Y o u r
g u i d e
t o
p r o f i t a b l e
p r o d u c t i o n
August 2016 | www.AggMan.com
Hillhead 2016: Check out the big iron debuts from the show
27 32
Vermeer offers an alternative to drilling and blasting
40
Court agrees to hear suit against MSHA’s POV rule
Get more from your loaders with performance conditioning monitoring
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*Extended warranty covers replaced powertrain components only. Additional parts are covered by the standard John Deere parts warranty.
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Production loaders set the pace for feeding material to the plant, so it’s important to efficiently operate and maintain these machines.
PAGE 32
On Our Cover: Hillhead, the biennial quarry show, registered more exhibitors and attendees. Cover photo by Therese Dunphy.
Terex Mineral Processing Systems rolls out its new cone plant, the CRC1150.
PAGE 11
TABLE OF CONTENTS AUGUST 2016 |
VOLUME 21, NUMBER 8
FEATURE ARTICLES
18
Hillhead is a Hit
27
Vermeer Debuts its New Terrain Leveler
32
Managing Wheel Loaders for Low Costs and High Productivity
Despite post-Brexit turmoil and less-than-ideal weather, crowds flock to England’s live quarry show.
The third generation machine offers an alternative to drill and blast.
From routine inspections and condition monitoring to best operating practices, there are plenty of ways to control wheel loader costs while producing efficiently.
37 Secondaries Size and Shape
Secondary and tertiary plants help operators meet market demands for tight specs.
OPERATIONS ILLUSTRATED Sampling for Quality
21
To ensure your aggregates meet or exceed customer expectations, consider which sampling method suits the needs of your operation.
COLUMNS & DEPARTMENTS 3 Editorial Lessons that convey from paint to pit. 5 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook. 8 State and Province News A roundup of the latest news in North America. 11 RollOuts John Deere’s 944K hybrid wheel loader, and other new equipment for the aggregates market. 40 Rock Law The mining industry finally gets an opportunity to present its case against MSHA’s Pattern of Violations rule. 42 Advertiser Index See who’s who and where to find their products. 43 Classified Ads Aggregate industry classifieds. 44 Carved in Stone Two intrepid cavers discovered the Kartchner Caverns and ensured they were protected before being made public.
CLOSE TO OUR CUSTOMERS
CLOSE TO OUR CUSTOMERS
Find out more: www.wirtgen-group.com
August 2016
EDITORIAL
Vol. 21, No. 8
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
aggman.com /AggregatesManager @AggMan_editor
Editorial
Lessons that Convey from the Paint to the Pit
Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson editorial@aggman.com
Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Linda Hapner production@aggman.com
Construction Media Vice President, Construction Media: Joe Donald sales@randallreillyconstruction.com
3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com
Corporate Chairman: 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 2016. 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.
Disclaimer: The author is a devout Cleveland Cavaliers fan and season ticket holder. All opinions expressed herein are her own and in no way diminish Randall Reilly’s utmost affection for football or the Crimson Tide.
I
confess; I am a diehard Cleveland Cavaliers fan. Not the recent, frontrunner breed, but the kind who watched games at the Richfield Coliseum, spent portions of my honeymoon watching the Cavs/Bulls Eastern Conference Finals in 1992, and delighted in rubbing elbows with Brad Daugherty and Lenny Wilkins at local establishments. So, while basketball comparisons may seem like a stretch, lessons from successful organizations cross many boundaries. • Build teamwork and chemistry within the organization. A controversial moment of the Cavs’ regular season came when head coach David Blatt was replaced with Tyronn Lue. With no disrespect to Blatt, having a leader who meshes with his team matters. As a former player, Ty Lue just gets his players. Consider this when promoting your next plant superintendent. • Take advantage of second-chance opportunities. In the winner-take-all final game, the Cavs were weak with the three-point shot, but strong around the rim and grabbed loose balls to take shots within the paint. If you don’t get the job the first time, retool your bid and make the next one count. • Help your co-workers. LeBron James’ triple-double in Game 7 gave the Cavs not only 27 points, but also 11 rebounds and 11 assists. Without those assists, the game could have had a different outcome. Getting production from the superstars in your operation is great, but encourage them to mentor coworkers as well. • Share the credit for a job well done. After a celebratory parade attended by 1.3 million people in Cleveland, LeBron James singled out accomplishments from every one of his 14 co-workers, recognized the importance of the management team, and credited the fans for all their support throughout the season. Acknowledging the accomplishments of your team motivates them to do their best work, and customer recognition makes them feel special. These actions impact your culture. • Being generous with your good fortune. While James may be considered a hometown hero for delivering a national championship, his charitable works also gain him a lot of local love. Area newspapers covered it when his foundation pledged $41 million to send 1,100 students to the local university. Many aggregates operations donate to local causes. Be sure to send a press release to the local news media and get a little credit for your good works. After a 52-year drought, Ohio is celebrating its championship team, but you don’t have to wait that long. Implement these principles and make your company a winner in 2016. AGGREGATES MANAGER / August 2016
3
Industry Focus. Powerful Results.
Where Vision Meets Value.
Select Assets of Eastern Industries, Inc. a division of
and Albany Asphalt & Aggregates
New Enterprise Stone & Lime Co., Inc.
has been acquired by
a subsidiary of
New Enterprise Stone & Lime Co., Inc.
have been acquired by
a portfolio company of BMC Enterprises, Inc.
a division of
has acquired select aggregate assets from
has been acquired by
has been acquired by
a subsidiary of
a division of Oldcastle, Inc.
*Represented by FMI Capital Advisors
FMI Capital Advisors, a subsidiary of FMI Corporation, is the leading investment banking firm serving the Construction Materials industry. With over 100 completed transactions in Construction Materials, our industry focus enables us to provide our clients with valuable insight and advice. Clients gain access to our unparalleled network of industry contacts and relationships, deep market knowledge and technical expertise, based on decades of experience.
George Reddin | 919.785.9286 | GReddin@fminet.com
Scott Duncan | 713.936.4930 | SDuncan@fminet.com
WWW.FMINET.COM
q
DATAMINING Stock Report Company
Ticker
Cemex, S.A.B. de C.V. CRH plc Eagle Materials Inc. Granite Construction Inc. Heidelberg Cement AG LafargeHolcim Ltd. ADR 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 HCMLY MLM MDU SUM USLM USCR VMC
Current Value
$6.55 p $28.70 q $79.87 p $48.74 p $78.47 q $8.64 p $196.53 p $24.04 p $21.44 p $59.90 p $62.06 q $123.98 p
52-Week High
52-Week Low
$8.82 $31.37 $87.04 $49.79 $88.53 $15.07 $199.87 $24.67 $27.48 $61.67 $69.66 $127.17
$3.50 $19.38 $45.03 $28.45 $64.38 $6.92 $108.31 $15.58 $13.12 $45.56 $39.82 $78.83
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 7/11/16.
U.S. On-Highway Diesel Fuel Prices 7/11/16
One Week
One Year
United States
$2.414
-0.009 q
-0.400 q
East Coast
$2.424
-0.014 q
-0.491 q
New England
$2.469
-0.013 q
-0.560 q
Central Atlantic
$2.521
-0.014 q
-0.517 q
Lower Atlantic
$2.341
-0.014 q
-0.456 q
Midwest
$2.385
-0.004 q
-0.319 q
Gulf Coast
$2.261
-0.021 q
-0.447 q
Rocky Mountain
$2.445
+0.009 p
-0.342 q
West Coast
$2.708
-0.001 q
-0.329 q
West Coast less California
$2.596
-0.323 q
California
$2.798
-0.003 q —
-0.335 q
Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
AGGREGATES MANAGER / August 2016
5
Aggregate Drones
“I was able to accurately measure the volumes of stockpiles at one of our quarries in just 10 minutes using the Kespry Drone System. Previously, it took me about 2 days of strenuous GPS work to cross-section those piles. This is an amazing technology!” —John P. Davenport, Construction Surveyor, Whitaker Contracting Corporation
Automatically measure aggregate stockpiles Kespry drones are saving mining companies time and money by automating the measurement of aggregate stockpiles and construction materials. Companies can fly their own sites and automatically get the perimeter and volumes for all their aggregate stockpiles as frequently as needed. The Kespry 2D and 3D aerial models also assist with mine surveying, planning and operations. With Kespry, what used to take weeks now takes hours.
Aggregates | Construction | Insurance
www.kespry.com/aggregates
Aggregates Industry Outlook 140 136
131.68
130.99
129.05
127.51
128.42
132
128.15 126.03
125.60 122.49
128
119.44
130.00
124 120
128.99 128.61
116 112 108 104 100
Jul. 2015
Aug. 2015
Sept. 2015
Oct. 2015
Nov. 2015
Dec. 2015
Jan. 2016
Feb. 2016
Mar. 2016
Apr. 2016
May 2016
Jun. 2016
Jul. 2016
In July, the Aggregates Industry Outlook (AIO) dropped 6.79 percent from June, to its lowest overall score to date of 119.44. With 100 as a neutral rating, respondents continue to be consistently positive. Responses varied, however, by nearly 100 points among individual respondents indicating strong differences in various regional markets and among operators themselves.
Comments: The construction aggregate business is rebounding as evidenced by records being set by the two largest producers during the first quarter. The second quarter results are also expected to show strong gains over 2015. — O.F. “Russ” Patterson, III, Chief Geologist, Patterson Exploration Services Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.
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7
STATE & PROVINCE
NEWS
To keep up to date with news from the United States and Canada, visit www.AggMan.com for daily updates.
by Therese Dunphy | Editor-in-Chief tdunphy@randallreilly.com
COLORADO State legislators and Fremont County elected officials, as well as county commission candidates, toured three Martin Marietta quarries in June, the Canton City Daily Record reports. The company has acquired the Parkdale Quarry and Rock ‘N Roll shortline railroad from Front Range Aggregates. It has also purchased the Red Canyon Quarry and Penrose Quarry from Rocky Mountain Materials, giving it a significant presence in the area. Between the three quarries and railroad, Martin Marietta employs approximately 40 people in the county.
CONNECTICUT According to the News Times, bats that have lived in an old tunnel at the Boardman Road Quarry will soon get a new home as O&G Industries constructs a new cave to replace their current home. A spokesman for the company noted that it has been working proactively with the state Department of Environmental Protection for the last five years to create a new home for the bats. The habitat, which includes a 40-foot tunnel that is 6 feet wide and 7 feet tall and feeds into a large underground chamber, will be completed in time to encourage the bats to use it this winter. Approximately 200 bats have been seen at the site.
ILLINOIS A Geneva man who was convicted in a fatal crash into a Naperville Quarry died after he was found unresponsive in the Waubonsee Community College library. The Aurora Beacon-News reports that 23-year-old Michael Szot was sentenced in March to periodic imprisonment after driving his car through a fence and into a quarry lake two summers ago. Two passengers were killed in the incident. His cause of death is pending toxicology and histology results.
INDIANA The Journal Gazette asked its readers to submit the Northeast Indiana “hidden gems” that they enjoy showing to friends and family. Featured in the resulting list is Hanson Aggregates’ Ardmore Quarry. The quarry has an observation deck that was installed in 1966 and continues to draw in 1,000 school groups for field trips, as well as 10 to 20 daily visitors. Plant manager Brett Pepple told the newspaper that he believes people are drawn to the landscape, which features highlights the man-made mountain created from the glacier till that once served as overburden to the limestone deposit. Newspaper reader Jean Podzielinski said, “The view from the overlook is breathtaking.”
8
AGGREGATES MANAGER / August 2016
NEW JERSEY Stoneco of Michigan’s Denniston Quarry was recently awarded the company’s Operation of the Year Award for its performance during the 2015 construction season. According to The Monroe News, the award recipient is selected by a vote of company management. All of the state’s 18 operations were evaluated on safety, plant performance, site appearance, and community involvement. “Denniston’s employees are leaders in striving for excellence in Stoneco of Michigan’s safety culture,” the company said in a press release. “Their core values are rooted in ‘Making Safety a Family Business’ to ensure that every person that comes on-site makes it home safe every day.” In 2015, the plant finished the season with zero recordable incidents, zero lost-time incidents, zero yellow iron incidents, and a world-class inspection record with the Mine Safety and Health Administration. The operation also made plant upgrades, including screens and other equipment, to increase production.
MINNESOTA The Buffalo County Board of Adjustment voted 3-0 to approve a conditional-use permit for Milestone Materials, a division of Mathy Construction. The Winona Daily News reports that the permit paves the way for its limestone quarry in the town of Mondovi. A plans call for expanding an existing quarry purchased in 2004 to 120 acres of adjoining land owned by Segerstrom & Sons. Milestone Materials has a 20-year lease agreement with the landowner and intends to mine limestone from an estimated 60 acres. Mining is expected to take place on weekdays as needed from March to November, with an estimated annual tonnage of 100,000 tons.
NEW JERSEY Some Bloomingdale residents, including two former council members, recently suggested that the Borough Council hold a referendum on a quarry overlay ordinance. According to NorthJersey. com, the council has been considering a proposal to expand the Tilcon Quarry on Federal Hill, and some residents want to put the issue to a non-binding vote. The town mayor noted that he does not support putting the expansion on a ballot. He said it would be impossible to make all voters aware of the facts to be considered. At the same time, he voiced concerns regarding the town’s revenue and the impact blocking the expansion might have on its affordable housing initiative.
PENNSYLVANIA In June, West Manchester Township Fire Department and several other neighboring departments were sent to Magnesia Refractories Co.’s quarry. The York Dispatch reports that a fire there was caused by a malfunctioning device. A company vice president told the newspaper that the fire was in an isolated area of the plant that was not in operation at the time, and employees followed the proper procedures and called 911. No one was injured, and employees successfully evacuated the plant. The company anticipates repairs, but no impact on its operations.
SOUTH DAKOTA
VIRGINIA
The hearing on a lawsuit brought by Croell Redi-Mix against the Pennington County Commission was expected to take place near Aggregates Manager’s press time. The hearing follows a delay in the $10 million lawsuit initiated by the operator. The board originally approved the company’s expansion request, but reversed its decision following an outcry from the public. According to NewsCenter1.com, the lawsuit alleges that the county violated the company’s property rights when it revoked its construction permit. An attorney for the operator said the county cannot prevent his client from the lawful use of its property without liability. He added that damages to the company are significant for every day it is prohibited from operating the quarry.
A renewed focus on its core crushed stone business led Luck Cos. to sell off its Har-Tru Sports tennis court clay and accessory unit, as well as its Luck Stone Center Division, which sells architectural stone. According to Richmond Biz Sense, four buyers purchased the retail locations in Virginia and North Carolina. Those buyers include Kildare Enterprises (Dulles, Va.; Leesburg, Va.; and Charlotte, N.C.), Frederick Block, Brick & Stone (Charlottesville, N.C.); Tucker Thorpe (Raleigh, N.C.). Thorpe is the former manager of the Raleigh site, which will now operate as Southern Stone Supply. Terra Stoneworks purchased the Luck Stone Center workshop in Leesburg. Har-Tru sold in mid-May to Tuckahoe Holdings.
TENNESSEE After a year of protests, Industrial Land Developers received a state permit for its quarry in Old Hickory, WKNO reports. State regulators focused on the company’s National Pollutant Discharge Elimination System permit and determined that rain water that falls into the pit and gets dirty should be pumped and treated before flowing into the Cumberland River. “We obviously empathize with the public, with a lot of their concerns — truck traffic… dust, noise, and things of that nature,” Bryah Epperson, mining operations manager for the state Division of Water Services, told the radio station. “However, we do not have purview or any kind of jurisdiction over those particular issues.” The company continues to work on its air quality permit, which is under review with a 30-day public comment period this summer.
WISCONSIN The Dane County Zoning and Land Regulation Committee voted 3-2 against revoking a conditional-use permit for Oak Park Quarry, the Wisconsin State Journal reports. The vote had been postponed several times in recent months to allow a closer study of the issue. Neighbors have complained about damage to buildings and structures that they blame on the operation’s blasting. The quarry has a 10-year conditional-use permit, which requires it to receive all applicable local, state, and federal permits. The quarry’s major violation, according to county staff, was that its owner did not have its mining and blasting permits from the town of Deerfield, which it has since received. The operation will now have to adhere to the town’s new, tighter blasting standards.
SOLID PERFORMANCE
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TENNESSEE
to stainless-steel heat exchangers submerged in the reservoir. * Prices are subject to change without notice. Water is cooled from 79 to about 63 degrees. The airport auVisit sdlgna.com for details. thority’s vice president of strategic planning and sustainability says the system is the largest of its kind in North America.
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L948F: 3.0 yd 3 / 171 hp
LG958L: 4.0 yd 3 / 241 hp
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Untitled-5 1
7/12/16 3:07 PM
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THE QS331 GYRATORY CONE YOUR ULTIMATE BASE PRODUCT SOLUTION You spoke, we listened. – – – –
3 Foot Cone 3 Foot Running Costs 4 Foot Performance 5 Foot Feed Size
Our QS331 is able to accept a feed size up to 90% larger than standard cones. Low operating costs, high performance. The QS331 is the ideal solution for your base product production needs. Don’t take our word for it, try it for yourself. Please contact us for details of your nearest dealer: 610-662-5405 / 289-439-6125 info.mobilecs@sandvik.com www.construction.sandvik.com
ROLLOUTS
Your complete guide to new and updated equipment and supplies in the aggregates industry.
by Therese Dunphy | Editor-in-Chief | tdunphy@randallreilly.com
Hybrid wheel loader offers efficiency, productivity John Deere says its 944K hybrid wheel loader bolsters the bottom line by offering maximized productivity and efficiency through its hybrid-electric drive system designed to lower daily operating costs. Coupled with a 536-horsepower Tier 4 Interim engine, the 10-cubic-yard loader is said to offer fuel savings over 9-cubic-yard loaders with conventional drivetrains. Its hybrid-electric drive recaptures energy while slowing the loader when the operator lets off the accelerator, lessening the load on the engine and reducing fuel consumption. Four modular, independent wheel drives with electronic traction control allow it to thrive in rugged conditions. The bucket width of 12 feet and breakout force of 103,388 pounds enable quick work around hoppers and stockpiles.
John Deere | www.johndeere.com
Crawler dozer boasts intelligent controls Komatsu America Corp. introduces the D39PXi-24 crawler dozer with first-to-last pass automatic dozing for more efficient production. Once engaged, the system automatically starts the cut and lowers the blade to grade in a typical dozing pass. If the load increases to a maximum, the blade automatically raises to minimize track slip to keep dozing productively. This is said to achieve up to 8-percent greater efficiency when moving material. In addition, a new standard, operator-selectable, automatic reverse grading mode enables automatic blade control while reversing to grade target surface. The dozer is powered by a 105-horsepower, tier 4 Final, SAAD953-7 engine.
Komatsu | www.komatsuamerica.com
New cone plant features automation, larger CSS Terex Minerals Processing Systems says its new, highly mobile CRC1150 portable cone plant features a new TC1150 cone crusher that uses high-efficiency roller bearings and boasts several advancements that enhance performance and functionality. New key features include automated cone controls and larger closed-side settings. The crusher is powered by a 300-horsepower motor and drive-mounted on a rubber-isolated frame. The plant includes an oversize cone feed hopper extension with overflow chute, straight-line undercrusher conveyor, metal detector, and service platforms. Ease of maintenance features are said to include conveniently located grease banks and a ground access cone lubrication module.
Terex Minerals Processing Systems | www.terexmps.com
AGGREGATES MANAGER / August 2016
11
ROLLOUTS Upgraded articulated trucks feature larger payload Cat unveils its C2 Series articulated dump trucks, including the 314-horsepower 725C2 and the 367-horsepower 730C2 and 730C2 EJ with ejector body. The trucks come with Tier 4 Final engines in the U.S. and feature payloads of 26.5 tons for the 725C2 and 31 tons for the larger trucks. The Cat 6F/1R powershift transmission electronically modulates clutch engagement pressures for smooth shifts while the Caterpillar Advanced Productivity Electronic Control Strategy (APECS) system improves acceleration, maintains torque converter lock-up during shifts, provides automatic speed holding, and modifies shift points to match operating conditions. To control downhill speeds, the larger models use an engine-compression brake while the 725C2 uses a fluid retarder with four operating modes. A new design dump body features a diverging flow design to promote clean dumping and minimize carryback. An optional Cat Production Measurement system brings payload weighing to the cab.
Caterpillar | www.cat.com
Specifications 725C2
730C2
730C2 EJ
Engine
Cat C9.3 Acert
Cat C13 Acert
Cat C13 Acert
Net power, horsepower SAE J1349
314
367
367
Rated payload, tons
26.5
31
31
Heaped capacity, cubic yards
19.6
22.1
22.1
Total loaded weight, pounds
103,707
114,034
120,186
Max. speed, forward, mph
34
34
34
Loader gains efficiency with power-split driveline Liebherr rolls out its large XPower wheel loaders with the power-split driveline as standard. It says this ensures power and efficiency as the transmission performs the same function as the traditional power-split transmission, but with a greater level of efficiency. It combines a hydrostatic drive — which it describes as the most efficient drive in short loading cycles — and the mechanical drive for long distances and driving up gradients. The result is a reduction in fuel consumption of up to 30 percent. In addition, strengthened Z lift arms provide up to 20 percent more breakout force, and the optimized bucket is said to offer improved penetration action.
Liebherr | www.liebherr.com
Updated jaw design features reversible dies McLanahan gave its line of Universal Jaw Crushers a series of design updates that make everything from installation to maintenance a safer, simpler, and smarter process. The new stationary jaw die design has a bevel that rests in a matched groove on the lower clamp plate and is secured by upper clamp plates with a groove to match the bevel. Dies are reversible to use more wear metal, and clamp plates match both upper and lower die bevels. The 64-inch jaw features stationary wear plates made of two dies with peaks in the middle and valleys on the outside. The company says the dies can be used on the movable side, if the right side die moves to the left side to put the valley in the middle. The new crusher design features lighter, replaceable upper and lower stationary jaw die clamp plates that are easy to install, replace, and secure. All clamp plates are interchangeable, and three cheek plates per side allow liners in high wear areas to be replaced independently of other liners.
McLanahan Corp. | www.mclanahan.com
12
AGGREGATES MANAGER / August 2016
Extreme Duty Motors
BRANDS You Count On, PEOPLE You Trust. Choosing the toughest high-starting torquedesigned motor for your quarry, mine or mill just got easier. The new line of Baldor•Reliance® Crusher Duty motors are high performance, NEMA Premium® efficient motors suitable for across the line or inverter duty use in extremely harsh environments. Designed for drop-in replacement and easy maintenance, Crusher Duty motors from Baldor keep your operation performing to its highest level. And, you can find Baldor•Reliance crusher duty motors at your local Motion Industries location. Our local sales and service specialists are experts in application and technical support, providing the parts and the know-how you need to stay up and running.
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WE’RE REBUILDING AMERICA’S INFRASTRUCTURE.
BE A PART OF IT.
When you join NSSGA you can be sure your voice is heard. As we work together to ensure adequate transportation funding, eliminate needless regulation and rebuild our infrastructure to world-class status.
Join us today in leading the way to an even stronger tomorrow. To be a part of it, visit us at www.nssga.org or email info@nssga.org.
www.nssga.org
ROLLOUTS Wear segments target hard-to-change parts HX900 wear segments, from Sandvik Construction, are said to help maintain the original shape of vital equipment surfaces such as crushers, loader buckets, chutes, excavators, rock box edges, and weld-on hammer tips. Available in three shapes — bars, buttons, and runners — they are intended for places that are inaccessible for installation of wear liners. This means fewer stops, lower maintenance and operating cost, and more time for production. The wear material combines the wear resistance of cemented carbide with the shock resistance, ductility, and forming capability of nodular iron. This combination results in a hard material that is said to stand up well in tough environments and have long wear life.
Sandvik Construction | www.construction.sandvik.com
Modular impact beds offer load-zone protection Flexco says its new Modular Impact Beds are engineered with maximum capacity in mind, while ensuring full containment, and designed with universal components that offer effective and affordable load-zone protection. They feature a 2-foot sectional design, which allows the users to fit the layout to their load zones, depending on application-specific performance requirements. The beds can be paired side-by-side with each other to match specific load-zone lengths and requirements. They also feature slide-out service, as well as long-lasting, 1-inch UHMW bars designed for use on reversing belts. Universal components and field-adjustable trough angles are said to reduce lead time and make the beds easier to service.
Flexco | www.flexco.com
Quality. Performance. Reliability. Materials Testing Equipment you can depend on!
Primary screens feed wash plants The R-Series range of primary screens, from CDE Global, is designed to optimize feed to wash plants and reduce the need for an operator to feed the processing plant. The line includes the R1500, which has a maximum feed capacity of 220 short tons per hour, and the R2500, which has a maximum feed capacity of 551 short tons per hour. The R-Series combines a feed hopper, screen, and conveyors in various configurations. Both machines are available with either a belt feed or an apron feed. Galvanized screens include patented side wall technology that eliminates weld and results in a stronger, lighter screen that produces the same acceleration as traditional screens while using less power. The R1500 includes an 8- by 5-foot screen, while the R2500 has a 16- by 5-foot screen.
Gilson Silent Sifter® II SS-22 • 16—18dB quieter than competing rotary sifters. • Advanced design and materials for better performance. • Accurate results. • Simple and efficient.
800.444.1508 • globalgilson.com
CDE Global | www.cdeglobal.com AGGREGATES MANAGER / August 2016
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ROLLOUTS Remote-controlled drive unit optimizes production rates Hartl Crusher rolls out Performance Skid, a remote-controlled drive unit and docking station for hydraulic processing attachments such as bucket crushers. It is said to optimize the production rates of the attachments and offer high energy-efficiency and minimal operating costs. The crushing unit can be detached from the skid frame and mounted on the excavator boom for solo jobs. The company says it’s a game changer in the world of mobile processing. In combination with a bucket crusher, the Performance Skid is said to offer improved performance, adjustable height, and tipping function. The unit can be transported with a hook lift truck.
Hartl Crusher | www.hartl-crushing.com/us
System removes conveyor carryback through vibration Superior Industries, Inc. offers a new option for eliminating carryback from the return side of a conveyor belt system. The Urathon Beater Roll combines a CEMA-rated return idler and a series of urethane lobed discs. The discs cause light vibration, which dislodges carryback material. According to the manufacturer, ideal locations include above a stockpile, screen, or bin so the ejected material hits an appropriate target point. The beater rolls can be purchased as full, pre-assembled idlers or individual urethane-lobed discs. Each disc is coupled with a hose clamp for assembly onto existing idlers in the field. They are made to fit CEMA C and D class return idlers in diameters of 4, 5, and 6 inches.
Superior Industries | www.superior-ind.com
Trailer-mounted dust control Dust Control Technology’s DustBoss DB-100-Fusion is its largest trailer-mounted dust control system. The range for its atomized mist is 328 feet, with a coverage area of 140,000 square feet. The mobile platform can be positioned at the source of dust-generating activities, even on sites without an available power supply. The unit features a 150-gallon fuel tank, providing for approximately 32 hours of run time without refueling. Doors are equipped with hinges and door stops for easy access. Day-to-day operations can be managed by the on/off switch outside the enclosure. A 120-volt receptacle for auxiliary tools and a plug-in for the battery charger and block heater are also located outside.
Dust Control Technology | www.dustboss.com
Experience: Retired November 2011 following 41 years with the U.S. Geological Survey • USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present
Services Offered: Applied geology and geological research for construction rocks and minerals, with an emphasis on aggregates. • Resource evaluation • Expert testimony
• Technical writing and review • Lecturer
Contact me at:
Bill-Langer@researchgeologist.com www.researchgeologist.com
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Hillhead is a Despite post-Brexit turmoil and less-than-ideal weather, crowds flock to England’s live quarry show.
D
espite chilly temperatures and steady torrents of rain, Hillhead 2016 was a success with 18,655 visitors and sold-out exhibition space. Located in Buxton, England, the biennial show saw a more than 7-percent increase in attendance compared to 2014. The show is unique in that it features live equipment demonstrations in a former Tarmac quarry. A total of 470 exhibitors, the largest number in the show’s history, showcased new products for the aggregates industry. Some of the highlights are included here, but watch the RollOuts section in upcoming issues for additional introductions.
Mobile equipment Hyundai Heavy Industries Europe featured 12 machines, including two world premiers — the HX430L excavator and
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AGGREGATES MANAGER / August 2016
the HX480L excavator. The new range of excavators includes a state-of-theart Advanced Around View Camera System, which provides a 360-degree field of vision. The system also alerts the operator when people or objects are detected within a 16.5feet radius of the machine. Volvo Trucks showcased its new five-axle FMX Triden 10x6 truck equipped with twin front steering axles and an air-sus-
Hit
pended double-drive bogie with an additional air-suspended tag-axle. The truck has a maximum gross vehicle weight of 61.7 short tons when used for off-the-road applications. A 10x4 configuration is said to be particularly well suited to quarrying applications. In addition, Volvo’s A60H articulated hauler — first introduced at bauma — was on display at the show. With an industry leading 60-ton payload, the truck is said to lower cost per ton of material moved using the existing frame and powertrain designs with the emphasis on fuel efficiency. Caterpillar highlighted its C2 Series of articulated trucks (see page 12) with Tier 4 Final engines, among a large display by dealer Finning. It also showcased advanced drone technology for the first time in the UK through its partnership with Redbird. “Hillhead this year is all about technology, with our live demonstrations combining the very latest equipment and cloud-based solutions,” says Phil Lewis, Finning Hillhead demonstration manager. “The drone data collection and Redbird’s image analytics capability will provide customers with a variety of solutions for their operations. These include material inventory management, haul road optimization, and project progress to name a few — all of which complement the other data-driven services.” Liebherr’s display included recent introductions such as its R970 super mass excavator, PR 726 dozer, and its XPower wheel loaders with power-split driveline.
Processing equipment Sandvik highlighted its popular QJ341 crusher, which has a new pre-screen that is said to provide high amplitude to remove more fines, improve efficiency, and lower wear on the crusher. The company also introduced a telescopic chute, the WE6000i; a new automation and control system, SanRemo for Crushers; and a new cone crusher, the CH540. “Our customers…require as few and as short of maintenance interruptions as possible,” says product line manager Martin Johansson. “So to increase performance, while reducing weight and height, we had to optimize all our components — and the end result is remarkable.” Australian company Striker used the show to launch its expansion into several regions and debuted its all-new U.S. range of machines. Based on its standard series of machines, the U.S. line includes a few tweaks to ensure the clients in the
U.S. get a tough machine that was customized to its requirements. For example, the H3000R is one of the company’s smallest impactors and is designed for use in a small quarry or by a recycling contractor as a single-pass machine or a closed-circuit machine. Kleemann featured two of its machines, the MC 100 R (the smallest jaw crusher in the Mobicat line-up), which produces up to 200 tph, and the MR 110 Z EVO 2 mobile impact crusher, with a production capacity of up to 350 tph. As part of the Wirtgen Group display, the exhibit marked the company’s first time to showcase its five brands — Wirtgen, Vogele, Hamm, Kleemann, and Benninghoven — together in the UK. McCloskey International focused on its jaw crusher duo, the J40V2 and J45R, during the show. The J40V2 was part of the crusher alley demonstration followed by an ST80T tracked stacker, while the J45R was in its display. As Powerscreen marked its 50th anniversary during Hillhead, it showcased a number of portable crushing and screening units. A standout is the new generation Powerscreen Premiertrak 400 jaw crusher. The latest iteration was redesigned to run at a low engine RPM to improve fuel efficiency, as well as lower noise emissions. The machine on display was fitted with an optional post screen system. It also expanded its Warrior 2100 triple-shaft screen with two new variations — the Spaleck and the single-shaft model. Terex Finlay unveiled two new portable crushers — the C-1540 direct-drive cone crusher and the I-140RS impact crusher — as well as the new 674 inclined screen. Nigel Irvine, sales and marketing director, described the company’s line up of machines at the show as “our largest presence ever at Hillhead.” The company also highlighted the recently introduced 1554 crusher as part of the show’s live crushing demonstration. Terex Mobile Processing Systems focused on the global launch of the MJ400R, a modular recycling jaw, as well as the TSV6203 screen. The jaw features what is said to be “industry-leading access.” The unit has the Terex TJ2844R single-toggle jaw crusher on a galvanized steel structure including walkways, steps, guardrails, and product conveyor. Terex Washing Systems rolled out the AggreScalp 125, a modular chassis-mounted scalping unit designed to work with other TWS systems; AggreStac, a track-mounted conveyor system; and the FM UltraFines fines recovery system. “As an industry segment, crushing and screening has somewhat plateaued; it’s not changing at the same rate it used to... The washing side is completely different. It’s at an earlier stage in its development and it’s changing rapidly,” says Oliver Donnelly, newly appointed global business line director for Terex Washing & Minerals Processing Systems. “It’s an exciting time for me to come into the business. There has been a heavy investment by Terex into Terex Washing Systems.” AM
AGGREGATES MANAGER / August 2016
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PULL-OUT GUIDE By Mary Foster, Contributing Editor
August 2016
Sampling for Quality
Proper sampling is critical to all quality control.
Automated belt cut samples eliminate the human safety factor.
Two schools of thought include stockpile sampling and conveyor belt sampling.
An experienced loader operator ensures consistent, accurate stockpile samples.
OPERAT
Quality Con
1
Primary methods
Sampling for Quality
“W
hat you have to recognize is that sampling is critical to a plant’s quality control. It’s just as important as testing,” says Tim Tipton, quality control director for Hinkle Contracting, a Summit Materials company. Tipton explains that production quality control has evolved over the years. Not only are producers more in control of testing their product quality than in the past, when the DOT agencies held all control, but the systems and methods for managing quality at aggregate facilities also have become more sophisticated. The first step in testing material for quality is taking a sample of a product that will provide a true picture of the product’s gradation for a customer’s need. Tipton says valid concerns for the final product also include contamination and segregation, which can occur on conveyors and in stockpiles — both of which provide methods for sampling. Of course, there are pros and cons for each method. According to Tipton, Hinkle prefers to use the stockpile sampling method, acquiring the sample with a loader, which is safer than using a shovel and bucket to pull samples directly from the pile. “The loader operator takes material from three to five locations in the stockpile, loading at a right angle to the flow of how the stockpile was built,” he AGGREGATES MANAGER
says. These samples are used to create a “mini” stockpile from which another sample is taken for testing. The method helps to address concerns of contamination and segregation, as long as an experienced operator is taking the sample. Conveyor belt cuts are another way to sample aggregate materials, and can be accurate for determining gradation. The traditional method for obtaining a belt cut sample requires the plant to stop production. A template that matches the curvature of the conveyor belt is used to manually cut and separate a cross section of the material. The worker takes three to five cuts, brushing the material into a bucket for testing. “This type of testing doesn’t give you the full picture of your material. It relies on the employee taking a complete sample, including fines; it can affect your production rates, and it also creates safety concerns,” Tipton says. Adam Orner, global product manager for wet and dry sampling at McLanahan Corp., agrees that the traditional belt cut method has its limitations and concerns. “This is why we promote the use of cross belt samplers,” Orner says. Cross belt samplers are automated, enclosed machines mounted on the conveyor. They use a “bucket” with a counterweight to swing and scoop samples from the moving conveyor, delivering them to a container. “With cross belt samplers, you have no downtime, and it eliminates safety concerns,” he says.
Sampling is a critical component of the entire quality control process — equally as important as testing. While there are a number of methods for sampling aggregates, two primary ways to obtain samples include stockpile sampling and conveyor belt sampling. With either procedure, the producer must make sure to be consistent in how, when, and where the sample is obtained.
4
Belt cuts and falling stream samples
Conveyor belt cuts and falling stream samples provide a good picture of the products being made, especially addressing concerns with gradation. Belt cuts require shutting off the belt and taking samples from three to five locations, using a template to cut out the samples. Manual sampling from the material flow falling from the head pulley leads to safety concerns. The belt cut method affects both production and safety.
TIONS ILLUSTRATED
ntrol: A Cross Section of Sampling Practices 2
Stockpile sampling
Samples from stockpiles may be obtained by a shovel and bucket or by a loader. Concerns with the shovel-and-bucket method of stockpile sampling — including safety factors and sample quality — have led to the practice of obtaining samples with a loader. A trained, experienced loader operator can ensure consistency with gradation and samples that are free from contamination and segregation issues.
5
Automated sampling
Automated cross belt or falling stream sampling can eliminate concerns with safety and consistency. In the simplest terms, the cross belt sampler operates inside an enclosure, with a counterweight and swinging cutter bucket that scoops material from the belt under production, emptying it into a sample container. A falling stream sampler automatically crosses the stream from the head pulley to obtain the sample from the flow.
3
EXPERTS
Loader sampling tips
For the best consistency in sampling, it is ideal to have the same experienced loader operator take all samples for a particular product. This eliminates issues that can arise from variables in technique. Ideally, the loader operator should obtain material from three to five locations in the stockpile, load at a right angle to the flow from which the stockpile was built, and then create a miniature stockpile.
6
OUR
With 40 years of aggregates production experience, Tim Tipton is quality control director for Hinkle Contracting, based in Paris, Ky. Tipton began his career with Hinkle in 1976, working initially as part of the cleanup crew at Hinkle’s Natural Bridge Stone facility. He was promoted to the position of aggregate technician at the plant in 1977, gaining certification as a bituminous technician in 1979. Six years later, Tipton became asphalt plant superintendent at Hinkle’s Central Paving division before his promotion to quality control director in 1986. He serves on advisory committees for the Kentucky Plant Mix Association and the Kentucky Crushed Stone Association.
Cross belt sampling tips
It is best to install a cut zone idler and cushion system beneath the conveyor as part of the cross belt sampler. The cut zone system forces the conveyor belt into the proper radius conformation to obtain a full cut from the belt — including fine material. The cutter bucket must be large enough to obtain a full cross section of material and should swing at a speed slightly higher than the speed of the conveyor.
Adam Orner is the global product manager – dry and wet sampling for McLanahan Corp., and is based in Hollidaysburg, Pa. He began his career with McLanahan Corp. in 2001 as mechanical engineering design specialist and project manager where he was involved in the design, fabrication, implementation, and field service of a wide variety of mechanical sampling systems and equipment. In 2008, Orner was promoted into the role of director of engineering for the company’s sampling product line, a role that he maintained until accepting his current global product manager position in 2016.
August 2016
Voices of Experience Tim Tipton
t
“Proper sampling is critical to successful quality control,” says Tim Tipton, quality control director for Paris, Ky.-based Hinkle Contracting. “You must be uniformly consistent in how and when and where you pull your samples.” Hinkle Contracting takes material sampling seriously. The company has a sampling qualification program for its own production foremen and employees, as well as for DOT personnel. “We prefer to sample from stockpiles,” Tipton says. “If you build your stockpiles right, we feel this method best addresses concerns with gradation, contamination, and segregation. A loader and an operator experienced in sampling will get you a very accurate picture of what is going out the gate to your customers.” Accuracy of the sample starts with stockpiling practices, Tipton explains. Variables in how a stockpile is built can affect its quality. “Do you stockpile by truck? Do you use a fixed or radial stacker? A Superstacker (telescoping stacker)?” he asks. Stockpiles built by truck grow in layers, keeping the material from cascading down the slope of the stockpile — reducing segregation. A radial stacker that moves back and forth also builds stockpiles in layers. In building a stockpile with a conventional fixed stacker, the key is to keep the stacker as low to the pile as possible. “If you let the material fall from 50 feet in the air, you are going to have segregation in your stockpile,” Tipton says. “I like the Superstacker style,” he adds. They’re both telescopic and radial, building the pile in windrows, for the best shot at eliminating segregation.” In obtaining the samples, Tipton recommends pulling three to five samples from the pile to create a miniature stockpile. “You want to get the bucket into the stockpile as deep as you can at a right angle,” he says. Of course the greatest piece of advice Tipton has is to be consistent with the sampling time, method, and operator. “Training is important, and you have to figure out which method is best and do it the same way every day,” he notes. “It also helps to make sure your operators — and all employees — understand what the customer needs, what their applications are, and the importance of producing quality products. “Always try to keep everyone in the loop, so someone isn’t trying to do it by himself. Quality control is a journey, not a destination,” Tipton concludes.
Adam Orner
t
Today’s methods for sampling aggregates can vary greatly. They include traditional methods such as taking shovels-full of material by hand or loader from a stockpile, manually holding a container under a conveyor head pulley, and obtaining conveyor belt cuts by hand. They also include more automated methods such as cross belt samplers. “We try to steer people away from manual sampling, particularly from stockpiles. We believe that the best methods remove human interaction — for safety and consistency,” says Adam Orner, global product manager for wet and dry sampling at McLanahan Corp., based in Hollidaysburg, Pa. “If you have a person taking discretionary samples from a stockpile, you may not be getting the best samples. If you’re taking traditional hand samples or stopped belt cuts, you are dealing not only with potential safety issues, but also with costly down time and labor associated with manual material handling.” A cross belt sampler collects a full cross section of material from a moving belt without human interaction. The operator can take samples with the push of a button or automatically set the sampler to take samples at certain times of a shift. “Cross belt samplers are cost-effective, easy to install, and collect manageable sample increments,” Orner says. The cross belt sampler is a fully enclosed machine, which contains a rotating, counterweighted cutter assembly. The cutter assembly rotates through a full 360-degree rotation to cut a material sample from the moving conveyor belt before decelerating to a stop back at its original parked position. The key to obtaining a complete and representative cut is to also install a Cut Zone multi segment idler and impact cradle system beneath the conveyor as part of the cross belt sampler. The Cut Zone system forces the conveyor belt to conform into the proper radius to obtain a full cut from the belt — including fine material. “With the cross belt sampler, you want to make sure that the cutter bucket capacity is larger than the cross section of material on the conveyor belt,” Orner explains. “The cutter opening varies based on your product size. We recommend a bucket width of three times greater than your top size material.” A consistent cutter speed is also important; the cutter should not slow down as it travels through the material flow. A good rule of thumb is a cutter speed greater than oneand-a-half times the belt speed to help assure a quality cut and minimize spillage,” he says. The time interval between cuts really depends on the producer’s sampling plan.
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FIRST LOOK by Marcia Gruver Doyle | Editorial Director
Vermeer debuts its new Terrain Leveler
The 600-horsepower T1255III weighs between 150,000 to 250,000 pounds, depending on the boom option chosen.
The third generation machine offers an alternative to drill and blast.
I
n its third iteration of the Terrain Leveler, the T1255III, Vermeer is taking direct aim at quarries. “Good ideas can come from all over, and this one started with our Italian dealer,” says Jason Andringa, president and CEO of Vermeer. “He said, ‘You have big rock trenchers, why not put a drum on it instead of a trencher?’ At the time, we had no idea of the scope of applications it could be used in.” Those applications have included road building, site preparation, and mining. But now, Vermeer feels the biggest opportunity for this machine is in quarries, particularly since the surface excavation method used by the Terrain Leveler addresses several key challenges as housing developments start to surround many once-rural quarries. It offers: • A less intrusive extraction method than traditional drilling
and blasting. Vermeer says the machine can be used either instead of, or as an adjunct to, drilling and blasting. • A way to precisely extract narrow seams of material, allowing quarries to work around pipelines, to avoid high water tables, or to continue to work in permitted areas that before might have been prematurely abandoned. • Reduced noise, dust, and vibration. An on-board dust suppression system helps minimize another common community complaint. “We can go after a specific seam,” says Patrick Robinson, Vermeer’s senior corporate account manager for mining. “It’s also been used in overburden removal, providing an alternative to using dozers with rippers,” Robinson says. “This machine is built for chewing up rocks.” AGGREGATES MANAGER / August 2016
27
FIRST LOOK
New drive system allows highwall operations Since it was introduced in 2001, the Terrain Leveler has used three distinct drive types: • A chain drive, placed in the middle of the machine, drove two side cutting heads. Although this design gave users good depth, it also consumed chains in production applications. • Direct drive, with motors placed on each side of the cutting head. With this design, productivity jumped 25 to 30 percent, and the wear costs went away, says Vermeer. But there was a downside: the machine lost its vertical wall capabilities, going from 90 degrees to 45 degrees. • With the introduction of the T1255III, a larger, single hydrostatic motor mounted to one side of the cutting head provides direct drive power to the drum, giving the machine the ability to excavate highwalls up to 80 degrees on one side. “This gives us the best of both worlds,” Robinson says. “We have the productivity improvements, no chain wear, and the ability to excavate an almost vertical wall.” The T1255III can cut to a depth of 21 inches and a width of 144 inches. It is powered by a 600-horsepower Cat C18 Tier 4 Final engine. Using a cutting head rotating counter clockwise, the machine engages with the surface from the drum’s 7 o’clock to 4 o’clock position, a method designed to create fewer fines. Since it leaves product that is 6-inches or less, the machine reduces fines and eliminates hauling material to a primary crusher. The product can go directly into a mobile cone crusher to produce a final product. A quarry could use it for site prep, haul road construction, or maintenance. “It’s really a mobile primary crusher,” says Mark Cooper, managing director, specialty excavation.
Grade and steering controls The Terrain Leveler is also one step toward Vermeer’s “road to autonomy.” In addition to load control, which has been on Terrain Levelers for several years, the T1255III uses GPS-enabled grade and steering control. The grade control directs cutting head depth and pitch, allowing the operator to cut to plan and produce a flat, smooth surface, or install drainage or sloped haul roads. It also eliminates rapid changes in cutting depth. The unit’s steering control can be used to create a mineby-line plan, following the quarry’s GPS-survey-created mine plan that has been uploaded into the machine. The T1255III then automatically cuts to plan, helping remove human error to cutting head overlaps by providing an overlap cutting of only 6 inches. Producers can also set parameters to where the machine can and cannot cut. In addition, the SmartTEC performance software on the machine assists operators with adjustments to machine controls, showing them the status of critical machine performance indicators, with prompts for recommended adjustments. The software also records machine performance for future analysis.
28
AGGREGATES MANAGER / August 2016
The cutting head is enclosed by the dust collection hood.
The cutting head features aggressive teeth. Vermeer recommends inspecting and replacing worn teeth on an hourly basis.
The end result: a 6-inch-minus material that does not have to go through a primary crusher.
FIRST LOOK
Rock lab “We knew we had to get smarter about the geology our products were encountering,” says Mark Cooper with Vermeer. And so in 2006, the company established a rock lab at its Pella, Iowa, headquarters. There, the company performs a number of tests designed to help it better predict machine performance when handling certain rock types. Using rock samples shipped from around the world, Vermeer uses compression and abrasiveness tests to discover measurements the company says help it find ways to handle certain types of rocks. In addition to industry standard tests, the company has also developed proprietary tests and a global rock properties database. “Quarries always ask us ‘What is your cost per ton?’” says Vermeer’s Patrick Robinson. “This gives us the ability to tell a customer that with a high degree of confidence.”
And the software has operator training capabilities. “The incab display will actually teach an operator how to run the machine,” Robinson says. “If an adjustment needs to be made, it will tell them to make that adjustment, which the operator can then decide to either do or not do. We wanted to give operators some knowledge about how to run the machine to get the best out of it. If their engine load is high and their hours are high, then they’ve gotten everything out of the machine.”
Dust suppression, operator safety Vermeer attacked dust by enclosing the cutting head with a hood and positioning two large vacuums to feed into Donaldson baghouses on either side of the machine. The collected dust is then deposited on the undercarriage tracks, to be reworked into the ground. “We’ve been working for at least three years to develop a waterless dust containment system,” Robinson says. “Water is not a great way to solve the dust problem, especially since there are areas where water is at a premium,” Robinson says. The cab has a filtered air system and air-ride suspension seats for an operator and trainer. Protected by both ROPS and FOPS systems, the cab elevates so the operator can be positioned for optimum visibility. A full-function wireless remote allows the operator to control the machine from outside the cab. The remote can also be used when an operator is changing cutting head teeth. AM
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AGGREGATES MANAGER / August 2016
Big Yellow Iron Event showcases Vermeer’s quarry machines The T1255III received its debut at Vermeer’s Big Yellow Iron 2016 event, hosted by its Vermeer Texas-Louisiana dealer in San Antonio, Texas. Three other machines also shared the spotlight: The HG6000TX horizontal grinder, used for site and right-of-way clearing, is a tool for greenfield sites, creating mulch out of what would be a waste product. The tracked machine has an option of 20- or 26-inch double grouser track pads and is powered by a 755-horsepower Cat C18 engine. The new T655 rock wheel can be used to cut dimensional stone, eliminating the need for finishing saws. It has a maximum cutting depth of 48 inches and maximum width of 3 inches, and uses quarry and utility wheels ranging from 6 inches to 10 inches. It’s powered by a 250-horsepower John Deere 6090 HF engine. The TR620 trommel screen, fitted with an auger drum design, can produce two to three products in one pass. Operated either through the DP10 display mounted on the control panel or through a remote, the machine is powered by a 120-horsepower Cummins QSB 3.8L engine.
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EQUIPMENT MANAGEMENT by Sean Gladieux, Jason Hurdis, and Christopher McKenna
MANAGING WHEEL LOADERS FOR LOW COSTS AND HIGH
PRODUCTIVITY
P
roduction wheel loaders set the pace for feeding material to the plant, and yard loaders keep material moving across the truck scales. Maintaining and operating these machines efficiently is key to keeping costs down and production up in aggregates operations. Historically, most maintenance and repair strategies have been built around a fixed interval approach. This includes a fixed interval for preventive maintenance tasks and fixed hour intervals for replacing or rebuilding power train
32
AGGREGATES MANAGER / August 2016
components and hydraulics, such as engines and pumps. Though fixed interval service remains common, many equipment managers are instituting condition-monitoring programs to get the most out of machines and components. Rather than review the familiar fixed interval program, we’ll outline the condition monitoring process, which builds on proven machine health monitoring techniques. Using the power of telematics data and analytical software, equipment
managers, often working with equipment suppliers or consulting organizations, can create condition monitoring programs where maintenance activities and component rebuilds are effectively determined based on measured factors and the predicted risk of failure. Specifically, data inputs for performing condition monitoring include: • Electronic machine data, • Fluid analysis, • Equipment inspections, • Equipment history and component tracking, and
Yard loaders must be in good condition to load customer trucks and keep material moving across the scales.
Production loaders set the pace for feeding material to the plant, so it’s important to efficiently operate and maintain these machines.
• Site conditions and application as it applies to condition monitoring. Electronic machine data includes both data downloaded from the machine by technicians and data transmitted via wireless telematics systems. Of course, fluids analysis includes engine oil, hydraulic oil, transmission oil, final drive oil, and coolant. Equipment inspections by trained personnel remain a cost effective way to immediately identify problems and to provide insight for the condition-monitoring program. Equipment service reports and machine history can
also provide insight to ongoing issues. The site assessment evaluates equipment application and the work environment including seasonal weather conditions. The next phase of condition monitoring, data analysis, is focused on using all the data sets listed previously and performing aggregation, correlation and analytics, interpretation, and, finally, making a recommendation for repair or other intervention. Aggregating all pertinent equipment and application data is the first step. Next is correlating the data to identify meaningful inter-re-
lationships and analysis to identify abnormal deviations. Then, a final review is performed by a condition-monitoring analyst, who creates value-based recommendations for repair, maintenance, or operational adjustment. The intent is to harness the power of automation and analytics to reduce the burden of manual reviews and correlation. Proper usage of analytics has been proven to be much more accurate and faster than any expert human analyst can be. The benefits that make these efforts worthwhile are significant: AGGREGATES MANAGER / August 2016
33
EQUIPMENT MANAGEMENT
Machine data can be gathered from the machine itself, as well as through telematics systems. Once data is gathered, it can be used to identify meaningful inter-relationships and identify abnormal deviations.
• •
Improved availability; Improvement in planned vs. unplanned maintenance — a measurement of the quality of the detection routines and overall effectiveness of the maintenance strategy; • Improvement in mean time between shutdown — a measurement of reliability; • Improvement in mean time to repair — a measurement of repair efficiency; • Extended planned component replacement intervals; • Reduced risk and enhanced cost control; and • Avoiding catastrophic component failures and the associated costs. Most mining equipment managers have been involved in some aspects of condition monitoring for a long time. Fluids analysis, drain plug inspections, formalized machine inspections, site studies, and some electronic data have been available for decades. Now, telematics data and the power of big data analytics result in more accurate and faster identification of issues.
Loader operating practices In addition to directly affecting production, wheel loader operating practices can have a significant impact on reliability and durability of the machine — and
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AGGREGATES MANAGER / August 2016
the maintenance and repair costs the machine demands. Based on countless production studies conducted at mines around the world and at Caterpillar proving grounds, Caterpillar wheel loader applications specialists recommend these best practices for most efficient face loading. Many of these tips apply to yard loader operation, too. Site prep for efficiency: The optimal bench height is at the maximum lift height of the loader. Higher benches have the potential to collapse and overload the bucket, which can damage the loader. Also, avoid a steep material slope angle, because it can cause material to fall unexpectedly into the bucket, overload the machine, and cause damage. Maintain a smooth floor and good drainage, because wet rocks cut tires easier. And clean the floor between trucks to maintain good floor conditions. This helps avoid loader and truck tire damage and helps minimize truck maneuvering, which wastes time and fuel, when pulling in and out of the loading site. Pile engagement and bucket fill: Begin loading the bucket as low as possible right above the floor for optimum pile penetration. To reduce potential for tire damage, do not drive into the pile with the front wheels, and avoid tire spin to reduce tire wear and tire cuts.
Keep the frame straight when digging to maximize pile penetration and production. Loading time in the face should be less than 15 seconds for high production, good fuel efficiency, and reduced heat generation and wear in the torque converter. Lift the bucket before crowding the bucket into the pile, because crowding is not producing material, but it is unnecessarily burning fuel. The bucket should be full when the lift arms are horizontal. Continuing to fill the bucket above horizontal is not efficient and does not use the strength of a wheel loader. Never operate a bare bucket edge, because it will ruin the bucket. Make sure ground engaging tools are in place and are replaced when worn out. Truck-loader interaction: Spot trucks with a loaded bucket. Spotting trucks with an empty bucket means the loader isn’t moving material during part of the cycle, which wastes time and fuel. Keep the rear tires of the truck off the pile to avoid damage to the truck tires, and spot trucks at 30 to 45 degrees for ease of pile-to-truck approach and to minimize cycle time. Use a tight V pattern with the loader into the truck to minimize loading time and maximize production. This also limits tire travel to reduce tire wear and fuel burn. Position the loader 1.0 to 1.5 wheel revolutions from the face to the truck to minimize cycle time and improve production. Pad the truck bed with smaller material when loading oversize rocks to protect the truck bed from damage. Of course, for good loader production efficiency, wait time for trucks should be minimized. Getting efficient production from loaders while keeping maintenance costs down is a cooperative effort of the operations and maintenance team, but telematics and powerful analytical tools offer more ways than ever to minimize downtime and keep loaders working efficiently. AM Sean Gladieux is the product manager, Cat Equipment Care Analysis; Jason Hurdis is senior market professional, Construction Materials Industry; and Christopher McKenna is the loader applications specialist for Peoria, Ill.-based Caterpillar Inc.
Fluids analysis revealed During fluids analysis, multiple tests are performed on engine, hydraulic, and drive train oils — plus coolant, too. They can reveal a lot. Component wear rate Each oil-washed system has a particular concentration of wear metals produced during normal operation. By evaluating wear inside the lubricated compartment, a technician can see if rates are normal or not. For example, high levels of iron and chrome can stem from problems with engine cylinder liners and/or piston rings. What are we looking for? • Wear metals — This includes iron, lead, copper, aluminum, and chrome. • Silicon — This may indicate dirt entry depending on local soil conditions. • Sodium — This is a potential indicator of water or coolant entry.
Oil condition Wear occurs when oil depletes its additives and begins to deteriorate. This can damage components in oil-washed compartments. So it’s important to know if the oil has reached the end of its useful life. What are we looking for? • Viscosity — If it is too low, wear can occur. If it is too high, the oil won’t do its job. • Oxidation (oxygen molecules joining with lubricant molecules) — In diesel engines, oxidation can trigger sticking piston rings. In hydraulics, oxidized lubricants will increase pump wear and damage valves. • Sulfation (sulfur combining with water during diesel fuel combustion) — This can corrode valves, cylinder liners, and more.
Oil contamination This robust analysis involving several tests can determine if anything harmful has entered the oil. What are we looking for? • Soot (from partially burned fuel) — This
An analysis of various fluids provides operators with many insights, including component wear rate.
can plug oil filters and cause engine wear. • Fuel — This can come from the combustion process and cause low viscosity. • Water (such as from condensation, leaks, wet conditions) — This can cause wear, rust, and sludge. • Coolant — This can contaminate engine oil.
Oil identification The wrong fluid in the wrong compartment can affect performance and lube protection or even severely damage major components. To tell if it’s the right fluid, it’s important to take an accurate sample with the right labeling. What are we looking for? • Viscosity — Is it optimal for the geared compartment and your application? • Additive chemistry — Is the oil appro-
priate based on its unique chemical makeup?
Coolant analysis Today’s heavy-duty engines produce a lot of power from a small package, and cooling systems have to do more with less. What are we looking for? • Coolant type — With so many on the market, they all have different chemistries. • Boil and freeze protection — This is important to monitor ability of the fluid to provide adequate protection. • Condition — This is necessary to test health for pH, conductivity, nitrite, solids, odor, color, and appearance. • Contamination — The operator must evaluate if anything harmful has entered.
AGGREGATES MANAGER / August 2016
35
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Secondaries Shape and Size Secondary and tertiary plants help operators meet market demands for tight specs.
Easy accessibility makes for quick maintenance Cemco, Inc., a 54-year-old industrial equipment manufacturing company, offers the Turbo 80 as the mid-size model in its line of nine vertical shaft impactors. The crusher can be equipped to operate between 100 and 275 tons per hour with a max feed size of 2.5-inch material. Cemco VSI crushers are designed to make the components that require routine maintenance easily accessible. Major servicing can be done in less than an hour, reducing the plant’s down time and lowering overall operating cost. Cemco, Inc. | www.cemcoturbo.com
Fuel-efficient secondary and tertiary plant The Mobicone MCO 9i EVO/MCO 9i S EVO mobile cone crushers from Kleemann offer aggregate producers secondary or tertiary crushing in a fuel-efficient, Tier 4 Final machine. Its 37-inch cone crusher diameter permits a feed capacity of 287 tons per hour, with a feed size maximum of 8.25 inches. The unit’s diesel-electrical drive provides low fuel consumption. Its power plant generates 332 horsepower at 1,500 rpm. The Sversion provides a discharge conveyor-mounted final classifying screen with oversized aggregate return conveyor. This permits a closed material cycle and production of final particle sizes without a stand-alone screen. Oversize can be optionally discharged via the swivel-mounted return conveyor. Kleemann | www.wirtgenamerica.com
Portable plant offers application versatility
NEW
The K300/6203CC portable crushing and screening plant from KPI-JCI and Astec Mobile Screens, combines a Kodiak Plus K300+ Cone Crusher with a triple-shaft, low-profile horizontal screen. In its closed-circuit configuration, the plant allows operators to use a single chassis to produce up to three products or supplement existing demand in a small footprint. It can also be converted to an open-circuit configuration by simply reversing the closedcircuit conveyor. Multiple axle configurations are available to meet portability needs. Several product discharge chutes are also available, as well as feed conveyor and feed conveyor drive options. KPI-JCI and Astec Mobile Screens | www.kpijci.com AGGREGATES MANAGER / August 2016
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SUPPLYLINES
NEW
Update builds upon the Symons Principle McLanahan Corp. says its MSP Cone Crusher combines the Symons Principle with technology factors such as a balanced eccentric, higher speeds, and fulcrum point position and stroke to offer superior performance. The design allows for highly effective compression crushing with minimized recirculation of loads. Through efficient processing, the unit also reduces liner wear, reducing wear costs and offering an overall lower cost per ton of finished product. An array of manganese liners is available for each model, and a patented feature allows the models to fit without the use of backing material. McLanahan | www.mclanahan.com
Efficient crushing in hard-rock applications Metso says the GP220 cone crusher is built to maximize operational efficiency in demanding hard-rock crushing applications. It features a large feed opening, as well as the ability to adjust the crusher cavity and stroke to fit the application. With process control based on Metso’s IC50C automation and with a limited number of service points that are easily accessible, the GP220 cone crusher is also said to be safe and easy to maintain and operate. Metso Minerals Industries, Inc. | www.metso.com
NEW HSI has robust chassis and substructures Powerscreen says the introduction of the new Trakpactor 550 horizontal impact crusher will provide operators with reliability, efficiency, and performance. The sleek and modern Trakpactor 550 is a horizontal shaft impactor targeting the mid-to-large range class. A screen-recirculating conveyor returns oversize product to the crusher. The unit is said to have a robust and heavily engineered chassis and sub-structures within the plant. Powerscreen | www.powerscreen.com
Cones have high crushing forces
NEW
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AGGREGATES MANAGER / August 2016
Sandvik has launched the CH860 and CH865 models, which are said to improve productivity and profitability in the mid-range segment. The CH860, for high-capacity secondary crushing, and the CH865, for high-reduction tertiary and pebble applications, feature a 670-horsepower motor and higher crushing forces relative to mantle diameter. The intelligent systems enable real-time performance optimization, while compact design solutions reduce dynamic loads and minimize installation work. The crushers feature fewer moving parts than competing models. Non-welded, bolted liners on the top and bottom shell enable safer, easier maintenance. Sandvik | www.sandvik.com
Tubular rotor offers high tip speeds A patented VSI Tubular Rotor, from Stedman Machine Co., is said to create higher tip-speeds, which increase first pass yield, produce tighter particle size distribution, and reduce recirculation loads. The rotor rotation is reversible, allowing wear on both sides of the tube. Rotating the indexing tube onequarter turn quadruples the wear surfaces. The Tubular Rotor and Reversible Anvils are retrofittable to any brand VSI. Raw feed sizes of up to 5 inches can be accepted, and models with production rates of up to 500 tons per hour are available. Stedman Machine Co. | www.stedman-machine.com
Cone combines productivity, safety, and ease of maintenance Rated with what Telsmith describes as the largest in-class clearing stroke and the highest in-class crushing force, the T400 Cone Crusher is engineered for maximum uptime and productivity while delivering 400-horsepower performance and a crushing capacity output range from 176 to 606 tons per hour in tough or abrasive quarry applications. With an emphasis on lower operating costs and increased safety, the cone features a large clearing circuit, which is engineered to safely and quickly allow any uncrushable materials to pass. Telsmith | www.telsmith.com
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ROCKLAW
by Adam J. Schwendeman
Who Will Hear Plaintiff’s Claims? The mining industry finally gets an opportunity to present its case agaist MSHA’s Pattern of Violations rule.
A
Adam J. Schwendeman is an associate in Jackson Kelly PLLC’s Charleston, W.Va., office, practicing in the Occupational Safety and Health Practice Group. He can be reached at 304-340-1077 or aschwendeman@jacksonkelly.com.
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fter several years of struggle, the mining industry has finally found a forum to hear its long-sought challenge of the Mine Safety and Health Administration’s (MSHA) 2013 Pattern of Violations (POV) rule. On June 16, 2016, Federal District Court Judge James Graham found that the U.S. District Court for the Southern District of Ohio has jurisdiction to hear the claims of multiple plaintiffs (including the National Mining Association, the National Stone, Sand & Gravel Association, and the Portland Cement Association) against the Secretary of Labor and MSHA challenging the validity of their POV rule. See Ohio Coal Assoc. et al. and Murray Energy Corp. et al. v. Sec’y of Labor, Case Nos. 2:14-CV-2646, 2:15-CV448, 2016 WL 3350466 (S.D. Ohio June 16, 2016). The plaintiffs’ journey began in March 2013 when they filed challenges to the POV rule in the U.S. Court of Appeals for the Sixth Circuit. The Secretary moved to dismiss the challenge, arguing that the court lacked subject matter jurisdiction to hear the claim because the federal appellate courts are only vested with jurisdiction to immediately review mandatory safety and health standards. The Sixth Circuit agreed with the Secretary and dismissed the challenges, holding that the POV rule was not a mandatory health or safety standard and, therefore, it lacked subject matter jurisdiction over the challenge. Plaintiffs then brought suit against the Secretary of Labor and MSHA in the U.S. District Court for the Southern District of Ohio.
AGGREGATES MANAGER / August 2016
The plaintiffs set forth several allegations in their complaints, arguing that the rule violated the Administrative Procedures Act (APA) as well as the Due Process Clause of the United States Constitution. With regard to the APA claims, the plaintiffs allege that the POV rule exceeds the statutory authority granted to MSHA by the Mine Act because the new rule uses non-final citations. The plaintiffs argue that the Mine Act requires the use of finalized violations rather than non-final citations in a pattern of violations determination. The plaintiffs also argue that MSHA failed to subject the POV and Corrective Action Plan criteria to notice-and-comment rulemaking and that the POV rule was arbitrary and capricious. With regard to due process, the plaintiffs allege that the POV rule eliminates the procedural safeguards in place under the 1990 rule and, with those safeguards removed, plaintiffs are not afforded notice or hearing before they are deprived of their property rights via withdrawal order. The Secretary once again moved to dismiss the plaintiffs’ claims, arguing, among other things, that the district court lacked subject matter jurisdiction. The Court rejected the Secretary’s arguments and found that it held jurisdiction to hear the claims. Citing Thunder Basin, the Court acknowledged that the Mine Act precludes district court jurisdiction over pre-enforcement claims that attempt to side-step or preempt the Mine Act’s review scheme. See Thunder Basin Coal Co. v. Reich, 510 U.S. 200, 207 (1994). The Court noted,
ROCKLAW however, that Thunder Basin permits district courts to exercise jurisdiction over claims provided that they are (1) wholly collateral, (2) outside an agency’s expertise, and (3) that precluding the claims would foreclose all meaningful review of the claim or issue. Weighing those factors, the Court concluded that siding with the Secretary and dismissing the plaintiffs’ claims would foreclose all meaningful review of plaintiffs’ claims. In light of the Federal Mine Safety and Health Review Commission’s decision in Pocahontas Coal Co., LLC, 38 FMSHRC 176, 181-82 (February 16, 2016), foreclosing jurisdiction to hear POV challenges absent a withdrawal order, and given the Sixth Circuit’s finding that it lacked jurisdiction, the Court acknowledged that plaintiffs were running out of legal forums to present their claims. The Court stated, “The courts of appeals lack subjectmatter jurisdiction to hear these claims. The Commission lacks subject-matter jurisdiction to hear these claims. Who can hear Plaintiffs’ claims?” (internal citations omitted). Furthermore, the Court concluded that the nature of the plaintiffs’ challenges under the APA and due process were outside of the Commission’s expertise. The Court noted that the Commission holds unique expertise in adjudicating contested enforcement actions by MSHA which involve detailed
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determinations concerning coal mining, MSHA’s regulations, and the parties’ duties and rights that arise under the Mine Act. The Court highlighted the fact that, although plaintiffs’ claims involve the POV rule within the Mine Act, plaintiffs’ claims were centered on claims surrounding the APA and the Due Process Clause. The Court concluded that the plaintiffs’ “higher-level procedural question” was “one not well-aided by the Commission’s particular expertise.” Finally, the Court found that plaintiffs’ claims were wholly collateral to the Mine Act’s review scheme because they challenge a rule-making procedure and the new rule’s content, not an enforcement action taken by MSHA. The Mine Act provides operators with a comprehensive review process for alleged violations of the Mine Act or the regulations that arise under the Mine Act. Here, the Court observed that the plaintiffs’ claims do not arise from a violation of the Act or any regulations and, therefore, the holding in Thunder Basin does not apply. The ruling is a clear victory for the mining industry. Not only does this ruling provide a forum for the industry’s current challenge of MSHA’s controversial POV rule, it also provides a procedural roadmap for the industry in future challenges of rules or regulations that are not mandatory safety and health standards. AM
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ADINDEX August 2016
Advertiser
Web
Aggregates Manager Atlas Data/CD Products
www.aggmanatlas.com
36
BekaWorld (formerly Beka-Max of America)
www.beka-lube.com
39
Bill Langer - Research Geologist
www.researchgeologist.com
16
BKT Tires
www.bkt-tires.com
25
C.L. Dews & Sons Foundry
www.dewsfoundry.com
43
Clearspan Fabric Structures
www.clearspan.com/adam
43
Elrus Aggregate System
www.elrus.com
FMI Corp.
www.fminet.com
Gilson Company, Inc.
www.globalgilson.com
15
Hammond Air Conditioning, Ltd
www.hammondac.com
41
Hazemag USA, Inc.
www.hazemag.com
29
John Deere Construction Equipment
www.johndeere.com/big
IFC
Kespry, Inc.
www.kespry.com/aggregates
6
Kleemann, A Wirtgen Group Co.
www.wirtgenamerica.com
2
KPI-JCI and Astec Mobile Screens
www.kpijci.com
31
Kruse Integration
www.kruseintegration.com
43
Motion Industries, Inc.
www.motionindustries.com
13
NSSGA Legislative
www.nssga.org
14
NSSGA Membership
www.nssga.org
20
Progressive Commercial Insurance
www.progressivecommercial.com
Pugmill Systems, Inc.
www.pugmillsystems.com
43
Rice Lake Weighing Systems
www.ricelake.com/truckscales
BC
Sandvik Construction Mobile Crushers & Screens USA
www.construction.sandvik.com
10
Scott Equipment
www.scottcompanies.com
17
SDLG North America
www.sdlgna.com
Stedman Machine Co.
www.stedman-machine.com/save
43
Sweet Manufacturing
www.sweetmfg.com
43
Volvo Construction Equipment
www.volvoce.com/na
17
This index is provided as a service. The publisher does not assume any liability for errors or omissions.
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AGGREGATES MANAGER / August 2016
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Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at Bill_Langer@hotmail.com
Kartchner Caverns: The Rest of the Story Two intrepid cavers discovered the caverns and ensured they were properly protected before being made public.
L
Photo copyright Arizona State Parks.
ast month, this column described the visit Pam, our grandkids, and I took to the world-class geologic wonder — Kartchner Caverns — located in southeastern Arizona. This is the rest of the story. In 1974, two amateur spelunkers removed their belts, exhaled to make themselves as skinny as possible, and squeezed through a tiny opening into a cave untouched and unseen by humans for hundreds of thousands of years. In cave terminology, the underground sanctuary was ‘living’ — because water still seeps down the limestone walls creating stunningly beautiful speleothems such as stalactites and stalagmites. Randy Tufts had been caving since fourth grade. In 1967, at age 18, he began searching for caves in southern Arizona in the Whetstone. A tip from a miner led him and some Kartchner Caverns were discovered by Randy Tufts and Gary Tenen. companions near the cave, and a cluster of ocotillo (a plant that loves limestone soil) led them to the sinkhole entrance to the cave. However, the only possible entrance at the bottom of the sinkhole did not appear to “go,” so the group left without entering the cave. In 1974, Randy returned with fellow caver and college roommate, Gary Tenen, to re-examine the sinkhole. “[E]verything seemed the same as before except for one thing: There was a breeze coming out of the crack we’d found before. It was warm, moist air — and it smelled like bats!” In a time when countless caves had been turned into tourist traps or destroyed by vandals and looters, the two young discoverers realized that their extraordinary find must be preserved. For the next two years, they secretly explored the cave. In 1978, they told the property owners, James and Lois Kartchner, about their amazing discovery and their interest in making the cave public while preserving its natural, near-pristine condition. James was a science teacher and a school superintendent and was delighted with the idea. A decade of hushed diplomacy followed. The cave’s existence became public knowledge in 1988 when its purchase was approved as an Arizona State Park. Kartchner Caverns’ development spanned nearly 11 years and included innovative ways to allow public access while protecting the cave. During our tours, we entered a tunnel to access the caves and passed through a series of conservation doors that prevents moisture from leaving the cave. Nothing would accidentally be left in the cave because we were not allowed to take anything in except what we were wearing. This meant no backpacks, food, gum, tobacco products, drinks (including bottled water), or cameras (including phones). Nothing. We were even sprayed with a mist that moistened the particles of lint, skin, and hair we might shed so they would fall onto the trail outside the cave and be washed away later in the day. Otherwise, those spare body parts might become food for fungus colonies that could ruin the beauty of the cave. Most importantly, everyone ABSOLUTELY had to stay on the trails. We were only allowed to touch the handrails and were admonished to not touch any of the natural formations. If anyone touched any natural formation, that spot would be flagged and carefully cleaned that night. None of these restrictions were unwelcome. All the visitors happily complied realizing what a privilege it was to visit a living cave and leave it unspoiled so that generations to come could enjoy the same breathtaking experience. Our thanks to Randy Tufts and Gary Tenen who deserve to sit at the table with other natural conservationists like John Muir and Teddy Roosevelt.
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AGGREGATES MANAGER / August 2016
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