Aggregates Manager September 2016

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

September 2016 | www.AggMan.com

Luck

Stone

Reinvents its Bull Run Plant 21

Prepare the plant for cold temperatures

30

Improve uptime on your drill rig

39

Learn the latest on workplace exam regulations

Sandvik ranger MOre eFFiCienCY with leSS Fuel Consuming approximately 27% less fuel per drilled foot* compared to the already low previous rate, our Ranger DX series top hammer drill rigs offer you the cream of the crop in today’s energy-efficient surface drilling. The Ranger DX series brings back the bold spirit and prestigious heritage of its renowned predecessors – allowing you to drill in conditions where others fear to tread. *At average work time distribution, depending on rock conditions.

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

Before opting for fabricated parts, consider hidden costs of not using OEM parts.

PAGE 27

On Our Cover: Luck Stone invests in a major upgrade of its Bull Run Plant.

Cover photo by Kerry Clines.

Volvo’s A60H is based on the same design and layout as its smaller trucks, but offers a 44.5-cubic-yard capacity.

PAGE 10

TABLE OF CONTENTS SEPTEMBER 2016 |

VOLUME 21, NUMBER 9

FEATURE ARTICLES

14

Getting Bullish on Stone

27

Fabricating Failure

Luck Stone’s Bull Run Plant prepares to service northern Virginia.

Are OEM parts worth the cost? Take a look at the lifetime costs of fabricated parts for vibrating screens.

30 Drill Down on Uptime

Systematic inspections and scheduled maintenance can keep drill rigs running for thousands of hours between major overhauls.

36 Weighs and Means

To keep track of the profits flowing through your operation, consider strategic placement of scales.

OPERATIONS ILLUSTRATED Preparing for Winter

21

Whether temporarily shutting down operations or working through the winter, colder weather requires some advanced care and maintenance throughout your plant.

COLUMNS & DEPARTMENTS 3 Editorial Keep your customers first.

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.

10 RollOuts Sandvik’s updated QJ341+ portable crusher, and other new equipment for the aggregates market.

39 Rock Law Following up on reactions to substantive changes in its Program Policy Letter, MSHA issues a proposed rule on workplace exams.

42 Advertiser Index See who’s who and where to find their products.

43 Classified Ads Aggregate industry classifieds.

44 Carved in Stone A conference in Hungary shows that geological exploration can have interesting, and unexpected, rewards.

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September 2016

EDITORIAL

Vol. 21, No. 9

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

aggman.com /AggregatesManager @AggMan_editor

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

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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.

Keep Your Customers First

W

hen was the last time you took a long, hard look at your customer service? Do customers perceive your business the same way you do? It’s easy to please customers when everything is going well, but how you handle them when something doesn’t go as planned can make the difference between retention and defection.

I gained experience on this particular issue through recent travels. In late June, I traveled to Buxton, England, for the Hillhead show. My husband tagged along, and we spent a week after the show in Paris. Excited for our international adventure, we headed to Cleveland Hopkins Airport to catch a United flight to Newark on our way to Manchester, England. Between weather delays and hours restrictions on the flight crew, we departed four hours late and had to be rerouted through London.

Inconvenient, but understandable.

We got to London Heathrow and checked in with British Airways for our final flight. When I had trouble with my boarding pass, the British Airways agent told me she was working through problems with the airline’s new computer system.

I didn’t think much of it until we arrived in Manchester and our bags did not. I wasn’t happy, but figured the bags would arrive shortly. They did not. Over the 11day trip, we never again saw our luggage, as they were repeatedly lost during their multi-national adventure.

This sad story isn’t the point of the piece. It’s how the two airlines responded to the situation. The United representatives were helpful. They looked up my baggage tag numbers and were able to locate them from the outbound flight and forward them on. They responded in a personal manner to my post-trip email and gave us a travel voucher to acknowledge the inconvenience. I’ve booked two United trips in recent weeks.

British Airways was not nearly as friendly or as accommodating. They couldn’t articulate any guidelines for their reimbursement policy as we purchased clothing and toiletries, telling us only to purchase any “necessities.” The stress of such ambiguity only compounded that of replacing our possessions during an international trip. To add insult to injury, our bags arrived in Paris a day after we did, but the airline couldn’t confirm their location or get them delivered to us...for seven straight days. And, unlike United, British Airways doesn’t issue travel vouchers to acknowledge customers inconvenienced by their incompetence.

Given that the airline lost 3,000 bags during the first three days of its new computer system’s rollout (at least, that’s what one baggage claim agent told me), I can understand that such compensation might be expensive. Lost future business, however, could prove more costly in the long run.

When you field a phone call from an upset customer, consider the snack made famous by a third airline — Southwest. Making a simple demonstration of good faith may help you retain a customer while costing the proverbial peanuts.

AGGREGATES MANAGER / September 2016

3

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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

$8.17 p $30.22 p $80.72 p $51.10 p $86.52 p $10.29 p $199.85 p $23.33 q $20.26 q $63.25 p $53.85 q $121.88 p

52-Week High

52-Week Low

$8.43 $31.74 $87.57 $51.35 $89.39 $13.21 $201.18 $24.67 $27.48 $64.09 $69.66 $127.20

$3.50 $23.31 $45.03 $28.45 $65.01 $6.92 $108.31 $15.58 $13.12 $45.56 $40.42 $78.83

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 8/10/16.

U.S. On-Highway Diesel Fuel Prices 8/11/16

One Week

One Year

United States

$2.316

-0.032 q

-0.301 q

East Coast

$2.321

-0.033 q

-0.392 q

New England

$2.378

-0.018 q

-0.469 q

Central Atlantic

$2.412

-0.029 q

-0.420 q

Lower Atlantic

$2.241

-0.038 q

-0.354 q

Midwest

$2.275

-0.029 q

-0.240 q

Gulf Coast

$2.184

-0.040 q

-0.303 q

Rocky Mountain

$2.396

-0.023 q

-0.244 q

West Coast

$2.595

-0.035 q

-0.251 q

West Coast less California

$2.454

-0.038 q

-0.252 q

California

$2.707

-0.034 q

-0.253 q

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

AGGREGATES MANAGER / September 2016

5

In August, the Aggregates Industry Outlook (AIO) dropped 6.72 percent from July, to its lowest overall score to date of 111.42. This marks the second month of significant decreases. With 100 as a neutral rating, most respondents continue to be positive, but a clear disparity in local market conditions is indicated. Once again, a wide range of responses was reported, with an individual low score of 61 and multiple respondents reporting scores of 155.

Aggregates Industry Outlook 140 127.51

128.42

132

128.15 126.03

125.60 122.49

128 124 120

131.68

130.99

136

119.44

130.00

128.99

128.61

111.42

116 112 108 104 100

Aug. 2015

Sept.

2015

Oct. 2015

Nov. 2015

Dec. 2015

Jan. 2016

Feb. 2016

Mar. 2016

Apr. 2016

May 2016

Jun. 2016

Jul. 2016

Aug. 2016

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Experience: Retired November 2011 following 41 years with the U.S. Geological Survey • USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present

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

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AGGREGATES MANAGER / September 2016 BillLanger_AGRM0115.indd 1

12/16/14 1:21 PM

COMMENTS While the passing of the FAST Act highway bill brought us a stable promising future of infrastructure work, the reality of it is the states have seen little change in the status quo. In New York, we have been promised an equally great long-term outlook with the PAVE-NY long-term infrastructure plan. Neither program has included a funding source, and the money is not being allocated timely.

— Bill Schmitz, Vice President, Quality Control and Sales, Gernatt Asphalt Products, Inc.

Commercial and residential continue to perform strongly. New infrastructure and maintenance continues to lag, though more agencies continue to seek funding solutions.

— Damian Murphy, Regional President, Summit Materials

We seem to be encountering the same mysterious mid-season slump in aggregate sales to construction interests as has been reported elsewhere in the four-state region. I’ve heard explanations from a mild winter/early spring construction start-up just catching up to us to tight budgets for states and private developers awaiting the fall election outcomes. Things could and should be busier this time of year and with this much work needing to get underway.

— Robert L. Stone, Manager of Sales and Compliance, Hunter Sand & Gravel, LLC

Projects and sales are still running strong along with first half of the year. (It is a) much better outlook than previous years. If things stay with the trend, it should finish out a good year.

— Grant Smith, Production/Mine Manager, Transit Mix Concrete Co.

Aggregate sales in the Ohio area seem weaker this time of year compared to 2015, whereas our recycled materials (RAP & RCA) asphalt/concrete sales have surpassed last year, mainly due to lower cost and increasing popularity of recycling.

— Jerry Mock, Chief Executive Officer, Zanesville Materials LLC

We are starting to see a drop in residential and commercial work in the Houston market.

— Rob Van Til, Managing Partner, River Aggregates, LLC

Second quarter profits of the two largest producers surged, as predicted. However, tonnage volumes have still yet to recover in most market areas. Companies continue acquisitions, and interest is up in greenfield sites. All in all, things look pretty good.

— 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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AGGREGATES MANAGER / September 2016

7

STATE & PROVINCE

NEWS

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

NEW JERSEY

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

CALIFORNIA In a recent meeting of the Madera County Planning Commission, the group voted 3-2 to approve Vulcan Material Co.’s Austin Quarry. According to the Sierra Star, the vote came during the early hours of the morning. The commission members who voted against the proposal were appointed by board of supervisor members who live near the future operation. Vulcan had submitted an 11,000-page Final Environmental Impact Report for the project. Proponents included hydrology experts, Vulcan employees, a representative from the Madera Unified School District, and a member of the Madera County Economic Development Commission. The company agreed to fund construction of lanes on highways around the site, as well as purchase carbon credits to offset greenhouse gas emissions.

CONNECTICUT

NEW YORK

Tilcon encountered a bump in the road as it plans to relocate its quarry in New Britain. The Bristol Press reports that the Council on Environmental Quality voted to recommend that the Water Planning Council rescind its vote to approve Lenard Engineering, Inc. to conduct an environmental study on its proposed move. Some local officials were concerned that a “multi-disciplinary consulting engineering firm” did not possess the correct qualifications to perform the study. Instead, the group is recommending that the Water Planning Council send out a new Request for Proposals to find a more suitable group. Tilcon plans to relocate its operation onto land belonging to the New Britain Water Department and would build a treed buffer zone around the site prior to mining. After it completes mining, the site would become a reservoir. The new site falls under the state’s Aquifer Protection Area plan, so legislators would need to approve an exemption to allow mining.

Frontier Stone won a decision on its proposed 215-acre operation but continues to face citizen opposition as it seeks to develop its Shelby site. The Daily News reports that an administrative law judge for the Department of Environmental Conservation ruled “no issue exists for adjudication and no supplementation of the DEIS is required, with respect to consideration and evaluation of alternatives.” While that response was met with satisfaction from the operator, members of the Citizens for Shelby Preservation vow to “make sure the Shelby Town Board does what is best for the town and rejects the mining overlay district. The town is going to be charged with doing the job that the SEQR review was designed to do, but failed miserably.”

MASSACHUSETTS Aggregate Industries won a partial victory in its effort to expand operating hours and conditions at a quarry. According to the Taunton Daily Gazette, the Taunton City Council renewed its earth removal permit, but denied a request to expand hauling hours. The newspaper reports that Aggregate Industries wanted to extend crushing hours from 7 a.m. to 7 p.m. Instead, council approved an additional half-day on Saturdays. The operator also asked for 7 a.m. to 7 p.m. hours for haulage, but that request was denied.

NEW JERSEY A 20-year-old man died in an abandoned quarry, Lehigh Valley Live reports.

The man, Andrew J. Grennan, was swimming with friends in the Seven Slopes Quarry when he decided to jump off a small ledge. He then attempted to swim to the other side, but never surfaced. His body was recovered from approximately 25 feet under water. The acting police chief told the newspaper that Grennan was believed to have landed on a ledge.

8

The Watchung Borough Council approved an ordinance that would extend the “QU” or quarry zone and make the corresponding changes in its land development ordinance. According to the Echoes-Sentinel, the council has been working on the ordinance with Weldon Materials Inc. since 2014. The effort came about due to a conflict between the zoning map and the land ordinance. Portions of Weldon’s property were zoned residential, and the operator wanted to extend the quarry zone along that property. After in-depth discussions about setbacks, the planning board was able to amend its master plan to meet the operator’s needs, while the operator will work with the buffer zones established by the council. “I felt like when we were having discussions, we thought we were trying to do what was good for the town, and I think the planning board also thought they were trying to do the same for the borough and the business,” Bob Weldon said at the council meeting. “I am proud to have been working with all of you on this and happy to continue working with you in the future.”

AGGREGATES MANAGER / September 2016

NEW YORK In August, Lafarge North America held an open house at its quarry in Lockport. According to The Buffalo News, visitors were to be taken by bus to a viewing area to observe a blast, as well as operating equipment.

Lafarge Project Manager Perry Galdenzi told the newspaper that it was the first open house Lafarge has held in about 10 years. The site, which produces between 1.5 million and 2 million tons of aggregate per year, has about two years of reserves remaining. Lafarge is seeking a permit to open a new site, but has to demonstrate that blasting wouldn’t harm the city’s drinking water supply. It also has to create a $500,000 repair fund to reimburse any blasting-related damage to the water pipeline and agree to pay the city $50,000 to replace the valve that connects the city’s water system to the county pipeline. The new quarry would have 50 years of estimated reserves.

TEXAS

NORTH CAROLINA In late July, the bodies of a mother and daughter were found after their car ran off an adjacent road and into the water at a Monroe quarry. WJZY reports that a passing motorist informed the fire department of evidence that a car had gone off the road. A dive team was brought in. The dive team located the first victim, and the second was found when the car was brought out of the water. The women were identified as Gwedolyn and Draya Rape. The road was closed until repairs could be made to the guardrail.

APAC Texas pulled its request to expand its operation in Marble Falls from 7.7 million tons per year to 12 million tons per year. The DailyTrib. com reports that, prior to the withdrawal of the permit, the Texas Commission on Environmental Quality (TCEQ) had hosted a public meeting during which residents voiced opposition to the quarry expansion. A group of public officials and attorneys for the Texas Hill Country Property Rights Coalition met with the TCEQ staff. Burnet County Judge James Oakley, one of those public officials, told the news agency that he didn’t think the permit application seemed complete, but expected a revised version would be put forward at a later date.

OHIO At the end of August, the Wood County Park District was scheduled to open the Sawyer Quarry Nature Preserve. According to the Sentinel-Tribune, the park would be opened on the 61-acre site that was formerly home to a quarry owned by the Sawyer family. Ann Sawyer donated the land, which had been in the family for more than a century, and the park district spent several years making improvements to it. Once roads were widened, a metal staircase was fabricated to allow visitors to climb down into the quarry, and public restrooms were installed, the site was ready for visitors. It features bike trails and rappelling.

PENNSYLVANIA A blast at Buzzi Unicem USA’s plant in Upper Nazareth Township produced flyrock that reportedly struck nearby houses. Lehigh Valley Live notes that residents complained to township officials, who say the Pennsylvania Department of Environmental Protection (DEP) has opened an investigation into the matter. Supervisors there approved a resolution to allow the quarry to expand. The operator’s request now goes to the DEP and Pennsylvania Department of Transportation for approvals. If approved, the expansion would give the 100-year-old cement plant an additional 20-year supply of limestone.

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TENNESSEE Opponents of Hoover’s Old Hickory Quarry, who fought the operation’s permit, are now turning their attention to complaints about trucks to and from the operation. According to Fox 17 News, they are claiming that Hoover’s 70,000-pound trucks are taking shortcuts on roads with 5,000-pound limits. A Metro Police spokesperson told the news station that officers were patrolling the area, while a council member said the operator may need to work with the public works department on improving and maintaining roads.

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AGGREGATES MANAGER / September 2016

9

ROLLOUTS

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

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

Radio-controlled dozer Komatsu America Corp. rolls out the D155AXi-8 Radio Control dozer, its first radio-controlled machine with intelligent Machine Control technology. Suited to applications where an operator may want to be removed from the cab, the “intelligence” features allow the machine to maintain high levels of efficiency and productivity in operations ranging from heavy dozing to fine grading. Powered by a 354-horsepower Komatsu SAA6D140E-7, Tier 4 Final engine, the machine emits 80 percent less nitrogen oxides than its Tier 4 Interim predecessor. An automatic gearshift transmission and lock-up torque converter select the optimal gear range for the site conditions and load, eliminating horsepower loss and cutting fuel consumption by up to 10 percent. A patented Sigmadozer blade, designed to dig and roll up more soil at the blade’s center, is said to hold more material, reduce digging resistance, and doze up to 15 percent more soil while using less power than a typical semi-U blade.

Komatsu America Corp. | www.komatsuamerica.com

Industry’s biggest artic hauler Volvo’s A60H articulated hauler is designed for heavy hauling in severe off-road applications. The 60-ton truck is powered by a 16-liter engine and delivers 663-horsepower and 2,360 footpounds of torque. The truck is based on the same design and layout as the smaller trucks in Volvo’s lineup, but offers a 44.5-cubicyard capacity. The A60H features intelligent systems including Matris, CareTrack, and an onboard weighing system. With a matched drivetrain, automatic drive combination — including 100-percent differential locks, all-terrain bogie, hydro-mechanical steering, and active suspension — the truck also focuses on operator comfort to address all aspects influencing productivity.

Volvo Construction Equipment | www.volvoce.com

Jaw update addresses fines Sandvik adds a new model to its jaw crusher lineup, the QJ341+. The portable crusher incorporates a double-deck pre-screen as standard. Said to provide high amplitude for improved separation, the unit can remove a large amount of fines to improve efficiency and productivity, while reducing wear. A new telescopic natural fines conveyor, with a discharge height of 10 feet, 3 inches, deals with the increased flow of pre-screened material. The dirt chute features a steeper angle for faster transfer, as well as improved handling of sticky material. Its three positions allow material to pass the pre-screen grizzly to be diverted onto either the main conveyor or natural fines conveyor, with the middle position able to feed either the main conveyor or natural fines conveyor. An improved self-locking hopper allows for quick setup from the ground level. Operators can choose between a Cat and Volvo engine.

Sandvik Construction | www.construction.sandvik.com

10

AGGREGATES MANAGER / September 2016

ROLLOUTS Heavy-duty electric screening Terex Washing Systems introduces the AggreScalp, a high-performance, heavy-duty electric screening machine that can operate as a two-way or three-way split screener. The aggressive screen can accept media including bofor bars, finger screens, woven mesh, and 3D punch plates, which allows it to be used across a wide variety of applications. With onboard hydraulic folding product conveyors, hydraulic screen angle adjustment, and single lift set-up, it is said to be easy to transport and easy to set-up. The AggreScalp can work in conjunction with the AggreSand range by providing a consistent feed material even in difficult applications.

Terex Washing Systems | www.terex.com

Motor grader gets multiple upgrades Cat unveils its 14M3 motor grader, which boasts a larger engine (the Cat C13 Acert engine), increased fuel efficiency, improved machine balance, enhanced transmission performance, advanced electro-hydraulic steering, more powerful telematics, and added operator safety and convenience features. A drawboardcircle-moldboard assembly is designed for productive performance in a range of applications, and long-term durability of major structures is said to offer low operating costs and serviceability for optimum value. A fully scalable, factoryintegrated Cat Grade with Cross Slope system allows operators to maintain the desired cross slope by automatically controlling one side of the blade. The newly patented Stable Grade and Auto Articulation technologies improve maneuverability and performance in tight working conditions. When paired with the optional Cat Advanced Control Joysticks, Cat Grade with Cross Slope allows precise operation with AccuGrade. Fleet management information is available through Cat Product Link telematics as well as through remote monitoring via VisionLink.

Caterpillar | www.cat.com

Expanded line of screens Powerscreen releases two new variations of its Warrior 2100 system: the Spaleck and a single-shaft screen. The Spaleck features a twodeck waste recycling screen with a Flip-Flow bottom deck, which uses rubber panels that move in a smooth wave motion expanding and contracting to keep the material in constant motion and break down sticky materials. The deck panels on the top and bottom deck are removable and can be replaced individually or together. The single-shaft screen uses a more conventional approach. Supported on 2- x 130-mm bearings, it provides screening angles of up to 18 degrees. The drive system is mounted directly to the screen side and is pulley driven to ensure that optimum hydraulic efficiency can be achieved at both standard and increased amplitudes. Both units are powered by a Cat C4.4 four-cylinder diesel engine designed to run at 1,800 rpm. Each can be ordered with a Dual Power option, which has a fully integrated control system allowing an operator to power the machine via diesel or directly from a power source.

Powerscreen | www.powerscreen.com

Compact cone crusher line Weir Minerals announces the release of its Trio TP cone crushers, which operate at a higher speed than their predecessors to provide higher reduction and better shape. The compact crushers are built with automation technology to ensure performance and versatility. They feature a steep crushing chamber angle, a large crushing stroke, and optimum speed to deliver a finer product through increased inter-particle comminution. Engineers designed a direct drive option for the crushers, which can be combined with a variable frequency drive to provide energy savings.

Weir Minerals | www.trio.weir

AGGREGATES MANAGER / September 2016

11

ROLLOUTS Flexible crushing technology Sandvik Construction debuts SanRemo for Crushers, its new approach to crusher automation. The system builds on its ASRi automation system and continues to ensure the desired closed-side setting by compensating for moisture and hardness in the feed. It builds upon that, however, with additional monitoring, control, and data features, with access provided via a cloud solution. The automation is available in three service levels — bronze, silver, and gold — with the flexibility to use only the features currently needed, but upgrade whenever necessary.

Sandvik Construction | www.construction.sandvik.com

Large-scale, semi-automatic excavator Komatsu America Corp. introduces the PC490LCi-11 hydraulic excavator, which is powered by a 359-horsepower, Tier 4 Final SAA6D125E-7 engine. It offers up to a 13-percent increase in productivity and 7 percent more arm crowd force and bucket digging force. With Intelligent Machine Control, it features a sensor package including stroke-sensing hydraulic cylinders, an IMU sensor, and GNSS antennas. The machine uses 3D design data loaded into its monitor to display machine position relative to the target grade. When the bucket reaches the target surface, automation kicks in to limit over excavation. Other features include: auto grade assist, auto stop control, minimum distance control, facing angle compass, realistic 3D display, and a control box.

Komatsu America Corp. | www.komatsuamerica.com

Fines recovery system The FM UltraFines, from Terex Washing Systems, offers an additional step toward efficient management and recovery of ultrafines sand from wastewater streams, produced from washing processes. This ultra-fines recovery unit can process up to 589 cubic yards of slurry per hour, recovering material as low as 40 microns to decrease the need for storage ponds or water treatment plants. The plant includes a centrifugal pump, a cluster of four hydrocyclones, and a high-frequency dewatering screen on one chassis. The FM UltraFines also features a uniquely designed conical tank and anti-turbulence system, which the manufacturer says is essential in the process of ultra-fines recovery.

Terex Washing Systems | www.terex.com

Cone crusher line evolves Sandvik Construction says its CH540 represents the second step in a new generation of cone crushers and is suitable for operators who want to increase production capacity, eliminate bottlenecks, reduce cost per ton, or improve product quality. The high-capacity crusher comes standard with Sandvik’s new automation and control system — SanRemo for Crushers. A dump valve ensures quick, safe tramp relief while wear parts have been adapted for longer life. Minimum welding is used on the crusher, which has also been designed to allow for faster change out of manganese. With feed sizes ranging from 1.7 to 7.3 inches, the crusher’s capacity is rated at up to 295 tons per hour.

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12

AGGREGATES MANAGER / September 2016

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PLANT PROFILE

by Kerry Clines | Contributing Editor

Quarry, at Luck Stone’s Bull Run The primary structure sher to cru the tall from the top of which stands 80 feet that all hw hig the in t slo lt into a the floor below, is bui placement . was blasted out for its

When the contractor poured the concrete for the primary, he stamped the quarry’s name and the date the structure was built into the side of the structure.

14

AGGREGATES MANAGER / September 2016

Material makes its way up from the primary in the pit to the surge pile and secondary plant for pro-cessing.

Getting

Bullish On Stone Luck Stone’s Bull Run Plant prepares to service northern Virginia.

T

he construction industry in northern Virginia is booming, with both housing starts and road construction on the rise.

In an effort to keep up with the market demand for aggregates, Luck Stone has been making major upgrades to its Bull Run Plant, which was purchased from the Bolen family in 2002.

Luck Stone’s expansion of the Bull Run Plant comes as the company’s Fairfax Plant, which opened in the 1930s and has been one of the main players in the area for many years, is becoming an aging operation.

Preparations to step it up

The benches in the pit can be seen in the background between equipment in the secondary plant.

Since its purchase in 2002, the Bull Run Plant has been undergoing some major changes. “In addition to the construction

of our new facility, we went through a permitting process; permitting additional reserves at the site,” says Warren Paulson, plant manager at the Bull Run Plant.

The next step was relocating a highway that ran through the middle of the property to open up part of the plant. The road was diverted to one side of the plant and a large grass and tree-covered berm was placed between the road and the operation.

In 2014, the company broke ground on a state-of-the-art plant expansion project, the first of several phases of upgrades, improvements, and additions to the operation. The new plant was designed to be more efficient, featuring leading-edge technology and increased production capabilities. It was also designed to be more environmentally and community friendly through the use of recycled materials, paved travel ways, lower power consumption, rainwater retention, and noise-reduction technology.

“This plant has been thoughtfully designed — we approached this effort with care for our associates, customers, and neighbors,” Paulson notes. “A lot of strategic thought went into the details, from how we safely access different areasand AGGREGATES MANAGER / September 2016

15

PLANT PROFILE

The primary structure includes a two-sided, 450-ton live-capacity hopper that feeds material into a large gyratory. Crushed material then goes into a 430-ton live-capacity surge hopper that feeds the material via twin feeders onto conveyors that transport it to the surge pile.

Run Plant is the source of all the water used at the site. The water system is completely automated and set up so that a water building and tank, located at the secondary, control everything. If the tank needs water, it turns on the pump and fills the tank. It then systematically checks with all the other tanks throughout the plant and an upper pond to see if any of them need water. If water levels are low, the system will fill up the areas and then shut itself off. A clarifying tank was recently added to the system to allow the plant to reclaim 80 percent of its used water and send any solids back to the pond to dry out.

The next phases of plant upgrades will include a more direct entry for customer trucks, a new set of scales, and a second scale house. The new inbound scales will allow the traffic flow to come in, cross the inbound scales, pass the new scale house, go to the pile of material needed, and circle around to the outbound scales and scale house.

“That’s part of trying to provide a great customer experience – keeping the trucks moving,” Paulson says. “We have learned so much from our customers, and we understand that their time is valuable.”

Processing operations

All of the screen houses, except in the primary, are enclosed in buildings to help control dust and noise.

service the equipment to using the latest technology our industry offers.”

The first phase of the project focused on the primary, secondary, tertiary, and base reclaim circuits, as well as a sand plant, a fines recovery system, and a hightech water and dust suppression system.

“Phase I of our construction just came to an end in February,” Paulson explains.

“We commissioned our new primary at the end of November, and the secondary

16

AGGREGATES MANAGER / September 2016

started up in January, followed by the tertiary and the sand plant in February.

Additionally, we just completed the fines recovery system. Over the next two years, we will continue improving the operation by installing scales, building new scale offices, and more. Overall, we’re really proud of this location, as it will provide a great experience for our associates, customers, and visitors.”

The clean-water pond at the Bull

Of course, everything starts in the pit.

The plant contracts out the drilling and uses Austin Powder blasting agents and powder, but the blasting is done inhouse by trained quarry personnel. After the blast, haul trucks carry the material to the primary plant located in the pit.

The primary structure, which is composed of concrete and steel, is built into the highwall that was blasted out for its placement. Keeping safety at the forefront, Luck Stone developed a remote-control Cat 988 pit loader to clear the area after the slot was blasted. When the contractor was pouring the concrete for the primary structure in June 2014, he stamped the company’s name and the day’s date into the concrete, commemorating the grit and teamwork that went into the construction of the sophisticated operation.

At the top of the primary structure is a two-sided, 450-ton live-capacity hopper where the 100-ton haul trucks dump

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PLANT PROFILE their loads. The hopper feeds material into a large gyratory crusher, one of only five of its size in the world. The crusher features an 800-horsepower motor and has a crushing capacity of 2,400 to 2,600 tons per hour. Beneath the crusher is a 430-ton live-capacity surge hopper that feeds the material via twin feeders onto conveyors that transport it to the surge pile. A conveyor running in the tunnel beneath the surge pile then feeds material to the secondary plant, which processes some of the material and sends the rest on to the tertiary plant.

The quarry’s location allows it to run 24 hours a day, five and a half days a week. “Everything runs during the day,” Paulson explains, adding that the primary shuts down when everyone leaves, but the other plants are automated and continue to run at night. “The secondary, tertiary, sand plant, fines recovery system, and base reclaim all run by themselves. The plant foreman, who can monitor things from an iPad, will be notified via text if there’s an issue.”

Keeping everyone safe “Safety is one of our core values — believing that all accidents are preventable,” Paulson says. “We make sure everyone is focused on safe production and aware of the hazards that exist in our work environment. Our associates understand what our safety goals are.

At Luck Stone, safety is everybody’s responsibility.”

In addition to the usual safety procedures, Luck Stone has an internal safety program called “The Talk Before the Task.” Paulson says that proper planning can prevent most mishaps and that “The Talk Before the Task” focuses on seven safety-minded steps to take before beginning any task at the plant.

It must be working, because the plant just came through its second MSHA inspection with zero citations this year. Plus, the plant has gone two years without an injury.

Listening to the community With a housing development right on the other side of the berm, maintaining a high aesthetic appearance is very

18

AGGREGATES MANAGER / September 2016

important to the operation, as is working with and listening to the neighbors.

Paulson says the company participates in homeowners’ association meetings and community meetings, and that they actively educate, listen, and respond to community concerns.

“We have open conversations with our neighbors about the design and expansion of our operation,” Paulson says.

“We work well within our permitted limits, and respond to any questions and concerns our neighbors may have. We want to support our neighbors however we possibly can.”

There are plans for putting in a wheel wash system and paving all the travel ways in the plant. That way, after the trucks are loaded, they can roll through the wheel wash before leaving the site so they don’t track anything out onto the highway and into the community.

All of the screens and crusher stations, except for in the primary, are enclosed in buildings. This helps to control dust and noise, which helps improve the air quality, thereby improving relations with neighbors in the surrounding community.

Another attribute at the Bull Run Plant that helps with noise reduction is the use of duck quacking back-up alarms on the mobile equipment (rather than the usual loud beeping).

“We do plant tours often,” Paulson adds. “I’ve extended an open invitation to our neighbors to give us a call if they’d like to learn more about the plant.

We will gladly set up a time to take them through the operation.”

Looking to the future “Our new plant has the capacity to meet the demands of our market area,” Paulson says. “We have all the basic infrastructure in place to add additional capacity, should the market demand grow. At this time, we constructed a single tertiary, but as market demands increase, we’ll add another tertiary. With this ability to add capacity, combined with the flexibility in the plant’s design, we are prepared to meet the challenges the future may hold.” AM

Equipment List • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

Caterpillar 773B haul truck Caterpillar 775E haul trucks (4) Caterpillar 775F haul truck Caterpillar 777C haul truck Caterpillar 980G II loaders (2) Caterpillar 980H loader Caterpillar 980H loader Caterpillar 980K loader Caterpillar 988G loader Caterpillar 998H loader Caterpillar 992G loader Caterpillar 904B clean-up loader Caterpillar track loader John Deere 770B motor grader John Deere 5400-2 tractor (GK) John Deere 5520 tractor Grove RT528C 28-ton crane FL Smidth 55x81 gyratory crusher Sandvik CS 660 cone crusher Sandvik CH 660 cone crusher Sandvik CH 440 cone crusher Sandvik CV 217 impact crusher ISC 66 impact crusher BTI boom system BXR 85 hammer Deister 8x24 screen Deister 8x20 screen Deister 2820 screen Deister 31024 screen Deister 3820 wash screen McLanahan VD-18 screen Kinergy pile discharge feeders (4) FMC MF-600 feeders (2) FMC MF-400 feeders (4) FMC F-380 feeders (4) FMC F-480 feeders (10) FMC F-450 feeders (2) FMC MF-200 feeder FMC F-330 feeder McLanahan twin sand screws Masaba stacking conveyors (5) Weigh-Tronix EZ7011-C-100 scale • Weigh-Tronix 10060-PRC scale • Eriez magnets (5)

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PULL-OUT GUIDE

By Mary Foster, Contributing Editor

September 2016

Preparing for Winter Shutdown

Plan to perform in-depth maintenance during the slower winter season.

If operating in lower temperatures, opt for the manufacturer’s cold weather package.

Keep unused mobile equipment sheltered from weather.

Avoid frozen lines by injecting air and antifreeze into lines and pipes to reduce condensation and resist freezing.

Schedule in-depth maintenance and equipment rebuilds.

OPERAT

Win

1

Shutdown considerations

Preparing for Winter

P

reparing a plant to shut down for the winter really falls under the larger umbrella of “winterizing” — whether for shutdown or to operate through the winter season. “Our shutdowns in the northern regions might be only for a few weeks, and many of our plants operate yearround,” says Trent Carney, Rogers Group Inc.’s area production manager for Indiana. “For those plants that we do shut down, we want to make sure our winterization leaves open the possibility to produce if we need to.”

That said, Carney explains that preparations for winter begin as early as August or September, when the company looks at long-term weather forecasts, production needs, and inventory. “We look at what kind of winter is expected. Will we need snow removal? Is it expected to be wet and rainy? We talk on a regular basis, planning a shutdown date and working toward that. From a cost standpoint, we want to make sure we produce each day that we have planned to produce.”

Wade Lippert, field service representative for Kolberg-Pioneer, Inc., says the primary villain every plant battles in the winter is moisture.

“Freezing liquid is freezing liquid — and it all is bad for a plant. And moisture in components will create rust over time, which can damage everything from bolts and fasteners AGGREGATES MANAGER

to gear teeth, bearings, shafts, and other parts — leading to malfunction or failure, as well as safety issues,” he says.

What is the answer? Lubrication is a producer’s best friend, notes Patrick McGuire, service manager for Johnson Crushers International, Inc. Bearings must be purged and cleaned, then fully greased to keep moisture out. Screens require lubrication of the wheel case to make sure there is no moisture. “In short, grease everything you can grease, “ he says.

Both McGuire and Lippert emphasize the importance of using the correct, factory-recommended lubricants. “Our engineering department spends a lot of time researching oils and grease so that we can recommend for specific pieces of equipment and specific applications,” Lippert says. “Our operating manuals provide all of the information you will need as to what lubricants are recommended.”

For washing equipment, the key is to completely drain everything.

“Make sure there is no standing water in lines or pipes or it will freeze and they’ll break, creating downtime and lost revenue later,” McGuire says. “Blow out lines and pipes with dry air and then fill with antifreeze, if applicable. And clean everything.

Properly cleaning the plant will remove buildup that can harbor moisture, leading to rust.”

With more operations choosing to produce through during the winter months than in the past, traditional, months-long winter shutdowns are not as prevalent as they once were. That said, producers in northern states and providences still may choose to shut down for a matter of several weeks. The down period provides opportunity for them to handle scheduled maintenance on equipment. Planning begins in August or September.

4

Wet processing plan

Water — when it freezes — can break steel; ruin hydraulic, air, and water lines; and damage fuel. For wet processing equipment, most care revolves around completely draining what is possible to drain. It is important that the ability to drain the equipment is designed from the start to be convenient, so that it will be done.

Automatic pressurized drains are a benefit. Prepare for winter by injecting air and antifreeze into lines and pipes to reduce condensation and resist freezing.

TIONS ILLUSTRATED

nter is Coming — Prepare Now 2

Mobile equipment concerns

Mobile equipment purchase options may include heaters for engines, tanks, fluids, and hydraulics. These are simply plugged into 110V or 480V systems. Before snow flies, be sure to install the correct engine, hydraulic, transmission, and final drive lubricants. Fuel stabilizers are recommended.When the machine is not being used, it’s best to keep it out of the elements. If indoor machine storage is not an option, storing the battery indoors at room temperature is advised.

5

Winter rebuilds

Producers will often use the winter months to provide thorough maintenance on equipment — making repairs that would normally cause shutdown during production. Many manufacturers and dealers offer winter rebuild programs. In addition to overhauling the machine to like-new condition, the manufacturer or dealer will return it completely packed with grease so that it is ready for proper storage until spring.

3

EXPERTS

Dry processing ideas

Today’s processing equipment is available with options that allow it to run through the winter months — or shut down without worry about the elements. Cold weather packages can maintain heat for hydraulics and motors, and also monitor fluids, pressures, temperatures, and flow throughout winter shutdown. A critical factor is making sure lines and electronics are moisture-free.

Grease whatever can be greased, filling all voids. Empty bins and chutes so that material does not freeze to them.

6

OUR

Safety first

During winter shutdown preparation, many workers may be asked to perform new or unfamiliar tasks or work with equipment with which they are not familiar. It is important that producers provide additional safety training for non-routine tasks — including a written job safety analysis (JSA). The JSA, performed as a team, identifies hazards and works to eliminate them or reduce the hazard as much as possible. If anything changes, the team should stop and re-evaluate the job before continuing.

Johnson Crushers International’s service manager Patrick McGuire joined the company a year-and-a-half ago. With 10 years of experience in manufacturing management, he has spent the past six years focused on heavy equipment product support and warranty management. He holds a bachelor’s degree in business administration and an MBA with an emphasis in finance.

Wade Lippert is field service representative for Kolberg-Pioneer, Inc. and has been based at the company’s Yankton, S.D., facility for 27 years.

In his position, Lippert provides onsite product support to the company’s dealers and customers and in-house support.

His primary focus is the customer, but he also supports all parts of the organization — including product development and quality assurance.

As Rogers Group Inc.’s area production manager for Indiana, Trent Carney has been with the company for 13 years.

Previously, he was a site manager, for Bloomington Crushed Stone, Bloomington Underground, and Bloomington Specialty Products.

He has also held a Six Sigma Blackbelt position for Rogers Group. He has a bachelor’s degree in geological engineering in 1995.

September 2016

Voices of Experience Trent Carney

t

Rogers Group plants often run year-round, and those that do shut down typically only close operations for a matter of several weeks. According to Trent Carney, the company’s area production manager for Indiana, within the winter months, daily shutdown procedures are put in place so that the plant is prepared to sit idle if necessary — or it might start up, depending on production needs and the weather.

These daily procedures include emptying all equipment and bins of material so that nothing freezes overnight, dressing belts to help melt snow off of them, and using vulcanized rubber on head pulleys and winged tail pulleys. “Lube manufacturers now provide cold weather blends, where before, we had to keep our grease barrels heated,” Carney adds. He explains that Rogers Group orders its mobile equipment with heating packages, including heating blocks and lubricant reservoirs. “These are in place at all times, so we can just plug them in. Most run on 110V, and some systems run on 480V,” he says.

With the fixed plant, winter preparation can include back flushing the dust suppression systems and adding antifreeze at the stations to protect all waterways. Fixed elements, like crushers and screens, are typically outfitted with cold weather packages that are thermostatically controlled to maintain all fluids at the proper temperatures. “We used to make these cold weather systems ourselves, but any more, manufacturers offer them as an option when you buy the equipment,” he notes.

For wet processing systems, Carney says most facilities have been designed with convenient ways to drain water. “Because the goal is to be able to produce if necessary, we might not drain the system every night. One night of cold weather doesn’t affect the system. But if a whole week of freezing temperatures is in the forecast, we’ll drain it,” he says.

Rogers Group also uses monitoring systems — either from a manufacturer or built in-house — to monitor all fluids including pressure, temperature, and flow. “Our larger plants have a winter staff that prepares the site for winter and then monitors it after shutdown. Our smaller plants receive periodic checks. A lot of our mobile equipment has monitoring packages that can remotely send a text or place a call. And we also have developed our own call system that sends an alert through a PLC,” Carney says.

Patrick McGuire and Wade Lippert

t

Preparing a plant for winter involves many of the same steps for both a plant that will sit idle, as well as one that will run all winter, says Wade Lippert, field service representative for Kolberg-Pioneer, Inc. “There are more and more producers who operate during the winter months, even in northern Canada and Alaska,” he says.

This is, in part, made possible by the evolution of processing equipment. Today’s crushers, screens, and washing equipment are much more sophisticated than equipment from years ago. “But what makes today’s equipment better able to operate in extreme temperatures also makes it sensitive to environmental changes,” explains Patrick McGuire, service manager for Johnson Crushers International, Inc. “For example, equipment is now run by electronics, which must be sealed against the elements.”

Lippert and McGuire offer universal maintenance practices that apply both to shutdown and operation in winter.

• Make sure all electrical components are sealed against the weather.

• Ensure all oil reservoirs are properly sealed; change or clean out all reservoir breathers.

• For portable plants and generators that run on diesel, add fuel stabilizers.

• Completely drain all wash plants; blow out pipes and lines with dry air and ethanol or alcohol; add antifreeze.

• Lubricate the rock impulse mechanism in screens and make sure there is no moisture in the case.

• Clean all equipment to remove material buildup, which can harbor moisture that creates rust.

• Grease bearings to lock out moisture and reduce possibility of brinelling from any ambient vibration.

• Cover crusher openings to avoid snow and ice pack.

• Rotate conveyor revolutions so that bearings don’t seize.

• Check belts and hoses; replace if necessary • For oil heaters, use the correct viscosity oil for the ambient temperature; synthetic oils are more stable.

• Take batteries inside at night or use battery warmers.

“If you’re operating in the winter, it’s important to grease everything at night at the end of the shift. Fill all voids so that no moisture can build up,” says Lippert. “It’s good to do this all year long, actually, because it gets you into the habit.”

“Take the worst extremes into account, and operate as if conditions are always like this,” McGuire adds.

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MINE MANAGEMENT

by Duncan High

Fabricating

Failure

Are OEM parts worth the cost? Take a look at the lifetime costs of fabricated parts for vibrating screens.

O

ne of the ways operation managers naturally presume to increase profits in a mining or aggregates operation is to cut costs. Parts are often an area that production managers eye as a way to save money, but it’s important to look beyond the price and understand the role that a component plays in the performance of a vibrating screen and long-term productivity.

Operation managers need to be sure they choose the most reliable parts for their equipment. They need to consider the knowledge, experience, and resources required to manufacture the part, the potential hazards of using a fabricated version, and the value of having the support of the original equipment manufacturer (OEM). Here’s a look at the difference between the two and how those differences can impact production.

OEM expertise Consider the difference between fabricated and OEM components. Fabrication shops have come a long way and are often able to produce quality components, but some equipment, such as vibrating screens, needs such a precise tolerance that a fabricated part might not work correctly, no matter how closely it resembles the OEM version. Only a machine’s manufacturer has the precise equipment drawings, measurements, plus/minus tolerances, material composition, and know-how on what needs to be heat-tempered. This means only the manufacturer can produce a component that fits those fine-tuned parameters. Even a reputable fabrication shop with capabilities similar to that of the OEM has to rely on reverse engineering and guesswork to fashion a replacement. The part may look identical, but if it’s even a little off, it could cause problems.

A vibrating screen isn’t so much a machine as a complete system where every component works in tandem to accom-

The original equipment manufacturer can offer an in-depth knowledge of an operation’s vibrating screen along with accountability and fast, reliable problem solving.

plish a specific goal. If an operation screens 1,200 tons per hour, for example, a manufacturer designs parts with different strength and rigidity than they would for a 200-tons-per-hour application. This customization ensures the entire system runs to the proper g-force and is strong enough to resist the forces of the material running over the screen. The weight of the parts, the required running speed, and amplitude are all taken into consideration when balancing the screen. If an operation chooses to fabricate a side plate and the weight is wrong, for example, it could impact the machine’s balance. This could lead to improper motion in the vibrating screen causing poor AGGREGATES MANAGER / September 2016

27

MINE MANAGEMENT

stratification of material, lower bearing life, or premature breakage of body components due to improper operation. In the end, this leads to unscheduled downtime, contaminated product, or the required tons per hour not being produced.

Call for backup Custom fabrication shops can’t offer the support benefits of the original equipment manufacturer. OEMs usually have the infrastructure to ensure efficient problem solving. If there is a problem with a part, a reputable OEM will take full responsibility, quickly assess the situation, and promptly send a replacement.

Most parts shops don’t have the resources for a quick, precise turn-around if the part doesn’t work right, and there is no guarantee the replacement fabricated part will be correct.

In addition, working with an OEM means having a support team that understands an operation, its production, and equipment. They know what parts will wear quickly and what parts need to be on hand to limit downtime. They often offer OEM supplier agreements that ensure they will have critical parts in stock for immediate delivery, limiting or eliminating extended downtimes.

OEMs’ focus on vibrating screens also brings an in-depth product knowledge that’s rare elsewhere. Some manufacturer’s certified technicians test machines as a system before each leaves the factory, and they run the same tests once the vibrating screen has been commissioned to ensure results are identical. They use this information to make sure every component is running at OEM standards. In addition, the machine and components are backed by a strong warranty program.

Not only do some manufacturers offer warranties on new equipment purchases, some guarantee parts for up to a year if an operation uses OEM-certified technicians and parts and performs regular maintenance. Any fabricated parts introduced to a machine during a warranty period will void the entire machine warranty.

Fabricated parts’ hidden price tag While at first a fabricated component seems to make sense because it can often cost less than an OEM part, those savings are often short term. Minor imperfections in the part or lower tolerances for the stress placed on the machine can cause the component to fail prematurely, resulting in additional replacement costs on top of unscheduled maintenance. Even while the part is functioning, it often adversely affects the production of the machine, diminishing the throughput and limiting profit potential.

But the potential damage from an imperfect part doesn’t stop there. Those imperfections could start a chain reaction that leads to the damage of a series of other parts. This is especially true for shaft components, which form the heart of a vibrating screen. For example, if the shaft shoulders are not machined within the OEM tolerances, an operation could see problems within hours of operation. This slight difference in

28

AGGREGATES MANAGER / September 2016

Manufacturers design and build vibrating screens as a total system. The weight of the parts, required running speed, and amplitude are all taken into consideration when balancing the machine.

Fabricated tension rails, if not built to original equipment manufacturer tolerances, may not correctly tension screen media. This could lead to broken screens and thousands of dollars in new screen media and downtime before the operator realizes the problem.

size can cause the shaft assembly stack up to be too tight or too loose, leading to excessive heat and or wear of the shaft components. This can cause bearing failure or premature breakage of shaft components or body components.

This chain reaction of issues could result in maintenance costs far greater than the price of the fabricated component, but the cost is compounded by the fact that rarely is the heart of the problem diagnosed on the first pass. Most operators miss the true cause of the problem and begin fixing the symptoms — a cracked panel, a cross member, or sections of screen media.

Then the damage is destined to repeat and those parts must be replaced again. These symptoms might become obvious within 48 hours; while the root cause might take a month before it’s realized. By the time technicians find the issue, the cost of the initial part fix could be greatly multiplied and could be much higher than what the OEM counterpart would have cost.

Take tension rails, for example. A customer might wonder why his screen media is breaking after just a week of use,

Imperfections in

can result in tens of thousands of dollars of profit losses. where before it lasted a month or more. An fabricated shaft components can This cost alone would quickly offset any savings from OEM representative visits the site and finds lead to excessive choosing fabricated parts. the operation has been buying tension rails heat, resulting in from a local fabrication shop to save monbearing failure and ey. The tension rails looked right, but were Stick with OEM premature wear of not tensioning the screen media properly While it’s good business practice to find ways to save other components. across the screen deck, causing the sections money, site managers should not compromise on the qualto break. What saved the operation a few ity of vital equipment. The risks of expensive repairs and bucks up front on new tension rails cost time wasted are just too high. them thousands of dollars in screen Choose carefully when looking at replacement parts. media and downtime for change-outs.

While fabricated components are usually cheaper and In addition, if the faulty part caused the may appear to work correctly, any variance could vibrating screen to operate incorrectly, cause damage and downtime down the line. Continue there’s a good chance that the stratito work with the original equipment manufacturer to fication didn’t occur correctly and that guarantee a supply of reliable parts and the backing of a materials may have to be rescreened or company with the resources to solve problems quickly. The discarded. right choice means more uptime, more profits, and the assurIf operators do notice a problem soon after ance that a part will only make a machine run better. AM installing a fabricated part, they can prevent further damage by shutting the machine down quickly. However, this still Duncan High is the division manager of processing results in costly downtime, as mechanics order parts and make equipment technology at Haver & Boecker Canada. repairs. Any time the vibrating screen can’t run will bite into He has 26 years of experience with the company, profits, particularly for operations in the midst of production which was formerly called W.S. Tyler. season or a mining operation, where a few hours of lost time

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29

EQUIPMENT MANAGEMENT

by Giles Lambertson

Drill Down on

Uptime

Daily maintenance is a drill operator’s most important maintenance habit.

30

AGGREGATES MANAGER / September 2016

Systematic inspections and scheduled maintenance can keep drill rigs running for thousands of hours between major overhauls.

W

hen a drill rig starts punching through soil or rock, the operator is not thinking about the fluid levels on the machine or the condition of its hydraulic hoses. Those considerations were addressed in the days and hours before the rig’s engine was started and the drilling unit was moved into position. If operator and service technicians faithfully follow a recommended maintenance protocol, the machine should perform as expected when the bit actually starts burrowing.

Bill Burgee knows something about how to keep a drill rig running. After 20 years in a tech support role, including teaching best practices to surface drill operators, the Sandvik technical supervisor is a firm believer in maintenance. The most important maintenance habit an operator and support technician can form, he says, is daily inspection of the machine.

“Performing their daily maintenance, that is the biggest thing in keeping a drill running,” says Burgee, whose entire working career has been in the industry.

“Anything less can lead to premature failure of a component.”

The hierarchy of daily inspection procedures looks something like this: Check (1) the level of fluids, (2) condition of hydraulic hoses; (3) condition of linkage; (4) tightness of bolts, nuts, and hose fittings; and (5) for evidence of wear in bushings, bearings, and other close tolerance components.

Burgee’s daily check-list is twophased.

Before starting the engine: • Check oil levels (engine, compressor, pump drive gear, shank lube, hydraulic), and other fluids including fuel, radiator — and fire extinguisher.

After starting the engine and engaging drives: • Inspect for leaks; • Grease all grease points on lower half of feed rail; • Check filter indicators; • Warm up rig to operating temperatures;

• Check condition of bit; and • Inspect working area for safety hazards.

His weekly maintenance schedule is more hands-on.

• Grease all grease points; • Clean radiator, oil coolers, and cab; • Check drifter accumulator, drifter tie rods, and drifter mounting bolts; • Check filter indicators and inspect dust collector filters; • Check feed cable/feed chain adjustment; and • Repair any hydraulic leaks.

Daily and weekly inspections are preventive maintenance procedures, so, as a rule, they are more cursory. Problems are not really expected and visual examination and hand-testing usually are

oil level in the tramming gear after 250 hours? Yes, if the maintenance manual says to do so.

Be safety conscious Note that among Burgee’s recommended pre-drill daily examinations are safety checks, such as checking the fire extinguisher. Instilling in operators the habit of being safety conscious is a reminder that a heavy drilling rig has the capacity to do harm.

“We are pretty adamant about safety,” Burgee says. “We promote it. In initial training, we go over all the safety features in a rig and make sure the operator is fully aware of the do’s and don’ts with the machine. We don’t try to create safety procedures. It all is in the manual, and we thoroughly review that with them.”

Daily maintenance is the most important way to keep a drill running. sufficient. “On the daily check, you don’t have to put a wrench on a bolt to see if it’s tight. It’s not like a scheduled maintenance examination. That’s when you don’t just look at things,” Burgee says.

When bolts do need tightening, technicians are advised to use torque standards recommended by a manufacturer.

Longer-term maintenance protocols are no less critical for being less frequent. Components simply wear out over time and must be replaced. A new bushing that tightly guides a drill shaft in the beginning may have 15-20 degrees of play in it at the end of a year of drilling. If so, it needs to be replaced.

Depending upon a manufacturer’s recommendation, coolant may need replacing after 600 hours or it might be good for 2,000 hours. Change out the fuel filter after 600 hours? Check the

Safety in maintenance actually begins in factories. To reduce or eliminate falls by someone clambering over a machine to inspect or service it, manufacturers try to give ground-level access to service points. They try to organize electrical and hydraulic systems so technicians can reach and service the systems without putting themselves in slip-and-fall situations. Some manufacturers clearly route hoses with technicians in mind — spacing the hoses for unencumbered access with a wrench and labeling them for easier identification.

These attempts to provide access to service areas and to lessen the burden of maintenance have the effect of encouraging technicians and operators to look after their machinery. This, in turn, contributes to optimum hours of production.

Still, modern drills can seem overAGGREGATES MANAGER / September 2016

31

EQUIPMENT MANAGEMENT whelmingly complex. Burgee doesn’t believe that really is the case. “It is just a technician’s opinion when he says a rig is too complex,” Burgee says. “Normally, it means the person doesn’t really understand a machine and needs some help in some way.”

Keep fluids clean The surface-drilling environment, as in most construction work, is not dustfree. Consequently, cab windows get dirty (hence, recommended regular cleaning of them for safety and functional reasons). More importantly, fluids circulating in the machine can get dirty, too. Operators are advised to keep an eye on monitors that track the condition of fluid filters. Blockage means it’s time to change filters. Another indicator is a spike in operating temperatures, which can mean contaminated oil is unable to lubricate as intended.

Slipshod maintenance practices also contribute to contamination. When hydraulic hoses are disconnected, for example, the couplings should be wiped clean before being reconnected. This moment of decoupling and recoupling is the most likely for introduction of foreign material into a hydraulic system. Such material compromises the system and leads to premature wear of hydraulic components.

Consider the role of training Operators and service technicians are trained in all of this when they are introduced to a new machine and in follow-up training sessions. Nevertheless, rigs still experience component or systemic failure that throws production out of whack. It is sad to say, but sometimes the breakdowns occur because maintenance protocols are being half-heartedly followed.

Burgee says failure to follow maintenance best practices is a management issue. “Being responsible about caring for equipment has to start at the top,” he says. “If management, as a rule, doesn’t have the right attitude about it, it trickles down to the maintenance shop. In most cases, end users are responsible people and keep their equipment up to snuff, but it all depends on the people in an organization. I’ve seen it from one end to the

32

AGGREGATES MANAGER / September 2016

Use daily and weekly checks to ensure proper function and care of the drill.

other, people caring or not caring.”

Regardless of the myriad other benefits of training, operators should absolutely consider the bottom line and protect the sizeable investment they’ve made in iron.

Leverage the power of telematics Telematics play a role in maintaining a surface drill so it can perform optimally.

The remote monitoring of a machine from a base unit in a shop or at a dealership helps prevent equipment neglect.

The long-distance monitoring systems keep technicians constantly apprised of operational hours on a machine and the date of its scheduled maintenance. But

Burgee notes that a drill operator has access to the same information. The operator needn’t solely rely on base station feedback for critical decision-making on maintenance. He should be pro-active about having tech support work on a machine as warranted.

Generally speaking, today’s surface drills are more durable and productive than previous generations of equipment.

This is partly because operators and technicians are better trained, and partly because they are better informed by electronic monitoring systems. Knowledge is power, as they say, and knowing what is — and isn’t — operating according to expectations gives operators an ad-

Telematics allow remote personnel to review machine use and prevent neglect, but an operator should not rely solely on base station feedback for maintenance, particularly if a machine isn’t operating according to expectations.

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vantage. “Now, something doesn’t have to completely fail before you recognize there’s a problem,” Burgee says.

Owners of surface drills and their rig operators should expect to crank up a drilling unit and run it, day in, day out, for thousands of hours before needing a major overhaul. Systematic inspections and scheduled maintenance are minimally disruptive processes and can virtually eliminate costly interrupted production. AM

Giles Lambertson is a freelance writer who has been writing about the construction industry for nearly two decades.

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AGGREGATES MANAGER / September 2016 10:54 AM 2016-08-03 8/16/16 3:07 PM

CELEBRATING 20 YEARS OF KNOWLEDGE THAT RUNS DEEP Aggregates Manager celebrates two decades of amplifying the successes of every strata of the aggregates industry from crushed stone, sand & gravel operators to equipment manufacturers and dealers, and providers of services and supplies. Aggregates Manager has provided knowledgable support to the aggregates industry through key editorial coverage, timely expert analysis, and fostering a constantly active online community. We, at Aggregates Manager, look forward to delivering the vital information that streamlines your operations in 2016 and beyond.

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AggregatesManager

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SUPPLYLINES

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

Weighs and Means To keep track of the profits flowing through your operation, consider strategic placement of scales.

Protection against adverse conditions Cardinal Scale’s Guardian Hydraulic Truck Scales offer a high level of protection against many of the conditions that can adversely affect truck scale installations. Water, lightning, power surges, explosive areas, shock loading, and extreme temperature fluctuations can cause scale problems, all at a cost to the owner. Cardinal Scale manufactures its own stainless steel SST hydraulic load cells for all Guardian truck scales. These load cells carry a lifetime warranty when installed by an authorized dealer. They are said to offer the highest level of protection possible. Concrete or steel deck options are available. Both options offer solid decks that stand up to heavy loads. Every scale is 100-percent factory assembled and tested before shipping.

Cardinal Scale | www.cardinalscale.com

Easily installed belt scales To address limitations of traditional, load-cell based belt scales, Etheridge Automation developed a new solution for the aggregates industry: Etheridge Software Scales. They are designed for installation in the motor starter of the conveyor, with no electrical components outside of the MCC and with no moving parts. They are said to be easy to install and offer automatic calibration and are easily transferrable from one conveyor to another. Accuracy is not compromised over time, and production can be measured accurately and reliably.

Etheridge Automation | www.etheridgeautomation.com

Safe, secure scale management software DataBridge Vehicle scale management software, from Mettler Toledo, gives users control of scale functions on their computer and stores a detailed record of each weighing transaction. From standard functions, such as generating reports and tickets, to advanced options, such as unattended terminal controls, invoicing, and image capture, this highly configurable package offers a powerful tool for capturing and analyzing data. Good data management software eliminates the inaccuracies of hand-written transactions and offers a safe, secure option for businesses to accurately track loads.

Mettler Toledo | www.mt.com AGGREGATES MANAGER / September 2016

35

SUPPLYLINES Dependable, flexible performance Rice Lake Weighing Systems says the Survivor ATV truck scale delivers durability, longevity, and consistency, with the added feature of portability.

It features a low 20-inch profile and provides easy setup and expandability for aggregate operations when portability is needed. The factory-wired, self-contained modules streamline installation, relocation, and expansion. The pre-assembled modules and self-seating hinge connectors are the key to its easy portability. Scale systems can range from 24 feet long to more than 160 feet long. Standard end-positioned clean outs ease debris removal to help maintain scale accuracy.

Rice Lake Weighing Systems | www.ricelake.com

Precision belt scales For weighing and totalizing continuous flow rates of sand, gravel, crushed rock, or other bulk material up to 15,000 tons per hour, the Schenck Process BEMP Single Idler Belt Scale is said to combine quality, performance, and affordability in a modular package. Suitable for conveyors using 18- to 60-inchwide CEMA idlers, the BEMP mounts to conveyor frame using only four bolts. Utilizing two NTEP-approved single point load cells with rated capacities up to 660 pounds and the INTECONT Satus Integrator, accuracies of Âą1 percent of total weight are possible. Fieldbus connections to operation management personnel are also available.

Schenck Process | www.schenckprocess.com

Loader scales offer improved metrics

Trimble Loadrite says its L2180 loader scale introduces a new range of metrics to empower the operator to perform and improve overall equipment effectiveness. These metrics help the operator improve accuracy and efficiency each day, compare with personal bests, and provide a real-time star rating. Metrics cover loading accuracy, consistency, and safety to encourage operators to monitor performance and improve. They can be used throughout an operation, in both the pit and loadout zone.

Trimble Loadrite | www.loadritescales.com

36

AGGREGATES MANAGER / September 2016

Get the the most current information with the 2016 Aggregates Industry Atlas and the Atlas on CD. While the printed version of the Aggregates Manager 2016 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.

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by Patrick W. Dennison and Benjamin J. Ross

ROCKLAW

Workplace Exams Update Following up on reactions to substantive changes in its Program Policy Letter, MSHA issues a proposed rule on workplace exams.

I

Patrick Wayne Dennison is an attorney in the Pittsburgh office of Jackson Kelly PLLC, practicing in the Occupational Safety and Health Practice Group.

He can be reached at 412434-9915 or pwdennison@ jacksonkelly.com. Benjamin J. Ross is an associate in the Denver office, also practicing in the Occupational Safety and Health Practice Group. He can be reached at 303-390-0026 or bross@jacksonkelly.com.

n the September, October, and November 2015 editions of Aggregates Manager, Jackson Kelly attorneys addressed the Mine Safety and Health Administration’s (MSHA) July 2015 Program Policy Letter No. P15-IV-01 (PPL) regarding examinations of working places. As you may recall, the PPL’s stated purpose was “to clarify that the examination of working places required under 30 C.F.R. §§ 56/57.18002 includes the requirement that the 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.” And despite MSHA’s Metal and Nonmetal Administrator Neil Merrifield stating that there was “nothing new” in the PPL, the September 2015 article detailed the substantive changes contained in the PPL, which we viewed as MSHA’s attempt to change a standard without conducting formal rulemaking.

Whether MSHA read any of the 2015 workplace examination articles remains a mystery, but the industry’s concerns regarding the substantive changes to the workplace examination rule were apparently too compelling to ignore. On June 7, 2016, MSHA notified stakeholders of two initiatives, one of which included a proposed rule regarding workplace examinations for metal/non-metal mines. The proposed rule states as follows: (a) A competent person designated by the operator shall examine each working place

at least once each shift, before miners begin work in that place, for conditions that may adversely affect safety or health.

(1) The operator shall promptly notify miners in any affected areas of any adverse conditions found that may adversely affect safety or health and promptly initiate appropriate action to correct such conditions.

(2) Conditions noted by the person conducting the examination that may present an imminent danger shall be brought to the immediate attention of the operator who shall withdraw all persons from the area affected (except persons referred to in section 104(c) of the Federal Mine Safety and Health Act of 1977) until the danger is abated. (b) A record of each examination shall be made, and the person conducting the examination shall sign and date the record before the end of the shift for which the examination is made.

(1) The record shall include the locations of all areas examined and a description of each condition found that may adversely affect the safety or health of miners.

(2) The record shall also include: (i) A description of the corrective action taken, (ii) The date that the corrective action was taken, and (iii) The name of the person who made the record of the corrective action and the date the record of the corrective action was made.

AGGREGATES MANAGER / September 2016

39

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.

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ROCKLAW (3) The operator shall maintain the examination records for at least one year; shall make the record available for inspection by authorized representatives of the Secretary and the representatives of miners; and shall provide these representatives a copy on request.

The significant changes in the proposed rule from the current rule include the following: examinations occur before miners begin work in a given shift; operators promptly notify miners in the affected areas of detected hazards; competent persons must sign and date the examination sheet before the end of each shift; examination records include any adverse conditions found and corrective actions taken; and operators make records available to miners and their representatives.

Despite these changes, Assistant Secretary of Labor for Mine Safety and Health Joseph A. Main stated during the stakeholder meeting that he believes the proposed examination rule is not as stringent as those rules governing examinations in underground coal mines.

Like the changes noted in the July 2015 PPL, the changes proposed in the new rule present concerns for operators. First, including adverse conditions and corrective actions on the examination records raises the concern that MSHA will cite operators for violations noted in records, even if operators are

in the process of abating or have already abated those conditions. Second, the requirement that competent persons must sign records suggests that MSHA may increase its focus upon § 110(c) penalties and other individual sanctions. Definitions of key terms remain the same, but the ambiguity that already exists may take on heightened significance. For example, the current definition of “working place” will remain as “any place in or about a mine where work is being performed.” Questions as to whether a certain location is a “working place” versus, for example, a “travelway” could result in confusion as to what locations require an examination before employees may be present. Additionally, the standard’s requirement that the operator “promptly initiate appropriate action” in response to conditions found on examinations could raise questions as to what is required of the competent person signing off on the examination.

Comments on this proposed rule must be received or postmarked by midnight Eastern Standard Time on Sept. 23, 2016. We would encourage all operators and industry groups to submit comments to MSHA concerning the proposed rule.

Providing meaningful comments is your chance to participate in the legislative process and have your voice heard before the changes become final. AM

AGGREGATES MANAGER / September 2016

41

ADINDEX September 2016

Advertiser

Web

Aggregates Manager Atlas Data/CD Products

www.aggmanatlas.com

37

Aggregates Manager Community Outreach

www.aggman.com/community-outreach

40

Atlas Copco Construction Mining Technology

www.atlascopco.us

BekaWorld (formerly Beka-Max of America)

www.beka-lube.com

33

Bill Langer - Research Geologist

www.researchgeologist.com

43

BKT Tires

www.bkt-tires.com

C.L. Dews & Sons Foundry

www.dewsfoundry.com

43

ConExpo-Con/Agg 2017

www.conexpoconagg.com

25

Cowin & Company, Inc.

www.cowin-co.com

Elrus Aggregate System

www.elrus.com

Kespry, Inc.

www.kespry.com/aggregates

Kleemann, A Wirtgen Group Co.

www.wirtgenamerica.com

4

Kruse Integration

www.kruseintegration.com

43

Laser Technology, Inc.

www.lasertech.com

41

Martin Sprocket & Gear, Inc.

www.martinsprocket.com

13

Midwestern Industries

www.midwesternind.com

9

NSSGA Legislative

www.nssga.org

20

NSSGA Membership

www.nssga.org

26

Progressive Commercial Insurance

www.progressivecommercial.com

29

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

IFC

Scott Equipment

www.scottcompanies.com

17A

Stedman Machine Co.

www.stedman-machine.com

Sweet Manufacturing

www.sweetmfg.com

43

United Employment Assoc.

www.unitedemployment.com

43

Volvo Construction Equipment

www.volvoce.com/na

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

42

AGGREGATES MANAGER / September 2016

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Experience: Retired November 2011 following 41 years with the U.S. Geological Survey • USGS Aggregate Resource Geologist 1977-2011 • Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division • Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present

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

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43

12/16/14 1:21 PM

CARVED IN STONE

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

Egerszalók Travertine Who knew that exploring geological wonders could lead to a hot bath and a glass of wine?

B

ack in 1998, I was a lecturer and subject matter expert in the NATO Advanced Study Institute workshop on Mineral Resource Exploitation.

The conference was held in Matráháza, Hungary, less than a decade after the fall of the Berlin Wall and drew scientists from a number of recently liberated communist bloc countries. Interacting with those folks was an experience in itself.

The workshop included a field trip throughout northeast Hungary. One field trip stop was near the small village of Egerszalók. As the bus approached the village, the geologist/tour guide pointed to what looked like a pile of steaming snow standing out from the green grassy hillside. A few people were wandering on the ‘snow’ and on the grass surrounding it. The ‘snow’ turned out to be the Egerszalók Travertine; one of the most unique and spectacular travertine sites in Central Europe.

This geologic wonder is an indirect product of human activity. In 1961, a 1,337-foot oil-exploratory borehole drilled on the hillside penetrated a highly permeable limestone aquifer. Hot (about 149°F), mineralized water discharged from the well about as fast as water comes from a fire hydrant. A 1-foot deep basin was dug to contain the water, and travertine began to form in the basin.

As the travertine deposit grew, so did the tourist traffic. In 1987, a second well was drilled to supply water for bathing and medical purposes. Water from the first well sustains the development of the travertine mound.

The mound is smaller than a football field, but impressive nonetheless. The waves of overflowing water create tiny dams called rimstones, and spectacular A borehole drilled into a highly permeable limestone aquifer resulted in hot mineralized water being diselements of the travertine mound include curtains, organs, ridges, and crests. charged. The deposit is now part of a four-star hotel Today, the deposit is part of a four-star hotel and spa conference resort. and spa.

There were no buildings when we were there; only a few tourists bathing in the pools of hot, healing waters. None of us was dressed for bathing, so we all piled back on the bus happier, but no healthier, than when we arrived. It was the only time I visited a geologic wonder that was younger than I was.

The next stop was to the famous wine cellars of the region. Many of the cellars date back to the early 1600s when Turkish invaders occupied the region. Local residents abandoned their homes and moved into caves dug into the tuffaceous rock (rock made from volcanic ash) hillsides. When the invaders left, the residents abandoned the caves and moved back to town. The empty caves were put to a variety of uses, including wine cellars.

Recently, and for a variety of reasons, some of the caves have begun to deteriorate. One of the most interesting reasons is that the area has shifted from well water to municipal water, causing the groundwater to rise. This is exacerbated by leaky water supply lines and sewer lines. The rock has very high water absorption and, when saturated, some of the minerals rapidly weather to clay. The weakened rocks lead to cave collapse.

To view the problem, we went to look at the tuffaceous rocks and, while there, to taste the wine. The seasoned wine sippers in the group told me it’s essential to expectorate when tasting a whole bunch of wine. You swirl your glass, sniff, sip, swish, and spit. Geologists sometimes spit on rocks to enhance their color. But eeewwwww, have you ever gotten an up-close view of those spit buckets? Nasty!

44

AGGREGATES MANAGER / September 2016

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