Aggregates Manager 0815 issuu

August 2015

www.AggMan.com

21

Seven steps for controlling dust

26

Get more tonnage from your impactor

38

ALJ highlights the difference between S&S and flagrant violations

Experience the Progress.

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The Group

26 On Our Cover: Luck Stone partners with Jaybridge Robotics on an autonomous haul truck.

Cover photo courtesy of Luck Stone’s Trevor Blanning and Matt Rise.

8

Regular maintenance, parts logs, and good recordkeeping help guarantee day-to-day reliability of impact crushers.

Volvo’s new EC140E excavator offers more power and an upgraded cab.

CONTENTS AUGUST 2015 VOLUME 20, NUMBER 8

COLUMNS & DEPARTMENTS

FEATURE ARTICLES

14

26 32

Under Development: Autonomous Trucks Luck Stone and Jaybridge Robotics are developing an aftermarket technology solution that could soon take the driver out of the haul truck.

Big Impact

With appropriate training, proper operation, and the right maintenance routine, your impact crushers can go the distance.

Wheel Loader Workhorses

New loaders offer better fuel economy and robust designs for maximum productivity.

3

5

EDITORIAL Tougher grades for workplace exams.

AGGMAN ONLINE Catch up on the latest news from our web site and social media channels.

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

Sandvik Construction’s new range of SK and SC screens, and other new 8 ROLLOUTS equipment for the aggregate market.

MINING The latest financial analysis of issues impacting in the industry.

37 DATA LAW An ALJ’s rejection of a flagrant designation brought by MSHA highlights 38 ROCK the difference between S&S and flagrant violations.

OPERATIONS ILLUSTRATED Dust Control Best Practices

21

Good dust control is good process control. Our experts offer a seven-step process for minimizing dust throughout your operation.

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

41 ADVERTISER ADS Aggregate industry classifieds.

42 CLASSIFIED IN STONE Despite a depressed economy, Barre, Vt., drew skilled tradesmen 44 CARVED from around the world and fueled growth.

FOR INDUSTRIAL MINERALS THIS IS THE SHAPE OF THINGS TO COME Shape matters more and more in future-focused applications such as industrial minerals.

Sandvik VSI crushers give you control over fractions down to micron level and virtually eliminate metal contamination. That means you can match the most demanding quality specifications and increase product value by up to tenfold. Our VSI crushers set the standard for energy efficiency and uptime, while our unique bi-flow feed system boosts capacity by up to 20% with no loss of crushing performance. It all adds up to maximum value at minimum cost per tonne.

Discover what Sandvik precision could mean for you bottom line.

Please contact us for details of your nearest dealer: 1-800-826-7625 info.cns@sandvik.com construction.sandvik.com/vsi

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

August 2015

Vol. 20, No. 8

aggman.com /AggregatesManager @AggMan_editor

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

Ready for a Tougher

WORKPLACE EXAM?

Online Managing Editor: Bobby Atkinson editorial@aggman.com

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3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com

Corporate Chairman: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Russell McEwen Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Vice President of Events: Stacy McCants Vice President, Audience Development: Prescott Shibles Vice President, Digital Services: Nick Reid Vice President, Marketing: Julie Arsenault For change of address and other subscription inquiries, please contact: aggregatesmanager@halldata.com.

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

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

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

F

or those operators responsible for tracking their site’s regulatory requirements and recordkeeping, be forewarned: you may be about to get a significant increase in workload. During a July 22 stakeholder call, the Mine Safety and Health Administration (MSHA) introduced a new program policy letter for workplace exams, and it creates a two-fold impact on recordkeeping.

The guidance, 30 CFR §§ 56/57.18002, includes requirements that an operator “shall examine each working place at least once each shift for conditions which adversely affect safety or health, that the examination must be conducted by a competent person, and that a record of the examination must be maintained and made available for review by the Secretary or his authorized representative.”

In addition, it requires that an operator “promptly initiate appropriate action to correct” conditions which may adversely affect safety or health. And, if there are conditions that present an imminent danger, the operator “shall withdrawal all persons from the area affected…until the danger is abated.” Records of these examinations must be maintained for one year, and MSHA will no longer accept an alternative to the 12-month retention period.

MSHA advises that a best practice would be for a foreman or other supervisor to conduct the examination, but an experienced non-supervisory miner may also be considered “competent.”

In a July 23 quarterly training call, Assistant Secretary of Labor for Mine Safety and Health Joseph A. Main reiterated that ensuring workplace examination is tasked to someone who can truly ensure a work area’s safety is a high priority for the agency. In fact, evidence of inadequate training could be the basis upon which MSHA may require training plan revisions — and the subsequent recordkeeping of that training — under Part 46 (30 CFR §§ 46.3(a) and (b)(3)) or Part 48 (30 CFR §§ 18.3(c)(8)/4823(c)(8)).

Finally, program policy notes “if a trained competent person fails to identify multiple safety hazards or if multiple trained competent persons fail to identify similar safety hazards, this may indicate that task training as required under Parts 46 and 48 was inadequate or did not occur.”

Once an inspector visits your site and shares elements of this program policy letter, it can be enforced upon the next inspection. So, get your training plans updated as needed, and keep good records of those workplace examinations.

This is an exam you’ll want to pass with flying colors.

AGGREGATES MANAGER August 2015

3

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Catch up on top news and content from our web site and social media channels.

TOP POST OF THE MONTH

Tweets Aggregates Manager @AggregatesMgr

July 6 Look inside the Dolese Bros.’ Davis Quarry: http://buff.ly/1gjTErT July 1 MSHA issued 176 citations in May. Take a look at a list of operations inspected: http://buff.ly/1NwuMba

The nation’s top 25 crushed stone producers

Crushed stone production figures from the U.S. Geological Survey show an increase

in domestic production. In 2013, a total of 1,457 companies produced or sold crushed

stone from 3,688 operations with 3,837 quarries and 204 sales and/or distribution sites.

A total of 1.30 billion short tons of crushed stone was produced in 2012, a slight increase from the total production of 2012, but 34 percent less than the record high of 1.96 billion short tons in 2006.

TOP READS Atlanta turning quarry into one of America’s largest reservoirs

Atlanta has decided to move forward with a project to turn a quarry that’s been around for more than 100 years into one of America’s largest water reservoirs. The Atlanta Journal Constitution reported that the city bought the mine years ago with plans to fill the 400-foot deep hole with water from the Chattahoochee River, and the Atlanta City Council approved the $270 million project.

VIDEO: World conference discusses Lafarge-Holcim merger

IndustriALL Global Union hosted aggregates industry leaders from around the world, as well as workers’ unions in Egerkingen, Switzerland, to discuss the merger between Holcim and Lafarge. Representatives from Lafarge made it to the event to discuss workers’ rights, but Holcim opted out of the meetings.

July 1 Watch some heavy equipment reshape a beach with sand and gravel: http://buff.ly/1IOvkVP June 30 MSHA is offering up $1 million in grants for safety training improvements. http://buff.ly/1eYuoXA June 30 Have you seen John Deere’s new articulated dump trucks? http://buff.ly/1NvnYKg June 30 The EPA’s Waters of the U.S. rule was added to the Federal Register. http://buff.ly/1RQ6MR0

Aggregates Manager magazine

Aggregates Manager magazine Posted by Therese Dunphy · July 6 at 10:47 a.m. ·

Check out the videos from Dolese Bros.’ Davis Quarry.

PHOTOS: Reclamation photo contest entries showcase post-mining opportunities

This spring, Aggregates Manager put out the call for entries into our second annual photo contest. While reclamation posed a bit of a challenge because fewer operators had projects that would allow them to enter, this year’s entries did not disappoint. Our top winner, Lemon Grove, Calif.-based RCP Block & Brick, earned not only bragging rights and being featured on our July cover, it will also receive a custom painting by noted artist Brad Burns.

CRH continues to eye large deals to grow the Irish aggregates company

Material producer CRH already was on track to become the world’s third largest aggregates company following deals made prior to the merger of cement giants Holcim and Lafarge, but the Irish company isn’t done expanding quite yet. The Irish Examiner reports that CRH is looking to spend nearly $900 million to purchase the second largest aggregates producer in South Korea, Tongyang Cement and Energy.

Location is key for Dolese Bros.

Co.’s Davis Quarry The processing plant at Dolese Bros.’ Davis Quarry is a copy of the company’s Richards Spur Quarry located near Lawton.

AGGMAN.COM | BY AGGREGATES MANAGER

AGGREGATES MANAGER August 2015

5

State & Province

NEWS

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

California

Despite a request from Syar Industries, the Napa County Transportation and Planning Agency declined to write a letter of support for the operator’s expansion. According to the Napa Valley Register, Syar Industries would like to enlarge its 497-acre quarry by 124 acres and wanted the agency to sign a letter stating that hauling aggregates from out-of-county quarries would significantly increase local road construction costs. The county agency unanimously tabled the letter request. After its meeting, Syar spokesman John Perry told the newspaper that the quarry currently has about a year’s worth of rock left for asphalt production, but could remain open for five years, based on the availability of other products.

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

Indiana

Citizens Energy Group announced that it plans to convert a former Fishers limestone quarry into a reservoir.

The Associated Press reports the project is expected to cost $20 million and provide up to 25 million gallons of water per day to an eight-county area. Set to open in 2020, the reservoir would capture water that is lost over Geist Dam during heavy rains. The utility provider says that studies show central Indiana will need an additional 50 million to 80 million gallons of water per day to meet growing demand over the next 25 years.

Massachusetts

At Aggregates Manager’s press time, a teenager who fell into an abandoned quarry in Southwick was in critical condition. According to MassLive, the 17-year-old fell approximately 100 feet down the quarry face to the floor, where he was rescued by firefighters. The teen underwent multiple surgeries for injuries sustained in the fall. Local authorities told the news agency that it was the third time in as many years that firefighters have been called to the quarry to help people injured in falls there.

Montana

Georgia

Vulcan Materials Co.’s former Bellwood Quarry in Atlanta — which initially gained fame as it served as the backdrop for scenes from The Walking Dead — will soon become one of the nation’s largest reservoirs, the Atlanta Journal Constitution reports. Following a vote by the Atlanta City Council to approve the $270 million project, the city will bore a five-mile long tunnel from the Chattahoochee River to fill the quarry with an estimated 2.5 billion gallons of water. That will create a 30-day raw water supply, according to Atlanta Department of Watershed Management Commissioner Jo Ann Macrina. Currently, the city has a three-day backup water supply in the event of a drought or an emergency. Once filled, the reservoir will be 250- to 300-feet deep. The first phase of construction is scheduled for completion in 18 months.

Indiana

Fireworks ignited a fire in The Quarry in Helena, the Independent Record reports. A police officer responded to a call reporting a fire at the former quarry, which currently serves as an event venue.

He told the newspaper that the site is surrounded by homes and woods, adding to the danger of the fire set by unidentified youths. Neighbors put out the fire quickly. Police are seeking leads to identify the persons responsible for the fire.

New Jersey

Police in Monroe Township have found and identified the body of a teenager who drowned while swimming in a former quarry.

According to NJ.com, the teen was identified as Darius Boyer, an athlete at the local high school. Boyer had been swimming with three others when he disappeared. Swimmers looked for him to no avail. The site, Jackson Road Blue Hole, has pockets of deep, cold water, and has been a popular spot for teens and adults.

As Singleton Stone LLC is set to begin development of a quarry in Eagle Creek Township, it faces a unique obstacle: the discovery of human remains that could be as old as 2,000 years. According to the Chicago Tribune, the Department of Natural Resources Division of Historic Preservation and Archeology will continue its investigation of the remains and work to determine their age, origin, and how they came to be on the property. The quarry is considered to be a Section 106 project by the state agency, which requires archaeological review. A spokesman for the quarry’s parent company, Rieth-Riley Construction Co., told the newspaper that he could not comment on the discovery and what it might mean for the quarry’s timeline, but noted, “The only thing I can say at this point is that proper procedures are being followed.” USA Today reported that, if the mummified body leads to the discovery of sacred grounds, use of the quarry will be halted until additional rules and restrictions are put in place.

6

AGGREGATES MANAGER August 2015

New York

The city of Lockport has retained an engineering firm to test its municipal water supply line to confirm that the 110-year-old pipeline can withstand blasting from a local quarry. The Buffalo News reports that its findings will weigh heavily in the Common Council’s decision on a permit request from Lafarge North America to expand its quarry by nearly 10 acres. A representative from the engineering firm told city officials that it generally agrees with the scientific analysis performed by a firm retained by Lafarge. The firm plans to dig a couple of test pits to examine the exterior condition of the pipeline and to insert a remote-controlled television camera inside the line to check interior conditions. The city intends to make the operator pay for any repair costs on the line, as well as the 75 cents-per-1,000 gallons fee the city would have to pay the local water district for backup water.

Washington

In June, golfers played the U.S. Open tournament at Chambers Bay Golf Course, the site of the former Steilacoom Plant. The former sand and gravel site was last owned by CalPortland and ceased operations in 2002. According to The Washington Post, a former county executive pushed through the idea of reclaiming the 1,000-acre site as a golf course, specifically with the goal of attracting the golf tournament. The course cost $20 million to construct and opened in 2007.

A year later, it was awarded this year’s U.S. Open tournament.

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Wisconsin

In mid-June, an 18-year-old woman from Appleton drowned in the Redgranite quarry. Wbay.com reports that police received a 911 call about a person swimming in the quarry who hadn’t surfaced. Divers found the body of Alaya HuaChee Lo approximately an hour later. The former quarry is now home to a 6-acre lake that’s up to 163 feet deep, according to the Wisconsin Department of Natural Resources.

Wisconsin

Less than a month after denying a conditional-use permit for Yahara Materials to operate a quarry in Windsor, the town board voted 4-1 to reconsider the proposal. According to the DeForest TimesTribune, town attorney Connie Anderson recommended the motion appear on the town board agenda. In her memo recommending the motion, she wrote that “any vote on the (application’s) merits occur after such time as the updated Comprehensive Plan has been approved

by Dane County.” According to the report, the permit request is expected to be heard in late August or September.

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

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

Efficient wet and dry screening Sandvik Construction has a new range of SK and SC screens that includes the new SK2462 screen. It makes life easier for aggregate producers by accurately and efficiently screening all of the materials, while working well in wet and dry conditions. The screens are available from 5 to 10 feet wide, 13 to 26 feet long, and with two, three, or four decks. The screens are made versatile through their adjustable incline and a wide range of stroke parameters.

Sandvik Construction | www.sandvik.com

Tier 4 excavator boasts upgraded cab Volvo’s new EC140E brings the same power expected from a Volvo excavator, while giving the cab an upgrade. The new machine has an 8-inch display in the cab that shows the rear camera and all of the essential information about the excavator. The EC140E has a control panel keypad that includes Bluetooth capabilities and can control the climate in the cab. As for the excavator’s power, it comes with a Volvo D4J, Tier 4 final engine with 119 horsepower, a 5-percent power increase. The machine can lift 8,200 pounds and has a max dig reach of over 27 feet.

Volvo Construction Equipment | www.VolvoCE.com

More machine intelligence Case Construction Equipment has combined its precision construction services such as telematics and machine control techniques under a new name: Case SiteSolutions. SiteSolutions will offer business solutions to help increase productivity and get the highest return on investment. The manufacturer hopes the new services will help it make data more practical for more operators. It will also improve machine control accessibility, add parameters for more comprehensive information, and seek to enhance connectivity with optional satellite coverage.

Case Construction | www.CaseCE.com

8

AGGREGATES MANAGER August 2015

ROLLOUTS

New 22-ton excavator Volvo Construction Equipment has announced its new 22-ton Volvo EC220E excavator that’s fitted with a Tier 4 Final Volvo D6 engine. The engine meets all of the new emissions standards in North America, while not giving up any of the power of previous Volvo excavators. The unit also comes with an optimized hydraulics system and ECO mode that give the excavator the power to precisely complete jobs. In addition, it has increased pump input power that boosts productivity and cycle times. On the inside of the machine, the excavator has a new human machine interface with joysticks, a keypad, and an 8-inch LCD monitor, which makes the machine more user friendly.

Volvo | www.VolvoCE.com

Updated telestacker software The new version 12.0 of TeleStacker Conveyor PilePro, from Superior Industries, updates the appearance of the telescoping radial stacker automation program. There were no changes to the physical function, but the new screen design is more user-friendly with bolder graphics and onscreen buttons. The navigation on the system was also updated to create a better user experience, and the software now has onscreen access to the TeleStacker Conveyor owner’s manual. The upgrade is available to all the TeleStackers dating back to 1997.

Superior Industries | www.superior-ind.com

Automated crawler dozer Komatsu American Corp. has a new D65PXi-18 crawler dozer with an intellegent machine control system to allow automated operation for heavy dozing and fine grading.

The new control system helps give the machine up to 8 percent greater efficency in moving material. The dozer comes equipped with the 217-horsepower SAA6D114E-6 engine that meets the EPA’s Tier 4 Final emissions standards. The dozers also come standard with an automatic gearshift transmission and lock up torque converter that reduces horsepower loss and cuts fuel consuption by up to 10 percent.

Komatsu | www.komatsuamerica.com

AGGREGATES MANAGER August 2015

9

Tier 4 Final multi-terrain loader Caterpillar’s new 297D2 Multi-Terrain Loader comes standard with a C3.8 98-horsepower engine that meets EPA Tier 4 Final emissions standards. The loader has an operating weight of 8,768 pounds and a rated operating capacity of 4,700 pounds. The machine has a unique dual-suspension undercarriage that offers another level of suspension, with oscillating roller wheel assemblies. The unit also has the same new features as the other D2 Series machines, including the advanced display and engine compartment sealing.

Caterpillar | www.cat.com

New thermal label printer Fairbanks Scales has a new PM43 Direct Thermal Label Printer for use in distribution centers, warehouses, manufacturing, and transportation environments. The industrial, mid-range, direct thermal and thermal transfer label, ticket, and tag printer has a durable metal build that is said to increase uptime and reduce maintenance costs. It also comes standard with a touch-screen interface and built-in web interface. The Precision Print feature lets the unit print smaller barcodes and other images without adjustment. Fairbanks says it’s the only CCX-certified printer to come with IPv6 implementation.

Fairbanks Scales | www.Fairbanks.com

Tier 4 Final excavators Hyundai Construction Equipment has revealed its new line of Tier 4 Final-compliant hydraulic excavators. The models include the HX220L, HX260L, HX300L, HX330L, HX380L, HX480L, and HX520L. All of the new excavators come with an interactive touch-screen monitor and an improved climate-controlled cab.

The machines also come with a new “Boom Float” mode for improved grading and “Fine Swing” mode for more accurate load control when swinging. Hyundai says the Scania engines are up to 10 percent more fuel efficient, while also providing 13 percent faster cycle speeds.

Hyundai | www.hceamericas.com

10

AGGREGATES MANAGER August 2015

UPTIME SHOULDN’T BE COMPLICATED. With SmartCare, it’s guaranteed.

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Dozer maintenance app John Deere released a new smart phone application that it says makes life easier for 1050K crawler dozer owners and operators. The GoPush application gives operators and fleet managers daily service information, recommendations based on the site conditions, a maintenance checklist, machine setup, and an icon glossary. John Deere says the goal of the app is to enhance productivity and efficiency. It is available for free in the iTunes Store and Google Play.

John Deere | www.JohnDeere.com

Upgraded Tier 4 Final loader John Deere updated its K-Series wheel loaders to meet the Tier 4 Final emissions standards, among other upgrades. The John Deere 444K is fitted with a new 124-horsepower “PowerTech” engine, while the 544K has 163 horsepower. The PowerTech torque-converter transmission can evaluate speed and load conditions with the new “Smart-Shift” technology. The 544K comes standard with a five-speed transmission that gives increased acceleration, speed cycles, and optimizes the power. In the cab, the new loaders also have an enhanced monitor to display diagnostic and maintenance information as well as a sound compression package to minimize noise.

John Deere | www.JohnDeere.com

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ROLLOUTS

Portable dust control Dust Control Technology has a new transportable atomized mist unit called the DustBoss DB-60 Fusion. The suppression system, combined with a 60-horsepower diesel generator, can deliver coverage of up to 62,800 square feet. The unit forces water through 30 atomizing spray nozzles and sprays the mist out with a 25-horsepower fan. It requires a constant supply pressure of 10 psi. The John Deere Tier III Flex engine provides the machine with 24 hours of runtime. The unit is just 80 inches wide and comes mounted on a trailer, along with the generator, for easy towing.

Dust Control Technology | www.dustboss.com

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13

TECHNOLOGY

by Therese Dunphy, Editor-in-Chief

GPS antenna Cell antenna

Lidar

Electronics

Video Camera

Lidar

14

AGGREGATES MANAGER August 2015

Cell antenna: The autonomous system uses a cellular signal to network the system together. This prevents the need for wifi installation throughout a quarry. The cell allows the lead truck to send its route to other trucks, and it allows the autonomous trucks to be managed by the lead driver, loader operator, and crusher operator, as needed.

GPS antenna: A GPS signal tracks the location of each unit. The system uses a TerraStar satellite connection so no base stations need to be installed.

The typical accuracy is +/10 centimeters.

Electronics: System electronics primarily consist of a small computer and an inertial system to improve navigational accuracy. On saleable units, this box is expected to be much smaller than the one shown on the prototype. The system is comprised of mostly off-theshelf components, while the software is a proprietary development by Jaybridge Robotics.

Lidar: High-angle (top) and low-angle (bottom) lidar units scan for obstacles from various angles to provide an accurate view of the road, regardless of curves and slopes. They have a range of approximately 260 feet.

Video camera: Video images from the front of the vehicle allow any human supervisory personnel to view operations from a remote location.

Under Development:

Autonomous Trucks

Luck Stone and Jaybridge Robotics are developing an aftermarket technology solution that could soon take the driver out of the haul truck.

M

ore than one equipment

wheel loader that enhances safe opera-

manufacturer has been

tions at a quarry face and gives it access

working on autonomous

to a greater amount of reserves.

trucks for years. Typi-

“As a business, we’re trying to make

cally, these large trucks operate as part

strides around the idea of being really

of a fleet management and optimization

intentional about innovation and creativ-

program at large mines. While intriguing,

ity,” says Travis Chewning, P.E., Luck

the technology has not yet been scaled

Stone’s senior director of engineering and

for use in aggregates applications.

operational support. In fact, the company

Now, however, Luck Stone and Jay-

created an innovation process to develop

bridge Robotics are collaborating on a

ideas. “We have a process, forum, and

system that fits the unique needs of this

resources available so that when folks in

market. Within 12 to 18 months, they

the organization have an idea, there is a

expect to have the prototype unit of a

place for them to go,” he adds.

lead-driver concept in place. This would

When Luck Stone was able to put a re-

allow a fleet of autonomous haul trucks

mote control loader into its first operation,

to follow a single operator-driven truck

Chewning says the company began to

throughout the load-haul-dump-return

think about other opportunities. “We were

route. Eventually, they expect to see the

amazed at how quickly we were able to

driver out of the truck all together.

move and the success of that project,” he

Exploring options

explains. “It got us asking the question, if we could remotely control a 988 loader,

Luck Stone has been on a roll with in-

could we automate the loader? Could we

novations over the last several years,

take the next step? We didn’t have the

including pioneering a remote control

ability to take that anywhere, but we

AGGREGATES MANAGER August 2015

15

TECHNOLOGY

“Every high-end car now has lidar and radar and all the sensing technology you need,” Chewning says. “There are companies producing those by the hundreds of thousands, so the unit cost is just dropping amazingly fast.

Jaybridge really sees an opportunity to leverage that.”

Determining the value proposition One of the challenges is determining the tradeoff between functionality and price. Chewning says that Luck Stone was in conversations with Jaybridge for nearly a year vetting out capability and cost issues, such as the following: • What kind of functionality would create value?

• What price point would be considered feasible?

• What are the performance requirements?

• What are the safety requirements?

• What equipment factors need to be considered?

“Within Luck Stone, the real motivation is that, when we looked at the future, there is no doubt that this is Lidar technology, shown on this prototype, uses a laser beam to detect objects in the truck’s path.

coming. If you read any article about where autonomous cars are going, this is going to be part of how the world

were very curious about it.”

At the same time, Jaybridge Robotics

He met with an aggregates producer

functions,” Chewning says. “We’d much

at MINExpo 2012 and spent much of

rather be on the front end of that than

was fresh off its success with autono-

2013 visiting quarries around the United

the back end.”

mous agricultural equipment and was

States to learn more about the needs of

Another consideration came from

exploring other markets where automa-

the market. “We became convinced that

a lesson Luck Stone learned when it

tion made sense — including the aggre-

the opportunity was real and that the

began automating plants in the early

gates industry. “The mining industry is

technology had just about gotten to the

80s: automation improves consistency.

familiar with the concept and is starting

point where what an aggregates opera-

“We learned that it helps a plant oper-

to become familiar with the benefits,”

tion needs from an autonomous system

ate in a more consistent process,” he

says Jeremy Brown, Ph.D., president and

was becoming cost effective,” he says.

explains. “It’s less expensive to operate,

CEO. “And the equipment price is high,

By using commodity, off-the-shelf parts,

and it gives us the best product for the

so the cost of autonomy equipment is a

Jaybridge is able to take advantage of

customer.”

relatively small capital cost compared to

the rapid pace of development in tech-

the trucks.”

nology and keep the parts cost down.

16

AGGREGATES MANAGER August 2015

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harder to find operators,” Brown says.

“The workforce across the country is urbanizing, so it’s more challenging to get people to drive out of the city to operate quarrying equipment.” Finding operators who meet the criteria of reliability and trainability is a significant concern for some aggregates companies, he explains.

Developing a prototype Once they defined the various parameters, the two companies began to collaborate on prototypes. Prior to A mix of off-the-shelf hardware, along with proprietary software, comprises the control system that is being installed onto the haul truck.

presenting the concept during an AGG1 presentation earlier this year, the project had reached the point that a driver

discussion centered

could drive the experimental truck from

around night-time

its cab. The driver used a joystick to

operations. Typically,

control the technology installed on the

reduced visibility

haul truck.

leads operators to lower their speed,

the operator’s hands off the wheel, al-

and productivity

lowing the vehicle to drive autonomously

drops. Visibility con-

and with repeatable performance along a

cerns aren’t an issue

pre-planned path. The operator was able

for an automated

to “land” the truck accurately at desig-

truck, so it creates an

nated locations. “We’ve taken the next

opportunity for in-

step,” Brown says.

creased productivity.

Shown here is the driver’s seat in the prototype truck.

Since then, they have been able to get

While automation is not intended to

“Every time they come down, we incrementally experiment one step further,” Chewning adds. “We’re tak-

costs as their behavior is modeled after

replace people at Luck Stone opera-

ing baby steps, really just trying to get

an operation’s best truck operator, and

tions, it does allow operators to focus on

experiences under our belt. The steps

driving technique impacts transmis-

plant maintenance and efficiency. “Our

now are to just keep building on that —

sion shifts, brake wear, suspension

associates are our most valuable asset,”

building knowledge, experiences, and

life, and tire life, among other factors.

Chewning explains. “We learned that,

confidence with the system so we can

“What would your performance be in an

by automating our plants, we provided

keep stretching it more and more.”

operation if every truck was function-

time for our operators to do other, more

ing like your best operator?” Chewning

valuable, things.”

asks. “We definitely see there to be an efficiency gain.”

He says the deeper they get into the

Although Luck Stone isn’t looking

Future steps include working through issues such as having the truck operate at higher speeds and in reverse. Brown

to downsize its workforce, automated

says they need to work through the

trucks may help offset workforce chal-

initial autonomous work flow, as well as

conversation, the more opportunities

lenges facing operators around the

user interfaces with the loader, crusher,

present themselves. For example, one

nation. “It is progressively harder and

and lead driver.

18

AGGREGATES MANAGER August 2015

TECHNOLOGY

“By late July, we hope to be doing lead driver, in the experimental context, where you still have an operator sitting in each of the autonomous trucks and serving as the safety system; keeping eyes on the road, eyes on the mirrors, and working out the work flow elements,” Brown says.

Additional factors, such as integration of obstacle detection, will be necessary before taking the operator out of the cab. Brown says they will work through scenarios where the truck must detect obstacles and ensure that the sensors do so accurately. “You have to put in place all of the safety protocols needed

Through early stages of the development process, the driver remained in the truck cab, but was hands free during the driving. In this case, the driver serves as the eyes and ears in the cab, but the autonomous system controls the vehicle.

to operate not just self-driving, but actually unpopulated trucks in an area,”

the truck where to go on a map or

months we won’t have a prototype run-

he says.

some kind of computer interface rather

ning unmanned in one of our quarries.

than instructing the truck by driving

That’s just awesome.”

“After we’ve been operating for a while, we should be able to characterize how quickly conditions on the

the truck first.”

The lead driver approach will likely be the first saleable model, Brown notes.

ground change and how the lead driver

Looking to the future

changes the way they are driving,”

To date, Jaybridge Robotics has worked

field, they can grow their experience

Brown adds.

exclusively with Luck Stone on the pro-

and address variables from site to site,

totype. Brown says that will continue

including how factors such as GPS and

those changes happen, they will learn

until they work through the basic work-

cellular coverage impact the system.

the tempo of the route and be able to

flow process.

As they can identify how quickly

gauge how long a driver can safely

“It’s high cost and low return until it’s

Once they have several out in the

While Luck Stone’s involvement has been vital to the early phases of de-

leave the vehicle. “It’s going to be a

actually working,” he says of the de-

velopment, Chewning says they would

journey of discovery to figure out how

velopment process. “As soon as the first

welcome other operators to join the

to get the driver out of the cab at all

one is working at one quarry site, we’re

project and help to refine the technol-

and to figure out how frequently they

going to want to install more at some

ogy: “The more industry engagement

have to get back in — and once there

other sites and make sure we can solve

there is, the more it helps advance the

isn’t a lead driver, who monitors a re-

problems at more than one place.”

thinking.” AM

mote console so that, if the truck sees

One of the challenges is to imagine all

an obstacle and stops for some reason,

the variables. “We can only experience

it can flag a human operator to address

so many scenarios in so many months

the situation.”

per year,” Chewning says. “The more ex-

Once the lead driver comes out of the truck, operations will still need a person to work in a supervisory fash-

Video link:

https://vimeo.com/131661981

periences we have, the more Jaybridge can adapt and grow the system.

“They have been able to move forward

ion, he reiterates. “The final step,”

so much faster than we would have ever

Brown says, “would be to give that

expected,” he adds. “We have no rea-

remote human the ability to command

son to think that in the next year to 18

AGGREGATES MANAGER August 2015

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PULL-OUT GUIDE

By Mary Foster, Contributing Editor

OPERATIONS ILLUSTRATED rac ic t o B D u st C o n r l e st P

Good dust control is good process control.

Enclose conveyor transfer and screen discharge points.

Choke feed crushers to reduce dust and also produce the best gradations.

Reduce speeds on paved and unpaved roads.

t es

OPERAT 1

Conduct a site survey

Dust Control Best Practices

D

ust control touches every part of an aggregate operation, from productivity, efficiency, and product quality to compliance, safety, and good neighbor relations. According to Mark Kestner, Ph.D., president and CEO of National Environmental Service Co. (NESCO), “My philosophy has always been that good dust control is good process control. If your stone isn’t spilling on the ground or going up in the air, it’s going across a scale and into a truck, railcar, or barge to make money.”

Dust in aggregate operations comes from three major source categories: roads, stockpiles, and processing operations. The most significant causes of dust from an operations standpoint include mobile equipment on unpaved roads, crusher discharge, screen discharge, conveyor transfer points, and stacking conveyor discharge, says Clif Morris, general manager of aggregates for Tilcon New York.

Engineered controls that are employed to contain dust and spillage should be an integral part of plant design, Kestner says. “Any owner/ operator of a new mine is required by federal and state laws to obtain permits to construct, install, and operate the facility. As part of the permitting process, the mine must specify the dust controls it will use and must demonstrate that it is able to comply with NSPS (New Source Performance Standards).”

As part of the design, transfer points should be enclosed on three AGGREGATES MANAGER

sides, covered, fitted with a dust curtain, and properly skirted. Load points should have sufficient idler support to prevent sagging between idlers that leads to visible dust and spillage. “I see more and more plants using impact beds to maintain uniform seals at load points and dual skirting at impact crusher discharges,” Kestner notes.

Kestner and Morris agree that the following steps are required when developing a dust control plan: 1. Conduct a site survey to identify all the sources of dust on the property.

2. Estimate “uncontrolled” dust emissions from these sources using EPA AP-42 emission factors; this provides a baseline to evaluate the performance of controls.

3. Specify Reasonably Available Control Measures (RACM) for each dust source.

4. Estimate “controlled” emissions using control efficiency ratings established by federal or state EPAs. 5. Establish a budget to purchase and install dust controls.

6. Implement the control plan.

7. Monitor the performance of the control plan and modify as necessary to maintain compliance.

Companies that ignore engineered controls to reduce the costs of new plant construction will pay for it later in time and labor to clean up dust and spillage. Additionally, when laborers have to sweep, shovel, or use a skid steer to remove spillage out from under screens, conveyors, and crushers, they are at their greatest risk for exposure to respirable dust.

The first step in taking control of dust is to conduct a site survey to identify all sources of dust on the property.

Plant operations produce dust from three major sources: roads, stockpiles, and processing operations. After identifying sources of dust emissions, producers should specify Reasonably Available Control Measures (RACMs) for each source and implement a control plan.

4

Control dust from stockpiles

Stockpiles are often a source of dust within the plant, starting with the stacking conveyor discharge. Stockpiles that are too high or that are situated within the flow of predominant winds can also lead to excess dust. Producers should minimize stockpile heights and consider spraying stockpiles to control dust. Loader operators should avoid overfilling buckets and spilling material when loading from stockpiles.

TIONS ILLUSTRATED Effective Dust Control 2

Control dust on roadways

3

Control dust at transfer points

While water works well in a variety of ways to control dust in operations, producers also should address operator practices. Operators should be trained to take responsibility for dust control. For instance, speed control on roadways will go a long way toward reducing dust from paved and unpaved roads — and will help reduce costs of more expensive controls such as watering or chemical suppressants.

Engineered controls are an integral part of plant design and are used to contain dust and spillage. Transfer points should be enclosed on three sides, covered, and fitted with a dust curtain and proper skirting. Load points should have sufficient idler support to prevent sagging between idlers, which leads to visible dust and spillage.

Impact beds also help to maintain uniform seals at loading points.

5

6

Operational best practices

Good operational best practices will not only reduce dust, but also improve production. Operators should avoid interruptions in process flow that can cause “windmilling” (running a crusher with no material, which wastes energy and causes dust). Instead, they should strive to choke feed crushers, which not only reduces dust, but also produces the best gradations in the first pass.

OUR EXPERTS

Mark Kestner, Ph.D., has 30 years of experience controlling fugitive emissions from utility, industrial, and mining operations. Coal mines, power plants, and steel mills were the first targets of the Clean Air Act, and his introduction to dust control occurred in 1978 when he worked as a research chemist to develop chemical additives that reduced particulate emissions from combustion and material handling processes.

In 1981, Dr. Kestner began a consulting practice that specialized in dust emissions.

Since 1989, he has served as president and CEO of the National Environmental Service Co. (NESCO).

Maintain dust control systems

Wet and dry suppression systems both require regular maintenance to operate properly. Operators must be responsible for maintaining the integrity of dust control systems, providing the same attention to these measures as they do to maintaining the plant’s processing equipment. Failure to do so will lead to citations and equipment issues, as well as time and labor spent cleaning up dust and spillage.

Clif Morris is general manager of aggregates for Tilcon New York Inc., New Jersey Region, and is responsible for overseeing the Mt. Hope, Oxford, Pompton Lakes, Riverdale, and Byram quarry locations. Previously, he had been an area manager for the Tilcon New Jersey Region, responsible for overseeing the Mt. Hope, Oxford, and Byram quarry locations. His tenure at Tilcon began in October of 2006. Prior to this, Morris was employed by Luck Stone Corp. and Florida Rock Industries. Morris is a graduate of Virginia Polytechnic Institute and State University, with a bachelor’s degree in mining and minerals engineering.

August 2015

Voices of Experience Mark Kestner

“T

t

hirty years ago, when I got into this business, a lot of producers thought that dust, dirt, and spillage was just something you had to live with. I even had one old-timer tell me that dust was good for you — actually helped to scour your lungs out! It was impossible to convince them that dust control measures, like avoiding interruptions in process flow and choke-feeding crushers, were not only good for dust control but also good for production,” says Mark Kestner, Ph.D., president and CEO of National Environmental Service Co. (NESCO).

In the intervening years, the industry has found that dust control and productivity aren’t mutually exclusive. Today, producers see that environmental compliance is the key to a sustainable and profitable aggregate industry.

For a new or expanding mine looking to get new permits, dust control measures must be part of the mine plan. But what should an existing mine do to add or upgrade dust control systems?

Kestner says that in today’s tough economy, a mine should begin by implementing the least expensive control measures first.

“These include training operators in best practices. For instance, speed control is a good example of an operating practice that can go a long way to reducing dust from paved and unpaved roads — as well as reducing the costs of more expensive controls like watering or chemical suppressants.”

Using in-house labor and material to improve the enclosure of dust sources is another, comparably inexpensive, way to control dust.

Kestner explains that dust enclosures can be fabricated and installed by plant personnel from scrap steel and used conveyor belting.

Once a producer has done what it can do with good operating and engineering practices to control dust, the next step would be to look at wet suppression systems. Water spray systems are the workhorse of dust control in the vast majority of aggregate plants.

They are relatively low cost, and a properly designed spray system can be easy to operate and maintain.

And maintenance should not be ignored. Proper preventive maintenance plays a large part in controlling dust. “Because I believe preventive maintenance is the key to compliance, dust control equipment deserves the same level of preventive maintenance as production equipment,” Kestner says. “Most of the fines and citations I see are not because plants don’t have dust controls, it’s because they are inoperable due to lack of maintenance.

“When you look at dust control as a process control problem rather than a compliance problem, you are much more likely to come up with an effective and affordable solution,” Kestner adds. “If you wait until you get fined or cited, you’re going to wind up spending a lot more money on dust controls.”

Clif Morris

A

t

ccording to Clif Morris, general manager of aggregates for Tilcon New York, dust control measures should be designed into both the pit/plant layout and also into the actual processing plant. For instance, dust control through a mine layout could include the placement of processing equipment and situation of stockpiles at lower elevations; stockpiles should also be positioned in areas that reduce the effects of the predominant wind, with care taken to minimize their height.

“Additional design considerations for the pit would include paving the most common travel ways and leaving adequate distance from the scale to the exit to minimize dust and silt that could make it onto public roadways,” Morris says. “And if you’re using water for dust suppression, it needs to be fed from a very clean source to prevent clogged filters and nozzles.”

From a processing standpoint, considerations for dust control should include covers on conveyors, at transfer points, and at the screen discharge, as well as hooded and sealed areas at crusher discharge points to allow spraying of water, making sure to maintain the skirting with tight seals. “Make sure you have an adequately high-pressure wet suppression system, and use automated controls to keep the proper amount of water in the plant,” he notes. “Nozzles should be placed in areas that allow easy inspection and service.

And drain valves should be installed at low points, which helps to prevent the effects of freezing during cold weather.”

Indeed, water is a producer’s best friend for dust control. Morris believes a water truck should always be part of an operation’s production fleet. “An overlooked, but effective, method is utilizing the water truck to soak down the shots in the pit. Wet or moist feed to the plant can go a long way to cut down dust,” he says. “Keeping stockpiles sprayed down also helps.”

Mobile equipment on unpaved roads and surfaces can account for more than 30 percent of total dust emissions, according to Morris. “The top thing operators can do to control dust from mobile equipment is to control the speed of the vehicles onsite,” he says. “Additionally, producers should shorten haul roads, if possible, and grade roads with clean aggregate wherever possible to keep silt off of the haulway.” A water truck also can come in handy to wet down roadways.

From a maintenance standpoint, two key items in a wet suppression system that require regular care are nozzles and filters.

“The nozzles need to be checked daily, and the filters need to be checked and cleaned monthly,” Morris says. “Solenoid valves are another component that must be checked and cleaned regularly, in order to operate properly.”

AGGREGATES MANAGER

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Big With appropriate training, proper operation, and the right maintenance routine, your impact crushers can go the distance.

by Eric Marcotte

26

T

here’s an urban legend out there

crucial for guaranteeing day-to-day reliability

about the company whose main-

and optimum product output. Did you know

tenance crew mistakenly installed

you can boost output and quality by doing

a new crusher with the rotor

just a little bit more? Even daily cleanups and

spinning backwards. It still worked! And you

inspections can increase service life. It’s a

think you have issues?

no-brainer, though possibly easier said than

To get the most from your equipment in-

done. Here are some steps and practices to

vestment, you need to put in the time. Yes,

incorporate in your ongoing operations and

a crusher costs a bit more than your aver-

maintenance. Beginning with maintenance

age automobile, but that doesn’t mean it’s

team education, parts logs, and general

maintenance-free. An automobile needs oil

maintenance record keeping, plus trouble-

changes too, right? Performing regularly

shooting, these guidelines will help your

scheduled maintenance on impact crushers is

crusher go the distance.

AGGREGATES MANAGER August 2015

EQUIPMENT MANAGEMENT

Training: • Proper training for consistent maintenance is one of

Lubrication: • Completely drain and thoroughly clean out the inside

the most fundamental requirements for successful, reli-

of the oil tank (if you have one) to eliminate any con-

able production. Begin with the crusher’s operation

taminants before refilling.

and maintenance manual. Incorporate the manual’s suggested routine maintenance schedule into the maintenance team’s duties. Appoint a “lead person” for each crusher as the go-to for that machine. This per-

• Find contaminant sources. Contaminants such as dust particles and water can get in where oil leaks out.

• Inspect hydraulic systems and tag any leaks for corrective action on the very next maintenance cycle.

son is the historian for the unique operational adjust-

• Use the proper grade of oil.

ments the producer has incorporated for raw feed and

• Use the proper specification of filters.

product requirements.

• Keep the oil breathers clean.

• Understand grease versus oil lubrication. Grease re-

Daily log (document the following every 8 hours):

quires less-intensive maintenance than that of oil-

• Amperage draw: See if it changes from day to day. If am-

lubricated systems. Automatic oil lubrication systems or

perage is exceeding normal levels, it could be a signal of

sealed cartridge bearings are for higher speed crushers

bearing problems, loose belts, or general feed issues.

like vertical shaft impactors, air swept fine grinders, or

• Coast-down time: You’re going to need to know (and

high-speed cage mills. Most horizontal shaft impactors,

log) how long it takes the machine to come to a complete stop after shutdown. Here’s why: If the time starts to shorten, this could indicate a bearing problem.

• Oil pressure: You’ll want to record performance in a

hammer mills, and cage mill applications are below 1,000 rpm and grease is sufficient.

• Maintain a scheduled oil sampling program. By creating a baseline of normal wear, it helps indicate when abnormal

variety of operating conditions. This will allow you to

wear or contamination is occurring. The exact condition of

identify trends and help to detect problems before they

a mechanical assembly is reflected in the oil.

cause costly damage or downtime.

Belts: Daily maintenance (every 8 hours): • Check oil level, sight glass, grease appearance, and other lubrication schedules.

• Check high temperature or low hydraulic pressure indi-

• Inspect V-belt drives for damaged belts or loose belt tension. By replacing cracked, glazed, torn, or separated belts, plus maintaining proper belt tension, you’ll optimize your plant’s performance.

cators and switches.

• Check wear parts.

• Tighten bolts.

Wear parts: • Don’t overextend wear parts. Avoid running them so

• Inspect belts.

long that they become too worn. You may find that

• Remove dirt and debris from crusher frame surfaces

you can no longer rotate breaker bars or interchange

and areas around the machine.

• Check intake/discharge chutes for any obstructions

wear plates to lower wear areas — and now, you’ve lost half of the wear.

and/or build up.

• Check alarms. If electrical changes are made or pro-

Guards:

grams are altered in automated systems, verify that all

• Rubber and chain curtains located in the feed and dis-

alarms and interlocks function properly. Don’t be afraid

charge openings of the crusher are subject to wear and

to replace switches or timers that appear damaged or

tear. Since they are a first line of protection, it’s impor-

are in poor condition. This is more economical than a

tant to inspect them regularly and to establish a sched-

major overhaul, but never disable or alter any alarms or

ule of regular maintenance.

interlocks!

AGGREGATES MANAGER August 2015

27

Electrical: • When (or if) electrical changes are made, you’ll need to verify that all alarms and interlocks still properly function. Same goes for programs when altered in automat-

Wear parts: • Index and or replace sleeves periodically.

• Inspect or replace hopper ring and shaft protector, if needed. Cage rebuilding is an option.

ed systems. Always check with the manufacturer before making any modifications.

Bearings: • Follow the manufacturer’s recommended specifications and

Spares recommendation: • Keep the recommended spares on hand and order re-

schedule for lubrications, temperature, and vibration ranges of spherical roller bearings in pillow block housings.

placements as soon as they are used. A list of recommended spares may be included with your equipment

Additional wear indexing sleeves

operations manual. If not, contact the manufacturer for recommendations.

Update your equipment: • All equipment evolves, and the recommended manufacturer upgrades are a good investment for increased life

Wear obtained running one direction

and better crusher performance. Check with the manufacturer for any possible updates.

Unapproved modifications: • Manufacturer design engineers have considerable field experience, which helps them as they calculate the

Additional wear reversed cage rotation

Typical sleeve wear patterns.

design and perform prototype testing. Their engineering tasks include calculating bearing loads and bearing clearances. They’ve also worked to maximize throughput by establishing the most efficient speed and setting combinations to optimize impact on the material undergoing reduction. So when plant personnel suggest mod-

Normal wear

ifications that alter the intended design, these changes will more than likely hurt the purpose of the original design. As a result, you’ll have a less productive and reliable crusher due to potential damage and overload.

Since the manufacturer has a vested interest in how well the crusher performs, contact them before making

Feed velocity too high

any modifications.

Cage mill operation and maintenance Requirements for optimum production and wear part

Worn hopper ring Overloaded mill

utilization include the following: • To increase multi-cage sleeve life, cage rotation should be reversed regularly, if possible. (Some cage mills can be reversed, while others cannot.) By reversing the

Plugged/sluggish discharge

cage direction, sleeves will be worn from both sides, thus extending wear life.

28

AGGREGATES MANAGER August 2015

Cage wear-pattern identification.

EQUIPMENT MANAGEMENT

Horizontal shaft impactor operation and maintenance

Requirements for optimum production and wear part utilization include the following:

Variables affecting product gradation include the fol-

• Protect inlet and outlet.

lowing:

• Restrict maximum feed size.

• Rotor speed - Higher rotor speeds produce finer product output.

• Maintain feed rate within allowable limits.

• Check rotor rotation.

• Apron gap settings - Closer gaps retain the feed longer producing a finer product.

• Use metal detection (required).

• Check for wear.

• Breaker bar wear - Regular inspection and turning will lower operating costs.

• Follow recommended breaker bar rotation setting sequence.

• Throughput (tons per hour) - Overfeeding a crusher can make the output more coarse, but it also causes a number of wear and longevity issues making overfeeding a major concern to avoid.

• Moisture - Moisture cushions the impact, producing a coarser product.

• Apron wear - Worn plates can be replaced or moved to ar-

• Check rotor breaker bar, wedge, and stop block or jack screws.

• Check liners and breaker plates.

Vertical shaft impactor operation and maintenance The vertical shaft impactor uses high rotor speeds (1,000 to 3,000 rpm) to apply high energies to the material, and

eas of lower wear.

• Spring bridge operation - Spring set height is critical to maintain proper operation of spring bridges. Spring bridges

since Energy + Material = Size Reduction, it can create sand from 2-inch feed.

return the aprons to their original positions after an overload situation. The use of altered or non-specified springs

Requirements for optimum production and wear part

can cause equipment damage or catastrophic failure.

utilization include the following: • Limit feed size.

New Edge

• Use metal detection (required).

• Observe any vibrations with the use of continuously

Worn Edge

monitored vibration sensors. Listen to the equipment, if something sounds unusual, shut down and inspect.

• Limit recirculating product in a closed system.

• If using water for dust suppression, introduce it into the discharge area if possible. Introducing water in the intake will increase wear.

• Place weight match shoes opposite one another.

Wear parts include the following: • Shoes and tubes,

Breaker bar wear. New edges crush finer.

• Anvil ring or other inserts, • Housing liners, and • Rotor table liners and assembly.

Spares recommendation: • Shoes (one complete set), • Table liner, • Anvils (one complete set), and

Breaker bar changes.

• Discharge plate.

AGGREGATES MANAGER August 2015

29

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Designed for U.S. producers operating a single location with less than 10 non-office staff, your eProducer membership is an excellent value at a cost of less than $1 per day.* As an NSSGA eProducer member, you will have access to the members’ only section of the NSSGA website, including: • Legislative and regulatory updates • Health & safety information • Environmental issues • And much, much more!

Other valuable benefits include: • Subscription to Digital Aggregate, NSSGA’s instant newsfeed • Subscription to the online version of NSSGA’s bi-monthly magazine, Stone, Sand & Gravel REVIEW

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*Some restrictions apply. For complete details, go to nssga.org, or call 1-800-342-1415 today!

EQUIPMENT MANAGEMENT

Table Liner Shoes

Discharge Plate

Anvil Ring

Anvils

The spare parts inventory shown above is recommended for vertical shaft impactors.

In this application, the rotor tubes have been rotated 90 degrees and rotation has been reversed to optimize the life of the wear parts. This operation is getting the most use from its wear parts.

Hammer mill operation and maintenance

Summary

Up running hammer mills combine impact and shear to

customer when the crusher is installed in the field. The

reduce material. Down running hammer mills primarily use

manufacturer needs the customer’s help as much as the

shear by immediately taking feed to the screen or grate

customer needs the manufacturer’s help to achieve the

bars where hammers shear the material, until it passes

highest performance possible. Maintenance service after the

through the openings.

sale, although mentioned last, is a central part of crusher

A partnership begins between the manufacturer and the

system performance. And just in case, the manufacturer will Requirements for optimum production and wear part

have the people and the parts available 24/7 to assist with

utilization include the following:

any problems.

• Lubricate bearings regularly.

• Regularly inspection (unclamp or unbolt front upper half

Regardless of the field application, the training of personnel is key to successfully and optimally operating

housing for access to screens and hammers) liners, ham-

equipment. For the size-reduction industry, crusher mainte-

mers, hammer bolts, rotor discs, grate bars, and screens.

nance problems are mostly related to inadequate training.

This exists at plants both large and small. The most effec-

Spares recommendation: • Hammers,

tive education is a current and ongoing program for crews — and that’s what will result in legendary performance. AM

• Screens, • Liners, and • Grinding plate.

Article courtesy of Stedman Machine Co.

AGGREGATES MANAGER August 2015

31

Supply

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

WHEEL LOADER WORKHORSES New loaders offer better fuel economy and robust designs for maximum productivity.

Production loader Caterpillar’s 990K wheel loader offers more power and increased payload for improved productivity and fuel efficiency. It features a redesigned cab that delivers a sleek operator interface and quiet environment, as well as several features to promote operator and maintenance technician safety and performance. It has a rated payload of 17.5 tons, while the Performance Series Buckets are said to promote quick and full bucket loading. A Cat C27 Acert engine powers the unit and delivers 699 horsepower to increase production. Fuel saving features include ECO Mode, an engine-idle shutdown system, and engine-idle kickdown/auto-resume mode.

Caterpillar | www.cat.com

Efficient Tier 4 Final loader The Case Construction Equipment 721F wheel loader meets Tier 4 Final emission standards. It is equipped with a selective catalytic reduction (SCR) solution that treats emissions separately with Diesel Exhaust Fluid (DEF) and does not require the engine to re-circulate exhaust gas. This is said to improve fuel efficiency by up to 20 percent, lower exhaust temperatures, and provide excellent throttle response and simplified maintenance without sacrificing power. It also requires no DPF regeneration or maintenance. Powered by a 6.7-liter engine, it produces 179 net rated horsepower. It is available with tool carrier or extended reach linkage and in specialty configurations.

Case Construction Equipment | www.casece.com

Auto shutdown feature added The Doosan DL250TC-5 wheel loader offers improvements in fuel efficiency, operator comfort, serviceability, reliability, and remote monitoring with Doosan Telematics. The Tier 4 Final loader is powered by a Doosan DL06 engine and has 172 horsepower. The tool carrier features a parallel lift-arm design that helps keep loads level while the wheel loader is moving. Limited-slip differentials give the machines more traction when excavating, grading, or loading trucks. The unit also features an auto-shutdown system to save fuel. Operators can configure the idle time before shutdown from 3 to 60 minutes.

Doosan Infracore Construction Equipment | www.doosanequipment.com

32

AGGREGATES MANAGER August 2015

Loader offers three power modes

Power and maneuverability

The largest model in the lineup of 9A Series wheel loaders from Hyundai Construction Equipment Americas, Inc., the 7.1-cubic-yard Hyundai HL780-9A, features a fuel-efficient, low-noise, 351-horsepower Cummins engine with advanced electronic controls and self-diagnostics. Three power modes allow for full power or reduced fuel consumption. An automatic transmission minimizes power loss, improves travel speed, and reduces noise. It is equipped with the Himate Remote Management System that can pinpoint the machine’s location, set work boundaries, identify working hours, regulate fuel use, and report maintenance issues.

Hyundai Construction Equipment Americas | www.hceamericas.com

The John Deere 824K-II Wheel Loader is equipped with a 333-horsepower, Tier 4 Final emission-certified engine that is said to deliver power without sacrificing torque. The manufacturer says the machine combines outstanding maneuverability, travel speed (24.9 mph), breakout force, reach, and stability. The loader comes equipped with large, higher-capacity Teammate V Axles with standard cooling and filtration, and on-the-fly engageable front differential lock, giving operators heavy-duty traction for the most demanding terrain — all of which are supported by the advanced diagnostics of Ultimate Uptime, featuring John Deere Worksight.

John Deere | www.deere.com

Load-and-carry loader KCMA Corp.’s 957Z XTreme wheel loader was designed in response to customer demand and is suitable for quarry load-and-carry applications. In recent years, there has been a demand for short boom, load-and-carry, or two-pass configuration loaders. This loader was designed in conjunction with Tier 4 interim loaders introduced in 2013. After numerous field tests, it is now in mass production. During testing, the manufacturer says the biggest surprise was the bucket heaping ability. The unit’s 9-cubic-yard bucket weighed in at 15+ tons in sand and 13+ tons in gravel.

KCMA Corp. | www.kawasakiloaders.com

Fuel-efficient new loader Komatsu America Corp.’s new WA470-8 wheel loader has a 272-horsepower Komatsu SAA6D125E-7, variable geometry turbo charged and after cooled Tier 4 Final certified engine. It is said to use up to 6 percent less fuel than its Tier 4 Interim predecessor. The loader is a utility performer featuring Komatsu’s SmartLoader Logic, combined with a lockup torque converter that activates in second, third, and fourth gears. Working together, the system is said to provide optimal engine torque for improved acceleration, hill climbing, a higher top speed, and fuel savings.

Komatsu America Corp. | www.komatsuamerica.com

AGGREGATES MANAGER August 2015

33

Cubee the AggMan helping educate children about the importance of aggregate since 1998 “The Story of Cubee the Aggregate” helps teach children at the youngest ages about the important role aggregate plays in their daily lives. Geared for students in grades K-3, Cubee and his aggregate friends will take children on a magical journey from Cubee’s birthplace in the neighborhood quarry to his new home in the schools, roads and other structures that enrich our communities and our lives.

The “You’re on Rock” Workbook presents basic earth science information while emphasizing the vital role of the industry in our world. An aggregate activity book for junior geologists, mining engineers and earth scientists. Geared for students in grades 4-6.

Cubee the AggMan T-Shirts are available.

To learn more about these great tools for community outreach, adopt-a-school programs, and receive sample copies of the coloring/workbooks,

Call 800-430-4540 e-mail: cubee@aggman.com

or visit www.AggMan.com

SUPPLY LINES

Easy on fuel and tires

Compact loader performance

Liebherr says it custom-engineers its wheel loaders to perform as efficiently as possible. The L 580 wheel loader features a 288-horsepower Liebherr diesel engine and a tipping load (articulated) of 40,785 pounds. It delivers fuel savings of up to 25 percent by constantly adjusting the power to the job. The self-braking drive system and continuous traction also reduce tire wear by 20 percent, saving maintenance costs. Its smooth control, hydraulic braking, and powerful breakout force and traction make it easy to handle. Like most Liebherr machines, the loader is built with Liebherr components to meet its quality standards.

Liebherr | www.liebherr.com

The TW80 Series 2 compact wheel loader, from Takeuchi-US, is designed to deliver increased performance, improved serviceability, and an enhanced operator’s cab for operator comfort. The compact design allows the loader to maneuver in tight spaces. The cab features air conditioning and heat, adjustable armrest and controller positions, and convenient storage compartments. An automotive-styled interior design features a frameless door for enhanced visibility, easy-tooperate function switches, inching pedal for precise machine control, and precision pilot controls.

Takeuchi | www.takeuchi-us.com

Experience: Retired November 2011 following 41 years with the U.S. Geological Survey

High production loader The Volvo L250H wheel loader is a high production machine designed to deliver excellent productivity and profitability in applications including quarrying, mining, and heavy infrastructure. The manufacturer says operators will experience short cycle times, high breakout force, and excellent controllability with this heavy-duty machine. Specifically in North America, the wheel loader is perfectly matched to on-highway trucks, and the L250H will load a 25-ton triaxle on-highway truck in two passes — two full buckets for one full truck.

Volvo Construction Equipment | www.volvoce.com

• USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present

Services Offered: Applied geology and geological research for construction rocks and minerals, with an emphasis on aggregates.

• Resource evaluation • Expert testimony

• Technical writing and review • Lecturer

Contact me at:

Bill-Langer@researchgeologist.com www.researchgeologist.com BillLanger_AGRM0115.indd 1

35

AGGREGATES MANAGER August 2015 12/16/14 1:21 PM

Need to navigate your way around the industry?

Get the the most current information with the Atlas on CD While the printed version of the Aggregates Manager 2015 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more.

The Atlas on CD contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2015 Aggregates Industry Atlas in pdf format.

Order additional copies of the Aggregates Manager 2015 Aggregates Industry Atlas on CD or the printed version of the Atlas today!

Atlas

Printed Version

1-5 copies 6-20 copies 21-49 copies 50 copies or more

$50 per copy $45 per copy $35 per copy $20 per copy

CD-ROM $250

Plus shipping and handling.

Shipping: $4.50 per Atlas $.70 per CD $8.00 Handling Fee

DATA FILE $200 (online download only)

To order, visit AggManAtlas.com or call 1-800-430-4540

Data Stock Report Company

Ticker

Cemex, S.A.B. de C.V. CRH plc Eagle Materials Inc. Granite Construction Inc. Heidelberg Cement AG Holcim Ltd. Martin Marietta Materials, Inc. MDU Resources Group, Inc. Summit Materials United States Lime & Minerals, Inc. U.S. Concrete Vulcan Materials Co.

CX CRG EXP GVA HEI HOLN MLM MDU SUM USLM USCR VMC

Current Value

$8.70 q $26.83 q $75.16 q $35.01 q $80.04 q $72.62 q $144.60 q $19.09 q 25.80 q $57.51 q $36.83 q $85.39 q

52-Week High

52-Week Low

$12.92 $33.45 $105.69 $39.09 $85.46 $84.37 $155.98 $34.19 $29.00 $76.98 $40.93 $93.07

$8.38 $19.02 $68.54 $30.44 $53.50 $59.77 $103.09 $18.93 $19.65 $55.35 $21.48 $54.10

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 7/8/2015.

U.S. On-Highway Diesel Fuel Prices 7/6/2015

United States East Coast New England Central Atlantic Lower Atlantic Midwest Gulf Coast Rocky Mountain West Coast West Coast less California California

$2.832 $2.938 $3.060 $3.073 $2.810 $2.724 $2.712 $2.785 $3.069 $2.978 $3.142

One Week

-0.011 q -0.016 q -0.011q -0.021 q -0.013 q -0.007 q -0.018 q +0.009 q +0.001 q 0.000 +0.001 q

One Year

-1.081 q -1.040 q -1.038 q -0.996 q -1.072 q -1.038 q -1.090 q -1.124 q -0.998 q -1.007 q -0.993 q

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

AGGREGATES MANAGER August 2015

37

Rock Rejection highlights the difference between S&S and flagrant violations.

by Adam J. Schwendeman

ALJFlagrant DISMISSES Designation A

Adam J. Schwendeman is an associate in Jackson Kelly PLLC’s Charleston office, practicing in the Occupational Safety and Health Practice Group.

He can be reached at 304-340-1077 or aschwendeman@ jacksonkelly.com.

38

AGGREGATES MANAGER August 2015

n Administrative Law Judge (ALJ) recently deleted a flagrant designation brought by the Mine Safety and Health Administration (MSHA) against Oak Grove Resources, LLC. MSHA issued the violation for an alleged § 75.400 violation for impermissible coal accumulations along a 2,100-foot expanse of conveyor belt at the underground Oak Grove Mine in Jefferson County, Ala., in 2012. Oak Grove was assessed a penalty of $146,400.

Since its creation in the 2006 MINER Act, the flagrant provision has been a tool MSHA has increasingly used against mine operators.

Congress defined a flagrant violation as “a reckless or repeated failure to make reasonable efforts to eliminate a known violation of a mandatory health or safety standard that substantially and proximately caused, or reasonably could have been expected to cause, death or serious bodily injury.” This created two possible theories MSHA can pursue: reckless or repeated flagrant violations. Congress gave MSHA the authority to assess a maximum penalty of $220,000 for such violations. After adjustment for inflation, the maximum penalty is now $242,000.

MSHA designated the alleged violation as a repeated flagrant because of the 91 impermissible accumulation violations issued to the operator in the prior two years. MSHA also claimed that the alleged violation was flagrant because the alleged accumulations reasonably

could have been expected to cause death or serious bodily injury.

In his June 1, 2015, decision, ALJ Jerold Feldman rejected MSHA’s contention that the alleged violation was a flagrant violation. In presenting his case, the Secretary argued that a violation is flagrant if: (1) it was the proximate (direct) cause of a death or serious bodily injury that has already occurred; or (2) it can be reasonably expected to be the contributing cause of death or serious bodily injury in instances where accidents have not occurred.

Thus, the Secretary essentially argued that the proximate cause requirement only applies to accidents that have already occurred and, in instances where no accident has occurred, the standard is equivalent with the proof necessary for an S&S violation.

ALJ Feldman rejected the Secretary’s interpretation as unreasonable. The ALJ highlighted the fact that the Secretary was conflating the requirements for an ordinary S&S designation with the requirements necessary to pursue a flagrant violation. Specifically, the ALJ noted that language present in the flagrant provision (“proximate cause,” “reasonably expected to cause,” and “serious bodily injury”) differs from the terms “contributing cause,” “reasonable likelihood,” and “injury of a reasonably serious nature” contained in § 104(d)(1). Disagreeing with the Secretary, the ALJ concluded that the Secretary must prove proximate or direct cause in both instances where an accident has oc-

ROCKLAW

over time in the course of normal mining operations. ALJ curred and instances where an accident has not occurred.

Feldman rejected this argument, noting that such an analyThe ALJ compared the imminent danger provision in the sis goes beyond the scope of a flagrant analysis. Instead, the Mine Act with the flagrant provision as an illustration to ALJ concluded that the proper analysis is “whether the facts highlight his conclusion that Congress intended only the surrounding a violation support a flagrant designation is demost serious violations — that can be reasonably expected termined by the facts as they existed at the time the citation to proximately (directly) cause death or serious bodily inwas issued.” (emphasis added). jury — to be designated as flagrant. The ALJ noted that the This decision is a positive development for mine operators language contained in the definition of imminent danger in and may help to prevent MSHA from designating ordinary the Mine Act is almost identical. Although there are mateS&S violations as flagrant violations in the future. Although rial differences between §107(a) imminent danger orders the decision does not hold precedential weight, Commission and flagrant violations, they both require the same degree case law concerning § 110(b)(2) flagrant violations and the of injury — one that can be reasonably expected to cause Secretary’s corresponding burden is sparse. Thus, until the death or serious bodily injury. ALJ Feldman contrasted these almost identical definitions with that contained in § 104(d)(1) Commission has the opportunity to issue a decision which addresses the significant issues surrounding flagrant violawhich clearly provides that, although the conditions created tions, operators will have to continue to look to decisions by a violation do not cause an imminent danger, they can such as the June 1, 2015, decision from ALJ Feldman for still be designated as significant and substantial. In doing guidance when defending against flagrant violations. AM so, he noted that the Federal Mine Safety and Health Review Commission “has articulated the importance of distinguishing serious violations that pose an extremely high degree of danger, such as imminent danger conditions, from routine S&S violations that could contribute to an injury based upon future continued Wherever the job takes you, our variety of surface mining operations.” crawlers will fit right in.

After analyzing the alleged flagrant 800-732-6762 violation against Oak Grove in the www.atlascopco.us context of whether the violation could have been reasonably expected to proximately (directly) cause death or serious bodily injury, ALJ Feldman concluded that the Secretary did not carry his burden of establishing that the alleged accumulations reasonably could have been expected to proximately cause death or serious injury.

The ALJ highlighted the fact that the Secretary could not establish that an actual ignition source was present at the time of the violation that would be reasonably expected to directly cause death or serious injury. The Secretary argued that there was a potential for ignition sources to arise

AT HOME ON ANY RANGE

AGGREGATES MANAGER August 2015

39

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Aggregates Manager Atlas Data/CD Products

www.aggmanatlas.com

Aggregates Manager Community Outreach

www.aggman.com/community-outreach

34

Atlas Copco Construction Mining Technology

www.atlascopco.us

39

Bill Langer - Research Geologist

www.researchgeologist.com

35

C.L. Dews & Sons Foundry

www.dewsfoundry.com

42

CEMCO, Inc.

www.cemcoturbo.com

43

Clearspan Fabric Structures

www.clearspan.com/adam

43

Elrus Aggregate System

www.elrus.com

IBC

FMI Corp.

www.fminet.com

4

Great American Truck Show

www.gatsonline.com

40

Hammond Air Conditioning, Ltd

www.hammondac.com

43

John Deere Construction Equipment

www.johndeere.com/loaders

BC

Kleemann, A Wirtgen Group Co.

www.wirtgenamerica.com

25

KPI-JCI and Astec Mobile Screens

www.kpijci.com

20

Kruse Integration

www.kruseintegration.com

43

Liebherr Construction Equipment Co.

www.liebherr.us

IFC

NSSGA Membership

www.nssga.org

30

Progressive Commercial Insurance

www.progressivecommercial.com

12

Pugmill Systems, Inc.

www.pugmillsystems.com

42

Rock Systems, Inc.

www.rocksystems.com

42

Sandvik Construction Mobile Crushers & Screens USA

www.construction.sandvik.com

2

SDLG North America

www.sdlgna.com

7

Terex Minerals Processing Systems

www.terexmps.com

17

Trimble Loadrite

www.loadritescales.com

13

Volvo Construction Equipment

www.volvoce.com/smartcare

11

36, 42

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

AGGREGATES MANAGER August 2015

41

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Get the the most current information with the 2015 Aggregates Industry Atlas and the Atlas on CD.

While the printed version of the Aggregates Manager 2015 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more.

The Atlas on CD contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2015 Aggregates Industry Atlas in pdf format.

2015 Aggregates Industry Atlas

Your guide to aggregates operations, locations & ownership

June 2015

Order additional copies of the Aggregates Manager 2015 Aggregates Industry Atlas on CD or the printed version of the Atlas today!

www.AggMan.com

7 15 23

Equipment investments pick up steam Meet the USGS’ top 25 crushed stone producers What will MSHA’s crystalline silica rule look like?

To order, visit AggManAtlas.com or call 1-800-430-4540

42

AGGREGATES MANAGER August 2015

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Be a cool operator

8/19/14 9:28 AM

Belen Mfg seeks a full time MECHANICAL ENGINEER

When you work hard in small spaces, you need AC big time!

• Masters degree required.

• Experience in mfg with crushing and associated equip preferred.

• Technical responsibility for the design of new products and upgrades to existing products from concept to completion.

• Must be proficient in Solid Works 2014, AutoCAD 2014.

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• Some travel may be required.

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With over 700 different kits engineered and developed, count on Arctic Wolf™ for factory-style integrated air conditioning systems in ready-to-fit kits. Loaders. Dozers. Excavators. Graders. Tractors.

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7/13/15 6/19/15 2:08 1:08 PM PM

1-800-267-2665 • sales@hammondac.com • www.hammondac.com AGGREGATES MANAGER August 2015

081-135A Equip World 4.5x4.5.indd 1

43

2015-03-17 12:12 PM

by Bill Langer

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

He can be reached at Bill_Langer@hotmail.com

Barre:

In Stone

THE LAND OF GOLDEN OPPORTUNITY

Despite a depressed economy and double-digit unemployment, Barre drew skilled tradesmen from around the world and fueled local growth.

‘Readers of STONE have been told of the wondrous natural resources of mineral wealth which only await development all over Vermont, and…the golden opportunities which await the capitalist who will apply his means to the development of these resources. Conspicuous among the towns thus favored stands… Barre, that phenomenal wonder among New England towns as regards its growth during the past two decades.’

(Editor, 1892, Stone Illustrated, Vol. V, p. 11) This year, this column chronicles the growth of the granite industry of Barre, Vt. During the 1890s, demand for Barre granite skyrocketed. The stone had been used in the famous Vermont State House, large amounts of grout (waste rock) from quarrying had been used for August Barre Granite Mausoleum paving stone, and the beautiful stone was recognized as a premier stone for monuments and mausoleums.

It was the use in monuments and mausoleums that caused the demand for Barre granite to skyrocket. Meeting the everincreasing demand required investors. During much of the 1880s and 1890s, large parts of the country were struggling with a depressed economy and double-digit unemployment. Nevertheless, Barre prospered as capitalists lined up to invest in Barre Granite. In 1881, the population of Barre was just over 2,000, and the real estate was valued at $712,439. By 1892, the population had surpassed 9,000, and the real estate was valued at $3,473,753. This phenomenal growth was due, almost entirely, to the development of the granite quarries and finishing sheds.

Barre became the land of golden opportunity. The unrelenting demand for skilled artisans with a knowledge of quarrying or working stone could not be met locally. Furthermore, there was unrest over most of Europe. These combined factors resulted in a wave of immigrants from Scotland, Italy, Sweden, England, Norway, Spain, and Canada. Each nationality made its contribution to the monumental stone industry.

Most immigrants sailed to America on packet ships in the steerage area below decks. Conditions varied from ship to ship, but steerage could be unbelievably bad. Normally, steerage was crowded, dark, and damp, and limited sanitation and stormy seas often combined to make it dirty and foul smelling. Rats, insects, and disease were common problems. On at least one ship line, one in 10 steerage passenger died during the transatlantic voyage.

Scottish immigration, which had begun in the 1840s, was well underway by the 1880s. Most Scotch immigrants to Barre were from Aberdeen, a region where artisans had been working granite as far back as the early 11th century. It was said that, as compared with the old country, the Scots in Barre worked harder, received higher wages, and spent more money, but they were no happier. By 1890, Scotch immigrants made up 20 percent of Barre’s population.

In the mid-1880s, many highly skilled Italian designers, sculptors, and carvers began to immigrate to Barre from the famous marble center of Carrara. Many of the artisans had studied sculpture in Italian arts academies and could trace their ancestry back to the medieval times of Michelangelo. By 1910, about 14 percent of Barre’s population was Italian, and Barre had become the home of Vermont’s largest Italian population.

Immigrants of other nationalities soon followed. The immigrants brought with them a myriad of stone carving styles which, when applied to the high quality of Barre granite, propelled the rock into the national spotlight.

44

AGGREGATES MANAGER August 2015

• • • • •

Sandvik Dealer in MT, WA, ID, OR, UT, CO, WY, AK, HI

YOUR IDEAS. BROUGHT TO THE SURFACE.

Building your aggregate business together. With input from loader users like you, our K-II Series Loaders are beefed up and back for more. Larger, highercapacity axles with standard axle coolers and fltration provide heavy-duty, on-the-fy differential locks for traction on tough terrain. Final Tier 4 engines use high-uptime exhaust flters and selective catalytic reduction (SCR) to meet emissions regulations, with no loss of power or effciency. And data from the optional L2180 payload scale can be viewed remotely in JDLink™. It’s all backed by our customizable support solution, Ultimate Uptime featuring John Deere WorkSight™. Learn more from your dealer, or visit our website.

JohnDeere.com/loaders