having a quarry nearby, and neither were the local officials. “It was really a battle with politicians to get started,” House says. “We had to go to the state house multiple times to appear in front of committees that were trying to deny us. It took two years to get the quarry running, from start until we finally got an operation.” The company went through all the legal requirements to get the quarry approved — public notice, public meetings, comment period — and then the Tennessee Department of Environmental Conservation (TDEC) had to respond to the comments. Luckily, the property was already zoned for a quarry, so that hurdle AGGREGATES MANAGER / July 2019
11
PLANT PROFILE was already behind them, leaving only the need for a stormwater permit. “It took a lot longer than usual,” House says, adding that it was very unusual to open a greenfield quarry in a metropolitan area. “Old Hickory Dam is close, and that was a big thing. They thought with us blasting, we would damage the dam and flood Nashville. They tried to stop us, but as long as we stay within our guidelines, we have convinced them that blasting is not a concern. We were successful because, if you come in and do the right thing, be good operators, and do our water samples, we’re in compliance.” The quarry paid for five seismographs, putting three of them across the Army Corps of Engineers earthen dam. A piezometer was also bought and placed in the ground to measure any increase in water flow through the dam. After a year, the three seismographs on the dam were given to the Corps to continue monitoring. The other two seismographs are on site. The quarry and the Corps share their readings to make sure everything is good. “The Corps comes out a couple times a year, and we take a tour of the facility,” House notes. “We’re good neighbors with them. We get along and haven’t had any issues.” At first the politicians and nearby residents were trying to stop the quarry from opening, but House says they rarely get a complaint now. Part of that can be attributed to good relations with the neighbors. “I’ve been doing this for a long time, and I always try to take care of my neighbors,” House says. “We’re in it to be a good neighbor. If it costs more to reduce the vibrations, that’s what we’ll do. If suggestions are made to us by the public, if it seems reasonable, we’ll do it. That goes a long way toward solving issues between the public and the quarry operation. Communication with the public also helps in resolving issues between our operation and the public.”
While the pit is still being developed, the primary plant is a portable plant fed by loaders.
The primary plant is a portable plant right now, but once the pit is developed, a dump hopper will be put in along with a fixed plant.
Daily operations The quarry is in a good location near downtown Nashville. It’s right in the middle of several other large quarries
12
AGGREGATES MANAGER / July 2019
A 15-truck fleet of Western Star tri-axles allows Hoover Materials to provide full service to its customers when they need it.
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PLANT PROFILE
Safety: Developing a culture that prevents unsafe acts When it comes to keeping the employees safe at the quarry, Tom House, quarry manager for Hoover Materials, says, “There’s no dollar amount we won’t spend on safety. A piece of machinery you can replace. A person you can’t replace. We have fun. We get our job done. We do it safe. And nobody’s afraid to say something to somebody else if they see something unsafe.” Many of the workers at Hoover Materials worked for House at other quarries in the past, some 20 or more years ago. So, most of them have several years of experience, which is great, but House notes that many of the mining fatalities in 2018 involved older workers with years of experience. “That can happen, because you can get to feeling like you’re invincible, and it’ll come up and get you,” House explains. “A majority of the fatalities aren’t from an unsafe condition, they’re from an unsafe act. Safety is a priority. It’s everybody’s responsibility, not just mine. They’re as responsible for safety as I am, and they know that.” When new hires come on site, they get the MSHAmandated 40 hours of task training, and they typically start out driving a haul truck, because House says it’s the easiest to master. An experienced driver rides with the new hires to train them. House says he doesn’t care if it takes one day or two days for training, the experienced driver will stay with the new hires until they feel comfortable operating the vehicle by themselves. When it comes to training new hires to operate a loader with just one seat, a trainer can’t stay with them, so House gives them the basics and tells them what to do. Then he takes them to a part of the quarry where there’s nothing they can hit or damage and turns them loose. He says he
in the area and produces the same products that its competitors make. There are approximately 30 employees at the operation, including quarry workers and truck drivers. “After about a year, Hoover turned in all the rented equipment and purchased all new equipment,” House notes. “Everything’s about two years old now.” The pit is still being developed. The walls are being pre-split to form the outer wall of the pit, so, for the time being, the primary plant is a portable plant being fed by loaders. Eventually, the portable plant will be replaced with a fixed primary plant with a dump hopper.
14
AGGREGATES MANAGER / July 2019
Because it believes employees are more important assets than equipment, Hoover Materials spares no expense on safety.
watches them for just a few minutes, then goes away and leaves them alone to practice, because he says sitting there watching them can cause them to make mistakes. He also doesn’t want them around conveyors until they’ve been around the quarry for a while, because of the possibility of getting caught in one. “Everybody here can do just about any job we have,” House explains. “We run a lean ship and don’t have extra people, so we can keep our costs down. The more cross trained they are, the more valuable they are to me. If your employees aren’t good, then it’s hard to be successful, because employees are the backbone of the business. I need them worse than they need me. They’re the ones who make it happen, and I think we have built a good team.”
“Once we get the pit developed, we’ll put a dump hopper in and start dumping directly into it,” House explains. “Then we’ll put another phase of the crushing plant in. Right now, the portable plant adds one more step to the process, but until we get developed in the pit, we decided to do that.” There’s approximately 8 feet of top soil and 20 feet of sand and gravel on top of the limestone. Top soil is in demand, so the quarry was able to sell all of the top soil before it even began crushing rock. Some of the gravel, which is brown sandstone, is quarried and sold to landscape companies. Sand is being
stockpiled at the back of the property for the time being. “We can’t keep the sand moved fast enough to keep the quarry going, so we’re having them move it out of the way to get to the limestone,” House explains. “We’re in the process of working on selling the sand, but our focus is on the limestone.” Some customers pick up their own material, but for those who need it delivered, Hoover Materials has a 15-truck fleet of Western Star tri-axles. Having its own trucks allows the quarry to provide full service to its customers when they need it.
The limestone in Nashville (Davidson County) is so close to the top of the ground that some local developers rent portable crushers and crush what they have on site to produce their own base. So, producers in the area are mostly limited to selling graded material and end up with a surplus of gray base stone. Plus, the Tennessee Department of Transportation changed the mix design for asphalt so that anti-skid rock is required in all mixes used on road surfaces, which takes away from being able to add screenings to the asphalt mix.
Looking to the future Only 66 acres were permitted in the beginning, because it was the quickest way to get the quarry approved. House says they will be mining that for several years, but they went ahead and permitted the rest of the property in mid-2018, so 130 acres are now permitted for mining. House says they drilled down 300 feet, and the deposit was still good and seems to get better the deeper they go.
A customer truck starts across the scale to weigh his load of material before proceeding to the scalehouse to get his ticket.
He expects the quarry to be there for 60 to 75 years, and is looking at buying the property next door as well. “This is the only site Hoover Materials owns, but we plan on growing,” House notes. “Business is increasing monthly,
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OPERATIONS ILLUSTRATED By Therese Dunphy, Editor-in-Chief
Digging Deep with Clamshell Dredges Sort oversized material and crush on the dredge, if necessary.
When material begins to cave, hold the bucket up and pause to keep it from being buried.
Cyclones and dewatering screens dry material for transport.
OUR EXPERTS
Have support boats to position the dredge and conveyors.
Mike Vigliarolo is president of Coram Materials in Miller Place, N.Y. He began working at the company while in high school and worked his way up in the family business. The company bought its first dredge in 2002 when the site’s surface reserves neared depletion. Since then, he has acquired two more dredges.
Neil Hoobler is president of Supreme Manufacturing, Inc. He has a bachelor’s degree in accounting from Thiel College and an MBA from the Florida Institute of Technology. He has spent approximately 30 years working in and around the aggregates industry. Supreme manufactured its first dredge 20 years ago.
Brian Ouellette is the plant manager of United Rock Products’ (URP) Irwindale, Calif., operation. URP is owned by Colas. Ouellette is a third-generation miner and attended college in southern California. He has been in the aggregates industry for 32 years, having previously worked for another large U.S. aggregates producer. He has 25 years of experience with dredges.
AGGREGATES MANAGER / July 2019
17
Prolong the life of a site by converting from dry processing to dredging.
A
s operators working near the water table near the end of their reserves for dry operations, they are increasingly turning to dredging to prolong the life of their deposit. For example, Miller Place, N.Y.-based Coram Materials began as an aboveground screening and trucking company. “We saw our supply dwindling, so we went to the next option — dredging — to prolong the life of the mine,” says Mike Vigliarolo, president. The operation began with an 8-yard clamshell dredge in 2002 and now has two: a twin 13-cubic-yard dredge and a single 16-cubic-yard dredge. “They are cool machines,” Neil Hoobler, president of Supreme Manufacturing, Inc. says of dredges. “You can tell somebody that it’s a 16-yard machine, measured by the capacity of the bucket, but it doesn’t register. Then, you tell them it’s a tri-axle truck loaded with every scoop, and they think, ‘Wow, that is big.’” On the opposite coast, nearly half a dozen clamshell dredges are operating in Irwindale, Calif., where the San Gabriel Basin Alluvial Deposit has been home to many of the sites since the 1960s, when their material was used to build Los Angeles. “Dredging is becoming more and more common as a lot of these operations are nearing the end of the life of their deposit,” says Brian Ouellette, plant manager of United Rock Product’s Ir-
1
windale operation. “If dredges weren’t available today, a lot of the big operators out here in southern California would be out of business today because our pits have been depleted of dry mining, and we’re all primarily digging under the water now to get reserves.” To convert a dry operation to dredging, it’s important to ensure the plant is properly outfitted for the change. “You have to set up your aggregate operation so the main operating plant is able to receive wet material,” Ouellette advises. “You’re going from a dry material to material that’s coming out from under the water and obviously saturated.” Depending on the site’s gradations, screen media may need to be changed. Hopper chutes may need to be widened. Primary and secondary scrapers may need to be installed on conveyors to prevent sticky material from building up on the belts. On the upside, wet material essentially eliminates dust problems — with the crusher serving as the only likely source of dust — and permits to go deeper are easier to obtain than those for new sites. By acquiring the rights to access material to greater depths, an operation can double its life expectancy. “Operators started getting wiser and smarter, and new machines came out,” Ouellette says. “It’s allowed these operators to go deeper and expand their pit life.”
Maximize production
As the dredge digs deeper, the integrity of the highwall toe is compromised and the slope is weakened. Material breaks off the highwall and becomes loose, allowing the dredge operator to ramp up tonnage. If operating a twin dredge, coarse and fine material can be mixed to create an even feed that minimizes adjustments to the plant.
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AGGREGATES MANAGER / July 2019
2
Work with the weather
A dredge is similar to a sailboat on water, so it must be tied down and well anchored during inclement weather. When experiencing high winds, such as 90- to 100-mile-per-hour winds from a nor’easter, additional means of securing the dredge may be necessary. Clamshell dredges typically shut down once temperatures reach around 30 degrees F when it is difficult to keep belts running due to freezing.
3
Maintain the dredge
Follow the manufacturer’s recommended guidance for maintenance intervals. A full-time oiler may be necessary to ensure appropriate lubrication, while an electrician should be available to troubleshoot any issues. Use seasonal breaks or scheduled preventive maintenance periods to perform larger maintenance items, such as screen changeouts.
4
Spotlight safety
Ensure that water safety is part of sitespecific hazard awareness training and adhere to strict policies on the use of life vests. Maintain all safety devices installed by the manufacturer and regularly inspect pontoons for holes to ensure their integrity. A partnership with local safety agencies builds good community bonds and allows them to become familiar with the plant layout.
AGGREGATES MANAGER / July 2019
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Voices of Experience Mike Vigliarolo
Neil Hoobler
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A
win dredges offer unique benefits for operations that have the space for them. “I needed higher production and figured that the twin would mix the material well because, even though the buckets are within a 50-foot radius, they can pull different material,” says Mike Vigliarolo. president of Coram Materials, based in Miller Place, N.Y. “It allows you to mix the material well.” For example, if a deposit has both coarse material with a fair amount of stone in it as well as sand, the dredge operator can leave one bucket in the coarse area and dig deeper with the other bucket to hit sand. The two materials can then be mixed so the plant doesn’t have to be constantly adjusted to process the two different types of material. Another difference between single and twin dredges comes into play if a bucket gets stuck from a post hole collapse created when sand collapses on top of the bucket, preventing it from being able to resurface. The twin dredge allows for quicker recovery. “You can move the dredge over with the second bucket and dig it out,” Vigliarolo explains. “If you get a single bucket stuck, you have to figure out a way to get it out. The same goes for a suction dredge. If you get the head buried, you have the same problem as a single clamshell.” To retrieve a stuck bucket, the operator typically cuts the cables, puts on another bucket, digs it out, attaches it with a diver, and pulls it out. “It’s a complicated, messy, expensive issue,” Vigliarolo says. “We got a bucket stuck once on a twin dredge, and we just moved it over. Within four or five hours, we got it free just by digging next to it with the other bucket.” In contrast, a neighboring suction dredge had its head stuck and was down for more than a week.
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AGGREGATES MANAGER / July 2019
clamshell dredge is basically a floating wash plant, says Neil Hoobler, president of Stoneboro, Pa.-based Supreme Manufacturing, Inc. While it can handle most types of dredging, a clamshell dredge is most commonly found in deeper and stonier sites, which are more likely to invest in a clamshell rather than a less costly suction dredge. Material is scooped from the water, then goes through dewatering screens, cyclones, and a fines recovery screen before being discharged to a conveyor that can transport it to the processing plant. “Our goal is to get it dry enough to go onto the conveyor,” Hoobler says. If necessary, crushing can also take place on the dredge. “With most sand and gravel deposits, the vast majority of material is smaller than 8 inches,” he explains, “but you could have a coarse deposit with a lot of softballs and basketballs in there. If you have more than 5 percent of your material bigger than 8 inches, you probably want to add a crusher so you don’t have to keep handling those big rocks.” While a clamshell is a significant expenditure, Hoobler says it is important to consider the overall owning and operating costs, not just the initial purchase price. The per-ton cost of a clamshell dredge, he says, is quite competitive. In addition, it provides access to valuable reserves that would otherwise be out of reach. “Most operators are already spending at least that amount of money,” he explains. “They’re just spending it on the dragline, the loader, and those two operators, as well as one, two, or three haul trucks and those operators, plus diesel fuel and maintenance. The capital cost seems like a big number, but when you break it down by ton produced, it’s by far the cheapest way to go. It’s all about educating the operators and then being able to help them with the financing.”
Brian Ouellette
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wo vital ingredients to a successful dredging operation include the appropriate support equipment and the right personnel, says Brian Ouellette, plant manager of United Rock Product’s Irwindale, Calif., operation. “To have a big dredge operation and to successfully move it across your pit, you will need support boats,” he explains. Multiple boats are needed, he says, to guide the dredge, to keep the conveyors in line as the dredge moves across the water, and to simply work on the floating conveyors.” Having the right people on staff is also critical to successful dredging. For United Rock Products, three essential employees assure the efficiency of its dredging operation: the dredge operator, oiler, and electrician. “You will need a full-time qualified electrician who is able to work on the dredge,” Ouellette advises. On the dredge itself, both the operator and oiler are onboard during 16 to 18 hours of daily operation. The oiler not only handles lubrication throughout the dredge, but also monitors conveyors and communicates with the dredge operator throughout the day via radio. “It takes a special person to be a dredge operator because you are essentially digging blind,” Ouellette says. “When that bucket breaks the water and goes under, you can’t see it. It’s all done by feel and watching your computer screens. It takes a person who is mechanically inclined, knows how to work on hydraulics, knows how to troubleshoot hydraulic issues, and knows how to run the dredge.” On top of all the technical requirements, everyone who works on the water at the site must be able to swim. Ouellette partners with the local rescue and fire departments for water rescue training. “Our guys have to be able to swim, operate boats, and work on water effectively,” he says. “There is just a ton they have to do.”
EQUIPMENT MANAGEMENT by Jonny Spendlove
11 Tips
to Extend Excavator Life From reviewing the tracks and bucket to maintaining a clean cab, these tips will lead to a more reliable and productive machine.
E
xcavators deal with a lot. From crushed stone and gravel that beat against the frame, to fine particles of sand and dust that settle into the components, the elements in which a machine operates are rough. That’s why it’s so critical to perform regular checks and maintenance to extend the life of the excavator. A few
22
AGGREGATES MANAGER / July 2019
extra minutes each day will not only help increase the machine’s durability, they will also improve its efficiency and reliability. 1. Take care of the tracks. To start, clean out the tracks daily. Muddy, rocky terrain can be extremely abrasive and will collect around the tracks, track shoes, undercarriage, and around the swing
bearing. Clean-out is important because — left in there — the accumulated mud hardens and accelerates the wear on the undercarriage and tracks. Be sure to perform weekly checks of the tracks’ tightness. Look for too much sag, which could damage the tracks or the rollers. 2. Clean the bucket. The longer
Regular checks help keep the machine running at optimum performance.
Keep the bucket clean so its full capacity is being utilized.
dirt and mud remains in a bucket, the tougher it becomes to clean out because of hardening. A daily cleaning of the bucket prevents the day’s mud from turning into a challenging cleaning job. Plus, if the bucket isn’t regularly cleaned, its capacity — and that of the overall load — is reduced. 3. Lubricate the front structure. Frequently lubricate and grease the front structure and lower linkage and conduct daily checks to ensure the structures have proper lubrication. Confirm that the linkages are not wearing out. Review the
machine’s service manual for suggested lubrication and grease intervals. 4. Maintain a clean cab. The cab and windows should always be clean in order to maximize job site safety and productivity. Operators need good visibility, and with a lot of wind and fine particles, it’s easy for those windows to be caked with dirt and dust. Use an approved cleaning solution to wash windows. Not all windows are made with the same materials — even on similar models from the same manufacturer. Check each individual machine’s
manual to ensure use of a solution that’s compatible with its windows. Make sure all windows are in place and intact — not gouged, cracked, or seriously scratched. This type of damage can compromise a window’s integrity and increase the likelihood of breaking or shattering. Clear the cab of any unnecessary clutter and materials. Get rid of loose spare parts or trash that could affect an operator’s ability to control the machine and ensure that items cannot be caught behind the seat. AGGREGATES MANAGER / July 2019
23
EQUIPMENT MANAGEMENT
Daily maintenance helps extend the life of the machine.
5. Fix damages immediately. Once excavator damage is discovered, take action immediately. The longer it takes to address existing damage, the more wear and tear that is created on other components that aren’t broken. Repairing damages immediately helps mitigate additional maintenance costs that would otherwise be incurred. 6. Pay attention to alerts. An excavator’s telematics are an important tool which should be utilized to increase
the lifespan of the machine. If alerts are ignored, a key advantage of telematics is being lost. Various brands of machines offer the ability to purchase access to data on fleet location, functions, hours, fuel consumption, alerts, and other essential machine data from the comfort of an office. Telematics keep operators updated on maintenance checkpoints and alert them to any failures or problems that need to be resolved.
Once an alert is received, act on it. Merely reading the alert negates the purpose of having that valuable data available. 7. Change out filters. The service manual should indicate how often a machine’s filters should be changed. Follow those guidelines and regularly change filters accordingly. It’s typically 500 hours for fuel, engine oil, and air filters, and 1,000 hours for hydraulic tank oil filters. Clean filters are an important part of the machine’s overall health. 8. Refuel your machine. After a shift, refuel the machine. Air in the system or the tank can result in synthetic moisture, which will water down the fuel. When refueling, top-off the DEF tank with diesel exhaust fluid. On excavators, the DEF tank is typically wider and shallower than on other machines. If it isn’t topped off, it can swish around in the tank, creating foam and clogging the system. In colder temperatures, keep water out of the fuel filter, so it does not freeze. 9. Check the handholds and steps. Make sure the handholds around the cab
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AGGREGATES MANAGER / July 2019
EQUIPMENT MANAGEMENT and service areas are secure. This is an important safety precaution. If one is found to be loose, make sure it’s tightened as soon as possible. The steps on the cab and walkways should be secure as well. Non-skid surfaces should be intact. If any non-skid material is worn or missing, have the local dealer repair or replace it. 10. Inspect screen guards. On equipment, where present, inspect screen guards over the windows and cab openings. Be sure they’re secure and in good condition. With such a wide range of materials such as sharp rocks and large pieces of debris, it’s important to keep those in top condition. 11. Inspect fire extinguishers and water tanks. Be sure fire extinguishers and water tanks are operable and easily accessible. Check the water pressure of the tanks. Ensure the safety of the operator and coworkers. While these tips may seem extensive, they can be accomplished in minimal time. Ground level inspections should not take longer than five to 10 minutes. Likewise,
Check with a local dealer with questions about replacing components.
checking the tracks should also take an easy five to 10 minutes. By regularly inspecting a machine, the operator will quickly know what to look for during the inspection. This will also make it easier to notice when something is out of place. Many more in-depth inspections can be done monthly, while some may be needed more often depending on individual operating conditions. When in doubt, always check with the local dealer.
By performing basic upkeep and regular inspections, an operator can extend the life of the machine. Plus, a clean, efficient machine contributes to a better work environment, enhanced safety, and increased productivity. Take pride in the machine. AM Jonny Spendlove is a product marketing manager, excavators, for Hitachi Construction Machinery – Americas.
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by K. Brad Oakley and Karen L. Johnston
ROCKLAW
More MSHA Changes Are Underway MSHA undertakes Phase Two of the ‘One MSHA’ initiative and implements additional transitions to modernize the agency.
S
K. Brad Oakley is a member in Jackson Kelly PLLC’s Lexington, Ky., office where he practices in the Construction, Manufacturing, and Mining Law industry groups, focusing primarily on workplace safety and health. He can be reached at 859-288-2835 or kboakley@ jacksonkelly.com. Karen L. Johnston is a member in Jackson Kelly PLLC’s Denver, Colo., office where she practices in the Construction and Manufacturing industry groups, focusing primarily on workplace health and safety litigation. She can be reached at 303-390-0008 or kjohnston@jacksonkelly.com.
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oon after his confirmation, David Zatezalo, the Assistant Secretary of Labor, Mine Safety and Health Administration (MSHA), began laying out his vision for MSHA under his leadership. A key aspect of his vision is ‘One MSHA,’ a mission to eliminate the historical separation within MSHA between metal/non-metal mines and coal mines and, instead, to operate as a single entity focused on overall mine safety. By implementing this vision, MSHA is striving to make more efficient uses of its resources. In furtherance of the mission, Assistant Secretary Zatezalo created the new position of administrator for mine safety and health enforcement. Timothy R. Watkins, former district manager for MSHA Coal District 12 in West Virginia, was appointed to the position and has responsibility for enforcement over all mines subject to MSHA jurisdiction. The first phase of ‘One MSHA’ started Oct. 1, 2018, and designated 90 mines to be inspected by inspectors who had been cross-trained. Approximately 21 inspectors received the training. At a recent industry safety conference in April 2019, Watkins discussed details of the ‘One MSHA’ initiative and the rollout of Phase Two, some of which is already underway. Watkins noted that MSHA does not yet have a final vision
AGGREGATES MANAGER / July 2019
of what ‘One MSHA’ will necessarily look like and stated, “We continue to look at opportunities to blur the distinction between coal and metal/ non-metal enforcement where it makes sense.” As previously noted, Phase One consisted of the crossover of inspectors between coal and metal/non-metal. For example, a quarry operator might see a couple of coal mine inspectors arrive to conduct an inspection or hazard complaint investigation. The crossover was dependent, in large part, on personnel availability. Now, with Phase Two, MSHA is being more intentional in its development of ‘One MSHA.’ Phase Two consists of re-aligning eight field offices to a district office that geographically makes more sense and moving inspection responsibility of certain mines to a different field office where it geographically makes more sense. This will result, for example, in some metal/non-metal mines being assigned to what was traditionally a coal field office and some coal field offices being assigned to a metal/non-metal district office. MSHA anticipates providing the regulated industry with more specific information about which field office and district office will have responsibility for a mine site. Affected mine
operators should be receiving phone calls from MSHA to advise of any change or re-assignment. In addition, approximately 117 more mines will be inspected by cross-trained inspectors starting in Phase Two as training of inspectors continues. MSHA developed a training module to prepare inspectors for the crossover into what is likely to be unfamiliar territory for many inspectors. The cross-training, which started this past October, has continued in the new year at the MSHA Academy in Beckley, W.Va., and approximately 200 inspectors have been cross-trained. However, MSHA has said that inspector expertise will still be required for certain mines. Watkins also stated at the conference that district offices will be renamed at some point, most likely to reflect the city in which the district office is situated. The days of coal districts being identified by number and the metal/non-metal districts being identified by a geographic designation, such as Rocky Mountain or Southeast, are numbered. At press time, MSHA expected to begin the re-alignment of offices on May 1, 2019. In addition to Watkins, a number of other MSHA officials attended and participated in the safety conference. Wayne Palmer, deputy assistant secretary – policy, spoke on the technological advancements that the agency is currently exploring
or implementing. MSHA has been beta testing a new Mine Data Retrieval System (MDRS), accessible through its home page. The agency expects to take it live in the near future. if it has not already done so. Palmer noted that the new MDRS will have enhanced search capabilities and will be compatible with mobile devices. It will also allow users to transfer data into Excel worksheets more easily. MSHA is also working on an updated website, one that would be more comparable to the Department of Labor’s website. As part of the conversion to a new website, the agency is removing a lot of old policy documents. It is unclear whether, once removed, the documents will be available through some sort of archival access. While MSHA’s stated mission “to prevent death, illness, and injury from mining and promote safe and healthful workplaces for U.S. miners” has not changed, MSHA is undeniably in a state of transition consistent with the changes the mining industry has experienced as a whole in recent years. As evident from the initiatives mentioned in this article, many changes within the agency have been implemented, and it appears many more will be implemented in the foreseeable future. During this transition period, mine operators must stay abreast of regulatory changes, have their voice heard, and help shape what appear to be significant changes in the regulatory environment. AM
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Experience: Retired November 2011 following 41 years with the U.S. Geological Survey • USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present
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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
Robotics Competitions and Mining The 2019 First Robotics World Championship highlights how today’s youth may shape the future of automation.
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he Convention Center in Houston, Texas, has been divided into four arenas. Each arena is set up like a space station on Mars with habitats and rocket ships with open cargo bays. On opposite sides of the arenas are two alliances, each consisting of three robots constructed by robotics clubs comprised of high school students. At the “GO” command, each robot has 15 seconds in which they must navigate autonomously; their vision being obscured by black curtains simulating a Martian sand storm. After the sand storm abates, the robots are guided by wireless remote control. Their goal is to secure covers on the hatches and to load payload into the secured cargo bays. Meanwhile, a robot from the other alliance can be running defense to keep opposing robots from accomplishing their goal. Near the end, each robot attempts tp return to its habitat and, if properly engineered and constructed, climb up onto raised tables. Three days of competition decide the winner. If you don’t think this is exciting, you are sorely mistaken, especially if your grandkids are on the rookie team, Anthem Bolts – Team 7620, their mom (your daughter) is the coach, and 7620 finished 13th place from more than As automation continues to grow, competitions such as this robotics 300 teams from 23 countries. championship foster interest in the field among young people. So how does all of this relate to aggregate mining? Well, Caterpillar, for one, was a strategic sponsor of the 2019 First Robotics World Championship. And why would they sponsor such an event? Because autonomous vehicles and robotics are certainly in the future of mining. Hundreds of millions of tons of mined material have already been moved by autonomous haul trucks using high-precision GPS, radar, and laser sensors to navigate haul roads while avoiding people, vehicles, and other obstacles. Because there are no shift changes, breaks, or lunches, the autonomous trucks have, perhaps, as much as 20 percent greater production than manned vehicles. And they have impeccable safety records. A number of companies manufacture automated drill rigs that can drill blasthole patterns and monitor ground conditions more quickly and accurately than human-operated equipment. And robotic mechanical shovels equipped with vehicle automation technology can operate in unstable or otherwise unsafe areas, while at the same time improving efficiency and productivity. Mines around the world are using drones to help gather information about their sites. For example, some mining companies use drones to measure stockpiles; confirm clearance before blasts; monitor traffic, road conditions, hazards; and provide real-time aerial footage. Some companies are also looking to take drones underground to inspect dusty, restricted cavities and map the environment using 3D laser scanner technology. Automation is not restricted to the confines of the mine. In the outback, near Pilbara, Australia, a fully autonomous heavy-haul railway is up and running with locomotives fitted with complex on-board computer systems and cameras. These systems are linked to 4G networks that send automatic reports on the train’s position, speed, and direction of travel to a control center located nearly 1,000 miles away. As an added safety measure, crossings along the route all have cameras to provide real-time feedback. We are living in an incredible age of invention and innovation. Autonomous operation and robotics have great potential to improve the efficiency and safety of the aggregate industry. Who knows, maybe sometime in the future, a graduate from the Anthem Bolts – Team 7620 will design a robot to help automate your aggregate operation on Mars. AM
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AGGREGATES MANAGER / July 2019
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