October 2014
www.AggMan.com
22 26 32
Hawaiian driller finds big fuel savings Four ways for managers to showcase safety MSHAʼs proposed rule means bigger penalties ahead
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12
On Our Cover: Essential information on haul road design and maintenance. Cover photo by Sergey Yakovlev.
Before you set and forget your submersible dewatering pump, make sure you’ve taken the proper maintenance precautions.
10
Atlas Copco’s SmartROC T35 and T40 are its first drills to offer the option of remote control operations.
CONTENTS OCTOBER 2014 VOLUME 19, NUMBER 10
FEATURE ARTICLES
12 22 26
Keep Moving
Proper selection and maintenance of your dewatering pumps goes a long way.
Big Improvements on the Big Island Hawaiian drilling and blasting contractor sees productivity improvements and fuel savings with new drill.
The View of the Top
Employee perceptions of how management views safety can shape the reality of their behavior. What’s the perception among your staff?
WEB EXCLUSIVES Visit www.aggman.com for expanded editorial coverage. Balancing Safety, Production, and Efficiency The key to balancing operational goals is to pay attention to all three and understand how each affects the others.
OPERATIONS ILLUSTRATED
17 Haul Roads
Shorter haul roads equal faster cycle times, but other factors should be considered during haul road design and maintenance to create the optimal route.
COLUMNS & DEPARTMENTS
3
EDITORIAL The turkey comes early this year.
AND PROVINCE NEWS A roundup of the latest news in North 4 STATE America. Terex Mineral Processing System’s new modular jaw crusher, and 7 ROLLOUTS other new equipment for the aggregate market.
MINING The latest financial analysis 31 DATA of issues impacting in the industry. LAW MSHA’s proposed revisions to regular assessment penalty scheme promise 32 ROCK higher penalties, less discretion. INDEX See who’s who and where to find their products. 34 ADVERTISER ADS Aggregate industry classifieds. 35 CLASSIFIED IN STONE Passage of the 1872 Mining Law spurred the development of 36 CARVED mining towns as the nation explored its Manifest Destiny.
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by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
October 2014
Vol. 19, No. 10
aggman.com /AggregatesManager @AggMan_editor
Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Online Managing Editor: Brian Ethridge editorial@aggman.com
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Turkey Comes
EARLY THIS YEAR
T
he process of buying property and developing a greenfield site can be daunting. Testing must be conducted to ensure the presence of economically viable reserves. Environmental impact studies must be performed to ensure the well-being of people, flora, and fauna near the proposed site. Meetings before planning commissions and zoning boards must be addressed. Environmental groups that protest the pillaging of nature must be countered with scientific research. These steps are a common part of the process. While operators might hope for a less contentious, more fact-based decision-making process, most can work through the crucial communication issues and appeal to the rational side of local decision-makers. Honesty and a sincere desire to create solutions that meet the needs of all are often met with open minds and good outcomes, at least eventually. At Aggregates Manager’s press time, the University of South Carolina and Vulcan Materials Co. were both about to bid on a 298-acre parcel going to auction due to a bankruptcy case. The land is located behind USC’s Gamecock Park, and Vulcan’s interest drew the attention of environmentalists and neighbors from the outset. Just over a week before the auction, The State reported that the director of the local environmental group declared that if Vulcan won the auction, the group would oppose rezoning for the land. That’s not particularly surprising. What was a little more unexpected, and aggravating, was the decision of two County Council members to issue statements saying they would oppose the mine before the auction had even taken place. At a meeting of the environmental group and concerned neighbors, County Council Member Seth Rose went so far as to say, “That football program and this university has a huge economic impact on the Midlands, and I don’t want to see what the university’s invested down there being tainted by a rock quarry next door.” Rose’s term expires this year, so his statements may have been political grandstanding to garner attention and votes. It’s an interesting gambit in a county that is home to five surface aggregates operations. No matter what his intent, the comment indicates an unwillingness to seek an outcome that benefits both the community and the company. Rose also failed to note that he is a USC graduate and may not be an impartial party in any future decisionmaking process. Whether or not Vulcan wins the bid for the land remains to be seen, but one thing is clear: When it comes to Rose, the former Gamecock is a turkey.
3
takeaways from this issue:
1
A super-elevated curve will allow haul trucks to maintain their downhill speed throughout a curve without applying the brake, page 17.
2
A simple evaluation of a manager’s emails can highlight the importance of safety within the company, page 26.
3
With the simple change of “will” to “could,” MSHA’s proposed penalty changes would lessen its burden to establish S&S criteria, page 32.
AGGREGATES MANAGER October 2014
3
State & Province
NEWS by by Therese Therese Dunphy, Dunphy, Editor-in-Chief Editor-in-Chief tdunphy@randallreilly.com
Alabama
Forbes magazine reports that Vulcan Materials moved up a spot in the S&P 500. Based on order by largest market capitalization, Vulcan bumped McCormick & Co., Inc. from the #421 spot. Forbes says that market capitalization provides for an apples-toapples look at stock values. It estimates the market cap for Vulcan to be $8.21 million.
Arizona
The Arizona Attorney General’s Office closed a criminal investigation into whether the Maricopa County Flood Control District violated open meetings laws by holding a secret meeting to discuss ABC Sand & Rock and tried to cover it up. The Arizona Republic reports that the investigation began after the producer accused the agency of trying to put it out of business. The suit was thrown out of court, but Attorney General investigators served a search warrant on the Flood Control District’s offices, with the warrant matching claims about potential open-meeting violations. In September, however, the AG office closed the investigation due to lack of evidence of criminal wrongdoing.
To keep up to date with this breakdown of news in the United States and Canada, visit www.AggMan.com for daily updates.
Illinois
Dupo-based Columbia Quarry Co. filed suit against Petroff Trucking, alleging that it failed to pay for services. The Madison-St. Clair Record reports that the operator has past due invoices totaling $122,983.77. It is seeking payment on invoices, finance charges of $31,869.46, and attorney fees, as well as any other relief the court provides.
Indiana
At Aggregates Manager’s press time, the Indiana Department of Environmental Management was planning a public hearing on how the proposed Singleton Stone quarry would impact local air quality. According to nwi.com, the operation’s developers have applied for an air permit that would comply with the local dust control regulations. It would limit its particulate matter to 25 tons a year and the total production to 1 million tons a year. Local residents who are opposing the quarry have voiced concerns about its affect on the water table.
Massachusetts
The Plymouth Planning Board voted 4-1 against recommending the Zoning Board of Appeals grant a local trucking company a permit to remove 250,000 cubic yards of sand and gravel off county land. Wicked Local Plymouth reports that Kingstown Trucking says it wants to move the material to create a solar array on 10 acres of the land parcel. The majority of Planning Board members said there are “far too many mining operations in town and there is no guarantee solar panels would be installed.”
New York
Illinois
An algal bloom in stormwater stored in the Elmhurst Quarry created an irregular odor just after Labor Day. According to Suburban Life Media, neighbors noticed the smell when DuPage County Stormwater Management pumped floodwater collected in the quarry back into Salt Creek. The intent was to create additional capacity in the quarry for future rain events and was coordinated with water levels in the river. Lack of oxygen in the stored floodwater caused the algal bloom, so the county staff is now re-oxygenating the standing water. Once treated, pump-back operations will resume.
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AGGREGATES MANAGER October 2014
An SUV reported stolen several months ago was found submerged at the Hanson Aggregates Quarry in Le Roy. According to the Penfield Post, a worker at the quarry spotted the Jeep Wrangler partially submerged, but no one was inside. The vehicle was 70 to 75 feet down in the quarry.
North Carolina
A portion of the $30.85 million bond issue facing Winston-Salem voters next month may be used to create a new park on 220 acres of a former Vulcan quarry acquired by the city. The Winston-Salem Journal reports $4 million could be used at the yet-to-be-named Quarry Park. Plans for the first phase of development include an elevated boardwalk through the trees leading from the top of the highwall to the water’s edge, picnic shelters, and an amphitheater with views of downtown.
South Carolina
Approximately 50 people gathered with Sustainable Midlands, an environmental group, to discuss Vulcan Materials Co.’s potential acquisition of 298 acres of land south of Columbia, according to The State. The operator is bidding against USC for the land, which was part of a bankruptcy case. The director for the environmental group told the newspaper that if Vulcan has the winning bid, his group will work to convince the county to reject a rezoning request for the land. One County Council member, Seth Rose, told the newspaper, “that football program and this university has a huge impact on the Midlands, and I don’t want to see what the university’s invested down there being tainted by a rock quarry next door.”
Wisconsin
Texas
Copper wires stolen from Texas Sand and Gravel Co. in Amarillo were recovered by the Potter County Sheriff’s Office. Approximately $35,000 of copper was cut off and stolen from the operation’s equipment, KVII reports. With lost production, equipment repairs, and replacement parts taken into account, the incident was estimated at nearly $1 million. A trailer with copper wires was found in the western part of the county. A Potter County attorney said that the thief would face a hefty fine and up to 10 years in prison. Law enforcement officials are still looking for the person or persons responsible.
Although it was denied a permit in 1999, Yahara Materials has submitted a new plan hoping to extract additional material at a current location. According to the DeForest Times-Tribune, the company has changed its mineral extraction policy to match state blasting regulations standards. The operator proposed hours of operation from 7 a.m. to 6 p.m., Monday through Friday, with blasting limited to 8 a.m. to 2 p.m. Before each blast, photos would be taken of all structures within 1/2 mile of the quarry, and 24-hour notice of a blast would be provided.
Province News
Summit Materials announced its acquisition of Mainland Sand and Gravel, a supplier of construction aggregates to the Vancouver and Lower Mainland region of British Columbia. It says the acquisition expands its footprint and creates a new growth platform for it in the attractive British Columbia market. Mainland operates two quarries and four river-served aggregates distribution depots. Mainland’s team will remain in place to manage and develop the business under the new ownership.
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Text INFO to 205-289-3782 or visit www.aggman.com/info AGGREGATES MANAGER October 2014
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Efficient direct drive: The new diesel direct drive of the crusher, in combination with electric drives for the feeder, prescreens and conveyor belts, ensures one of the lowest fuel consumption levels in its class. The crusher is driven directly via a fluid coupling which ensures high operational reliability. High production, quality product with maximum efficiency, the all new Kleemann EVO jaw crusher.
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For
FREE Product Information Text INFO to
205-289-3782,
by Therese Dunphy, Editor-in-Chief tdunphy@randallreilly.com
Your complete guide to new and updated equipment and supplies in the aggregates industry.
or visit
aggman.com/info.
Largest jaw in modular line Terex Minerals Processing Systems (MPS) rolls out its MJ47 primary jaw crusher module, which is said to increase the application capabilities and crushing capacity of its existing modular product range with its largest jaw module to date. Designed for large quarries or contractors who want a stationary type design without the complexity of a typical stick-built plant, the module features a 36- by 48-inch Terex Jaques ST47 jaw crusher. Other key features include the Terex Simplicity 51-inch by 24-foot heavy-duty, doubledeck vibrating grizzly feeder; large capacity truck dump hopper; discharge conveyor; extra heavy-duty galvanized/painted I-beam frame; wraparound maintenance access platform; stairs; and guardrails. Terex MPS | www.terexmps.com
Chevron pulleys Superior Industries, Inc. offers a new longer-lasting model of its chevron pulleys, which are v-shaped wing pulleys designed to deflect fugitive material. Made from special high-tensile steel, the new AR Chevron Pulley model is designed for conveyor owners who require extra high performance and guaranteed uptime with their material handling applications. The pulleys are available in Mine Duty and Super Duty model, with diameters ranging from 10 to 42 inches and face widths from 12 to 75 inches. Superior Industries, Inc. | www.superior-ind.com
Tier 4 interim wheel loader The HL760-9A wheel loader, from Hyundai Construction Equipment Americas, Inc., offers numerous improvements over the previous models, including a Tier 4 interim engine upgrade. The unit is equipped with a low-emission, low-noise 222-horsepower Cummins engine. Operators can choose between three engine modes — power, standard, and economy — that enable the machine to switch between full power and reduced fuel consumption according to user preference. The loader has an operating weight of 40,450 pounds, a 4.3-cubic-yard bucket capacity, and a bucket breakout force of 35,780 pounds. An extended reach option is available for applications requiring a higher dump height. The larger, redesigned cab is said to improve visibility from all angles, while a 5.7-inch touch-screen LCD monitor allows the operator to view the integrated weighing system and monitor crucial system functions, as well as serving as a rearview backup camera screen. Hyundai | www.hceamerias.com
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AGGREGATES MANAGER October 2014
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Remote-control drilling
Fuel-efficient excavators The Volvo EC250E and EC300E crawler excavators deliver a 5-percent improvement in fuel efficiency compared to past models. The gain is attributed not only to the Tier 4 Final Volvo engine, but also to a range of features that optimize flow and minimize pressure losses in the hydraulic system, including ECO mode, which automatically reduces fuel consumption without any loss of performance in most operating conditions. In addition, the excavators can be equipped with automatic idling and auto-engine shut down systems as optional equipment. All operator interfaces — including joysticks, keypad, and LCD monitor — have been ergonomically designed and positioned for comfort and efficiency. JCB | www.jcb.com
The Atlas Copco SmartROC T35 and SmartROC T40 are the first surface drill rigs from the manufacturer to offer the option of radio remote control operations by upgrading either rig with a SmartROC radio remote control kit. The T35, for hole diameters of 2 1/2 to 4 1/2 inches, and the T40, for hole diameters of 3 to 4 1/2 inches, drill to a maximum depth of 92 feet. The rigs are designed with a low center of gravity and a high ground clearance so they can operate safely on rough terrain. The T35 is fitted with the 27-horsepower Cop 1840 rock drill, while the T40 comes with a 33.5-horsepower Cop 2560 rock drill. A boom reach of 25 feet in height for horizontal drilling and 18 feet forward for vertical drilling offers flexible operations. Atlas Copco | www.atlascopco.us
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AGGREGATES MANAGER October 2014
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Text INFO to 205-289-3782, or visit aggman.com/info. 5/15/13
BillLanger_AGRM0213.indd 1
9:04 AM
MEMBERSHIP MAKES A DIFFERENCE It’s time to rebuild America. None of us can do it alone, but together we form a powerful voice that will be heard from the heartland to Capitol Hill. You can be a part of this effort by becoming a member of the National Stone, Sand & Gravel Association. We are the only national organization focused solely on the interests of the aggregates industry. So join us today and make a difference. For more information on how to join, call (800) 342-1415, email info@nssga.org, or visit our website at www.nssga.org.
ROLLOUTS
Secondary belt cleaner Flexco’s Y-Type Secondary Belt Cleaner improves beltcleaning efficiency while easing maintenance, the manufacturer says. The cleaner comes with 3-inch urethane blade segments that conform to worn or damaged belts, while the spring tensioner keeps consistent blade-to-belt contact and constant pressure on the belt. Available in sizes to fit belt widths from 18 to 48 inches, the secondary cleaner is available with a standard abrasion-resistant purple blade. Blades can be removed or replaced individually or at one time. Flexco | www.flexco.com
High output tracked jaw crusher Irock expands its product line to include the TJ-3046 Tracked Jaw Crusher. The primary jaw plant is designed for medium-scale operators in quarrying, demolition, recycling, and mining applications. It features a 13-cubic-yard feeder and a grizzly pre-screening grid. An optional sensor can be fitted to the jaw and controls the feed rate to the crusher to maximize production. The jaw crusher has an inlet opening of 46 inches by 30 inches and is equipped with a hydraulic wedge adjustment to give operators control of product size down to 2 inches. The high-swing jaw is said to generate an aggressive crushing action and accelerate movement of material into the crushing chamber. A 48-inch crusher discharge conveyor can stockpile up to 11 feet, 6 inches. The 110,250-pound unit can be equipped with a wireless remote control and is powered by a 350-horsepower Cat C-9 Acert Tier 3 engine. It can produce up to 445 tons per hour. Irock Crushers | www.irockcrushers.com
Jaw update increases energy Streamlined filter press McLanahan Corp. introduces its own line of filter presses. Designed to help operators better use wash water and land resources, the filter presses are said to eliminate the need for settling ponds. The dry, easy-to-handle byproducts produced through the filter presses can be safely handled and disposed of. The filter press line is said to use few moving parts and was engineered with a single hydraulic cylinder. McLanahan Corp. | www.mclanahan.com
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AGGREGATES MANAGER October 2014
Significant changes to KPI-JCI and Astec Mobile Screens’ new generation of Vanguard Jaw Crushers are said to reduce maintenance and increase energy and performance. Operator investment is protected through replaceable wear parts such as the jaw die seats and barrel protector plate. Maintenance is simplified with a new jaw die wedge design that holds the jaw die in place. The manual shim adjustment method was eliminated as the closed-side setting is now adjusted through the use of hydraulic cylinders. New design components — including increased stroke, toggle angle, and flywheel inertia — enable operators to increase performance. The largest crushers in the line crush with a 1 1/2-inch stroke that opens wider and compresses material more to get material through the jaw quickly. KPI-JCI and Astec Mobile Screens | www.kpijci.com
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Keep Moving Proper selection and maintenance of your dewatering pumps goes a long way. by Joe Moser
12
S
ubmersible dewatering pumps have one clear goal — to move water, whether it’s to another location for reuse or to simply remove water from a low-lying area. For the most part, they require little maintenance. But before you set and forget your submers-
AGGREGATES MANAGER October 2014
ible dewatering pumps, there are some preventive maintenance practices you should follow to keep them operating at their best day in and day out so productivity keeps flowing in the right direction. And some of the most important practices start long before your submersible pumps hit the jobsite.
EQUIPMENT MANAGEMENT
To select the correct pump, consider the material being pumped, the distance it is being pumped, and the elevation to which it is being pumped.
A pump that sizes up
Electric submersible pumps are the most commonly used pumps for dewatering aggregate mines. They are small and lightweight, and when it comes to maintaining the pumps, choosing the right one for the application is one of the biggest decisions you’ll make. Using a pump that isn’t sized for the application can lead to issues down the road, such as a broken shaft, dislodged seal, or thrown impeller. In aggregate mines where dewatering is often critical to production, that means costly downtime. To avoid this, there are three things to consider: the material you are pumping, how far you need to pump it, and the elevation to which it will be pumped. If it will be moving water and aggregates rather than just water, you’ll need a model that is rated for that application and is equipped with impellers made of a durable material, such as cast iron. Other materials, like polyurethane, can handle water, but the abrasive materials such as aggregates can cause them to wear out quickly. Electric submersible pumps rated for these applications can typically move aggregates as large as 1 inch in diameter with minimal wear to components. From there, you will want to confirm the pump can move water as far as you need it to go. Generally, the farther the pump is from the water site, the greater the gallons per minute (gpm) it will
need to move the water to or from that location. And if the water has to move uphill, the pump also will need more head capacity; in other words, how high the pump can raise water. Electric submersible pumps operate with as much as 5,300 gpm and can pump water as high as 275 feet. Outputs can be as wide as 10 inches in diameter for even greater flow capacities.
Get immersed in the details Once you’ve determined the right size, make sure the pump is built with durable materials and has features that will withstand long run times and the harsh conditions of aggregate applications. The pump’s wear plates and seals play an important role in that, since they help protect the internal components. Choose pumps with double mechanical seals, which provide a consistent, watertight interface. Some manufacturers offer stainless steel seals, which last longer than rubber seals and are more durable, making them a good fit for aggregate applications. Also look for mechanisms that stop the unit if it overheats or the electric current overloads the pump. On most models, the pump will automatically restart after it has cooled. This helps protect the motor from damage and extends the life of the pump.
AGGREGATES MANAGER October 2014
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If your pump will be unattended, consider installing a float that automatically shuts off the pump when the water level becomes too low, then restarts it as the level rises. This prevents damage to the seal and prevents premature motor failure. In addition to pump components that keep damage from occurring, there are others that make maintenance faster and easier on the jobsite. For example, some pumps offer access to their interiors with the removal of just a few bolts rather than numerous ones. Some pumps also don’t require users to remove additional components, such as the seal, to access the interior. For even faster maintenance on the jobsite, many manufacturers offer a complete replacement package that includes a seal, shaft, and impeller, and everything users need to install them. Also, consider where you can get parts and how long you might have to wait for them. Now you’re ready to get things moving. But once you have your pump in place, don’t forget to pay it a visit once in a while.
A little goes a long way
While every piece of equipment with moving parts needs regular, preventive maintenance, it’s particularly important for
Double mechanical seals provide a consistent, watertight seal and play an important role in protecting the pump’s internal components.
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AGGREGATES MANAGER October 2014
9/19/14 9:41 AM
EQUIPMENT MANAGEMENT
equipment used in rugged applications such as dewatering aggregate mines. Electric submersible pumps have three main wear parts: the impeller, seal, and shaft. A drop of preventive maintenance goes a long way with all of them. Since the seal is one of the most critical parts of a pump, it’s important to check the seal oil as often as once a week in heavyuse applications and refill it as needed. This will ensure the seal remains properly lubricated and watertight. Inspecting hoses and cables for damage should be on your weekly checklist, too, especially if they are exposed to the elements or in areas where traffic could cause damage. Typically, a damaged pump hose is easy to spot, as you’ll see water flowing from the hose. A damaged cord, on the other hand, might not be as noticeable, and, if left unrepaired, could be a danger to personnel or short the motor. For pumps in permanent applications, you’ll also want to take them out of service about every four months to thoroughly inspect internal components such as the impeller and shaft. Damage to these areas can allow water to leak into the pump and
damage components. This also is a good time to change the seal oil as it can become thick and gummy over time and cause the pump to burn out. Don’t forget to shut down the power supply before performing any maintenance to eliminate the risk of injuries. Finally, keep a backup pump on hand to keep water flowing if your pump breaks down or when you take your primary pump out of service.
Go with the flow
The longevity and performance of your pump all trickles down from the preventive maintenance practices you perform. From the time you purchase a pump to the last day it’s on site, a clear preventive maintenance plan will keep water moving and productivity flowing in the right direction. AM
Joe Moser is the pump product line manager at Atlas Copco Construction Equipment.
Introducing the new Nordberg NP15 impact crusher Metso’s new Nordberg NP15 impact crusher takes you 3 steps forward:
NP15 3 steps forward
• Steeper feed angle improves crushing performance • Automation and smart wear-part design increase cost efficiency • New 2-part rear frame makes maintenance easier and safer Discover more at www.metso.com
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AGGREGATES MANAGER October 2014
15
MAXIMIZE UPTIME because results drive business Telsmith T-Series™ Cone Crushers are engineered to deliver un-compromising productivity, safety and ease of maintenance for maximum uptime in tough, abrasive aggregate and mining applications. The Telsmith T-Series™ line-up of cone crushers delivers the reliability, productivity, and safety needed for your bottom line.
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PULL-OUT GUIDE By Kerry Clines, Contributing Editor
OPERATIONS ILLUSTRATED
d Maintenance n a n o i t c u r t s n o C d a Haul Ro
Make haul roads wide enough for two trucks. Build a haul road in the pit floor to aid drainage.
Use a water truck to reduce dust levels. Design haul roads with space for berms.
Haul roads should be smooth and well maintained.
OPERAT 1
Allow space for trucks to pass
Design and Maintain Good Haul Roads
H
aul roads are the lifeline of a quarry, providing a safe route for materials to be transported from one place to another, mainly between the pit and the crusher or processing plant. The shorter the haul road, the faster the truck cycle time, but the local terrain may require a longer road in order to make it safe for travel. The ideal haul road should be smooth and free from potholes, ruts, and washouts. The grade should be smooth and constant with plenty of room for vehicles to pass each other. Corners should allow trucks and other vehicles to operate safely and reliably at optimum speed. All these things should be considered during the design phase of the pit. Many factors can affect the placement and design of haul roads, including climate, environmental conditions, and the local geology, as well as the size of the haul trucks that will be operating on them. In rainy climates, drainage ditches can keep haul roads from washing out, causing delays in cycle times. Geologic conditions, such as cracks and faults in the highwall, can determine how close a haul road can come to the highwall or edge without becoming a safety concern. These things should all be considered during the design phase, but afterwards as well. AGGREGATES MANAGER
“Sometimes, we place haul roads in slightly different locations,” says Bryan Smith, mine development and blasting manager at Luck Stone. “When we get down to a certain bench or portion of the pit where we want to place a haul road and realize we have some unfavorable geology, we have to make some changes to make sure the haul road location is safe.” Close attention should be paid to turns and crests in the roads. Operators need a good line of sight in order to avoid hazards without having to slow down. Super-elevated curves are important, especially in switchback areas. A good super-elevated curve will allow haul trucks to maintain their downhill speed throughout the curve without having to apply the brakes, thus reducing brake wear and extending the life of the tire. “Advance the time and the money up front to design and build the correct haul roads,” says Kent Clifton, senior market professional – Mining Equipment Application at Caterpillar, Inc. “After you start running trucks on the road, it’s hard to go back and do a redesign. And once you’ve gone through the steps of designing a good haul road, and you’ve used good material to construct it, you need to maintain that haul road to the design standards you had when it was built.”
Haul roads should be designed wide enough for two haul trucks to pass each other safely. On one-way haul roads, the recommended width is two to two and a half truck widths. On two-way haul roads, a minimum of three to three and a half truck widths is recommended on straightaways and a minimum of three and a half to four truck widths for curves and corners. The haul road width should also allow for berms and drainage. A slight 2- to 3-percent crossfall helps with drainage.
4
Haul road maintenance is a must
Once the haul road is designed and constructed, maintenance is a must. Any washouts or pot holes should be repaired immediately, and the road should be kept as smooth as possible. A good way to test haul roads for smoothness is to take a light vehicle out to the pit and run the road. If it’s extremely rough in the light vehicle, it’s having the same effect on the mining equipment.
TIONS ILLUSTRATED Haul Road Construction and Maintenance 2
Design roads with a constant grade
3
Curves should allow clear line of sight
A well-designed haul road should maintain a smooth, constant grade of no more than 12 percent. This will minimize the number of transmission shifts necessary for a haul truck to travel the road and will enable it to maintain a good speed. In switchback areas, a good super-elevated curve will allow a truck to maintain its downhill speed through the curve without having to apply the brakes.
Keep the edges of haul roads clear of any vegetation or other obstructions that might block the vision of haul truck drivers or equipment operators. Corners and crests in the road should be designed so that operators have good visibility in order to avoid hazards, such as on-coming traffic or material spillage, without having to slow down. Slowing down means less production.
5
6
Maintenance, maintenance, and more maintenance
Motor graders are considered the best tool for maintaining haul roads, but they aren’t the only viable tool. Wheel loaders can handle repairs and patches quickly and easily. Loaders are almost constantly traveling in the pit and loadout areas, so it’s easy for them to pick up a load of material, drop it into a pothole or a washout after a rainstorm, and drag the bucket across the material to press it into the damaged area and smooth out the road.
OUR EXPERTS
Kent Clifton is senior market professional – Mining Equipment Application at Caterpillar, Inc. He joined Caterpillar in 1991 after 12 years working with Cat Dealers and as a contractor in the quarry industry. He worked as product operator/demonstrator at the Tinaja Hills Demonstration & Learning Center, then as product operator/specialist for large mining products. He worked two years as application/marketing specialist in the Asia Pacific Division before taking his current position as a mining machine application specialist focusing on helping mines reduce their cost per ton and increase production.
Control dust with water trucks
Water trucks can help with haul road maintenance by reducing the air-borne dust level. Be sure to use a pumped spray to spread the water out evenly across the haul road to help prevent the water from pooling in one area. Pooling water can cause rutting and potholes, which can cause haul trucks to travel at a slower speed.
Bryan Smith is mine development and blasting manager at Luck Stone. He graduated from Virginia Tech with a mining engineering degree, and has been involved in the aggregates industry for 34 years, in both operations and engineering positions. Roles have included foreman, plant manager, area manager, mining engineering manager, and director of engineering. He has routinely dealt with everything associated with operations, including haul roads.
OCTOBER 2014
OPERATIONS ILLUSTRATED Voices of Experience Kent Clifton
T
t
here are several key factors to consider when it comes to haul roads — design, good material, and maintenance. “You have to look at what effect a haul road has on haul trucks,” says Kent Clifton, senior market professional – Mining Equipment Application, Caterpillar, Inc. “You need to design the road with constant grades of no more than a total effective grade of 12 percent. You have to use good material to build the road, and you have to maintain it once it’s built. If you don’t maintain it, the downside is going to be a reduction in tire life, an increase in fuel burn, a reduction in component life, and an increase in cycle time.” Clifton says it’s important to eliminate water as much as possible on the haul road and to maintain excellent compaction. Haul roads should be designed with a dual cross fall of 2 to 3 percent with a slight crest at the centerline that will allow water to run into drainage ditches on both sides of the road. Bonding the materials together by adding compaction to the haul road will remove air pockets and prevent water from penetrating the road. If water is allowed to percolate under the road, it can provide soft spots and create an opportunity for the road to come apart. “Haul road width is key,” Clifton continues. “Haul roads should be three times the width of your widest truck. That will allow for loaded and empty trucks, as well as motor graders or other support vehicles to work on the road at the same time. At no time do you ever want to stop a truck, loaded or empty, because the haul roads are too narrow.” Clifton adds that all haul roads need proper safety berms at the proper height. So, the design of the haul road should include the width of the road, the drainage ditch, and the safety berm. And when it comes to designing the curves and crowns, make sure the operator will have excellent visibility with no blind spots. Once the haul road is in place, maintenance is very important. “The best tool for maintaining the haul road is, obviously, the motor grader,” Clifton says, adding that the size of the haul trucks running on the road will determine the size of the motor grader. “Wheel loaders can be used to maintain haul roads, but they don’t do it as cost effectively. Ag tractors with drag boxes are sometimes used, but the one that will deliver the most value to a haul road is constant motor grader support.” Focusing on the haul road can easily reduce an operation’s cost per ton by 3 to 5 percent.
Bryan Smith
H
t
aul road design is important. “We create an ideal long-term mine plan that includes haul roads that have been worked many different ways in order to maximize our reserves,” says Luck Stone Mine Development and Blasting Manager Bryan Smith. “However, we may choose to put a haul road in a location that makes for the shortest travel distance to get to a bulk of reserves and later relocate it to a perimeter route to respect the final mine plan.” To help design haul roads, Luck Stone uses a Caterpillar software program called Fleet Production and Cost Analysis (FPC). The program allows the company to look at numerous routes to see how each will impact productivity and cost per ton to find the optimum location for the final haul roads. “When we first design the haul road and begin shooting it, we start pretty wide,” Smith says. “We can always trim it down if everything is perfect, but we may need a little more width to protect our associates from local geologic conditions.” Grade is an important parameter. “A grade of 10 to 12 percent is recommended, but we typically design for 12 percent,” Smith says, explaining that a little bit steeper haul road gains reserves over the life of the pit. “We do our best to shoot that road to a consistent grade to reduce transmission shifts in the haul truck. We try to minimize sub-drilling so we can cut a grade that’s really close to solid rock, which makes the haul road easier to maintain over time.” Smith would ideally like to see a motor grader maintaining the haul roads once a month, but that isn’t always the case. “The local operations teams make up for that by patching and repairing the haul roads with front-end loaders,” he says. “If a washout occurs, they go in immediately and patch it.” Often, it’s worthwhile to construct an intentional road across the pit floor to help maintain drainage. Even though the floor may be fairly level, there are high spots and low spots, and pooling water in the low spots can cause haul trucks to slow down. “If you put a little crown on the road, it will keep the water off,” Smith explains. “A well-maintained road in the pit will allow haul trucks to maintain a greater maximum speed. It’s worth it to spend extra time to create the better road to reduce the cost per ton and increase safety and productivity in the long run. Routine use of a water truck designed with a pumped water spray can also help operators run at higher safe speeds, by reducing air-borne dust and eliminating the pooling of water that can cause rutting.” AGGREGATES MANAGER
Text INFO to 205-289-3782 or visit www.aggman.com/info
Blasting Technologies found fuel savings of five gallons an hour when invested it in a new generation of drill rigs.
Hawaiian drilling and blasting contractor sees productivity improvements and fuel savings with new drills.
Big Big
Improvements
on the Big Island 22
AGGREGATES MANAGER October 2014
APPLICATIONS
O
ver many eons, volcanoes have erupted from the floor of the Pacific Ocean and formed the Hawaiian Islands, which slowly rise from the bottom. Today, those mountains of volcanic rock are a boon for Blasting Technology Inc., a drilling and blasting company that is hard at work on each of the major islands in the archipelago, operating a fleet of seven surface top hammer drill rigs tapping into this exotic land’s solidified lava. Blasting Technology began operations in 1987, becoming a subsidiary of Goodfellow Bros. Inc., which dates back to 1921. Over time, the business progressed from using small machines to employing cab drill units as it found work on “The Big Island” (Hawaii), Maui, Oahu, and Kauai, as well as in rocky soils of a Pacific neighbor, Guam, and in the U.S. mainland coastal states of Oregon and Alaska. The company, which began working on the islands with Tamrock drills (Tamrock was acquired by Sandvik in 1997) and Sandvik bits, has now switched exclusively to Sandvik products, with the backbone of the company’s equipment fleet being the Sandvik DX800 drill, four of which are being operated on construction sites and in quarries. This drill rig has a record of reliably and productively puncturing the island rock, leaving behind smooth, vertical holes for the blasters. Now, however, Blasting Technology is quarrying rock with a new generation of drill rigs, the Sandvik DP1500i. “Accountants must love this machine,” says Chris Haynes, Blasting Technology foreman. “I can’t imagine how anyone would not want to use these machines, just for the fuel savings.” General Manager Ted Fritzen runs the numbers. He notes that, with the five-gallon-an-hour savings and 40 hours of operation a week, annual fuel savings are nearly $50,000. “That’s remark-
able,” he says. The savings are not theoretical either, as Fritzen reached that conclusion after fueling and monitoring DP1500 and DP1500i drills that were working side by side. Lower fuel usage has the corollary effect of creating less polluted air. Sandvik engineers say the DP1500i’s fuel efficiency results in 35 tons less carbon dioxide emissions at 2,500 engine hours than what is produced by its predecessor. The drill rig also has a patented dust-binding system that contains the worst of the airborne refuse thrown up by a penetrating drill bit, which means that the machine is friendly to the environment. This is an important consideration anywhere, but a necessity on projects in Hawaii. The DP1500i is a 24-ton, tracked, self-propelled top hammer rock drill rig standing 10 1/2 feet high at the cab, with a lower center of gravity than earlier models, meaning that this center of gravity provides greater stability while operating. The rig carries a pivoting, telescopic boom, which allows the working end to drill holes 3.5 to 6 inches in diameter, and is fitted with a highfrequency drifter, which boosts the rate of penetration. The unit is powered by a Tier 4 interim Caterpillar engine, with the engine’s fuel efficiency stemming from smart electronic control of engine speed and air compressor and oil cooler fan operations. The heritage of the Sandvik DPi series can be traced to the Tamrock Pantera family of drills, but includes a package of features developed over the last decade by engineers who refined the parameters for efficient top hammer drilling of 3 1/2- to 6-inch holes. Sandvik engineers say the result is a machine with exemplary performance, day in and day out, paired with practical improvements such as a larger fuel tank, which holds 180 gallons so refueling need not occur every shift. Additional benefits are derived from the new features found on the Sandvik tools used on the unit. “I really like the new Sandvik GT60 tube steels. It helps to keep the holes straight,” Fritzen says, comparing the GT60 87-millimeter tube to the 60-millimeter rod on the 1500. “I like the GT60 shoulder drive component and the way the shank lines up. You get a better transfer of the drill’s energy to the bit and into the rock. That’s another reason why the machine is drilling faster and more efficiently. It’s a great performer.” Fritzen estimates the new rig was 20 percent more productive “right off the bat” compared to the older model. “With the move up in bit diameter to 4.5 and 5 inches, we were able to maintain the footage and spread the pattern of drilled holes, which also reduces the drilling costs per produced ton,” he adds. “We’re very pleased with that.” AGGREGATES MANAGER October 2014
23
Printed version of the Aggregates Manager 2014 Aggregates Industry Atlas
not enough for Then you’ll want you? its companion… Atlas on CD
While the printed version of the Aggregates Manager 2014 Aggregates Industry Atlas, will become an integral part of doing your job, perhaps you’ll need additional information about companies listed in the atlas.
If so, we have the perfect companion, the Atlas on CD, which contains information about mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more. The Atlas on CD, which contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2014 Aggregates Industry Atlas in pdf format. Order additional copies of the Aggregates Manager 2014 Aggregates Industry Atlas on CD or the printed version of the Atlas today!
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APPLICATIONS
The drill rig is laid out to ensure ease of maintenance and troubleshooting. Hoses are conveniently routed, and the service doors provide easy access.
tioning unit, so the person at the controls isn’t distracted by discomfort. Bright and clear monitoring screens, armrest-integrated joy sticks, and a nimble drilling control system provide the operator firm control of their work, with the cab’s glass front providing high visibility with a high-tensile steel grille to protect it against flying rock. “The visibility is better; the windows are bigger, and there are more of them,” Haynes says. He notes that the company’s drill operator, Pete Peterson, appreciates the improvements made on the machines. With the fuel tank and water tank inside the carrier, the tip factor is reduced, making operation easier, which Peterson also enjoys. As Blasting Technology plans to expand its operations, the greater efficiency of the new models means that it can keep its current work crew of less than a dozen people and still take on more projects because of the 20-percent increase in drilling productivity — just one more boon for a drilling and blasting contractor based in paradise. AM
The new generation of button drill bits is a factor in increased production. However, it is the machine’s software that plays a crucial role in its enhanced function, with the “i” in the model number standing for “intelligence.” The system can communicate to the operator information such as the condition of a hole being reamed from the rock, the parts and systems that need servicing, and the number of hours the drifter has been operating. Article courtesy of Sandvik Construction. When something fails on the computercontrolled rig, a self-diagnostics system is able to determine what part or circuit is experiencing the problem. “Trouble-shooting is much easier,” says Haynes, whose job is to keep rigs out of trouble and to fix them when trouble arises. “You get all the error messages on the screen in the cabin and they tell you where to look. The drill rig is laid out better than the older model to do trouble-shooting — With over 700 different kits engineered and the way the hoses are routed, the gullwing developed, count on Arctic Wolf™ for factory-style service doors, the way the components are integrated air conditioning systems in ready-to-fit installed. If the computer finds an error, it kits. Loaders. Dozers. Excavators. Graders. Tractors. tells you exactly where to look.” The unit If your equipment has an engine and a cab on it, we also has a new air control circuit, which can put cool air into it. increases the efficiency of the compressor, Call today. 1-800-2 MR COOL or go online at a significant upgrade. “The DP1500i has www.hammondac.com and order your system and plenty of air and power,” Fritzen notes. parts today. A machine’s efficiency is not divorced from an operator’s efficiency, and the DPi series provides a safe and comfortable workspace for the operator. The operator’s pressurized and insulated cabin has an air 1-800-267-2665 • sales@hammondac.com • www.hammondac.com filtration system, as well as an air condi-
Be a cool operator
When you work hard in small spaces, you need AC big time!
Text INFO to 205-289-3782 or visit www.aggman.com/info
Job
081-135A
Filename
081-135A Equip World 4.5x4.5.indd
AGGREGATES MANAGER October 2014
Last Modified
4-18-2011 2:02 PM
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Prev. Users
Adam
The View
of the
Top
Employee perceptions of how management views safety can shape the reality of their behavior. What’s the perception among your staff? by Zach Knoop
26
“F
or many, many years I had in my mind we were a real ‘safety’ company, because that was all that was ever preached to us. Safety first. We’ve always had safety meetings. We always had incentive programs. We had safety dinners back when I was younger. But were we really safe? Did we really believe safety? And it really made me question myself and this company after we got into these other safety programs. Did we really believe that, or was production really the primary thing? Unfortunately, I have to say, we addressed safety when it became an issue. We always preached safety, but we didn’t address safety until it was an issue to us. That’s what’s really sad.” These are the words of Daryl Moomey, a vice president at Dolese Bros. Co. based in Oklahoma City, Okla., (an aggregate and ready-mix supplier in Oklahoma), and I expect what he described is a current reality for many organizations. Most leaders’ hearts and intentions are in the right place — they don’t want anybody to get hurt. Employees, however, can’t see a leader’s intentions. Employees judge
AGGREGATES MANAGER October 2014
what is important to leaders by their visible actions. So how can leaders put their intentions into action, and why is it critical that they do so? According to Dr. Dan Petersen, who is considered by many to be the father of modern day safety management, one of his Six Criteria for Safety Excellence is that “Top Management must Demonstrate its Visible Commitment to Safety.” This is moving beyond “supporting” safety by allowing for the purchase of personal protective equipment, providing time for safety training, and signing a safety policy that was written by the safety director. It is about defining the leader’s role in managing safety through establishing “actionable” safety accountabilities that cascade down through the organization. A robust safety system will have clearly defined and integrated safety activities for all levels of the organization that are regularly measured and incorporated into performance evaluations, just like other business functions. This takes time and effort to establish. There are, however, simple ways in which all leaders can demonstrate their visible commitment to safety.
SAFETY EXCELLENCE
Here are four ways top management can visibly demonstrate commitment to achieving safety excellence.
1
Integrate a safety message into regular business discussions with subordinates, leaders, and all employees at every opportunity. As you talk about production, quality, customer service, and finance in your business communications, safety should also be discussed. All too often, leaders only address safety when something bad happens, such as an injury, property damage, or MSHA citation. If those things are not occurring, safety tends to take a back seat to production, quality, and so forth. A simple exercise to evaluate the frequency of your safety communications compared to communications around other business functions is to look at your email sent folder. In the last month, how many emails did you send addressing safety, compared to emails related to production or quality? Of the emails sent about safety, how many were positive messages that recognized safe behaviors?
2
Personally model all the safety behaviors you expect of others in the workplace. There are many ways to do this. One is simply by carrying personal protective equipment in your vehicle when visiting work sites so you are prepared to demonstrate your visible commitment at all times by wearing the appropriate personal protective equipment. Your employees are always watching the leaders of the organization and what the employees see shapes their perception of what is important to you and the organization. In his
Six Criteria for Safety Excellence Top management is visibly committed. Middle management is actively involved. Front-line supervision is performance-focused. Employees are actively participating. System is flexible to accommodate the culture. Safety system is positively perceived by the workforce. program, The Challenge of Change, Dr. Petersen says that management credibility in safety is earned over time and based on the decisions they make, how they reward/recognize employees for safety, the measurements used (lagging versus leading indicators), money spent or not spent on safety, and their visibility within the safety system. I personally have never met a CEO, owner, or vice president of a company that didn’t profess support and desire for a safe workplace, but as Ralph Waldo Emerson said, “Your actions speak so loudly, I cannot hear the words you say.” Role model all desired safety behaviors 24/7 — at home and at work. If your company does not allow employees to talk on their cell phones while driving company vehicles, what message will it send if you are seen doing it in your personal vehicle?
3
Visit your work sites a few times per year to observe safety in action and provide positive feedback to employees on identified safe behaviors and safe conditions. You may have to be intentional in doing
this by scheduling work site visits on your calendar. You might even have to bring your safety professional with you if you’re unsure of what to look for. A former CEO/president of a large construction materials and heavy civil contracting company that I used to work for would frequently fly to various locations to participate in safety improvement team report-outs to local management and spend time in the field getting to know employees. There was no question about where he stood when it came to safety. Another division president would gather his management team into a van and visit as many operations as possible in a couple days. At each location, they would stop work, gather the troops, and spend time listening to them — truly understanding their unique challenges. “When the employees see that their ideas matter and their ideas count, then they’ll believe we are truly committed to safety. We have to show that. If they tell us they want to do something because they believe it will make a positive difference, then we’ll do it,” says Ed Kernaughan, vice president/general manager AGGREGATES MANAGER October 2014
27
www.elrus.com
• • • • •
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SAFETY EXCELLENCE PS Form 3526
Statement of Ownership, Management, and Circulation (Requester Publications Only)
1. Publication Title AGGREGATES MANAGER/RANDALL REILLY PUBLISHING COMPANY
2. Publication Number 19277
ISSN 15523071
3. Filing Date 09/08/2014
4. Issue Frequency MONTHLY
5. Number of Issues Published Annually 6. Annual Subscription Price 12 $ 24.00
7. Complete Mailing Address of Known Office of Publication 3200 RICE MINE RD NE TUSCALOOSA, TUSCALOOSA AL, AL 35406-1510
Contact Person JULIE PUCKETT Telephone (224) 577-6882
8. Complete Mailing Address of Headquarters or General Business Office of Publisher 3200 RICE MINE RD, NE TUSCALOOSA, AL 35406-1510
of J.F. Shea Co., Inc. — Redding (a supplier of aggregate materials and highway/bridge construction in Northern California), as he emphasizes the importance of top leadership listening to and engaging with their employees. “And there may be some things we’ll do that we think are kind of crazy, but part of the cultural transformation is employees seeing that, as management, we’re doing what they want us to do.” Keep in mind, when it comes to understanding your organization’s safety culture, perceptions are reality. Do you know what perception your employees have on how safety is being managed?
4
Take every opportunity to kick off safety meetings and training sessions, such as MSHA Annual Refresher training. Demonstrate to your employees that safety is important to you by verbally communicating your personal perspective of its value to the organization. Stay a while, if possible, to let employees see you in action and to get to know you better. At the end of the day, what employees want to know is whether their organization cares about their safety. When they repeatedly see actions that align with what top leadership is saying about safety, perceptions and beliefs start to change. As reflected in their earlier sentiments, leaders at Dolese Bros. Co. and J.F. Shea Co., Inc. know that safety excellence starts with the tone they set from the top, but materializes through the engagement of their employees who know that the organization is truly committed to safety as a value. Leaders, I encourage you to follow Moomey and Kernaughan’s example, by getting out and about throughout your organization to visibly demonstrate how important safety is to you. AM Zach Knoop is a senior safety consultant and project manager for Caterpillar Safety Services. He works with Caterpillar customers in the aggregates and construction industries to coach leaders, train supervisors and engage employees in building cultures of safety excellence. He can be reached at SafetyServices@cat.com.
9. Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor Publisher (Name and complete mailing address) JOE DONALD 3200 RICE MINE RD NE TUSCALOOSA, AL 35406 Editor (Name and complete mailing address) THERESE DUNPHY 2849 LEE ROAD SILVER LAKE, OH 44224 Managing Editor (Name and complete mailing address) MARCIA GRUVER DOYLE 3200 RICE MINE RD NE TUSCALOOSA, AL 35406 10. Owner (Do not leave blank. If the publication is owned by a corporation, give the name and address of the corporation immediately followed by the names and addresses of all stockholders owning or holding 1 percent or more of the total amount of stock. If not owned by a corporation, give names and addresses of the individual owners. If owned by a partnership or other unincorporated firm, give its name and address as well as those of each individual owner. If the publication is published by a nonprofit organization, give its name and address.) Full Name
Complete Mailing Address
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11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Hoding 1 Percent or More of Total Amount of Bonds. Mortgages, or Other Securities. If none, check box Full Name Complete Mailing Address GE CAPITAL
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PS Form 3526-R, September 2007 (Page 1)
PRIVACY NOTICE: See our privacy policy on www.usps.com
13. Publication Title
14. Issue Date for Circulation Data Below
AGGREGATES MANAGER/RANDALL REILLY PUBLISHING COMPANY
08/01/2014 Average No. Copies Each Issue No. Copies of Single Issue During Preceding 12 Months Published Nearest to Filing Date
15. Extend and Nature of Circulation a. Total Numbers of Copies (Net press run) Outside County Paid/Requested Mail Subscriptions stated on PS Form 3541. (Include direct written request from telemarketing and Internet requests from (1) recipient, recipient, paid subscriptions including nominal rate subscriptions, employer requests, advertiser's proof copies, and exchange copies.) b. Legitimate In-County Paid/Requested Mail Subscriptions stated on Paid PS Form 3541. (Include direct written request from and/or recipient, telemarketing and Internet requests from Requested (2) recipient, paid subscriptions including nominal rate Distribution subscriptions, employer requests, advertiser's proof (By Mail copies, and exchange copies.) and Sales through Dealers and Carriers, Street Vendors, Outside (3) Counter Sales, and Other Paid or Requested Distribution the Mail) Outside USPS
19605
20346
14559
13919
0
0
332
346
Copies Distributed by Other Mail Classes (4) Requested Through the USPS (e.g. First-Class Mail) c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), (4))
0
0
14891
14265
4282
5177
0
0
Outside County Nonrequested Copies stated on PS Form 3541 (include Sample copies, Requests Over years old, Requests induced by a Premium, Bulk (1) 3 Sales and Requests including Association Requests, Names obtained from Business Directories, Lists, and other soruces) d. NonreIn-County Nonrequested Copies stated on PS Form quested 3541 (include Sample copies, Requests Over 3 Distribution old, Requests induced by a Premium, Bulk (2) years (By Mail Sales and Requests including Association Requests, and Names obtained from Business Directories, Lists, Outside the and other soruces) Mail) Nonrequested Copies Distributed Through the USPS (3) by Other Classes of Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Limit Nonrequested Copies Distributed Outside the Mail (4) (include Pickup Stands, Trade Shows, Showrooms and Other Sources) e. Total Nonrequested Distribution (Sum of 15d (1), (2), (3), (4)) f. Total Distribution (Sum of 15c and 15e)
i. Percent Paid and/or Requested Circulation ((15c / 15f) times 100)
0 108
4408
5285
19299
19550
g. Copies not Distributed h. Total (Sum of 15f and 15g)
0 126
305
796
19604
20346
77.16 %
72.97 %
16. If total circulation includes electronic copies, report that circulation on lines below. a. Requested and Paid Electronic Copies(Sum of 15c and 15e) b. Total Requested and Paid Print Copies(Line 15c) + Requested/Paid Electronic Copies Total Requested Copy Distribution(Line 15f)+ Requested/Paid c. Electronic Copies Paid and/or Requested Circulation (Both print and Electronic d. Percent Copies)
0
0
14891
14265
19299
19550
77.00 %
72.00 %
I Certify that 50% of all my distributed copies (Electronic & Print) are legitimate requests. 17. Publication of Statement of Ownership for a Requester Publication is required and will be printed in the 10/01/2014 issue of this publication. 18. Signature and Title of Editor, Publisher, Business Manager, or Owner Title KELLI KITCHENS
Date
AUDIENCE DEV. MGR.
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I certify that all information furnished on this form is true and complete. I understand that anyone who furnishes false or misleading information on this form or who omits material or information requested on the form may be subject to criminal sanctions (including fines and imprisonment) and/or civil sanctions (including civil penalties). PS Form 3526-R, September 2007 (Page 2)
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9/19/14 9:58 AM
www.AGGMan.com Aggregates Manager Magazine is proud to announce the launch of the new mobile version of AGGMan.com. Stay up-to-date while you are on the go, with the latest news in the aggregates industry along with insight from our award-winning editorial team.
Data Stock Report Company Cemex, S.A.B. de C.V.
U.S. On-Highway Diesel Fuel Prices Ticker CX
Current Value
52-Week 52-Week High Low
$13.33 p
$13.81
$9.43
9/8/2014
One Week
One Year
United States
$3.814
0.000
-0.167 q
East Coast
$3.844
+0.002 p
-0.144 q
CRH plc
CRG
$21.97 q
$28.26
$21.48
Eagle Materials Inc.
EXP
$101.94 p
$103.15
$63.03
New England
$3.933
-0.011 q
-0.158 q
Granite Construction Inc.
GVA
$34.61 p
$40.55
$28.35
Central Atlantic
$3.928
+0.003 p
-0.128 q
$88.72
$67.13
Lower Atlantic
$3.760
+0.004 p
-0.157 q
Heidelberg Cement AG
HEI
$75.99 p
Holcim Ltd.
HOLN
$78.90 p
$91.87
$67.15
Midwest
$3.751
-0.001 q
-0.213 q
Martin Marietta Materials, Inc.
MLM
$130.67 p
$136.36
$94.01
Gulf Coast
$3.715
-0.005 q
-0.183 q
$26.46
Rocky Mountain
$3.869
+0.001 p
-0.065 q
West Coast
$4.034
+0.004 p
-0.108 q
MDU Resources Group, Inc.
MDU
$30.50 q
$36.05
United States Lime & Minerals, Inc. USLM
$60.45 p
$68.50
$52.53
U.S. Concrete
USCR
$25.73 p
$28.64
$18.28
West Coast less California
$3.979
+0.006 p
-0.066 q
Vulcan Materials Co.
VMC
$61.25 q
$69.50
$50.32
California
$4.079
0.000
-0.146 q
Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 9/10/14.
Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).
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31
7/9/14 1:29 PM
AGGREGATES MANAGER October 2014
by Meredith A. Kapushion
Rock MSHA’s proposed revisions to regular assessment penalty scheme promise higher penalties, less discretion.
Bigger
PENALTIES AHEAD
O
Meredith A. Kapushion is an attorney practicing in the Occupational Safety and Health Practice of Jackson Kelly PLLC’s Denver office. She can be reached at 303-390-0520 or via email at makapushion@jacksonkelly.com.
32
n July 31, MSHA published proposed revisions to the current criteria and procedures for assessment of civil penalties. 79 Fed. Reg. 147. MSHA’s stated purpose in promulgating the revisions is to place a greater emphasis on more serious safety and health conditions; reduce the number of decisions made by inspectors; promote consistency, objectivity, and efficiency; and result in fewer areas of dispute and earlier resolution of enforcement issues. Whether the proposed rule is able to achieve these goals is up for debate, but the proposed rule will be a less nuanced approach that will lump assessed violations into large categories with increased overall penalty amounts. Under the Mine Act, six criteria determine the amount of the penalty for regular assessments: the appropriateness of the penalty to the size of the business, the operator’s history of prior violations, whether the operator was negligent, the gravity of the violation, the good faith demonstrated in abating the violation, and the effect of the penalty on the operator’s ability to remain in business. 30 U.S.C. § 110(i); 30 C.F.R. § 100.3. MSHA proposes a number of changes to how these criteria are evaluated: • Less emphasis placed on the size of the business as a percentage of total penalty points. However, greater weight will be given to an
AGGREGATES MANAGER October 2014
•
•
•
•
operator’s violation history, the assessed negligence of the operator, and the assessed gravity of a violation. Mines with fewer than 10 inspection days per year will not be assigned history points or assessed repeat violations. This will benefit very small operations that do not have lengthy inspections. Repeat violations will apply when a mine has a minimum of 10 violations, which become final orders, and more than 10 inspection days over the prior 15-month period; and six repeat violations of the same citable provision of a standard, which became final orders. The points assessed for incidence rates will generally increase, and larger operations are likely to see an uptick in the point assessment for repeat violations. The current categories of negligence (no, low, moderate, high, and reckless disregard) will be reduced to three categories (not negligent, negligent, and reckless disregard). In the current scheme, the presence of mitigating circumstances distinguishes low, moderate, and high negligence. In the proposed scheme, mitigating circumstances are absent from the analysis. With respect to gravity, the proposed rule will also decrease the relative weight of
ROCKLAW
likelihood penalty points and increase the relative weight of severity penalty points as a percentage of total penalty points. The likelihood of an occurrence will be reduced from five categories (no likelihood, unlikely, reasonably likely, highly likely, and occurred) to three categories (unlikely, reasonably likely, and occurred). The four existing categories of severity will be reduced from four categories to three: No Lost Workdays; Lost Workdays or Restricted Duty (LWRD); and Fatal. “Permanently Disabling” will be eliminated. The persons affected will also be reduced from 11 categories to two: no persons to one or more persons affected. • The overall point scheme is recalibrated to a 100-point scale, and the penalty amounts are increased. For most violations that are neither de minimus nor particularly egregious, the assessments are likely to fall beneath the categories of “negligent,” “reasonably likely,” and “LWRD” or “fatal,” and “one or more persons affected.” While this will result in the majority of violations being assessed with identical designations, MSHA’s desired consistency will come at the expense of fairness and the discretion that inspectors, district personnel, and even commission judges are currently able to exercise. The penalties will also substantially increase, particularly impacting mines with significant violation histories or repeat violations. To illustrate the change in penalty amounts, for a metal/non-metal operator with 50,000 annual hours worked at the mine, with no controlling entity and no repeat violation history, the penalty amounts would change as follows: Current Scheme 50,000 Annual Hours No Repeat/History Points Negligent Reasonably Likely LWRD 1 Person Affected Total Points Penalty (per table)
Proposed Scheme
(208 possible points) (100 possible points) 4 1 0 0 15 30 14 5 5 1 1 60 36 $112 $200
For the same violation, a similar mine (with more than 10 inspection days per year) with a violation history and repeated violations would face substantially larger penalties:
Current Scheme
Proposed Scheme
(208 possible points) (100 possible points) 50,000 Annual Hours 4 1 1.0 violations/inspection day 16 13 and 0.05 repeat violations/inspection day Negligent 20 (moderate) 15 Reasonably Likely 30 14 LWRD 5 5 1 Person Affected 1 1 Total Points 76 49 Penalty (per table) $403 $1,600
By shifting the relative weight of each assessment point and increasing the penalty amounts, the new scheme appears to result in substantially larger penalties. For a run-of-the-mill minor violation, the penalty amount nearly doubles for a mine with no history. For a significant, but not egregious history of violations, the penalty amount quadruples. The penalties would only go up for more egregious violations (potentially fatal, or designated as reckless). While the existing minimum penalty of $112 and the maximum penalty of $70,000 for non-flagrant violations would be unchanged, the reality is that the point scheme is likely to raise the amounts of violations across the board. Under the proposed scheme, minimum penalties for unwarrantable failure violations would also increase. With the proposed revisions, the vast majority of violations would also fall within the Significant and Substantial (S&S) designation. As part of the proposed revisions, MSHA proposes defining “reasonably likely” as a “condition or practice cited is likely to cause an event that could result in an injury or illness.” The current S&S criteria requires that MSHA prove a violation “will” result in an injury or illness. While this does not appear to be a drastic change, from a legal standpoint, it greatly lessens MSHA’s burden to establish the S&S criteria. As the number of S&S designations factors into a Pattern of Violations (POV) determination, the likelihood of a mine finding itself on a POV status will increase with the proposed changes. The greatest impact from MSHA’s proposed changes will be in the overall rigidity of the system. There will likely be higher penalties, less discretion in assessment of citations, more S&S findings, and higher POV rates. This is a significant increase in the regulatory burden upon mine operators, already greatly taxed by regulations. AM
AGGREGATES MANAGER October 2014
33
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Aggregates Manager Atlas Data/CD Products . . . . . . . . . . . .www.aggmanatlas.com. . . . . . . . . . . . . . . . . . . . . 24
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Miller-Bradford & Risberg, Inc.. . . . . . . . . . . . . . . . . . . . . . .www.miller-bradford.com . . . . . . . . . . . . . . . . .Insert NSSGA Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.nssga.org. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Peterbilt Motors Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.peterbilt.com . . . . . . . . . . . . . . . . . . . . . . . . 21 Progressive Commercial Insurance . . . . . . . . . . . . . . . . . . . .www.progressivecommercial.com . . . . . . . . . . . . . 31
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Pugmill Systems, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.pugmillsystems.com . . . . . . . . . . . . . . . . . . . 35 Telsmith . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.telsmith.com . . . . . . . . . . . . . . . . . . . . . . . . 16 Terex Minerals Processing Systems. . . . . . . . . . . . . . . . . . . .www.terexmps.com . . . . . . . . . . . . . . . . . . . . . . IBC Volvo Penta. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .www.volvopenta.com/us . . . . . . . . . . . . . . . . . . . BC Worldwide Electric Corp.. . . . . . . . . . . . . . . . . . . . . . . . . . . .www.worldwideelectric.net . . . . . . . . . . . . . . . . . . . 5 This index is provided as a service. The publisher does not assume any liability for errors or omissions.
34
AGGREGATES MANAGER October 2014
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AGGREGATES MANAGER October 2014 7/14/14 10:16 AM Untitled-3 1 DNH_AGRM0913_PG031.indd 1 8/16/13 2:18 PM
In Stone THE BONESCountry OF A
by Bill Langer
Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at Bill_Langer@hotmail.com
L
Passage of the 1872 Mining Law spurred the development of mining towns as the nation explored its Manifest Destiny.
eaving Winslow, Ariz., we follow the same path described by Steinbeck, past Flagstaff and Williams (the Gateway to the Grand Canyon), and on to Seligman. Route 66 has roughly paralleled I-40 since Oklahoma, and, finally, it veers north away from the interstate. We will travel all the way to the California border on the longest unbroken original stretch of the Mother Road. Manifest Destiny was the belief held in the late 1800s that Americans were destined to settle across the continent. The federal government provided a powerful incentive to fulfill that destiny through the passage of the 1872 Mining Law. The law allowed miners to make claims on federal land for just a few dollars and to extract ore with no royalties paid to the U.S. Treasury. After passage of the mining law, small mining towns popped up throughout the West. The biggest mining town in this part of Arizona was Oatman. During 1863, gold was discovered at Camp Mohave near the Colorado River. Ultimately, Mohave County would become the second-highest gold-producing county in Arizona. Initially, mining occurred at a slow pace due to an uprising among the Hualapai Indians in 1866 and the discovery of gold 25 miles to the northAnd then the tall trees began, and the cars spouted steam east in the 1880s. Around the turn of the century, several highly productive and labored up the slopes. And there was Flagstaff, and that mines were opened, and, during 1909, the town of Oatman was established to was the top of it all. Down from Flagstaff over the great plaservice the prospering local mines. teaus… The sun drained the dry rocky country, and ahead Oatman was named in the honor of Olive Oatman, a young girl who was were jagged broken peaks, the western wall of Arizona. taken captive by a Native American tribe, traded to Mohave people who adGrapes of Wrath, 1939, John Steinbeck, Chapter 18. opted her as a daughter, and later returned to the white world. During World War I, Oatman was the largest gold producing camp in the United States, but as mine depths reached deeper than 1,000 feet, the gold and silver content of some of the ores decreased. In 1924, a number of major ore bodies became exhausted. By then, the mining district had produced more than $34 million worth of gold, or more than $2 billion at today’s gold market value. The final blow to the district occurred during World War II, when the government issued Limitation Order No. 208, closing gold mines. The purpose was to focus the country’s mining on copper, zinc, and other strategic metals necessary for the war effort. But there’s still gold in them thar hills around Oatman, and, since WWII, there have been sporadic attempts to mine the precious metal. Oatman was able to cater to Route 66 travelers until 1953 when a new route between Kingman and Needles was built. But Oatman, like its namesake, survived. Today, the burgeoning worldwide interest in Historic Route 66 brings tourists from near and far, many to see the wild burros that roam the streets; descendants of the original miners’ burros which were set free when the mining stopped. Continuing west out of Oatman, we drive over Sitgreaves Pass and down to the Colorado River; the border between Arizona and California. Looking back at the mountains from whence we just came, we can almost hear Tom Joad (from Steinbeck’s Grapes of Wrath) say, “Never seen such tough mountains… This here’s the bones of a country.” AM
36
AGGREGATES MANAGER October 2014
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Terex, the Terex Crown design, Cedarapids, Simplicity and Canica are trademarks of Terex Corporation or its subsidiaries. Copyright 2014 Terex Corporation. *Terms and conditions apply; please contact your local distributor.
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