AggMan 0814 issuu by Sandy Turner Jr

August 2014

www.AggMan.com

12 19 28

Building better roads with new technology Earn your good housekeeping seal of approval California operator tackles new market niche

Where vision meets value.

Everett Quarries has acquired certain assets of

acquired assets of the

has been acquired by

*Represented by FMI Capital Advisors

FMI Capital Advisors is a leading Investment Bank serving the Engineering and Construction industry. Our unique industry focus, serving a broad range of industry sub-sectors, enables us to provide our clients with valuable insight and advice. With over 600 completed transactions, FMI combines advisory expertise with industry-focused knowledge and relationships in order to achieve value for clients.

Will Hill | 303.398.7237 | WHill@fminet.com

George Reddin | 919.785.9286 | GReddin@fminet.com

www.fminet.com Text INFO to 205-289-3782 or visit www.aggman.com/info

From dairy farming roots, California-based Canyon Rock takes on a second quarry and tackles a new market opportunity.

On Our Cover: New truck options improve safety and access to operational information. Cover photo by Kerry Clines.

McLanahan enters the cone crusher market with its new line of crushers.

CONTENTS AUGUST 2014 VOLUME 19, NUMBER 8

FEATURE ARTICLES

12 16 24 28

Building Better Roads

Road-gripping technologies already in place in Europe and Asia are now being implemented in the United States. Learn what this means for material producers.

Ready for the Long Haul

Manufacturers focus on fuel efficiency, safety, ease of maintenance, and operator insights when updating models.

Sensor Solutions

Tips and tricks for troubleshooting dredge sensors and other electronic equipment.

Ready for Rip Rap

California producer leverages crushing and screening investments to take on a new market niche.

SCREENING SUPPLEMENT Trends in Screening

30 31

Quick and efficient screening is a must if a producer wants to remain profitable.

Screen RollOuts aggregates market.

New screening products for the

OPERATIONS ILLUSTRATED

19Good Housekeeping

Operators share their expertise to keeping plants and equipment neat, tidy, and more likely to earn MSHA’s seal of approval.

COLUMNS & DEPARTMENTS

EDITORIAL The ripple effect.

AND PROVINCE NEWS A roundup of the latest news in North 4 STATE America. Terex Washing System’s new AggreScrub 150, and other new equipment 6 ROLLOUTS for the aggregate market. MINING The latest financial 11 DATA analysis of issues impacting in the industry. LAW Recent orders by an ALJ help to clarify the criteria for repeated flagrant 34 ROCK violations. ADS Aggregate industry classifieds. 36 CLASSIFIED INDEX See who’s who and where to find their products. 39 ADVERTISER IN STONE As the trip on Route 66 travels through Grants, N.M., it’s time to 40 CARVED revisit uranium mining.

WEB EXCLUSIVES Visit www.aggman.com for expanded editorial coverage. Top 10 tips for maximizing articulated truck life.

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

August 2014

Vol. 19, No. 8

aggman.com /AggregatesManager @AggMan_editor

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THE RIPPLE Effect

s the megadeal between Lafarge and Holcim proceeds, it will be interesting to watch the ripple effect across the aggregates industry, both in the United States and around the world. Three months after the merger was announced, the companies released a list of the assets it plans to dispose of in order to avoid market monopolies. Their statement came on the heels of Anglo American’s disclosure that it sold its 50-percent stake in joint assets with Lafarge to that company for approximately $1.5 billion. Highlights of Holcim and Lafarge’s proposed divestiture include the following: • Austria: Lafarge’s Mannersdorf cement plant; • Brazil: The companies say they will soon file a comprehensive package of divestitures with the Brazilian regulator, CADE, but haven’t released package details; • Canada: Holcim’s assets; • France: Holicm’s assets in metropolitan France (except its Altkirch cement plant and aggregates and ready-mix sites in the Haut-Rhin market) and Lafarge’s assets on Reunion island, except its shareholdings in Ciments de Bourbon; • Germany: Lafarge’s assets; • Hungary: Holcim’s assets; • Mauritius: Holcim’s assets; • The Philippines: The associated companies of Lafarge and Holcim are exploring the combination of their businesses, other than LRI’s Bulacan, Norzagaray, and Iligan plants, which will be divested as part of the rollup; • Serbia: Holcim’s assets; and • The U.K.: Lafarge Tarmac assets, with the possible exception of one cement plant. Immediately, I thought of the Lafarge Tarmac operation in Buxton, Derbyshire, England, that is home to the Hillhead quarry show (see RollOuts, beginning on page 6, to see some of the new equipment that debuted at the event). The quarry will likely have new owners by the time the 2016 show is held. Closer to home, Holcim’s Canadian assets include Dufferin Aggregates, a well-respected group with nearly a dozen aggregates plants in the greater Toronto and Montreal areas. What will be the impact of the series of buying and selling about to ensue? Anglo American has already announced it will pay down debt with the proceeds of its sale to Lafarge. Lafarge and Holcim clearly hope to shape their own divestitures rather than leave it to regulators in the various global markets. What about the buyers? We’ve seen a lot of big deals in recent months. Will another global company emerge from this divestiture? Could Dufferin Aggregates be acquired by a U.S. company and once again change the landscape of the North American market? Time will tell, and Aggregates Manager will be watching. AGGREGATES MANAGER August 2014

State & Province

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

NEWS

Massachusetts

Dive teams recovered the body of a Rhode Island teen who went missing while swimming in a Massachusetts quarry. The Associated Press reports that the body of 18-year-old Nentor Dahn was found on July 7 in about 60 feet of water and 10 feet from the highwall of Fletcher Quarry in Milford. Witnesses say Dahn jumped about 50 feet from a ledge the previous afternoon. He and friends had been swimming in the privately owned quarry.

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

Arizona

A permitting snafu could change the way Mat-Su Borough works with contractors, the Mat-Su Valley Frontiersman reports. Until now, the general contractor was responsible for ensuring the gravel used in area road projects was permitted, but the borough may now take a closer look at that process. The issue came to light with regards to the pit supplying a $6 million project to extend local roads. When the borough inspected the property, an official noticed gravel trucks on the site. An inspection of the gravel company’s permit showed that it expired in 2010. An area assemblyman told the newspaper that the ensuing work stoppage was unfair, and she wanted the permit to be issued as “expeditiously as possible.” Borough officials said it could be issued within 17 days.

Connecticut

Members of the newly formed Congamond Lake Environmental Protection Organization have appealed Suffield Zoning and Planning Commission’s approval of a special permit renewal for a local sand and gravel operation. The Journal Inquirer says the appeal claims the commission acted beyond its authority when it unanimously approved a permit renewal for Lake Road Materials LLC. Further, it claims that the permit was expired and the site had been abandoned for 10 years. It called the permit approval “arbitrary and capricious.”

Illinois

In mid-July, Thornton Quarry served as a feature destination on the Southeast Environmental Task Force’s Brown Bag Eco-Tour, entitled “Deep Tunnel Tour and Thornton Quarry.” According to the Southtown Star, the four-hour tour stopped at Thornton Quarry to view the stormwater reservoir before visiting the pumping station and the Metropolitan Water Reclamation District’s site. Quarry experts served as tour guides, and tickets were sold at $25 per person.

AGGREGATES MANAGER August 2014

New Mexico

The Sante Fe County Commission postponed a decision regarding the creation of a mining zone that would allow an Albuquerque company to develop a sand and gravel operation on La Bajada Mesa. According to the Albuquerque Journal, about 600 people attended the commission’s meeting, which included more than six hours of testimony from applicants and more than 50 members of the public speaking against the plan. The application received a recommendation for approval from the county staff. The proposed site is in an area zoned for residential and agricultural use, but it is set to be rezoned under the county’s sustainable growth management plan.

North Dakota

The U.S. Department of Labor filed a lawsuit against Jamestown-based Northern Excavating Co. and its owner in early July. It alleges the company denied federal officials entry to the mine site at least three times since May, the Associated Press reports. Court documents indicate that the Mine Safety and Health Administration (MSHA) received complaints of several violations, including failure to provide protective equipment for workers. An inspector visited the site, but was turned away by a company employee shortly after MSHA received the complaint. The gate was locked, and the inspector was unable to access the site. The next day, the inspector returned to serve the operation with an order to halt operations “but everything was locked and no one was there.” An inspector returned weeks later and was again denied entry by an employee. He said, however, that the mine had clearly been in operation during the time of the shutdown. MSHA is waiting for a judge’s ruling on its lawsuit, which accuses the company of violating its right to access the mine. A spokesman for the agency said that, if it is denied entry again, it would enlist the help of U.S. Marshals to accompany them to the site.

Oregon

At Aggregates Manager press time, the owners of Sunny Valley Sand and Gravel were waiting for a decision from the Josephine County Board of Commissioners with regard to its proposed gravel mine. Its decision could provide insight into the effectiveness of the state’s Goal 5 land-use plan, designed to protect aggregate resources, among other resources. According to the Grants Pass Daily Courier, the planning commission sent the permit request to the board of commissioners with no consensus. Andreas Blech, president of the company, told the newspaper that its request is the “culmination of six years of work, with two dozen consultants, and 20 agencies.” His team made its presentation to the board of commissioners and was followed by residents speaking against it. Due to the number of people who signed up to talk, the meeting was extended to another date.

Washington

The bard is making a month-long appearance at the Rexville-Blackrock Amphitheater, a former quarry in Skagit County. According to The Bellingham Herald, the Shakespeare Northwest troupe will present alternating performances of “Macbeth” and “Much Ado About Nothing” through mid-August.

Pennsylvania

The FBI will conduct explosives training in an Upper Macungie quarry in September. The Morning Call reports the agency will work with small explosives, ranging from 1 to 5 pounds. One of the two days it does so, local fire, police, and other first responders will be allowed to observe from a safe distance.

Washington

The Washington Department of Ecology says it issued a $20,000 penalty to Mason Quarry for illegally discharging surface water at its Port Ludlow site and impacting nearby wetlands, properties, and roads. Numerous inspections found muddy water being discharged without the proper permit or any monitoring, and one inspection found muddy water flowing from the entrance of the quarry, along a haul road, and into a ditch that flows into Shine Creek. The agency began to issue warnings to the operator in 2011. It has now issued the fine and an order for it to fix damage caused by the runoff, erosion, and sediment by the end of the month. In addition, it must submit an erosion-control plan and use best practices to prevent tracking sediment from the site onto roadways. It must also seek a sand and gravel general permit that sets limits and establishes best management practices for safely discharging water and comply with its current general permit, which does not allow for discharging to surface waters.

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For

FREE Product Information Text INFO to

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

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

Scrubs stubborn clay

Hillhead

Track processing solution Telsmith’s 820 Track Screening Plant includes an 8203 Telsmith TL screen, a 54-inch feed conveyor, and a 72-inch under screen conveyor. The track can produce up to four products at a rate of 999 tons per hour. It can also be operated through a wireless remote control. Telsmith | www.telsmith.com

Streamlined secondary and tertiary crushing McLanahan Corp. is expanding its product line to include cone crushers. Capable of secondary, tertiary, and quaternary crushing, the units feature top-down maintenance. Safe unblocking is also engineered into the cone, with no need to dig it out when stalled. Simply press a button to open and restart when fully opened. Streamline design features include an all-roller bearing design, simple hydraulic controls, and easy manganese changes. McLanahan Corp. | www.mclanahan.com AGGREGATES MANAGER August 2014

or visit

aggman.com/info.

As seen at

Terex Washing System’s AggreScrub 150 is designed to separate stubborn clay material that cannot be removed by rinsing or screening alone. Introduced at Hillhead, the system can work as a standalone unit or in conjunction with Terex’s Aggresand plant. The modular plant includes a web frame chassis design that supports a scrubbing hull, a 6- by 2-foot trash dewatering screen, a 12- by 5-foot two-deck rinsing and sizing screen, and an integrated sump and pump. Galvanized walkways are said to provide unprecedented levels of access to all areas of the plant. The control system used on the Aggresand plant has been adapted for this plant. Radio control of all main functions is available as an option, as well as remote telemetry, which enables data to be sent to the plant owner remotely through email or SMS alerts. Terex Washing Systems | www.terex.com

205-289-3782,

See it in action at www.aggman.com

Tier 4 final loaders Case Construction Equipment offers Tier 4 final loader options with its 821F and 921F wheel loaders. Each is equipped with a selective catalytic reduction (SCR)-only solution that treats emissions separately with Diesel Exhaust Fluid (DEF) and does not require the engine to recirculate exhaust gas. Case says this optimizes combustion and machine performance, lowers engine temperatures, and eliminates maintenance and downtime associated with filter replacement and regeneration. The loaders sport a 6.7-liter Tier 4 final engine. The 821F and 921F loaders produce 212 and 241 net peak horsepower, respectively. The 821F features a bucket range from 3.2 to 4.5 cubic yards, while the 921F has a bucket range from 3.8 to 4.75 cubic yards. Case Construction Equipment | www.casece.com

Reduces need for settling ponds McLanahan Corp. says its deep cone thickener helps producers do more with their existing resources by reducing or eliminating the need for settling ponds and other structures. They are meant to achieve the highest solids concentration possible through gravity separation. A full-time operator is not necessary. McLanahan Corp. | www.mclanahan.com

As seen at

Hillhead

Radar obstacle detection Brigade Electronics offers a line of radar obstacle detection systems. All four models of the Backsense radar system divide a specified detection area into five zones and provide a visual and audible warning when objects enter the hazard area. The cab display includes five LEDs corresponding to each of the five distance zones from the vehicle. A warning buzzer has an adjustable sound level of 65 to 90 dB. The manufacturer says the sensor is impervious to water, dust, and mud. The system controls the radar beam pattern, so the spread of the beam can be restricted to the desired width to minimize false alerts. Detection areas up to nearly 100 feet are available. Brigade Electronics | www.brigade-electronics.com

MIND-BLOWING EFFICIENCY Performance and efficiency with a fuel economy that will blow you away. Using half as much fuel as similar rigs, the Atlas Copco FlexiROC T45 also comes with 50 percent fewer hoses and 70 percent fewer couplings for easier maintenance and reduced risk of leakage. 800-732-6762 www.atlascopco.us

Text INFO to 205-289-3782, or visit aggman.com/info.

Text INFO to 205-289-3789 or visit www.betterroads.com/info AGGREGATES MANAGER August 2014

As seen at

Large secondary crushing

Hillhead

Larger wash plant Terex Washing Systems upsizes its Aggresand 165 with a new, larger version, the Aggresand 206. The new wash plant, which debuted at Hillhead, has capacity of up to 400 tons per hour. It includes a 20- by 6-foot screen with two- and three-deck options. The plant is designed to be easily transportable. It is pre-wired and pre-plumbed and features plug-and-play componentry. It also features rolling chutes and rolling centrifugal pumps. Sensors throughout the machine provide information on water pressure, cyclone feed pressure, and electrical power consumption. Terex Washing Systems | www.terex.com

As seen at

Hillhead

KPI-JCI and Astec Mobile Screensâ&#x20AC;&#x2122; Kodiak Plus K500+ crusher is the newest and largest in its family of cone crushers. The 500-horsepower, remote-adjust cone crusher fills a demand for larger secondary and cone crushers in high-production operations. A new hybrid cast/fabricated base frame design, automated control system, patented linter retention system, patented thread locking ring, and anti-spin cone brake are among its refinements. Other features include replaceable brass thread inserts, patented internal counterweights, a heavy-duty tramp iron system, and brass v-seat liners. KPI-JCI and Astec Mobile Screens | www.kpijci.com

Dual crushing options

Sandvik Construction continued to expand its Prisec line with the introduction of the CI531 primary and CI532 secondary Prisec 3 horizontal shaft impact crushers. As with the rest of the product line, the HSI crushers can be configured into either a primary or secondary crushing mode. In addition, single-stage crushing is also an option with the ability to recirculate material to the primary versions of the crushers. A new crushing chamber design is said to allow for impressive reduction ratios through the use of two uniquely designed curtains, which have traditionally required a three-curtain configuration crusher. The maximum feed size is 39 inches in the primary configuration and just under 14 inches in secondary operation. Throughput ranges from 441 to 772 tons per hour as a primary and 276 to 441 tons per hour as a secondary. Sandvik Construction | www.construction.sandvik.com

Laboratory shaker sieve Cleveland Vibrator Co. now offers the Model HK Dual Drive Laboratory Sieve Shaker. Available in 8-inch, 10-inch, 12-inch, and 18-inch sieve frame sizes, the shaker can accommodate up to eight sieves. Enhancements include dual vibratory electric drives mounted on opposing sides of the test sieves, creating a three-dimensional motion. This allows the sample to work over the entire area of the sieve surface. The shaker operates on standard 110V and comes equipped with on/off controls and timer. Cleveland Vibrator Co. | www.clevelandvibrator.com

AGGREGATES MANAGER August 2014

As seen at

ROLLOUTS

Hillhead

Loader features all-new cab

Small footprint welder/generator

Fabco Power offers the Hydro Arc 7500 portable welder/generator. The 7.5 kW unit operates AC tools, compressors, lights, and pumps, among other equipment. The unit weighs 165 pounds and takes up a compact footprint of 27 by 10 inches, while standing 17 inches high. It is available standard with either an 11 gpm or 21 gpm high-efficiency, piston-type motor. Fabco Power | www.fabcopower.com

At Hillhead, JCB debuted its 457 wheel loader with the all-new JCB CommandPlus cab. The machine is the first to show off the completely new cab structure, engine cover, and rear counterweight design, which are said to contribute to improved visibility, lower noise levels, increased cab room, and an enhanced working environment for the operator. In addition, the 457 is the first large JCB wheel loader to meet Tier 4 final emission standards. An MTU diesel engine contributes to fuel savings of approximately 16 percent, compared to the previous model. It meets emission standards without the need for a diesel particulate filter. JCB | www.jcb.com

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AGGREGATES MANAGER August 2014

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superiorindustries

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www.superior-ind.com

Data Stock Report Company

U.S. On-Highway Diesel Fuel Prices Ticker

Current Value

52-Week 52-Week High Low

7/7/2014

One Week

One Year

United States

$3.913

-0.007 q

+0.085 p

East Coast

$3.978

-0.005 q

+0.147 p

New England

$4.098

-0.009 q

+0.133 p

Central Atlantic

$4.069

-0.004 q

+0.174 p

$3.882

-0.005 q

+0.125 p

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

$13.39 p

$13.81

$9.43

CRH plc

CRG

$25.66 q

$29.83

$20.66

Eagle Materials Inc.

EXP

$92.25 p

$97.25

$63.53

Granite Construction Inc.

GVA

$36.09 q

$40.55

$27.88 $67.89

Lower Atlantic

Heidelberg Cement AG

HEI

Holcim Ltd.

HOLN

$89.25 q

$95.54

$70.34

Midwest

$3.862

-0.007 q

+0.041 p

Martin Marietta Materials, Inc.

MLM

$126.26 q

$136.36

$94.01

Gulf Coast

$3.802

-0.014 q

+0.049 p

$25.94

Rocky Mountain

$3.909

-0.008 q

+0.098 p

$51.70

West Coast

$4.067

-0.006 q

+0.116 p

MDU Resources Group, Inc.

MDU

$85.17 q

$34.06 p

$93.65

$36.05

United States Lime & Minerals, Inc. USLM

$64.26 q

$68.50

U.S. Concrete

USCR

$25.57 p

$28.64

$16.05

West Coast less California

$3.985

-0.009 q

+0.121 p

Vulcan Materials Co.

VMC

$64.94 p

$69.50

$46.50

California

$4.135

-0.003 q

+0.109 p

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 7/8/14.

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

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7/9/14 1:29 PM

AGGREGATES MANAGER August 2014

Building Better Roads Road-gripping technologies already in place in Europe and Asia are now being implemented in the United States. Learn what this means for material producers. by Robert N. Dingess

oughly 33,000 people are killed annually in motor vehicle crashes on U.S. roadways. According to the National Highway Traffic Safety Administration (NHTSA), the annual economic costs of motor vehicle crashes is $277 billion. Thanks to renewed efforts by the Federal Highway Administration (FHWA) and the American Association of State Highway and Transportation Officials (AASHTO), a technology used in Europe and Asia is being applied to improve roadway safety at high-risk locations such as curves and certain intersections. The technique, known as high-friction surfacing, uses a specialized epoxy binder into which processed calcined bauxite is dropped. The result is a dramatic increase in the grip provided by the roadway surface.

Calcined bauxite

Calcined bauxite is used in the refractory process in the iron and steel industries. High-end calcined bauxite is also the key component in a high-friction surface. Creating a calcined bauxite that meets the standard for roadway application requires heating the bauxite to 2,732 degrees Farenheit (1,500 degrees Celsius). The current minimum aluminum oxide content requirement in AASHTO’s specifica-

AGGREGATES MANAGER August 2014

High-friction surfacing, which uses a specialized epoxy binder into which processed calcined bauxite is dropped, is being found to improve the gripping of road surfaces on curved roads, dramatically improving safety. tion is 87 percent. The resulting material has a hardness just below that of diamonds. The process for applying high-friction surfacing is similar to that of sealing bridge decks. The key difference is that most bridge deck surfaces are not subjected to the friction demand levels found in horizontal curve or intersection applications. The binding systems for high-friction surfacing are required to account for this additional friction demand through higher compressive strength. A properly installed high-friction surface treatment is expected, on average, to last up to 10 years.

FHWA “Every Day Counts”

While comprising only about 5 percent of roadway miles, roughly 25 percent of all fatal crashes occur at horizontal curves. The FHWA initiated a number of test projects using high-friction surfacing at curves with a history of severe crashes. The crash reductions following application were so remarkable that in 2012 the FHWA included high-friction

MARKETING

surfacing as part of its “Every Day Counts” initiative. The FHWA has partnered with AASHTO and the American Traffic Safety Services Association (ATSSA) on a number of projects designed to increase the use of high-friction surfacing around the United States. Although there were a small number of high-friction surfacing projects in 2012 and 2013, a dramatic increase in the number of projects in 2014 and 2015 is expected as state transportation departments develop specifications and locate potential project sites. Nearly a dozen states have projects scheduled for 2014 and expect more than double that number for 2015. Kentucky, Tennessee, Florida, West Virginia, Oklahoma, and California are aggressively working on large-scale programs. Texas, Utah, Georgia, Alabama, Virginia, and Illinois are well on their way to developing significant high-friction surfacing programs as well.

Calcined bauxite is provided in 3,400-pound bags.

Sourcing calcined bauxite

Nearly all calcined bauxite used for roadway surfacing is imported from China and India. In developing the AASHTO Standard Specification for High-Friction Surfacing, it was decided that refractory-grade calcined bauxite would be required. The single greatest benefit of using refractorygrade calcined bauxite stems from quality control. The material cost for a unique specification would have increased cost and decreased availability. Refractorygrade material has easy-to-access supply chains and creates transparency and accessibility through globally available pricing options. Given the foreign sourcing of this material, some have speculated that the market

Most calcined bauxite is shipped from Chinese producers processed, bagged, and ready for distribution to customers. may not be able to provide sufficient quantities to meet demand. Ken Jones, plant manager at C-E Minerals, in Newell, W.Va., disagrees. “Supply of calcined bauxite should remain strong, and prices are likely to drop over the next few years due to the slowing of global demand for refractory materials.” C-E Minerals has already provided calcined bauxite for use in high-friction surfacing. “We did not even know that this market existed until we were approached a couple of years ago,” Jones says. “We will certainly be monitor-

ing its progress as we attempt to gauge demand.” The calcined bauxite is provided in 3,400-pound bags. Most suppliers are having materials shipped to them from Chinese producers processed, bagged, and ready for distribution to customers. Others are securing raw calcined bauxite and processing the material at their own facilities. Price and timing seem to be key drivers for U.S. aggregate providers. It takes approximately three to four months for orders to be processed and shipped. AGGREGATES MANAGER August 2014

MARKETING

Information

ATSSA has developed a website containing information about high-friction surfacing. The website, www.highfrictionsurface. net, contains updates on research, specifications, press coverage of high friction surfacing, case studies, and publications. The frequently asked questions section has videos from industry leaders answering questions related to installation and testing.

The National Center for Asphalt Technology conducted a side-by-side tests of eight aggregates (calcined bauxite, flint, granite, basalt, silica, taconite, emery, and coal slag). While calcined bauxite was the most durable and retained the highest friction numbers, there may be opportunities for local aggregates that provide high initial friction numbers at locations with low traffic volumes.

Other aggregates

As the FHWA started its examination of high-friction surfacing as a safety countermeasure, there was a strong effort initiated to find domestic aggregates that provided friction numbers and polishing resistance similar to refractory grade calcined bauxite. The FHWAâ&#x20AC;&#x2122;s Office of Pavement Technologiesâ&#x20AC;&#x2122; Surface Enhancements at Horizontal Curves (SEAHC) project funded the installation of demonstration projects throughout the country. In addition, the National Center for Asphalt Technology conducted a side-by-side evaluation of eight aggregates (calcined bauxite, flint, granite, basalt, silica, taconite, emery, and coal slag). The results confirmed that refractory-grade calcined bauxite is the most durable and retains highest friction numbers. There may be opportunities, however, to use certain local aggregates that provide high initial friction numbers at locations with low traffic volumes.

AGGREGATES MANAGER August 2014

Cost/benefit

There have been a number of cost/benefit evaluations conducted on the use of high-friction surfacing. Some evaluators attempt to compare it to other friction improvement options. Others push for the use of lesser aggregates, citing cost reductions. The bottom-line is that high-friction surfacing using calcined bauxite should be compared with the cost of engineering reconstruction, not against other friction materials. When compared with the cost of redesigning and straightening a horizontal curve, high-friction surfacing is a quick, low-impact solution. Unlike reconstruction, there are no environmental impact studies and no long periods in which the roadway is taken out or provides reduced service. No land purchases or other expensive measures need to be addressed. Instead of years of delay, highfriction surfacing provides agencies with a relatively low-cost and quick solution to make roadways safer.

Future

The effort to find low-cost, systemic methods to make roadways safer continues. In addition to high-friction surfacing, the use of colorized aggregates and binders will soon be in wide use to designate bicycle lanes (green), transit lanes (red), and electronic toll lanes (purple). The push by agencies to find ways to use local aggregates for some of these systemic solutions should provide new use for a variety of traditional aggregates. The time for material suppliers to get educated and monitor the potential for these new markets has arrived. AM Robert N. Dingess is the president of Fredericksburg, Va.-based Mercer Strategic Alliance, Inc. and serves as chair of ATSSAâ&#x20AC;&#x2122;s HighFriction Surfacing Council.

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Features of the NEW MVPX Series Cone Crushers: Patented Rollercone® design and super bearing increase efficiency, increasing the horsepower available for crushing Pinned cylinder ends remove quickly to allow fast cone separation for quick manganese changes, reducing downtime At the press of a button, relief cylinders provide easy clearing of jammed feed material, reducing downtime, increasing productivity Hydro-pneumatic tramp iron relief system instantly resets the crusher setting after passing uncrushable material without having to activate valves and pumps Rugged, computer optimized and field proven mainframe, head and bowl nut castings for high-force, demanding crushing applications

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

READY FOR THE LONG HAUL

Manufacturers focus on fuel efficiency, safety, ease of maintenance, and operator insights when updating models.

High rimpull for heavy-duty applications Robust and reliable, new Volvo A25G and A30G articulated haulers have powerful, turbocharged six-cylinder Volvo engines. The Volvo drivetrain and a unique inline dropbox designed for high ground clearance are purpose-built to ensure perfect harmony and optimized performance. The drivetrain’s unique design delivers high rimpull, lowers fuel consumption, and provides reliability in heavy-duty applications. Oil-cooled wet multiple disc brakes reduce maintenance costs and increase uptime, even on muddy or dusty jobsites. The retardation system controls downhill hauling speeds using wheel brakes and the Volvo engine brake. To keep the G-Series sure-footed in the most demanding jobsites, automatic traction control (ATC) and unique differential locks are standard. Volvo Construction Equipment | www.volvoce.com

Higher torque, lower fuel consumption Doosan Infracore Construction Equipment offers the DA40 articulated dump truck. An agile undercarriage, designed to ensure that all six wheels are in permanent contact with the ground, means that it can operate on rough or soft terrain. Powered by a six-cylinder Tier 4 interim compliant diesel engine with net output of 490 horsepower, the unit offers an 11-percent increase in engine power compared to the previous model. It also boasts a 28-percent increase in gross torque to 1,750 foot-pounds. Contributing to an 8-percent reduction in fuel consumption is the new transmission offering eight forward and four reverse speeds. The transmission is said to improve the transfer of power from the engine to the wheels for outstanding traction. The truck has top operating speeds of 34.2 mph and a body capacity of 34 cubic yards. The payload is rated at 48.5 tons. Doosan Infracore | www.doosanequipment.com

Quick pickup and travel speeds Komatsu America Corp.’s HD785-7 truck is said to deliver fast acceleration and high travel speeds with a maximum gross vehicle weight of 360,253 pounds. Its turbo-charged Komatsu SAAS12V140E-3 engine meets Tier 4 interim emission standards and has a maximum net output of 1,178 horsepower. Komatsu’s variable horsepower control system selects an appropriate mode based on working conditions. It detects if the truck is loaded and selects the optimum horsepower setting. The truck has two speed reverse gears: one for normal operation and the other for job sites with steep conditions. The unit is also equipped with an anti-pitching four-wheel oil-cooled multiple disc retarder that applies retarding force on all four wheels. Komatsu America | www.komatsuamerica.com

AGGREGATES MANAGER August 2014

Tackles poor conditions

Handles tough conditions

The largest of the E-Series, John Deereâ&#x20AC;&#x2122;s 460E articulated dump truck is equipped with a 481-horsepower Tier 4 interim engine and has a heaped capacity of 33.4 cubic yards. The 50-ton machine is designed for heavy-duty applications and features a ZF transmission with a high-capacity retarder, eight forward gears, and four reverse gears. Responding to customer feedback, the unit is enhanced by on-the-fly differential locks, which can be applied for improved performance in poor conditions. In addition, it comes standard with JDLink Ultimate, which provides operators with 24/7 online access to machine health, utilization, and fuel consumption. John Deere | www.deere.com

With a transport capacity of up to 33 tons, Liebherrâ&#x20AC;&#x2122;s TA 230 Litronic is configured for maximum work performance. The large dump body, combined with a robust drivetrain, is engineered for efficiency. Impressive retarder performance is said to ensure safe operations, while the unit achieves fast turnover rates with its intelligent drive concept. Maintenance-free bearing points and easy-access service points reduce maintenance costs and downtime. The TA 230 features Liebherr components, including its diesel engine, hydraulic cylinder, ball slewing ring, and electronics. Liebherr says it is ready for the tough operating conditions in quarries and will provide operational reliability and availability. Liebherr | www.liebherr.us.com

Handles hills smoothly The Cat 775G Off-Highway Truck delivers a 70-ton payload, improved fuel efficiency, and advanced transmission controls to enhance productivity and drivetrain durability. Two different economy shift mode selections enable quarry managers to tailor performance to the needs of the business. Advanced control systems also integrate the optional engine compression brake with automatic retarder control to enable faster downhill travel and reduced cycle times. The Cat C27 ACERT engine provides 729 net horsepower and meets Tier 4 final emission requirements. Compared to the previous model, the 775G can hold a higher gear when climbing 10-percent grades. Caterpillar | www.cat.com

Lightweight design The DuraClass Alumax heavy-duty aluminum dump body is said to offer high strength and low body weight for long life and maximum payloads. Typically up to 50-percent lighter than traditional steel, the decreased body weight of aluminum bodies increases payload capacity and minimizes fuel consumption. The truck features a heavy-duty, 8-inch extruded top rail that resists bowing from heavy internal loads. The bottom rail, which includes an inside radius for faster and cleaner dumping, ties the deck, sides, cross members, vertical posts, and outside dirt shedders together and enhances structural integrity. Aluminum 5 3/4-inch I-beam long members have an integrated rubber track and rubber riser to reduce shock and noise. The 4-inch stacked U-shaped cross members provide extra load-bearing vertical walls. DuraClass | www.duraclass.com

Underground loading The Atlas Copco Scooptram ST7 LHD is built for underground applications requiring small size and high performance. The high-visibility FOPS/ROPS-approved cabin is said to put safety first. Easy access to daily service points supports efficient maintenance, and the Atlas Copco Rig Control System enables service information and diagnostics to be logged and displayed on the screen in the cab. Traction control allows full use of the 193-horsepower Cummins diesel engine to fill the 7.5-ton bucket to capacity, which has a 7-foot tramming height. An automatic lubrication system option is available. Atlas Copco | www.atlascopco.us

AGGREGATES MANAGER August 2014

THE LEADER IN TECHNOLOGY: THE NEW MC 110 EVO

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Text INFO to 205-289-3782 or visit www.aggman.com/info

PULL-OUT GUIDE By Kerry Clines, Contributing Editor

OPERATIONS ILLUSTRATED Good Housekeeping

Keep roadway clear of obstructions.

Put away all hand tools.

Thoroughly inspect plant at end of day.

Keep areas around processing plants clear of debris.

Wash away any material buildup under plant.

OPERAT 1

Appearance is important

Keep Your Operation Clean and Tidy

ood housekeeping is extremely important for aggregate operations, especially in this day and age. Not only does it make a good first impression with customers and visitors, it improves overall safety for everyone who enters the operation. “Housekeeping is important because it plays into the safety end of things,” says John Perkowski, plant foreman at Tilcon Connecticut’s Southington Pit. “It comes into play both inside the buildings and outside around the vehicles. We make sure every area is clean so there are no tripping hazards and no obstructed views for vehicles coming in.” According to the Mine Safety and Health Administration (MSHA), good housekeeping means keeping work areas, passageways, store rooms, and service rooms clean and orderly. This includes keeping platforms and catwalks free of debris and other tripping or slipping hazards. It also means keeping roadways clear of obstructions. All of these housekeeping efforts improve the looks of the operation and improve safety, but they can help an operation with inspections as well. “I frequently tell our operations guys that, if they can get through the opening conference with MSHA inspectors without a citation, they’re off to a good start,” says Randall “Randy” Mucha, corporate director of safety and health at Lehigh Hanson. “That AGGREGATES MANAGER

pretty much means the inspectors have come through the door and have gone through the paperwork. If the place looks good and the paperwork is in order, it sets the mood for the rest of the inspection.” A clean and tidy operation goes a long way toward creating a good first impression with the surrounding community. And a good first impression can result in a good lasting impression, which can positively impact future interactions with neighbors. “Part of our cleanup is on the roads coming into the operation, driving through the operation, going into the pit, coming up from the pit, and going up to the spoil pile,” says George Grguric, plant manager at Vulcan Materials’ Fort Payne Quarry in Alabama. “The better the roads look, the better we feel, and the more the employees take ownership and pride in our operation. That’s what we try to hang onto.” For haul road housekeeping, MSHA recommends grading the roadway as level as possible to minimize the bouncing of mobile equipment, which can cause spillage, damage to the equipment, or injury to the operator. Keeping the roadway maintained and avoiding spillage by not overloading haulage equipment is also important. MSHA suggests that all miners be instructed to stop and clear debris from roadways, if it can be done safely. If not, the location should be reported to a supervisor or manager for cleanup.

Make sure every part of your operation is clean and tidy, from the entrance to the processing plant to the scale house. Any customers or visitors who come in should be impressed with the appearance of the entire operation, as first impressions are often lasting impressions. Once the operation is in good order, keep it that way through constant maintenance and cleanup.

Store everything in its proper place

Hand tools are a necessity at aggregate operations, but are not always needed. When not in use, make sure all tools are stored in their proper place. The storage building should be neat and orderly. The floor should be clear of objects that can cause trips and falls. Mark where each tool hangs on the wall so that a quick glance will let you know if any tools are missing.

TIONS ILLUSTRATED Good Housekeeping 2

Keep the processing plant clean

At the end of daily operations, thoroughly clear away any material buildup found around and under screens, crushers, and conveyors in the processing plant, as the buildup can be a safety hazard. If possible, wash down the area with a water hose, as this is easier on the employees. However, if there is a large amount of buildup, cleanup may require the use of shovels or a skid-steer loader.

Empower your employees

Ensure that all employees are on the same page and know whatâ&#x20AC;&#x2122;s expected of them. Use training sessions to empower your employees to take ownership of the operation. Take advantage of this time to discuss any housekeeping issues with employees and encourage them to speak up, make observations, and discuss their ideas and suggestions.

Keep haul roads clear of obstructions

Be sure to remove any material that is spilled on roadways. Large rocks can cause damage to the tires and wheels of vehicles, which can be expensive to repair, and can cause discomfort for equipment operators. Keep the edges of roadways clear of any vegetation or other obstructions that might block the vision of haul truck drivers or equipment operators.

OUR EXPERTS

Show off your operation

Nothing encourages good housekeeping like an open house or family day at an operation. It allows employees to become more engaged in the upkeep and beautification of the plant, so they can show it off to their families and the surrounding community. Open houses that showcase a clean, orderly operation are an excellent way to improve community relations and gain community support.

Randall Mucha began his career in 1975 with Republic Steel. In 1986, he joined Material Service Corp., where he became director of safety and insurance. After Hanson plc purchased Material Service, Mucha relocated and became the corporate director of health and safety for Lehigh Hanson. He also serves as chairman of the NSSGAâ&#x20AC;&#x2122;s Health and Safety Committee.

John Perkowski originally worked for New Haven Trap Rock, which became Tilcon Connecticut. He worked at several Tilcon locations before settling at Southington Sand & Gravel in 1981. His job duties include working foreman in charge of a wash plant and portable screening plant. He is also a public weigher for the scale house and a loader operator for the site.

George Grguric entered the building materials industry in the late 1980s with Pioneer Mid Atlantic/Hanson PLC. In 2006, he joined Vulcan Materials Co. as a plant manager for the newly acquired business in Fort Payne, Ala. As plant manager, his responsibilities include safety and health, community relations, and efficient operating practices.

August 2014

OPERATIONS ILLUSTRATED Voices of Experience Randall “Randy” Mucha

“H

ousekeeping is pretty much a staple as far as setting a culture for our company’s health and safety program,” says Randall “Randy” Mucha, corporate director of safety and health at Lehigh Hanson. “Many times, the first impression is a lasting impression. If you go into a plant where the housekeeping is very good, it puts in your mind that they have their hands wrapped around safety at that location. It tells the story very quickly.” Company health and safety professionals look at housekeeping as they go through each plant. During health and safety meetings, the company takes employee suggestions and stresses the importance of a clean operation. Employees are empowered to fix a problem before a supervisor has to call someone to fix it. “Our focus on safety is about culture and leadership,” Mucha explains. “The company is focusing on the fact that, when it comes to safety, everybody can be a leader. You don’t have to be a manager or supervisor. If you see something wrong, you have the authority and power to fix it. That cultural empowerment isn’t unique to Lehigh Hanson, but it is something we’ve been deliberately focusing on over the past few years. When we empower everybody, housekeeping doesn’t just happen on a certain day or at a certain time, it is ongoing.” Lehigh Hanson shows off its good housekeeping during Family Safety Days when employees are invited to bring their families to work. Employees get a chance to explain to their families what they do and how they do it. It shows off the plants and gives the employees a sense of pride in their operation. “We want to show the families that we are happy that their family member works for us, and that we are glad that he goes home safely every day,” Mucha says. “And part of that is having a clean house.” AGGREGATES MANAGER

John Perkowski

outhington Sand and Gravel Plant, a Tilcon Connecticut Inc., Oldcastle Materials company, received a Gold Safety Excellence Award from the National Stone, Sand and Gravel Association at its 2014 Annual Convention. John Perkowski, plant foreman, says that he attributes much of the operation’s excellent safety ratings to its housekeeping efforts. Southington Sand and Gravel incorporates a program called 5S – Workplace Organization & Standardization, which is followed at all of Tilcon’s facilities in every division. The program addresses the importance of housekeeping and consists of the following: • Sort: When in doubt, move it out – The Red Tag technique. • Simplify: A place for everything and everything in its place. • Sweep: Clean and inspect or inspect through cleaning. • Standardize: Make up the rules and follow them. • Self-Discipline: Part of daily work and it becomes a habit. “Our goal is to get rid of anything we’re not using,” Perkowski explains. “If we haven’t used it in two or three years, then it makes sense to get rid of it, scrap it, or sell it. In our storage facility, we have pegboard on the wall that has all our tools outlined on it. With a simple glance, we can quickly tell if any tools are missing. It simplifies things a lot.” During the last several years, Oldcastle has highlighted a program at all its operations — When I see something, I will stop and do something. The slogan is on stickers, t-shirts, sweatshirts, and posters, and is addressed in a video message from Oldcastle Materials CEO Randy Lake. “We really want employees to get engaged,” Perkowski says. “If you recognize anything, please stop and do something about it. Get involved. Correct it. That’s all an aspect of good housekeeping.”

George Grguric

ousekeeping is an important part of the regular routine at Vulcan Materials’ Fort Payne Quarry in Alabama. “It’s part of the job,” says George Grguric, plant manager. “We schedule eight hours per day — six hours of production and two hours of general maintenance and repair. The idea is not to have to clean up much at all. The idea is to find what’s causing the problem, such as a buildup of material, and repair that. We try to make the plant run and operate at maximum capacity without spillage, which can cause a lot of extra cleanup.” At the end of the day, the first items to be checked are all the tail pulleys and head pulleys at the dumping points in the plant. If there’s any buildup of material, it is either washed out with a hose, cleared by a skid-steer loader, or cleared away with shovels. Use of the water hose is preferred, rather than the use of shovels, because there is less risk of a back injury with the water hose. Appearance is important. “We don’t have papers lying around the shop,” Grguric notes. “You don’t see anyone throw a drink can or an empty chip bag out of the window of a vehicle. If there’s a scrap on the ground, we stop, pick it up, and take it to the garbage can. You don’t see grease spots. You don’t see debris on catwalks. It’s almost habitual now. That presents itself well to anyone coming in.” Before the economic downturn in 2008, when business was booming, there was a designated clean-up person at the quarry. Now, the responsibility lies with every employee. “Everybody has their priority when it comes to good housekeeping,” Grguric says. “I think, for me, it solidifies ownership in the quarry and the business. It’s motivational, it’s safe, it’s efficient, and it’s contagious.”

• •

•

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Sensor Solutions

Tips and tricks for troubleshooting dredge sensors and other electronic equipment. by Jay Wise

owntime on dredges due to electronic This is where you will find wire numbers to specific equipment failure varies based on the level field devices (such as transmitter sensors, switches, thermocouples, push buttons, motor starters, VFD of automation, age, hardware brand, size, use, and environment on each dredge. interconnections, etc.) that will guide you to the Additionally, downtime varies based on the response proper field terminal when doing your field voltage or and level of competence to individual trouble issues. milliamp (ma) current testing. One thing is for certain: Downtime can last days or weeks as opposed to minutes Figure 1. Typical PLC I/O section of a dredge control wiring diagram. or hours without the proper in-house skill set competence or spares parts.

Understanding control wiring diagrams Wiring diagrams typically begin with the power and power-supply sections. Next, comes the actual PLC (Programmable Logic Controller) field inputs and outputs (see Figure 1), also known as I/O, or the relay ladder logic wiring for older relay style control systems.

AGGREGATES MANAGER August 2014

EQUIPMENT MANAGEMENT

Note the numbered lines to the left of each section on the page. These reference other sections in the drawing set. You will occasionally find a wire or device that continues to another area in the drawing set.

Using a multi-meter for troubleshooting

Multi-meters come in a variety of styles, but often carry similar features. Most will allow AC and DC voltage readings up to 300 volts, resistance, and continuity checking, as well as current and milliamp readings up to 10 amps. Some of the higher end units offer auto scaling and even source milliamps, voltage, and RTD for simulations. It is important for the technician to recognize the selection of lead plug-ins. This is necessary to change for reading amps or transmitter signal milliamps (ma). Since amperage is read in series of a circuit and voltage is read in parallel, the leads must be plugged into the proper ports for operation. If leads are left in the amperage ports while testing for voltage, you will most likely blow the internal fuse. Make sure you keep spares because this is a common mistake. When testing voltage or current, always start at the highest setting on the meter if signal values are unknown. You can then select lower ranges to improve the reading resolution. When measuring resistance, always verify that power is off and locked out. It is usually a good idea to lift field wires from terminals when measuring resistance to isolate your components and avoid reading paralleled resistance elsewhere in the circuit. When reading fuses for continuity, pull them out first. You could read a low resisClamp-on amp meter tance through motor windings or a transformer and think the fuse is good! When troubleshooting power circuits such as 480vac or 600vac motor circuits, it is often necessary to own a clamp current meter. This will allow

for independent phase current testing without lifting any wires on terminals.

Motor circuit troubleshooting

Recognizing issues in the motor control circuit should be a straightforward task. Motor issues typically present themselves as blown fuses, tripped feeder breakers, open windings in a phase, bad contactor, defective overload, seized motor, or mechanical jam. First, check the fuses or feeder breaker above the starter contactor. With power off, each of the three-phase fuses can be pulled to check for continuity. Analyzing the motor circuit requires a clamp-on amp meter. Watch the motor control circuit while an operator engages the run command. If the contactor energizes and trips a breaker and immediately blows a fuse, this is a sign of a short in either the motor windings or the wiring. With power off, read resistance between each phase on the starter load side outgoing terminals. The larger the motor, the lower the resistance, but the resistance should be the same across each phase. If a phase is shorted in the motor or wiring, you would read 0 resistance. Also measure resistance between each phase and ground. This resistance should be in the millions of ohms. If a short exists in the motor or wiring to ground, you will read very low resistance. Now, isolate the motor at the motor terminal junction box and see if the short is in the wiring back to the starter or in the motor windings. On dredges, old corroded wiring or water in field terminal boxes is often the culprit. If a short is not discovered, the issue may be an open wire or winding on the motor. A bad contact in the starter contactor will cause the same open effect. When one of the three phases is open, the motor will hum loudly while vibrating, and the two phases with connectivity to the motor will read high locked rotor current with a clamp-on amp meter. The phase that reads no current is the open circuit. With power off and locked out, you can test the starter contactor contacts and overloads with a continuity test across the individual phase of the contactor. You should read open circuit until you physically press in the contactor. While pressed in, you would read 0 ohms if the contactor and overloads are good. If this proves okay, the next step is to check your wiring and isolate the motor windings with resistance checks along the way.

PLC I/O troubleshooting

It is common for laymen to blame PLC code or hardware for AGGREGATES MANAGER August 2014

problems. The fact is, if your dredge has been operational for several months, the code is probably solid, and it will not change. Most cases of a system not starting or display reading not working involve a faulty field device or connection. PLC input field devices are used as system interlocks, as well as operator display annotations for alarms and status. If the PLC code is well written, these interlocks not only ensure safe operation of the system, but should annunciate alarm failures if the interlock is not valid. Being familiar with the PLC code or interlock schedule will be very helpful in troubleshooting control issues. When an operator comments that he can’t start his hydraulic pump or has a bad reading on his display for the discharge pressure, knowing which transmitter and field device is the interlock is necessary. This can be found using the electrical diagrams, as Figure 1 shows, along with the PLC ladder logic printout. Go to the field device in question and look for physical damage. Next, open any junction boxes that the wiring would pass through to get from the PLC cabinet to the field device. Check for water, corrosion, or frayed wiring, which is a common issue on older dredges. If the device and all wiring appear intact, it is necessary to troubleshoot with the meter. You need to determine if the problem is the field device or an actual input module failure. If you are troubleshooting a transmitter, there is a dedicated heading for this task. For the common field switch (pressure switch, push button, flow switch, level switch, etc.), use your multi-meter set for voltage and test voltage between the input terminal at the I/O cabinet and the neutral common while the field device is exercised. If the device and wiring is good, you should see the associated voltage at the input. Now, verify if the proper PLC input light illuminates on the input module window. You may have a bad input module. If input power is not at the input terminal when testing, go to the device and open the connection box while testing for voltage there. One side of the switch should always have input power applied. If not, you probably have a bad isolated fuse, which could simply feed that field device or a bank of devices. Usually, when a complaint is that several instruments suddenly stopped working, it is narrowed down to a fuse. Now, you need to find what blew the fuse. With the fuse pulled, check which field power wire is shorted. You may have to lift them from the terminal blocks individually to find the offensive short. It’s probably a pinched wire in a junction box or water in the field box somewhere.

Dredge instrumentation

Typical transmitters found on dredges include pressure sensors,

AGGREGATES MANAGER August 2014

magnetic flow meters, encoders, density meters, ladder angle sensors (inclinometer), and RTDs. Most of these transmitters are 4-20ma signal instruments. Each of these transmitters can come in two-wire, three-wire, or four-wire configuration. It’s important to know which you have for troubleshooting purposes, and they typically have the wiring termination connection and unit measure range stamped on them. When replacing a transmitter, make sure to purchase the same range and wiring configuration as the original unit. This is necessary for scaling in the PLC. When testing 4-20ma signals, the meter is required to be in line (series) with the ma current signal. Fluke sells a 773 meter that is a nice addition to any technician’s toolbox. This meter has a small retractable clamp designed to clamp Pressure transmitter around the small signal wires found in a 4-20ma circuit. This avoids the requirement to break a connection somewhere to read the signal.

Production metering

Production is usually read in tons per hour or cubic meters per hour. In some cases, an on-board computer calculates the production rate with signals from density meter and velocity (flow meter). Some dredges still prefer the yield meters, which have independent flow and density needles and an analog scale to infer the production via the cross needles. In either case, they rely on the accuracy

Mag flow meter

EQUIPMENT MANAGEMENT

affected, which, in turn, becomes a weaker electrical signal. This can be calculated into density based on the dry specific gravity of the material being read. For accurate computation, an operator must know the material count (specific gravity offset) of the media (pond, lake, channel, river). These setup values are entered as fixed parameters.

Fluke 773 clamp-on ma signal meter

Conclusions

of the flow meter and density meter. As magnetic flow meters are exposed and wear, the effect can change the accuracy. It is important to calibrate flow meters upon installation and during annual service. Nuclear density meters rely on variable material amounts to interrupt the scintillator’s crystal pickup of the nuclear source. When material interrupts the path from the source to the crystal, oscillation is

Each dredging operator or dredge owner should have a good downtime database or method to validate his individual downtime occurrences and reasons. You can’t control what you don’t measure. This would certainly shed light on the amount of downtime and the cost of issues due to control or electronic equipment failures. I’m certain if this downtime was measured, management would recognize the need for skilled technicians with the ability to react to and resolve issues associated with the evolving automation and controls found on today’s dredges. AM Jay Wise is the owner of Baltimore-based Kruse Integration. He has 35 years of experience in industrial automation, with 20 years in dredge automation.

CUSTOM LUBE TRUCKS

BECAUSE NOT EVERY JOB SITE IS THE SAME.

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Text INFO to 205-289-3782 or visit www.aggman.com/info AGGREGATES MANAGER August 2014

The 243 Complex consists of 243 Lime, a pulverized (or fine grind) limestone operation; 243 Quarry, a crushed limestone operation that, among its traditional rock markets, supplies high-calcium limestone to its sister operation, 243 Lime; and hundreds of acres of additional reserves that will ensure that the facility is producing high quality limestone for decades into the future.

California producer leverages crushing and screening investment to take on a new market niche.

Ready for

Rip Rap

orestville, Calif.-based Canyon Rock is a family-owned company with a reputation for operating with optimal efficiency, but it took an interesting path into the aggregates business. Quarrying began as a sideline to its dairy business, which goes back approximately 70 years and several generations. From a small quarry on the dairy farm, the Trappe family hauled occasional truckloads of rock to larger quarry companies. In 1972, the family began digging rock seriously when it bought an operating quarry near Forestville. The quarry is a full-service operation featuring a complete line of aggregate and recycled material, and an auxiliary division offering ready-mix and concrete products. The company is now owned by Wendell Trappe and his sons, Jonathan and James. Together, they comprise its second and third generations of leadership. Earlier this year, Canyon Rock took another

AGGREGATES MANAGER August 2014

leap forward as it acquired a second quarry and entered the rip rap market to provide stone for the Sonoma-Marin Area Rail Transit project, a 70-milelong rail and bikeway crossing the region. Purchasing the Cazadero quarry instantly created a need for a machine that could produce rip rap. Family patriarch Wendell had a long-standing relationship with Allis-Chalmers aggregate equipment and considered them “good crushers.” The family followed the brand through various acquisitions. It had purchased a Svedala H4800 cone crusher and a Sandvik CH 660 cone from local dealer ACS. As it looked for a primary crusher that could handle heavy-duty quarrying applications, it considered the Sandvik UJ440i mobile jaw crusher. “The UJ440i is a step up,” says Jonathan. “The chassis, the frame, the belt — everything is sturdier. We were looking for something that would last a lot longer than a regular contractor’s primary

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To meet a market opportunity for rip rap, Canyon Rock invested in mobile jaw crusher with pre-screen, as well as a mobile scalping screen.

jaw, something that would run well and last for 15 to 20 years.” The unit’s ability to turn out two finished products from the quarried rock was a deal-clincher. “The jaw can handle major openings,” he says. “We can open it up and make finished rip rap. Other jaw crusher manufacturers say the jaws can be opened to 8 inches, but even that is pushing it.” The 48-inch by 32-inch jaw is capable of reducing large volumes of rock at high rates of production — up to 771 tons per hour. Push buttons operate the hydraulic closed-side setting, which can squeeze the opening down to 4 inches from 11 inches. The unit’s conveyor belts are 54 inches wide and ride on hydraulic drive units that can be reversed as needed. A 300-gallon fuel tank ensures the crusher can process rock all day without interruption for fueling. When it is necessary to abruptly interrupt operation, emergency stop buttons are located at several places on the frame of the machine, which is important to safety-conscious Canyon Rock executives. A 425-horsepower Volvo diesel engine directly drives the crushing processes without critical loss of power, while consuming only about 8 gallons of fuel per hour. Sandvik flew brothers Jonathan and James to the U.K. to get a close-up look at the crusher prior to purchase. “It was key for us to see (the crusher) in action,” Jonathan says. “After seeing how well one was running after 10,000 hours of operation, we knew that was what we were looking for.” One key feature was the unit’s pre-screen, which allows Canyon Rock to make splits of the material. The separate pre-screen is located between the pan feeder and the crushing chamber and is topped by the grizzly section. According to Gareth Orritt, Sandvik’s business line manager, the pre-screen allows for quick elimination of fines. “Because of the large screening capacity of up to 150 tons per hour and

Pictured left to right are Wendell Trappe, Gareth Orritt (Sandvik), Martin Keegan (Interval), Jonathan Trappe, and James Trappe. the large screening area, it ensures that Canyon Rock puts only clean rock into the jaw, which allows the screening plant further down the line to be so much more efficient in making the coarse rip rap products that Canyon Rock needs to supply its customer base,” Orritt explains. By opting for a mobile crusher, the unit is not only able to follow the contour of the quarry face as the stone is blasted away, but also provides the necessary flexibility to meet permit limitations that will see the bottom of the quarry drop down. “Although the UJ440i is much larger and heavier, we did need a mobile machine,” Jonathan says. Canyon Rock also bought a Sandvik QE440 mobile scalping screen unit to enhance the two-product output at Cazadero. The screen has what Sandvik says is the largest total scalping area in its class. It features three hydraulic material conveyors with high discharge heights for stockpiling and can produce up to 992 tons per hour. The Trappes worked with Martin Keegan at Sandvik dealer, Interval. Canyon Rock has been doing business with Keegan since he served as an Extec representative and trusted his knowledge and ability to provide parts and service. “We were worried that parts would be a problem,” says James, who manages the Cazadero dig. “When something goes down, we can’t be shut down for a couple of weeks waiting on a part. Having a dealer who will stock parts and take care of issues that might come up was important.” Being able to efficiently churn out rip rap in volume is what drove the purchase of both new machines, adds Jonathan, noting that Canyon Rock now has the critical pieces of equipment in place to meet demand for the coarse rock. AM This article courtesy of Sandvik Construction. AGGREGATES MANAGER August 2014

Screening Supplement

Trends in Screening by Kerry Clines, Contributing Editor

creening is considered one of the most important parts of aggregate production. Without proper screening, aggregate producers would end up with a pile of material in all different sizes that couldn’t meet department of transportation, or any other, specs. Screens and screen media have changed and improved. Manufacturers have spent a lot of time on research and development to meet the needs of their customers, helping them increase production levels, decrease maintenance requirements, and improve the quality of their products. According to Ed Sauser, product manager for Terex Minerals Processing Systems, there are several things trending in screening today. One of these trends is to make the screen products more user-friendly so they require less downtime for maintenance and replacement. This can help reduce the cost of ownership for producers. Another trend in screening is the incorporation of vibrator mechanisms to shake the screen box. By modifying the motion of the stroke, particle separation can be improved. There are three basic types of motion that screen boxes use today. The oldest and most simple stroke is a circular motion, which is most commonly used on an incline screen where gravity helps move the material down the sloped screen. Then there’s a linear stroke where the screen shakes back and forth in a straight line. This motion is more aggressive than the circular motion and can be used on both incline and horizontal screens. The third type of motion is the oval stroke where the screen box moves in an elliptical motion, rather than a circular motion. This is the most aggressive of the three strokes and is becoming more popular because of its higher efficiency rate. The aggressive shaking tends to keep the screen cloth cleaner, which reduces blinding and pegging. When used on an

incline screen, the elliptical motion throws the material almost straight up initially, which helps drive the material through the screen. “There has been a lot of development with the oval stroke,” Sauser says. “Manufacturers are trying to incorporate the motion into a lot of different screening products.” Flexible screen media, such as Flex-Mat and Z-wire, is another trend that is becoming more prevalent in the aggregate industry. Flexibility keeps the media from blinding and pegging, which means more efficient screening and less downtime for cleaning the screens. Most of the major screen media suppliers now offer some type of flexible screen media and are developing new products using that technology. Then, there’s the debate about which type of screen media should be used — wire or synthetic. Wire screen media has been around for a long time, but over the past decade, the quality and design of synthetic screen media has greatly improved and has gained acceptance in the industry. Synthetic screen media offers greater durability, and may offer better consistency in material separation and sizing. Wet material tends to work better with synthetic screens, where dry material works well with wire screens. There are many things to consider when choosing the right screens and screen media. What type of material is being screened? How much moisture is in the material? How is the material being fed into the screens? What percentage of fines is in the feed? These, and other factors, should be considered when determining the right screening system to use. However, the most important step producers can take is to work with their supplier to figure out what combination of screens and screen media will work best for their unique operation.