Aggregates Manager October 2015 by Sandy Turner Jr

October 2015

www.AggMan.com

12 18 26

Explore the high-value frac sand market Save fuel on equipment and extensions with telematics Planned maintenance contracts can extend the life of your artic

PUSH. BACK. PRESENTING THE ALL-NEW 1050K. BEHIND EVERY GREAT INNOVATION STANDS A CUSTOMER WHO’S HAD ENOUGH.

We call it the 1050K. You’ll call it a welcome choice. Because it’s our frst production-class dozer designed alongside operators like you. And it’s packed with long overdue features. Like a hydrostatic powertrain that delivers the muscle you need and responsive control the way you want it. And rugged components that stand up to the most demanding job sites. All supported around the clock by your local dealer who is standing by with a robust service and parts program dedicated exclusively to the production-class market. Because it’s time we all pushed back.

JohnDeere.com/PushBack

On Our Cover: Aggregate producers are increasingly considering alternative energy sources to lower their overall costs. Cover photo by Kerry Clines.

Inspecting the auto-lubrication system, checking tire pressure, and using diagnostic tools to monitor engine temperature and rpm history can extend the life of your artic.

Terex Finlay’s new C-1545 mobile cone offers high-capacity, efficient production.

CONTENTS OCTOBER 2015 VOLUME 20, NUMBER 10

FEATURE ARTICLES

12 18 26 31 36

Frac Sand 101 Interested in the high-value proppant market? Learn more about the U.S. frac sand industry with this primer.

Save Fuel with the Benefits of Telematics

With the right equipment insights, managers can learn how to track the fuel from both equipment and extensions.

Plan and Predict ADT Maintenance One tool for extending equipment life, increasing uptime, and lowering ownership costs may be a planned maintenance contract.

Attachments Add Versatility

A broad assortment of attachments can transform your equipment fleet into multi-purpose machines.

Get More From Your Neighborhood Council

Remember that the three C’s of community relations could be cookies, cake, and coffee.

OPERATIONS ILLUSTRATED Improve Your Plant’s Energy Efficiency

Savvy producers can lower operational expenses by focusing on energy audit, tracking usage, and educating employees.

COLUMNS & DEPARTMENTS

EDITORIAL It’s time to put an end to extensions.

AND PROVINCE NEWS A roundup of 4 STATE the latest news in North America. MINING The latest financial analysis of issues impacting in the industry and 6 DATA Aggregates Manager’s exclusive aggregates industry outlook.

Sandvik’s new AQ336 Doublescreen, and other new equipment for 9 ROLLOUTS the aggregate market. LAW The Mine Safety and Health Administration announces increased 38 ROCK enforcement efforts with a focus on workplace examinations.

ADS Aggregate industry classifieds. 40 CLASSIFIED INDEX See who’s who and where to find their products. 43 ADVERTISER IN STONE When it came to combating silicosis in the late 1800s, 44 CARVED the discovery of the bacteria that causes

tuberculosis set safety precautions back by nearly 50 years.

Crushing Performance

Choosing the toughest high-starting torquedesigned motor for your quarry, mine or mill just got easier. The new line of Baldor•Reliance® Crusher Duty motors are high-performance, NEMA Premium efficient motors suitable for across the line or inverter duty use in extremely harsh environments. Best of all, Baldor•Reliance Crusher Duty motors are designed for easy drop-in field replacement, built for easy maintenance and are kept in stock for quick delivery. Conquer the task of keeping your operation up and running with the crushing performance of Crusher Duty motors from Baldor. baldor.com

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

October 2015

Vol. 20, 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: Bobby Atkinson editorial@aggman.com

Design & Production Art Director: Sandy Turner, Jr. Production Designer: Timothy Smith Advertising Production Manager: Linda Hapner production@aggman.com

Construction Media VP of Sales, Construction Media: Joe Donald sales@randallreillyconstruction.com

It’s Time to Put an End to

EXTENSIONS

n Oct. 29, the latest extension of Moving Ahead for Progress in the 21st Century, or MAP-21, will expire. And if you’ll recall, MAP-21 itself was a 27-month bill passed to prevent an endless succession of three-month SAFETEA-LU extensions. In fact, according to The Hill,

there have been 34 highway funding patches approved by Congress during the last decade. When the most recent extension was passed in July, Rep. Alcee Hastings

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

Corporate Chairman: Mike Reilly

(D-Fla.) told The Hill, “If kicking the can down the road was an Olympic sport… we would win the gold, we would win the bronze, we would win the silver, and we’d win the aluminum.” It’s time for Congress, specifically the House, to get down to business and pass long-term highway funding. The challenge, of course, is money. The primary funding source is the 18.4

President and CEO: Brent Reilly

cents per gallon gas tax, which generates about $34 billion of the approximately

Chief Operations Officer: Shane Elmore

$50 billion spent annually on transportation projects. The gas tax hasn’t

Chief Financial Officer: Russell McEwen Senior Vice President, Sales: Scott Miller

been raised since 1993 and higher fuel efficiency requirements have reduced

Senior Vice President, Editorial and Research: Linda Longton

fuel consumption. Let’s put that particular issue into perspective. If the 1993

Vice President of Events: Stacy McCants

Congress had the foresight to index gas taxes to inflation, gas taxes would collect

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.

more than $56 billion per year today (based on the CPI inflation calculator). Adjusting for inflation would not only cover the cost of transportation funding, but also allow for a healthy increase in investment. According to the National Stone, Sand and Gravel Association, vehicle travel on the nation’s highways increased by 38 percent from 1990 to 2010, while new road mileage increased by only 4 percent. It’s no wonder why congestion is increasing while safety and the ability to efficiently transport goods is decreasing. Sadly, today’s Congress also seems to lack long-term vision. While I applaud Sen. Mitch McConnell for helping to design Developing a Reliable and Innovative

Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2015. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

Vision for the Economy — the DRIVE Act — the stance against an increase in gas tax is illogical. Americans understand the concept of inflation. The longer Congress refuses to consider indexing the gas tax, the larger the increase will be and the longer it will take to achieve. Before we get into another presidential election, when progress is highly unlikely, Congress needs to get the job done and pass long-term highway funding. Call your representative today, and tell them you expect an end to extensions. AGGREGATES MANAGER October 2015

State & Province

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

California

At Aggregates Manager’s press time, the Napa County Planning Commission was planning a second round of public testimony regarding Syar Industries request to expand its operation there. According to the Napa Valley Register, the operator is seeking a 110-acre expansion of its 497-acre quarry. The planning staff recommended a 77-acre expansion, but company officials said that would not yield enough basalt for local construction projects. An earlier hearing led to four hours of comments and a barrage of letters to the commission, including a packet from a group called the Coalition Engaged Against Syar Expansion. That group is opposed to any expansion of the operation. Syar submitted more than 300 cards signed by people in support of the expansion.

Connecticut

The owner of Mountain Spring Quarry has pressed charges against two town employees, alleging that they illegally entered a trailer on his property and stole files this spring. The Journal Inquirer reports that operation owner Vincent DeFilippo says he has pictures taken by security cameras that show Town Engineer William Dwinells and former Town Planner Linda Farmer entering the trailer without permission and stealing files.

Indiana

Lake County residents continue to pursue their options against Singleton Stone Quarry as work at the operation moves along. According to the Chicago Tribune, the operation still needs its Indiana Department of Environmental Management Section 401 water permit, which is currently under review. The U.S. Fish and Wildlife Service requested that the permit be denied. A spokesman for the agency told the newspaper that it had received between 45 and 60 comments regarding the property.

AGGREGATES MANAGER October 2015

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

Minnesota

Officials do not know the cost of draining Quarry 8 at the Quarry Park and Nature Preserve while searching for the body of a missing St. Cloud man. The St. Cloud-Times reports that the search for Phillip Miller led to a joint effort between the Sterns County sheriff’s office, the parks department, and the highway department. The water level was lowered from 100 feet to 10 feet, draining 4.7 million gallons. Officials estimate it will take eight to 10 years for the water levels to return to their previous depths.

New York

An Ohio man was hospitalized after being pursued by state police. According to The Buffalo News, state police followed Andrew Betancur Jr., who was driving a car reported as stolen. During the pursuit, Betacur veered off a thruway and down a 100-foot embankment into the Buffalo Crushed Stone quarry. He was listed in good condition.

North Carolina

Sen. Richard Burr attended a North Carolina Aggregates Association meeting and toured Vulcan Materials Co.’s Gold Hill Quarry. The Salisbury Post reported that Burr talked with senior quarry officials about highway reauthorization. He said having a federal highway bill would allow for more adequate planning of major highway projects.

North Carolina

Grove Stone & Sand Co. partnered with Carolina Cat to host its 8th annual Rock the Quarry 5K Trail Challenge and Kids Fun Run on Sept. 19. According to the Citizen-Times, the run features some of the best views of Western North Carolina and combines scenic views, private trails, multiple stream crossings, and a half-mile span through the active quarry operation. Each participant in the Kids Fun Run received a customized race day medal. All proceeds from the event benefit the operation’s neighbor, the Black Mountain Home for Children, and long-time partner, the Colburn Earth Science Museum.

Pennsylvania

Police charged seven people with trespassing after finding them swimming in a quarry, WFMZ TV reports. The quarry, located in Lower Mount Bethel Township, is near another quarry where two people died earlier in the summer, and both inactive operations are owned by the same company. Alan Daniel Longo,18, Dominic Victor Martinez-Soto, 19, Nicholas Ryan Iezzi, 18, Nicholas Mark Kakascik, 19, Kyle R. Moore, 22, Joshua A. Kinney, 19, and Ajinkkya U. Kelkar, 19, were charged with criminal trespass by the state police.

Rhode Island

The town of Westerly has 40 days to respond to a request from residents to drop or modify a consent agreement it signed with the owner and tenants of Copar Quarries. According to Rhode Island NPR, under the consent agreement, any new ordinances regulating quarries wouldn’t apply to the operator’s property in Westerly. A lawyer for the residents says the town could file a petition at the Rhode Island Supreme Court where the consent agreement is still undergoing appeal. The operator, Armetta LLC, formerly known as Copar Quarries, recently shut down its operations and filed for bankruptcy, but the quarry owner could find new tenants and continue operations under the consent agreement. The lawyer claimed that the consent agreement “wrongfully strips away the town’s right to regulate quarrying activities that affect neighbors.”

Texas

The Cedar Park City Council approved the purchase of the Lime Creek Quarry from the city of Austin for $4.1 million. The Statesman reports that the city eventually plans to close the quarry and redevelop it. The city has not yet determined reclamation plans for the 215-acre property.

Wisconsin

Neighbors of a Sister Bay quarry have voiced concerns about its potential expansion. According to the Door County Advocate, the discussion revolves around a request to amend the village zoning code to allow quarries as a conditional use in the general business district. Approximately 40 people showed up to a village meeting to voice their concerns. To date, a judge has ordered mediation between the village and the quarry, which is owned by Sister Bay Properties LLC. The property was in existence prior to zoning prohibiting quarries. Quarry owner and operator Brandon Small told the newspaper that, if the quarry is allowed to expand, he would apply dust control, address vehicle backup alarm noise, and shut down operations after 10 more years. The Plan Commission passed a motion recommending the Village Board approve the zoning code amendment. Village Administrator Zeke Jackson pointed out that, without the permit, the quarry could “operate in perpetuity, and there is nothing, other than $500 fines, stopping them from creating dust.”

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AD224_enUS_224_HPvert_Aggman_0615.indd 1 Untitled-4 1

6/10/15 AGGREGATES MANAGER October 20157:20 AM

6/15/15 1:32 PM

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

$7.76 q $29.78 q $80.43 q $33.70 q $74.01 q $11.87 q $170.77 q $16.40 q 22.96 q $52.78 q $49.89 q $98.25 p

52-Week High

52-Week Low

$12.84 $31.91 $105.69 $39.09 $87.05 $15.49 $177.59 $30.71 $29.00 $76.98 $57.57 $99.72

$6.12 $17.20 $66.78 $30.44 $54.50 $11.78 $103.09 $16.22 $19.65 $47.50 $21.48 $54.10

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 9/10/2015.

U.S. On-Highway Diesel Fuel Prices 9/7/2015

One Week

United States

$2.534

+0.020 p

-1.280 q

East Coast

$2.594

+0.004 p

-1.250 q

New England

$2.663

-0.010 q

-1.270 q

Central Atlantic

$2.716

+0.002 p

-1.212 q

Lower Atlantic

$2.489

+0.011 p

-1.271 q

Midwest

$2.483

+0.040 p

-1.268 q

Gulf Coast

$2.385

+0.009 p

-1.330 q

Rocky Mountain

$2.567

+0.005 p

-1.302 q

West Coast

$2.746

+0.023 p

-1.288 q

West Coast less California

$2.590

+0.026 p

-1.389 q

California

$2.872

+0.021 p

-1.207 q

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

One Year

AGGREGATES MANAGER October 2015

150 120 90

Raw score: 129.05

Raw score: 130.00

Raw score: 128.42

July

August

September

60 30 0

The Aggregates Industry Outlook (AIO) fell 1.21 percent against August, to an overall score of 128.42. Although the overall result is well into the positive outlook, it is the lowest number recorded in the AIO’s three-month tenure. Two primary drivers were noted for the decrease: weather-related issues and concerns regarding federal and state transportation funding.

Comments: With the heavy rains in our area this summer, many contractors are behind on their jobs and will be working to get them completed by the end of the year. — Todd Whitehall, Performance Manager, Oldcastle Materials

Winter weather will be a contributing factor on aggregate sales in our area as construction slows down. — Jerry Mock, CEO, Zanesville Materials LLC

Weather and funding delays have pushed sales that we normally would have had in late spring/early summer into the late summer and fall. I suspect that this will push activities further into the fall, and potentially early winter, than we have typically seen. — David Bieber, Growth and Development Manager, Front Range Aggregates, LLC

Locally, a couple of highway projects have kicked off along with large commercial projects and are going to carry through into 2016, but the variable with these and others is going to be the winter weather. — Grant Smith, Production Manager, Transit Mix Concrete Co.

(I’m) very concerned as to how federal government and states will fund future transportation projects. — David Denton, Corporate Manager of Quality Assurance, Rogers Group Inc.

We’ve noted consistent demand with instances of a few shortfalls of supply for some grades of aggregate. — Robert L. Stone, Manager of Sales and Compliance, Hunter Sand & Gravel, LLC

Over the past year, we have seen more interest in new locations (greenfield sites) than in the previous seven years. Most of this activity is in Texas, North Carolina, South Carolina, and Georgia. — O.F. “Russ” Patterson, III, Chief Geologist, Patterson Exploration Services

AGGREGATES MANAGER October 2015

The World’s Number 1 Washing Equipment Company Visit our Wash Plant Demo Event Metroplex Sand & Gravel 27th & 29th October 2015 Fort Worth, Texas

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

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

Doublescreen technology offers more screening flexibility Sandvik Construction introduced the new QA335 Doublescreen to give more screening flexibility. The new mid-size version of the Doublescreen has patented two-deck screens to perform two processes with one plant. The QA335 has two high-velocity screen boxes with independent screen drives that can be adjusted for each application. It also has wrap-around walkways to give operators easy access for service and maintenance. Sandvik Construction | www.sandvik.com

New simulator training system Simformation LLC’s new simulator training system, the Cat Simulators Off-Highway Truck System, is set in a quarry environment so workers can learn what they would do in a real-world mine. The system has authentic controls and teaches controls familiarization, how to do a machine walkaround, systems testing, driving, hauling, braking, loading, unloading, and an open training mode for users to try any of the techniques. The simulator comes with the SimU Campus software that sends information back to the instructors. Simformation | www.Simformation.com

Reversing belt trainer Flexco released its first reversing belt trainer, called the PT Pro, as the final piece of the company’s line of trackers. The PT Pro Belt Trainer has a “pivot and tilt” design that can track single-direction and reversing belts. The belt trainer has tapered rollers to eliminate the need for sensor rollers. It can also be used for belts that are mistracking or wandering on each side. The PT Pro comes in standard and heavy-duty options. Flexco | www.flexco.com

AGGREGATES MANAGER October 2015

ROLLOUTS

Scraper tractors increase productivity John Deere announced its new enhanced 9R/9T Scraper Special Series Tractor line up with upgraded models and a new 9620R that’s the company’s largest model yet. All of the scraper tractors – 9570R, 9570RT, 9620R, 9470R, 9470RT, 9520R, and 9520RT – come with the HydraCushion suspension system, the fuel-saving Effiency Manager, as well as an increase in horsepower, productivity, and uptime. The 9570R, 9570RT, and 9620R models all come with a Cummins QSX15 Final Tier 4 diesel engine. The other four models come with a John Deere PowerTech 13.5L PSS Final Tier 4 engine. John Deere | www.JohnDeere.com

High-capacity mobile cone crusher Terex Finlay rolled out a new cone crusher for operators looking for high-capacity, efficient production. The new C-1545 tracked mobile cone crusher has Terex’s new TC 1150 cone crusher with a direct speed clutch driver, automatic tramp relief, and hydraulic closed-side setting adjustment. The feeder has an automatic metal detector and purge system that protects the cone and reduces downtime by getting rid of all of the metal contaminants on the feed belt with the press of a button. Terex Finlay | www.TerexFinlay.com

Baghouse products meet NESHAP standards FilterSense has a new series of B-PAC Baghouse Performance Analyzers and Controllers that help meet the new NESHAP regulatory compliance standards for bulk powder processing, air pollution control, and dust collection processing at cement plants. The controllers’ integrated controls, sensing, and high-speed digital signal analysis make it possiblbe to detect and locate leaks before emissions are visible, tol detect and locate pulse solenoids, and to detect and locate ruptured or frozen pulse-jet diaphragms. FilterSense | www.FilterSense.com

Roller provides continuous compaction Global Stabilization’s Handy Hitch Grader Mounted Packer/Roller gives continuous compaction for a smooth service. The packer/roller helps to conserve moisture during road maintenance in dry weather and seals moisture out of a new road during wet weather. Each lift can be individually packed to make for a safer travelling road surface. The equipment comes in widths of 75, 90, and 120 feet. Global Stabilization | www.globalstabilization.com

AGGREGATES MANAGER October 2015

GAME CHANGER NEW Terex® Cedarapids “V” Screens Deliver UNMATCHED Production The revolutionary design of our new LJ-TSV screen combines the legendary El-Jay™ oval stroke with the unique ability to vary the screen slope to increase production and handle applications that are not possible with traditional horizontal screens.

Features of the NEW LJ-TSV Horizontal Screens: *Screen installs from 0° up to 10° in 2.5° increments to best fit the application for increased capabilities *Variable slope allows screen to handle larger deck loads and bigger screen openings for increased production More steel in “rock zone” for industry leading durability High G-force, El-Jay™ oval stroke design for high efficiency *Optional bottom deck deflector plates boost efficiency Easy to maintain — new maintenance reducing features *Patent Pending

5'x16' to 8'x up 20'

Visit www.terexmps.com to find your local distributor and learn how we can work for you.

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Frac Sand 101 Interested in the high-value proppant market? Learn more about the U.S. frac sand market with this primer.

rac sand is a type of proppant, a ma-

with hydraulic fracturing to produce oil and gas

terial consisting of uniform, specialized

from the U.S. shale plays.

grains used in hydraulic fracturing.

The rise in hydraulic fracturing has driven

Hydraulic fracturing, or â&#x20AC;&#x153;frackingâ&#x20AC;? is

demand for frac sand up from 41 million tons in

a technique where fluids and proppants are

2013 to about 54 million tons in 2014. The top

forced under pressure down a hole to stimulate,

five producers in the United States are Unimin,

or crack open, the source rock to release oil and

U.S. Silica, Fairmount Santrol, Hi-Crush Prop-

gas. Proppant props open the cracks, allowing

pants, and Preferred Sands.

oil and gas to be released during pumping. by Holly Bellmund

AGGREGATES MANAGER October 2015

Fracking has been a widely adopted commercial

Frac sand and proppant

practice in the United States since the 1980s,

Frac sand is a natural proppant; proppant can

with explosive growth beginning in 2010, when

be manufactured from clays or polymers. Frac

horizontal drilling technology was combined

sand and manufactured proppants can be coated

MINE MANAGEMENT

sand grains predict the ability of the material to allow conductivity of oil and gas. Tested qualities include particle distribution, grain roundness and sphericity, turbidity, specific gravity, acid solubility, and crush resistance. Crush resistance, also called crush stress level, or K-value, measures the ability of the proppant to resist breaking down under pressure.

Frac sand products Frac sand is sold in graded sizes, much like aggregates. The sand grains are sieved on woven wire mesh screens and blended to meet specifications. Products are named by their size relative to the top and bottom mesh numbers which relates to maximum and minimum grain diameter. The coarsest standard product for frac ÂŠ 2015 Proppant Today, LLC

sand is 20/40. This means that 90 percent of the proppant product is small enough to pass

with substances, like resin, to change its physical and chemical

through the 20 mesh screen (an opening of 0.85 mm) and

properties. No matter the type, proppant is designed to remain

large enough to be retained on the 40 mesh screen (0.425

in place over the life of a well. The ideal proppant is flowable

mm). Each product allows for a distribution of grain sizes

to allow it to move deep into the fissures and strong enough to

within the range. Other standard proppant sizes are 30/50,

keep the fissures propped open without fracturing the grain.

40/70, and 50/140 also known as â&#x20AC;&#x153;100 mesh.â&#x20AC;?

Proppant is often specified by its strength, known as crush

Frac sands typically exhibit crush strengths as high as

resistance or crush strength. It is measured in pounds per

8,000 psi for the 20/40 and 30/50 products and 10,000 to

square inch (psi), with a higher psi indicating its ability to

13,000 psi for the 40/70 and 100 mesh products. Proppant

perform at greater pressure. Since proppant is used in large

products are typically specified based on the particular appli-

quantities, typically between 1,000 and 6,000 tons per well,

cation in the oil field or gas field, which are dependent on a

proppant must also be economically feasible and transportable

number of features including depth, pressure, and tempera-

without impacting product quality.

ture of the well. Generally, shallower wells and softer source

About 92 percent of proppant used in the United States

rocks can accept lower crush-resistant products. They can be

today is frac sand. Frac sand is naturally occurring silica sand

as low as 2,000 to 4,000 psi for the larger 20/40 and 30/50

that has been tested and found to meet certain physical and

proppants, while 4,000 to 6,000 psi is typically specified for

chemical parameters that allow for the optimal conductivity

the finer 40/70 and 100 mesh sizes. Deeper wells and high

of oil and gas. Silica sands, or sands that are monocrystalline

temperature wells often require the proppant to exhibit crush

quartz with a silica content of 99 percent or greater, are pre-

resistance of 6,500 to greater than 14,000 psi.

ferred because they are chemically inert and do not interact with other chemicals used in the fracking fluid.

Frac sand sources, mining, and production Silica sands that are suitable as frac sand are found in several

Frac sand quality

regions across the United States. Frac sand mine locations

Frac sand is subjected to quality test protocols recognized by

are also established based on the ability to transport mate-

the American Petroleum Institute (API) and the International

rial economically to the oil and gas fields. Location is critical

Organization for Standardization (ISO) using methods API RP

because the cost to transport frac sand is usually the highest

19C and ISO 13503-2. Both the shape and strength of the

contributor to total cost. AGGREGATES MANAGER October 2015

MINE MANAGEMENT

are recognized as being of superior quality and are known as Ottawa White or Ottawa District sands. Active sand mines in Texas are located around the towns of Brady and Voca; other quality “native Texas” sands are mined in Granbury and Kosse. As compared to the Northern white sands, native Texas sands tend to be coarser, the grains slightly more angular, with a weaker, though suitable, crush resistance for several fracking applications.

The U.S. Geological Survey recently

Frac sand active mines and reserves.

compiled a map showing the areas of the continental United States where there are active silica sand mining operations and areas where silica sand may qualify as frac sand. Similar to aggregates reserves, the potential for a frac sand mine to be profitable relies on the quality and quantity of the reserve. Frac sand mines and processing plants must be permitted just like aggregate sites with local, state, and, often, federal agencies. Permits must be obtained for air, water, land use, sensitive species, and sites of cultural significance. One main difference between frac sand and aggregates is that the application for frac sand is in the oil field, most often a distance of 500 miles from the

mine site. Like aggregates, the customer

Frac sand mining and production

may pick up product at the plant or the producer transports it to the customer. As a distribution strategy, leading frac sand producers develop a network of frac sand storage terminals. Fairmount Santrol’s distribution network includes approximately 50 terminals, a fleet of more than

Frac sands are often identified by the names of the locations in which the formations are found. For example,

8,500 railcars, and is capable of delivering to each of North America’s major oil and gas producing basins. Frac sand is sourced from sandstone, composed mainly of

white colored grains of several sandstone formations found

sand grains which may be unconsolidated (loose) or cement-

in the upper Midwest, led by Wisconsin. Within the category

ed together as a sandstone. Material is mined and transport-

of Northern white sand, the La Salle County, Illinois, sands

ed to the processing plant by hauling, pumping, or convey-

“Northern white” typically refers to the high purity, clear to

AGGREGATES MANAGER October 2015

Our Volvo E-Series excavator has allowed us to do things that are hard to believe — that are just plain amazing.

That’s our Ex Factor. – Jim Whitaker, fleet manager, Whitaker Construction

Whitaker Construction has more than 60 years’ experience in underground construction. As one of the largest utility contractors in their region, they have to operate with a cutting edge. Jim says the EC380E gives them that edge — working up to a 480 class size, while fitting in tighter spaces — allowing them to tackle challenging jobs with more efficiency. Find tips to get the most from your excavator at volvoce.com/ExFactor.

ing. At the processing plant, sandstone may be crushed to

cies such as improved scheduling, forecasting, and predictive

liberate the grains of sand from the matrix of the sandstone.

maintenance can reduce production cost by about 10 to 15

The sand grains are washed and scrubbed to remove clays

percent. Other gains can be achieved through mine planning,

and silts; oversized material is removed during wet screen-

plant and/or mobile equipment capacity increases, or changes

ing. Moisture is reduced from the grains by gravity (draining

to permits allowing for increased hours of operation.

stockpiled sand) or mechanically by vacuuming or blowing air on the sand using filter belts or filter presses. The moist sand grains are dried using either fluid bed or

Operational excellence, or OPEX, is an approach that focuses on continuous improvement of key processes like mining, drying, sizing, and shipping to reduce plant bottlenecks and drive

rotary drum dryers. Fluid bed dryers use forced air to move

out waste. In the near term, I believe that the producers that

the grains across a heated plate; rotary drum dryers, common

emphasize a culture of OPEX will reduce production cost.

in asphalt plants, tumble the grains while the grains pass through heated air. Both types of dryers have broad appli-

Transporting frac sand to the oil field

cability and are in use at plants across the United States.

Total delivered cost to the oil field is the key metric to evaluate

Whichever dryer type is used, the sand grains are less than

a frac sand site’s ability to be profitable over time. Just like

1 perecent water by weight upon exit. Following drying,

aggregates, optimal sites have an advantage in proximity to

the grains are separated into sizes using rotating or shaking

the job site. However, most frac sand originates from the upper

mesh screens. The dried and sized sand is blended for sale to

Midwest states and is delivered to Texas, Pennsylvania, North

conform to product specifications and is then stored in final

Dakota, and Colorado and into Canada mainly by rail, and also

product silos at the plant for shipping.

by truck or barge.

Similar to aggregates, production cost per ton is a key metric for producers to monitor and control costs. Operational efficien-

For this reason, producers that can ship on more than one transportation route by rail, barge, and truck have the ability to

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AGGREGATES MANAGER October 2015 Untitled-14 1

WE BUILD LEGENDS.

5/13/15 9:22 AM

MINE MANAGEMENT

move higher volumes. Most of the top five producers have the

wells anticipated to supply domestic energy increases and as

ability to ship by unit train to the oil field. In July 2015, Unimin

the price of oil begins to rebound.

set a record for shipping the largest single frac sand rail delivery when it shipped a 140-car train to Elmendorf, Texas. Operations that can ship by barge can access the Pennsyl-

Frac sand producers have become cautious due to the depressed demand driven by the slump in oil prices. However, each of the top five frac sand producers have indicated plans to

vania, West Virginia, and Ohio oil and gas plays by the Ohio

grow organically or through acquisition in 2015. Given expected

River; or can move material on the Mississippi River, supplying

demand for proppant, opportunities exist for new entrants.

terminals in coastal Texas. Texas plants have the advantage to ship in-state, howev-

Opportunities for aggregate producers

er, the quantity and quality of frac sand needed in the major

In 2014, the average price of frac sand was between $50 and

basins exceeds the production capacity of the Texas mines.

$60 per ton. Frac sand and aggregates mining and production

Because of the distance from the mines to the oil field within

have significant overlap, however, the markets they supply

Texas, frac sand is also moved by rail in-state.

have little in common. Aggregate producers would be wise to investigate the potential of developing frac sand mines as

Frac sand market size and pricing

long as they invest in a logistics and marketing strategy that

Frac sand comprises 92 percent of proppant used in the

matches their opportunity to produce. AM

United States with a total market size of about 54 million tons of frac sand sold in 2014. In the current low oil price environment, frac sand volume sold is expected to decline by about CIM_CIM 7 xbeginning 4.875 1/20/15 8:37 and AM through Page 1 15 percent1/2inHORIZONTAL2015; however, in 2016

2020, market growth is expected to resume as the number of

Holly Bellmund is the president of Proppant Today, LLC a research, media, and consulting firm. She can be reached at hbellmund@ proppanttoday.com. Proppant Today has released the US Proppant Market & Forecast Report: 2015 to 2020, available at www. ProppantToday.com.

RULMECA MADE BY RULMECA. We strongly believe in continually challenging the status-quo. All of us at Rulmeca are driven to find new and better ways to extend conveyor life and decrease down times. We believe all conveyors can and should run much safer and quieter than they do today. www.rulmeca.ca

Moving ahead. Rulmeca_AGrm0515_Pg.indd 1

AGGREGATES MANAGER October 2015

4/20/15 3:34 PM

Save Fuel with the Benefits of Telematics With the right equipment insights, managers can learn how to track the fuel from equipment and extensions. by Wyn Partington

ggregate operators and manufacturers use a

that can be used to improve operations and company perfor-

wide range of equipment during day-to-day

mance. When it comes to monitoring fuel usage of equipment,

operations, from wheel loaders to excavators to

an Engine On Report provides a color-coded description of an

haul trucks. These assets are vital to business

individual mobile unitâ&#x20AC;&#x2122;s engine status, displayed on a 24-hour

operations, and managers need easy access to usage and performance information to assess efficiency and identify any costly issues. Most know that telematics solutions are used in a number of industries and that these solutions provide a number of benefits including increased productivity, streamlined operations, and cost savings. However, many may not realize that introducing a GPS fleet tracking solution can directly improve the efficiency of company equipment. Telematics solutions include features such as reports, Power Take Off (PTO) sensors, and maintenance management modules that directly improve fuel efficiency and overall operations for the company. Reports are valuable tools, providing actionable information

AGGREGATES MANAGER October 2015

A GPS fleet tracking solution can help aggregates operators maximize equipment utilization.

TECHNOLOGY

timeline. Managers can evaluate this report to confirm hours of use for heavy equipment, identifying any excessive fuel usage, and to validate jobs. Companies in the aggregates industry often use equipment that have extensions. However, the issue is that not all companies are able to track the fuel usage separately. For example, if an excavator is being used onsite, many fuel management or monitoring tools may only provide data regarding the main engine. However, what about the fuel being used by the power shovel? Aggregates operators need to utilize a telematics solution that offers Power Take Off (PTO) sensors, which measure utilization and fuel usage of these equipment extensions. Operators can use PTO sensors together with reports and

Managers can use an Engine On Report to confirm hours of use for heavy equipment, identifying any excess fuel usage, and to validate jobs.

alerts to monitor any extension of the vehicle used in the working process, sending an instant notification when the PTO mechanism is engaged. As an added benefit, these reports provide information showing the time, location, and duration of equipment usage. All of this data is pulled into the comprehensive telematics solution, providing managers and operators with detailed information regarding fuel usage and asset utilization in one central platform. Well-maintained assets are more fuel efficient than others, but it can be challenging for managers to keep up with all necessary preventive maintenance. A comprehensive telematics solution will offer a maintenance module, assisting companies to track and schedule regular maintenance for assets and equipment with logs, reports, and alerts.

A comprehensive telematics solution will include a maintenance module to help operators trak and schedule regular maintenance for assets and equipment with logs, reports, and alerts.

Automated maintenance schedules can be set up to alert managers or owners when it is time for upkeep or repairs.

usage at efficient levels, even onsite. Having a solution that

This ensures preventive maintenance is occurring consis-

better helps manage fuel-related expenses provides manag-

tently and on schedule. Maintenance logs provide details of

ers with peace of mind and the tools they need to operate a

all services performed ensuring maintenance policies are fol-

successful business. AM

lowed. With maintenance reports, aggregates managers can customize and generate the data they need for a complete picture of their fleet. Alerts can be set to odometer readings or engine hours to ensure that all assets can be monitored accurately. Being able to automate this process makes it easier to monitor and track maintenance, which in turn, leads to healthier, more fuel-efficient vehicles.

Wyn Partington is vice president of marketing at NexTraq. Learn more at www.nextraq.com.

Using a GPS fleet tracking solution can help aggregates operators function at their full potential while keeping fuel

AGGREGATES MANAGER October 2015

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PULL-OUT GUIDE By Kerry Clines, Contributing Editor

OPERATIONS ILLUSTRATED â&#x20AC;&#x2122; n r E fi i

nt s E e g y f c en c y a l P r u o Y e v o r p Im

Use adjustable speed drives in the plant. Consider using alternative energy.

Use software to track plant energy use.

Develop an energy management program.

OPERAT 1

Start an energy management program

Using Energy Wisely

nergy efficiency and sustainability have become common words for industries, including the aggregates industry. Energy is one of the largest expenses for aggregate producers, so it is naturally one of the areas of focus when trying to cut back on operating expenses. Conserving energy is important, whether it’s electricity used to run the plant or fuel to run the fleet of equipment. “Being energy efficient or sustainable has always been at the forefront of electrical project design and is an integral part of the way I contribute to the overall goals of our sustainability program,” says Leroy Goree, senior electrical engineering manager at Lehigh Hanson. “On the supply side, one of my functions within the company is to work with our purchasing group to ensure the most reliable and lowest priced power is delivered to the gate when we retrofit or build a plant. On the demand side, we look at how we can make the most efficient use of that power within our facility.” There are many ways to address the high cost of energy. One way is through the use of alternative energy. Some operations are embracing solar power and wind energy at their operations to reduce the amount of energy they need from the grid. Operations also adjust their hours of operation around peak-use hours when electricity prices can be higher. High fuel costs can be addressed through the use of technology. Most manufacturers outfit AGGREGATES MANAGER

their new equipment with tracking software to monitor idle time and fuel consumption. Plus, aftermarket software is available to retrofit on older equipment. A good energy management program that encourages using energy wisely and following best practices is essential. The Environmental Protection Agency offers help to companies that want to set up an energy management program. It also offers a wide selection of ideas and tools to help producers attain energy efficiency through its Energy Star Challenge for Industry, which can be accessed at www.energystar.gov/. Cemex has an energy management program in place that employs a corporate energy management team and site energy teams at each plant. “The program, based on Energy Star guidelines, is implemented across all divisions of the company,” says Bhaskar Dusi, corporate energy manager. “Cemex has received numerous local and national energy and environmental awards, and is a strong advocate for energy conservation and sustainable manufacturing practices.” Another important part of successfully maintaining energy efficiency is getting everyone in the company onboard. “It’s all about the people really,” says William Jerald, chief energy engineer for CalPortland. “Buyin is the only way it works. When the managers and operators see that we can actually do things that make the plant better, then we have a win and start gaining momentum with the people.”

Energy efficiency begins with a good energy management program. The Environmental Protection Agency offers information to help companies get a program started through its Energy Star Challenge for Industry program. Once a program is established, an energy audit, or Energy Treasure Hunt, should be conducted at each plant to identify areas where excess energy is consumed. The Energy Treasure Hunt Guide: Simple Steps to Finding Energy Savings, found on the Energy Star website at www.energystar.gov, provides guidelines and tools for conducting an energy audit.

Address energy consumption problems

Many things that can be done to improve energy efficiency, such as determining when to run an operation, making sure equipment isn’t running when employees go home, and using energy-efficient lighting. The use of adjustable speed drives in the plant allows operators to vary the speed of a crusher, adjust the flow of water throughout the plant, or change the speed of a baghouse exhaust fan so that the plant uses only the energy that is needed. Air compressor leaks can be major issues, as well, but can be identified and fixed easily to provide a quick return.

TIONS ILLUSTRATED Improve Your Plant’s Energy Efficiency 2

Provide training for employees

Use tracking software

Energy efficiency is all about people, and training is essential. Every employee needs to be trained on how to identify excessive energy consumption issues, as well as how to correct them. Training seminars can help supply the necessary instruction, but Lehigh Hanson takes it a step further with its Aggregate Academy. Employees are brought in from different regions across the nation for one to three days of training focused on best practices for energy use and what’s most important. Information is spread through the company’s internal magazine.

Tracking software for processing plants and asphalt plants, as well as fleets of equipment, can help an operation become more energy efficient. Most new fleet equipment comes with tracking software to monitor idle time and fuel consumption, and aftermarket software is available to retrofit onto older equipment. The data collected is stored and made accessible to management for operational reports. Software is also available to track a plant’s operational and energy performance to provide real-time power usage data and generate daily and monthly reports.

Consider alternative energy

Some aggregate producers have turned to alternative energy to supply all or part of their energy needs. In California, Cemex installed wind turbines at three of its operations in hopes of reducing energy costs. The company entered into an agreement to purchase the generated wind power from Foundation Wind Power, which built, owns, operates, and maintains the wind turbines located at the aggregate sites. Cemex also entered into an agreement with the local electric company, Pacific Gas & Electric, so that any wind energy not used by the plant is fed to the grid.

OUR EXPERTS

Buy-in is essential

To ensure a successful energy management program, everyone in the company should not only talk the talk, but walk the walk. That means getting out of the office and into the plants. Lehigh Hanson calls it a Boots on the Ground approach, which starts with a kick-off meeting with key employees, followed by a tour of the site. After reviewing specific operations and systems at the plant, a recap meeting is held to discuss potential projects and do an economic analysis. A detailed energy action plan is then prepared that identifies which projects will be implemented.

William Jerald, chief energy engineer for CalPortland, served in the U.S. Navy before beginning work at CalPortland. After graduating from the University of Arizona with a nuclear engineering degree in 1997, he became the senior electrical supervisor and was promoted to corporate energy manager in 2007. Jerold began in his current position in 2014.

Leroy Goree, senior electrical engineering manager at Lehigh Hanson, has 28 years of experience. His responsibilities include energy management, power system design, automation, plant optimization, new plant construction, and major plant upgrades. Goree has a bachelor’s degree in electrical engineering technology from the University of Alabama.

Bhaskar Dusi, corporate energy manager for Cemex, earned a master’s degree in chemical engineering from the Indian Institute of Technology. Prior to joining Cemex, he performed energy and process audits, process optimization, techno-economic feasibility evaluations, and commissioned new equipment and plants for government and private industries. October 2015

Voices of Experience William Jerald

“A

t CalPortland, we’ve had a formal energy management program since 2003,” says William Jerald, chief energy engineer. “There are many ways to manage how you use your energy that can save money. What really got us motivated was the Environmental Protection Agency’s Energy Star program. We use the program as a guiding light and use its energy management tools to get our people interested in saving energy.” Jerald has been running the energy management program since 2007. One of his key jobs is to get people to understand the need for energy efficiency. He says many companies don’t realize that energy is a variable cost, and that by identifying energy consumers and resolving problems, energy bills can be lowered. “The managers and operators who run the plants are laser-focused on production and creating products that can be sold, so they don’t spend time focusing on things like air compressor leaks,” Jerald says. “Those leaks are a huge part of an energy management focus because they are easy to identify and quick on return.” Energy efficiency is also about fuel. One-third of CalPortland’s energy cost is from its fleet of haul trucks, loaders, and ready-mix trucks. The company uses tools, such as Caterpillar’s VisionLink, to collect data about fuel efficiency and idle time so that operators can be trained on how to operate the machinery more efficiently. One of the ideas CalPortland took from the Energy Star toolbox is called an Energy Treasure Hunt. Jerald goes out to operations to search for energy waste and efficiency problems, and also works to get employees involved. “A Treasure Hunt is an energy audit, but it’s also an educational process that I’m trying to teach and share with plant personnel,” Jerald says. “I try to bring in as much knowledge as I can and give them the tools they need to be successful.” AGGREGATES MANAGER

Leroy Goree

ehigh Hanson formalized an energy efficiency program in 2010. As it looked for tools to help achieve its goals, it joined with the Environmental Protection Agency (EPA) through its Energy Star Challenge for Industry. “No aggregate operation had ever achieved Energy Star status, so we were able to get in on the ground floor of the program,” says Leroy Goree, senior electrical engineering manager. “We worked with the EPA to refine the rules and guidelines aggregates operations must follow to achieve recognition.” Lehigh identified its top 10 to 15 largest energy users, performed energy analyses, and implemented energy saving projects at those locations. Every year, operations are reevaluated to determine which ones need help to become more energy efficient. The tools available through the EPA and other energy management courses and helps the company determine what works best for each location. “We identify what we can apply to our plants and spread it throughout the company with our programs and best practices,” Goree says. “We address things like demand management to determine when to run an operation; parasitic load management to make sure things aren’t running when employees go home; pumping control; and utilizing adjustable speed drives to vary water flow, the speed of crushers, conveyors, or baghouse exhaust fans so a plant uses only the energy that is needed.” The company’s Aggregate Academy helps educate employees on energy management by promoting and coordinating technical training and knowledge sharing through seminars. “We spread best practices throughout the company and get people to think of what they can do to save energy,” Goree says. “We want to change the culture of our plant managers and employees so they are thinking about energy management. The key to that is our Boots on the Ground approach. We get out into the plants and work with the operations.”

Bhaskar Dusi

“C

emex has focused on improving the environment and reducing energy consumption since its inception,” says Bhaskar Dusi, corporate energy manager. “It has made energy management a core activity in its business plan and commitment to sustainability.” Dusi says technology helps Cemex enhance energy efficiency at its operations. Equipment and power meters are linked to a plant-wide information management system, which allows the tracking of production, process, and energy consumption data. Several programs were developed internally to allow the company to track performance and generate reports, including the following: • Grafoper assesses the plants’ operational and energy performance and provides data for easy comparison, evaluation, and benchmarking. • The Fuel Management System offers real-time information on fuels inventory, shipment, quality, market price, and energy information. • The Power Monitoring System offers real-time power usage data and generates daily and monthly power usage reports to track efficiency and costs. • The Alternative Fuel Management System provides real-time data of the plants’ alternative fuel use. “Information from these tools is integrated into a daily operating report called DiaOper,” Dusi says. “This contains all operating and energy performance indicators, efficiencies, and down times. Each plant prepares its daily production reports using the information to review its operational performance.” Cemex employs various initiatives to improve energy efficiency — high-efficiency process equipment, modernized compressed air systems, alternative fuels, upgraded plant lighting systems, reduced equipment idle times, and purchase of higher efficiency motors. In addition, the company has embraced alternative energy by installing wind turbines at three of its California aggregate operations.

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Proper and timely scheduled maintenance will extend the life of equipment and increase a truck’s resale value.

One tool for extending equipment life, increasing uptime, and lowering ownership costs may be a planned maintenance contract. by Allison McNeal

AGGREGATES MANAGER October 2015

o one can fully predict when a ma-

Predicting expenses

chine will experience maintenance

Unplanned maintenance can result in a loss of

issues. However, when maintenance

production, create higher costs for parts, and

issues arise, understanding how to

increase service time. By assessing what equip-

properly maintain your articulated dump truck

ment and tools you use on a daily basis, you can

(ADT) can save you significant downtime and

better predict your expenses and use that infor-

reduce your overall cost of ownership.

mation when creating a planned maintenance

Brian Bereika, Doosan ADT product specialist,

(PM) contract.

explains how you can predict expenses, min-

“Like any piece of heavy equipment, proper

imize downtime, easily service your ADT, and

and timely scheduled maintenance will extend

increase the resale value by planning ahead for

the life of the equipment and save the owner

maintenance.

money over time,” Bereika says. “A PM contract

EQUIPMENT MANAGEMENT

also means the owner can complete maintenance during off hours, rather than having to shut down the machine on the jobsite.” Additionally, a planned maintenance contract can provide your company future hourly costs to better understand the current operating costs of the machine. By working with your equipment dealer on a PM contract, you can help better predict expenses, reduce downtime, and extend the life of your machine. “Dealers know what parts should be stocked, not only by themselves, but by equipment owners,” Bereika says. “They ensure that scheduled maintenance is performed on time and at a convenient time to the equipment owner. All this helps

Ease of access to filters and other preventive maintenance points helps contain the labor costs associated with regular upkeep.

control costs.” Making a PM schedule easy to follow and documenting

Minimizing downtime

service intervals allows you and your operators to easily make

ADTs are designed to haul the most amount of dirt, rock, stone,

sure each item is completed weekly, monthly, quarterly, or as

and gravel with the lowest cost per ton transported in mind.

scheduled. You should also assess parts, labor, travel, supplies,

These machines also excel in soft and slippery loading and

lubricants, and GPS fleet tracking systems, such as telematics,

dumping applications, and particularly in overburden removal,

to better budget for ongoing maintenance, Bereika adds.

transport to crusher, crusher to stockpile, and site reclamation

“Wear items should be in stock and common supplies

applications compared to other heavy equipment. So if your

should be on hand to help reduce downtime,” he says. “As

machine is experiencing issues, the last thing you want to do is

far as lubricants go, owners should know the manufacturer’s

to waste valuable time servicing your machine.

requirements. Using the wrong lubricants can lead to expensive and unnecessary repairs.” If you are experiencing mechanical issues, Bereika rec-

With a PM contract, servicing time is typically based on the manufacturers’ and equipment owners’ schedules. According to Bereika, a PM contract also ensures that maintenance will

ommends completing a visual and on-board diagnostic check

be performed as required to help minimize any machine issues

and then following up with your in-house mechanic to better

that can be caused because of lack of scheduled maintenance.

understand what repairs are needed prior to calling a service

In addition to a PM contract, Bereika encourages ADT own-

technician, if necessary. Collecting as much information about

ers and operators to perform three other preventive mainte-

the problem as possible before talking to the service depart-

nance procedures:

ment will greatly simplify the repair process and reduce down-

• Inspecting the auto-lubrication system, if installed, to

time. However, Bereika adds that working on major components

ensure that there is no premature component failure

on your ADT requires specialized training, so many times a

due to lack of grease;

dealer service technician is needed. A standard maintenance schedule is affixed to the ADT cab for easy reference and can be found in your Operation and Maintenance Manual. Knowing the fixed costs of planned maintenance upfront can help you minimize unexpected business

• Assessing tire air pressure, wear, and damage on a regular basis; and • Using diagnostic tools to monitor engine temperature and rpm history, for example, to prevent future engine damage and major premature repairs.

expenses. Fixed costs can give you confidence in knowing how

The auto-lubrication system greases the major components

much the operating costs will be, and by incorporating planned

approximately every 30 to 45 minutes when the machine is in

maintenance, you can make sure your machine gets serviced

operation, Bereika says. Although the system saves valuable

on time.

labor, the system must be monitored to ensure that the grease AGGREGATES MANAGER October 2015

than the equipment,” he says. “By doing this, it can also save owners a considerable amount of money and time in the long-run due to the fact that pre-failure repair costs are less than total failure costs.”

Easy serviceability ADTs work hard in all terrains, so scheduling proactive site maintenance intervals is crucial to extending your machine life. If properly serviced, ADTs — even those used in extreme environments — can have a life expectancy of approximately 10 years An auto-lubrication system greases the major components every 30 to 45 minutes of operation, but must be monitored to ensure the grease reservoir is filled and there are no fault codes.

(between 10,000 and 20,000 hours). “What is really necessary is

reservoir is filled and there are no fault codes associated with

easy access to filters and other parts involved in PM,” Bereika

the system.

says. “Labor is a major component of PM cost, and easy

Another preventive maintenance item is to visually and manually check tires for wear and damage. “Low tire pressure can cause sidewall failure and machine

access to all areas of the engine compartment helps keep costs low.” For instance, ADTs used in extremely hot or cold tempera-

instability,” Bereika says. “A visual inspection will show if the

tures require more frequent maintenance schedules, as well as

tire has tread punctures or sidewall damage because of road

alternative oils, Bereika says. Machines working in extremely

hazards. Also, look for rocks wedged in between dual tires,

dusty conditions may require multiple air filter replacements

which can cause tire failure.”

and daily cleaning. When used in muddy applications, ADTs

Radial two-star E3 tires come standard on many ADTs and

may have to be greased more often because the driveshaft

will work in most mining applications. However, if the tires are

and other bearings come into constant contact with the mud.

coming into contact with sharp objects such as shale, Bereika

Failure to schedule maintenance can affect engine perfor-

recommends using E4 tires. This type of tire has stronger side-

mance, lower productivity, and burn more fuel.

walls and deeper treads. A tire specialist should be consulted for more information. Diagnostic tools can be used as preventive maintenance procedures by analyzing component historical data, especially in regard to the engine, transmission, electronics, and the au-

Using bio fuels can also lead to fuel thickening and fuel filters clogging, requiring shorter service intervals. Bereika says that, if you are using bio fuels, check with your engine manufacturer to learn about proper service intervals. Visit your dealership to create a unique package that can

to-lubrication system. Owners and operators should ask their

address your maintenance needs and assess key machine

dealership about purchasing diagnostic tools.

features — parts, labor, travel, supplies, and lubricants — before

Bereika also notes that you should immediately repair components that are failing rather than wait until later when components are more likely to fail. “It is less costly to repair the component before failure because it can be done based off of the owner’s schedule rather

AGGREGATES MANAGER October 2015

servicing the machines. “Your dealership should know you and how you utilize your machines,” Bereika says. “They can cater a maintenance schedule to fit your specific requirements.” Additionally, by reviewing GPS fleet tracking systems,

EQUIPMENT MANAGEMENT

owners and dealers can see when an ADT needs to be serviced and can better budget for ongoing maintenance.

4) Identify the length of term you would like to establish preventive maintenance; 5) Discuss the plan with your dealership; and

Increase resale value

6) Create a PM contract.

The machine condition dramatically impacts the resale price

After the truck’s operating hours reach a certain predictable

of the equipment. For instance, if there are visible signs that

level, many ADTs can be rebuilt for a so-called “second life.”

the equipment hasn’t been properly maintained, has visible

Other times, ADTs are used as back-up units or converted into

damage, or major component wear, the resale value can be

water trucks.

dramatically reduced.

“All major components, such as the engine, transmission and

“A low resale value can severely affect the machine’s cost

differentials, have an expected life and have to be rebuilt period-

of ownership, possibly making it questionable to own,” Bereika

ically,” he says. “If they are, the machine’s life can be extended

says. “The most important thing (when reselling) is that the ma-

at a cost lower than the replacement cost.” This time frame will

jor components, such as the engine, transmission, and differen-

vary greatly depending on whether the ADT has had light, medi-

tials, are in good working order. Proof of a PM contract is also

um, or heavy-duty use.

valuable in maintaining resale value.”

By planning ahead for maintenance, you can help predict

In order to maximize your resale value, Bereika suggests following these tips:

expenses, minimize downtime, easily service the machine, and increase the resale value of your ADT.

1) Review the machine’s scheduled maintenance chart; 2) Identify how you are going to use the equipment;

Article courtesy of Doosan Infracore Construction Equipment

3) Identify low utilization times for maintenance;

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by Amy Materson, Contributing Editor

ATTACHMENTS ADD VERSATILITY

A broad assortment of attachments can transform your equipment fleet into multi-purpose machines.

COUPLERS

Low-hassle, low-cost alternative to hydraulic couplers Change attachments without having to hammer out and change the pin with the Manual Multi-Grab Quick Coupler from TRK. An adjustable screw mechanism allows the operator to grab multiple pin centers, and the difference in speed when changing attachments is minimal when compared to a hydraulic coupler. With no plumbing or hydraulic maintenance, initial and ongoing costs are lower. TRK | www.trkattach.ca

Coupler features fewer moving parts Wedgelock’s excavator couplers are available in both hydraulic and mechanical models, and provide the ability to quickly and easily change attachments. Both models feature the company’s Wedge Locking Principle, which delivers a wedging effect that keeps the coupler-to-attachment connection tight, eliminating movement and minimizing wear. Both models are easy to install. Wedgelock | www.wedgelockna.com

BREAKERS

Tie-rod free breakers simplify maintenance Allied’s Rammer Model 2577 mid-range hammer is the newest addition to its lineup. Weighing in at 3,880 pounds, it is matched for use on 46,300 to 66,100-pound excavators. The hammer features Rammer’s vibration dampened tie rod system and uses new materials to make it lighter, while retaining high levels of productivity. Incorporating the manufacturer’s Fixed Blow Energy design, the unit delivers maximum impact energy for every blow for higher productivity, regardless of flow fluctations. Its sound-suppressed housing increasings operator comfort and lowers noise levels. Operators can choose between Idle Blow Protector or a Soft Blow Sensor, depending on their needs. Allied Construction Products www.AlliedCP.com

Hydraulic breaker maximizes efficiency Bobcat’s hydraulic breaker attachment, which quickly mounts to the carrier machine via the Bob-Tach and X-Change mounting systems, delivers maximum efficiency by matching the hydraulic capacity of the carrier to the breaker, allowing consistent machine-to-breaker performance. Suitable for a range of demolition jobs, the breaker is available in models ranging from 60 to 1,000 foot-pound impact energy classes. Bobcat | www.bobcat.com AGGREGATES MANAGER October 2015

Specialized working end fits range of breakers Choose from a wide array of demolition tools with Brunner and Lay’s product line, which includes conical point, pyramid point, x type point, chisel, grooved chisel, wide chisel, blunt, super blunt, elephant’s foot, driving tool, and detachable shanks and pads. Suitable for most types of heavy-duty, boom-mounted breaker machines, the tools are manufactured from high quality steel, which is heat-treated for hardness, impact strength, and durability. Brunner and Lay | www.brunnerlay.com

Breaker delivers power in demanding conditions Montabert’s V65 heavy-range hydraulic breaker features a unique automatic speed variation system, adjusting its impact energy and striking rate to match material hardness in excavation and quarrying applications. Designed for use on excavators weighing between 121,250 and 198,400 pounds, the 12,324-pound hydraulic breaker delivers between 380 and 950 blows per minute. Standard features include a progressive start system that sets the tool into the material prior to the delivery of higher energy, a blank-fire protection system that reduces harmful metal-to-metal contact, and an energy recovery system that recycles recoil energy to increase strike power. Montabert | www.montabert.com

CRUSHERS

Screener crusher bucket handles 6-inch material Screen, crush, pulverize, aerate, blend, mix, separate, feed, and load materials all in one stage with Allu’s D-Series Screener Crusher Bucket attachment, designed for wheel loaders, excavators, and skid steers. The bucket has a power adjustment valve for powerful startup and rotation, which enables the attachment to screen and crush wet or dry material from 0.60- to 6-inch fragment sizes. Straight side plate construction ensures the bucket is easy to fill and holds a greater volume of material. Sixty models are available. Allu | www.allu.net

Pulverizes stone quickly Quickly pulverize asphalt, concrete, and stone with Atlas Copco’s compact bucket crushers, which eliminate the need for additional crushing equipment. Designed for a long service life, the bucket crushers have replaceable top and bottom jaws, and single jaws that can be rotated. Four models are available, with diameters ranging from 0.5 to 4.75 inches. Atlas Copco | www.atlascopco.us

BUCKETS

Heavy-duty bucket is double reinforced for strength Handle heaped capacities of up to 30 cubic feet with Berlon Industries’ heavyduty extended lip skid-steer bucket. Built with quarter-inch steel and fitted with a heavy-duty dimple plate, Berlon says the floor is five times stronger than floors with wear bars under the bucket. A fully welded body enhances structure strength and features double reinforcement in critical areas. The bucket is 23 1/2 inches tall, 36 inches deep, and is available in widths of 72, 28, 24, and 90 inches. Heaped capacities range between 24 and 30 cubic feet. Berlon Industries | www.berlon.com

AGGREGATES MANAGER October 2015

SUPPLY LINES

Move more material with ditching bucket Efficiently complete a range of excavating projects with Doosan’s heavy-duty ditching buckets. Designed for Doosan crawler excavators ranging from the DX140LC-3 through the DX530LC-5, the buckets feature a deep profile to improve operation when loading material, backfilling, and working on slopes. With no internal gussets, the bucket has a greater capacity for moving more material per cycle. Doosan | www.doosanequipment.com

Simplify material sorting Perform on-site material sorting with Esco’s Sifter Bucket. The bucket features Esco’s Ultralok tooth system with an integrated hammerless lock that provides safe, easy tooth replacement. The Sifter Bucket is composed of premium materials to boost reliability. Esco | www.escocorp.com

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MACHINE ENHANCEMENTS

Grade control eliminates guesswork Take the guesswork out of digging with ExcaVision, which provides grade control for excavators, backhoes, dozers, scrapers, and graders. With accuracy up to 0.02 feet, no re-checking or redoing work is necessary. The latest version of the DozerVision software allows the operator to monitor both absolute and relative lateral slope of the blade. ExcaVision | www.ExcaVision.com

Teeth install without tools H & L Tooth’s top-locking teeth are designed for backhoes that use side flexpin teeth and shanks, including Case, Deere, JCB, and more. The teeth install without tools and can be removed with either a prybar or punch. Designed to fit existing shanks, there are no flexpin hassles with the top-locking teeth. Available in self-sharpening single, twin, and triple penetrator dirt, fang, and flare styles, the starter kit contains five teeth and all components. H&L Tooth | www.hltooth.com

Belting increases track life McLaren Industries’ NextGen TDF series of track loader rubber tracks has SpoolRite belting technology, a proprietary system that increases the tensile strength of the tracks’ internal structure to handle tough workloads. The pre-stressed, aligned, non-overlapping continuous belting system ensures equal tension throughout the belt, and a Crack and Cut Quarantine System uses a multiple lug profile to contain the growth of cut and cracks. McLaren Industries | www.mclarenindustries.com

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Get back to work faster with Pengoâ&#x20AC;&#x2122;s Strata Conical Teeth, which enable efficient drilling and provide extended intervals between tooth change-outs. The Strata Series has a drilling grade carbide tip to boost effectiveness in hardrock drilling applications. The Strata teeth are available in five sizes: 0.74 shank, .076 shank, 1-inch shank, 1.16-inch shank, and step shank. Pengo | www.pengoattachments.com

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Remember that the three C’s of community relations could be cookies, cake, and coffee. by Dave Thomey

ecently, Maryland Materials, Inc. (MMI), a company for which I

50 people with properties adjacent to, or

served as executive vice presi-

strategically located near, the quarry. About

dent for many years, was sold to

15 to 20 neighbors attended most meetings.

Bluegrass Materials. Among the many factors

During one of our first meetings, we told

that made me proud of Maryland Materials

our neighbors that we wanted “to share our

was our community outreach program.

dreams with you and hope that you would

Part of that program was what we called

share your dreams with us.” Each time we

our “Neighborhood Council.” Through the

met during the last 20-plus years, we have

council, we would invite neighbors into our

tried to adhere to that philosophy.

operation on a regular basis. During this

The program was simple. We invited about

The meetings, for the most part, occurred

meeting, we would review quarry operations

quarterly. We met on a Wednesday or Thurs-

and listen to any challenges they may have

day evening for about one hour over coffee,

due to their proximity to the site. The pro-

cake, and cookies. Stock agenda items included

gram was not original to us. I borrowed the

sales and production forecasts for the quarter,

idea from industry veterans Bernie Grove and

the amount of night work to be performed by a

Kim Snyder, who then worked for a Mary-

hot-mix company that leased property from us,

land-based company called Genstar.

and any future plans we had for improvement

AGGREGATES MANAGER October 2015

COMMUNITY RELATIONS

Evoco Partners, LLC Closes First Transaction

or growth. This usually took between

but stated that we were making the

15 and 20 minutes. We then spent

repair because we wanted to be a

the rest of the time listening to our

good neighbor, and we also appreci-

neighbors’ concerns.

ated their efforts at being a good

There have been many lessons learned from these meetings, in-

neighbor. When planning for an improve-

cluding the following:

ment or expansion, we would at-

1) Always be honest and open

tempt to get the information to

when answering questions. A

our neighborhood group six to 12

corollary to that rule is to always

months before we went to public

be positive about our terrific in-

hearing. This allowed the neighbors

dustry and the wonderful people

time to talk with one another and

that make up its workforce.

come back with their thoughts. We

2) Be responsive to neighborhood concerns.

acquired by

listened to them and, in several cases, made minor adjustments to

3) Listen and respond in a non-

Evoco Partners acted as a financial advisor to Lewis and Lewis in its sale to Summit Materials

the plan. The results were very

confrontational way during the

gratifying. During the time the

meetings.

neighborhood council has been in

Basic neighbor concerns included

place, we have permitted and built

vibrations due to blasts, dust when

a rail siding and permitted and built

the wind blew, and truck traffic, es-

a new production plant without any

pecially at night. The most frequent-

community opposition.

ly mentioned concern was vibrations

And the news keeps getting better.

that may have cracked the plaster

When Bluegrass Materials bought

on the walls of neighbor’s homes.

Maryland Materials, it had already

We would listen to the neighbors’

started a more formalized and im-

concerns during the meeting. The

proved community relations program

next day, we would call to set up

at its Churchville Quarry, about 20

an appointment to meet the home-

miles south of MMI. And they have

owner at his home, assess his

hired a terrific consultant (yours truly)

concerns, and have a more detailed

to act as its director of public affairs.

discussion about his home and the

We hope to build upon past successes

importance of our business. If the

and improve an already good pro-

damage was small, we set up a date

gram. We want the communities that

for a local contractor, usually one of

we serve to think of us as pillars of

our small customers, to fix the crack

that community. We are on our way

at our cost. We never admitted fault,

to doing just that. AM

Dave Thomey is a industry veteran and well respected leader. He has served in both operation and association management positions.tdunphy@randallreilly.com.

Do you have a community relations strategy you’d like to share? Please email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.

Evoco Partners was established in late 2014 to help business owners successfully manage the often complex process of acquisitions and divestitures. With over 20 years of M&A experience, including more than 10 years for one of the largest construction materials companies in the U.S., we understand what it takes to help buyers and sellers execute their growth and exit strategies. Evoco Partners is passionate about honesty, integrity, and personalized service. We act as trusted advisors and business partners to help our clients successfully meet their goals. Please contact us to discuss how we can be come a valued business partner for you.

Contact: Nathan Green Managing Partner 979-595-6811 nathan.green@evocopartners.com

AGGREGATES MANAGER October 2015 EvocoPartners_AGRM0915.indd 1

8/17/15 3:19 PM

Rock MSHA announces increased enforcement efforts with a focus on workplace examinations. by Benjamin J. Ross

Tips for Workplace

EXAMINATIONS T

Benjamin J. Ross is an associate in Jackson Kelly PLLC’s Denver office, practicing in the Occupational Safety and Health Practice Group. He can be reached at 303-390-0026 or bross@ jacksonkelly.com.

AGGREGATES MANAGER October 2015

he Mine Safety and Health Administration (MSHA) recently announced that it was “beefing up” its inspections, enforcement activity, and training in the metal/non-metal (M/NM) sector beginning Aug. 10, 2015. This announcement comes in the wake of 15 fatalities in the M/NM sector from January 2015 to Aug. 3, 2015, including three fatalities on the same day on Aug. 3, 2015. MSHA informed the mining industry of these increased efforts by issuing a letter to stakeholders and via a conference call with interested persons on Aug. 5, 2015. During the call with stakeholders, Neal Merrifield, M/ NM administrator, identified powered haulage and falling/sliding as areas of focus, while Joe Main, the Assistant Secretary of Labor, focused upon workplace examinations. MSHA announced at the same time that, to facilitate this increased enforcement activity, 17 coal inspectors will begin inspecting M/ NM mines, and it had authorized funds to hire 21 new inspectors. MSHA, with the help of operators in the M/NM sector, seeks to prevent future fatalities by focusing upon hazards that contributed to fatalities up to the time of the announcement. The Assistant Secretary’s focus upon workplace examinations is not MSHA’s first emphasis upon the issue. MSHA announced a fatality prevention initiative on Jan. 30, 2015, in response to the 37 fatalities that occurred in

the M/NM sector between October 2013 and January 2015. The fatality prevention initiative focuses upon “safety fundamentals,” which MSHA believed played a significant role in those fatalities, including workplace examinations. On July 22, 2015, MSHA issued a Program Policy Letter, No. P15-IV-01, addressing workplace examinations as required by 30 C.F.R. §§ 56/57.18002. PPL No. P15-IV-01 expanded §§ 56/57.18002 to require workplace examinations for more areas in a mine. It also provides that every hazard not identified by an examiner can lead to the issuance of three citations: one for the hazard found, one for an inadequate workplace examination, and one for a task training violation based upon the inadequate examination. As part of MSHA’s heightened enforcement activity, the inspectors will, no doubt, focus upon workplace examinations. It is likely that multiple violations in the same area or multiple violations of the same standard will lead to MSHA issuing a workplace examination citation under § 56/57.18002. Any hazards that inspectors deem obvious, or that the inspector believes an examiner should have noticed, may also merit an examination citation. Considering MSHA’s focus upon workplace examinations and given the potential hazards that may result from an inadequate workplace examination, it is essential that examiners perform adequate workplace examinations.

Tips to perform adequate workplace examinations During the call with stakeholders, Assistant Secretary Main stressed three main points regarding an adequate workplace exam and stated that “workplace examinations include the requirement that mine operators 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.” The regulations define “working place” as “any place in or about a mine where work is being performed.” The PPL expands on this definition by stating that the term “includes areas where work is performed on an infrequent basis, such as areas accessed primarily during periods of maintenance or clean-up.” This means that any area where a miner may enter, not just active areas, should be examined every shift. Examinations must be done by a “competent person,” defined as “a person having abilities and experience that fully qualify him to perform the duty to which he is assigned.” 30 C.F.R. §§ 56/57.2. MSHA may assert that the existence of hazards not identified in an examination show that the examiner lacks “experience that fully qualify him,” and this may form the basis for a task training violation, in addition to a workplace examination violation. Of note, PPL No. P15IV-01 also suggests that it is a “best practice” to assign a foreman or other supervisor to perform the examination duties. If a supervisor is not used, it is imperative that examiners be experienced miners. An examiner should also be knowledgeable about safety hazards. Mine operators should develop a written program for training mine examiners that complies with Parts 46 and 48. In addition to the requirements in the Mine Act, examiners should be familiar with hazards common to any area that they are assigned to examine. Examiners should be familiar with equipment used in the working place, as well as common hazards associated with that equipment. Different working places present different safety hazards, as seen in the following examples: • Drop-offs, especially those leading to standing water, pose an overtravel hazard to mobile equipment. Examiners should evaluate the condition and possible hazards of roads, where hazards or travelways are not

apparent, and install barriers and markers. • Stockpiles of sand as well as pits, highwalls, and banks all pose falling and sliding hazards. Examiners should evaluate conditions, especially after a rain, freeze, or thaw. In addition to both mine and area specific knowledge, examiners should review and be familiar with MSHA’s Rules to Live By and its fatal accident reports. Knowing and understanding the causes of various accidents prepares examiners to identify and correct common problems. Also, by reviewing previous examination records, the examiner can identify which hazards are common or most likely to occur at the mine. Examiners should be on alert to recognize such hazards and ensure all hazards are corrected. Examiners should also keep accurate records of examinations. Any hazards found should be recorded, and records should document the corrective measures taken. Records may also show examiners common problems in given areas and can provide a focus for future examinations. It is essential to maintain the records as MSHA will undoubtedly issue a citation if records are missing. Pursuant to PPL No. P15-IV-01, mine operators may no longer discard records of examinations prior to one year, even where an MSHA inspector has reviewed them. Inspectors may also use the records to guide their inspection, inspecting identified areas to ensure previous hazards were corrected and do not persist. Examinations should be done with a specific focus upon protecting miners. Although they can be time consuming, examinations should not be viewed as a chore or something to be done as quickly as possible. Rather, examinations are one of the most important and effective tools available to protect miners. Many safety practices or requirements prevent specific hazards. Performing correct workplace examinations, however, can prevent a multitude of different hazards.

Conclusion MSHA’s increased focus upon workplace examinations means that inspectors will likely issue more inadequate workplace examination citations than in the past. More importantly, a good workplace examination saves lives. Competent examiners performing adequate workplace examinations are a necessary component to ensure a safe workplace. AM

AGGREGATES MANAGER October 2015

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2014-01-24 5:39 PM

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15. Extend and Nature of Circulation

08/01/2015 Average No. Copies Each Issue No. Copies of Single Issue During Preceding 12 Months Published Nearest to Filing Date

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 Requested Copies Distributed by Other Mail Classes (4) Through the USPS (e.g. First-Class Mail) c. Total Paid and/or Requested Circulation (Sum of 15b (1), (2), (3), (4)) 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 years old, Requests induced by a Premium, Bulk (2) Sales (By Mail 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) g. Copies not Distributed

20250

19296

12313

10868

306

241

12619

11109

6810

7591

297

7107

7653

19726

18762

525

534

20251

19296

63.97 %

59.21 %

a. Requested and Paid Electronic Copies(Sum of 15c and 15e)

Total Requested and Paid Print Copies(Line 15c) + Requested/Paid b. Electronic Copies

c. Total Requested Copy Distribution(Line 15f)+ Requested/Paid Electronic Copies

0.00 %

h. Total (Sum of 15f and 15g) i. Percent Paid and/or Requested Circulation ((15c / 15f) times 100) 16. If total circulation includes electronic copies, report that circulation on lines below.

Percent Paid and/or Requested Circulation (Both print and Electronic d. Copies) 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 10/01/2015 issue of this publication. 18. Signature and Title of Editor, Publisher, Business Manager, or Owner Title JULIE PUCKETT

Date AUD DEV DIR

09/16/2015 00:00:00 AM

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)

PRIVACY NOTICE: See our privacy policy on www.usps.com

Advertising COMPANY

WEB

PAGE #

Baldor Electric Co.

www.baldor.com

Beka-Max of America, Inc.

www.beka-lube.com

Bill Langer - Research Geologist

www.researchgeologist.com

Breaker Technology, Inc.

www.rockbreaker.com

C.L. Dews & Sons Foundry

www.dewsfoundry.com

CDE Global, Ltd.

www.cdeusa.com

Clearspan Fabric Structures

www.clearspan.com/adam

Elrus Aggregate System

www.elrus.com

IBC

Evoco Partners, LLC

www.evocopartners.com

Flexco

www.flexco.com

Historical Construction Equipment Assoc.

www.hcea.net

John Deere Construction Equipment

www.johndeere.com/pushback

IFC

Kruse Integration

www.kruseintegration.com

NSSGA Membership

www.nssga.org

Petersen Industries

www.petersenind.com

Progressive Commercial Insurance

www.progressivecommercial.com

Pugmill Systems, Inc.

www.pugmillsystems.com

Rice Lake Weighing Systems

www.ricelake.com/truckscales

Rock Systems, Inc.

www.rocksystems.com

Rulmeca Group

www.rulmeca.ca

SDLG North America

www.sdlgna.com

Snoby Separation Systems LLC

www.snobyllc.com

Stedman Machine Co.

www.stedman-machine.com/impact

Sweet Manufacturing

www.sweetmfg.com

Terex Minerals Processing Systems

www.terexmps.com

Top Bid

www.topbid.com

Volvo Construction Equipment

www.volvoce.com/exfactor

40, 41

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

AGGREGATES MANAGER October 2015

In Stone

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

Combating

SILICOSIS

The discovery of the bacteria that causes tuberculosis set safety precautions back by nearly 50 years.

y 1892, Barre granite had become a premier stone for monuments, mausoleums, and gravestones. PneuRockmatic machinery was introduced to help meet the skyrocketing demand. Along with pneumatic machinery came dust and silicosis. Silicosis plagued the Barre granite cutters who worked in the manufacturing sheds during the first few decades of the 20th century. Doctors and laymen alike had long recognized dust as a problem for granite cutters and other dusty trades, but, ironically, a major medical breakthrough confounded the discussions about phthisis (lung disease) in granite cutters. During the 1870s, the work of Louis Pasteur brought microscopic bacteria and germs to the attention of the medical community. Robert Koch, a German physician, followed his lead and, in 1882, he discovered Mycobacterium tuberculosis, the bacterium that causes tuberculosis (TB). Koch’s discovery led to almost universal agreement among American medical personnel that germs, not dust, caused phthisis. All cases of lung disease suddenly were diagnosed as TB. Researchers mocked the theory of quartz lungs, and, in the U.S., the study of industrial causes of phthisis ceased. Many granite cutters, including shed owners who worked alongside them, accepted the medical opinion that their illness was a form of TB caused by germs from unsanitary practices at work and home. Support of the biological cause of phthisis continued into the mid 1920s. Monument of Louis Brusa, a Barre sculptor, and his wife, Mary. Brusa But beginning in 1912, British investigators published a series of papers documenting that nondied of silicosis. infectious cases of phthisis could occur when tuberculosis was grafted onto a fibroid growth in the lung originally caused by dust. Unfortunately, many of their reports did not reach American researchers. Around 1922, the U.S. Bureau of Labor Statistics (BLS) published a report that concluded phthisis from exposure to dust was distinct from TB and was caused by the inhalation of minute particles of silica. Insurance company statisticians reported that exposure to dust from silicarich rocks such as granite produced a statistically significant predisposition to phthisis whereas dust from limestone did not. The BLS admonished the medical community for focusing on bacteriological causes of phthisis and ignoring workplace related causes. Concurrently, D.C. Jarvis, a doctor practicing in Barre, observed that granite cutters’ phthisis was not recognized by local doctors. He endeavored to convince both physicians and granite cutters that the disease was caused by work in a dusty environment, not from biological sources. Meanwhile, the workforce of skilled stonecutters was being greatly impacted through the silicosis-based deaths of some of its most skilled and senior workers. Those workers not only left the workforce prematurely, but were unable to mentor apprentices. Immigration quotas passed during 1917, 1921, and 1924, greatly complicated the ability of shed owners to replenish the workforce with skilled stonecutters from Europe. With a clearer understanding of the causes of stonecutters’ phthisis, and faced with a shortage of workers, shed owners looked in earnest for means to protect their workers from the harmful effects of dust. During the 1920s and 1930s, they introduced dust control methods including sweeping the floors, wearing masks, and the installation of what turned out to be ineffective ventilation equipment in the sheds. More efficient dust control systems were developed, and during 1936, an agreement was reached that required all manufacturing sheds to install effective suction equipment on all dust-generating machines. There have been no silicosis deaths in Vermont granite industry workers that were hired after 1940.

AGGREGATES MANAGER October 2015

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