Aggregates Manager October 2018 by Sandy Turner Jr

New equipment PG6

| Skid steer maintenance PG16

Your guide to profitable production

ALJ appointment errors PG28

October 2018 | www.AggMan.com

sure product 19 Make quality is king data more 24 Mine accurately with drones

AGGREGATE SYSTEMS

I love changing screens! (said nobody, ever)

Get rid of the worst job! • • • • •

Change 3 decks in 1/3 the time Screens last longer so fewer changes per year No confined spaces Less chance of someone getting hurt Lower your cost per ton

Find out more about the MS612 Screen Plant www.elrus.com/ms612

Post-shift inspections allow for any necessary equipment repairs before the next day’s shift.

PAGE 16 On Our Cover: NIOSH software offers a new way to train for hazard recognition. Cover illustration by Sandy Turner

Use of drones lowers the amount of foot traffic in dangerous areas, keeping workers safe.

PAGE 24

TABLE OF CONTENTS OCTOBER 2018 |

VOLUME 23, NUMBER 10

COLUMNS & DEPARTMENTS FEATURE ARTICLES

Improve Your Hazard Recognition Skills New software from NIOSH, EXAMiner, helps mineworkers recognize hazards at their sites.

16 Keep Your Skid Steer Rolling

Reduce downtime and maximize productivity with daily maintenance.

24 Drones and Data Mining

Drone data can help operators overcome common challenges in three simple ways.

3 Editorial Focus on thes three areas to improve site safety. 4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook. 6 RollOuts John Deere’s G-Series mastless motor graders, and other new equipment for the aggregates market. 28 Rock Law Errors in ALJ appointments create an opportunity for rehearings, but they may not be worthwhile. 30 Advertiser Index See who’s who and where to find their products.

OPERATIONS ILLUSTRATED

Quality is King

Working together, production and quality control teams can ensure a seamless production process that yields high-quality aggregate.

31 Classified Ads Aggregates industry classifieds. 32 Carved in Stone Dating back to the Miocene age, a set of rocks tells the story of how they were created.

IF YOU’RE NOT MOVING, YOU’RE NOT EARNING.

COMPLETE FLEET DIAGNOSTICS

Hi Mate onboard diagnostics lets you monitor your equipment from anywhere and alerts you to potential issues before they become a problem, keeping you up and running and earning more.

MOBILE& DESKTOP

TOMORROWSEDGETODAY.COM

October 2018

EDITORIAL

Vol. 23, No. 10

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

aggman.com /AggregatesManager /AggManEditor

Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Senior Editor: Kerry Clines Online Editor: Wayne Grayson editorial@aggman.com

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

Construction Media Vice President, Construction Media: Joe Donald sales@randallreillyconstruction.com

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

Corporate Chairman Emeritus: Mike Reilly President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore Chief Financial Officer: Kim Fieldbinder Senior Vice President, Sales: Scott Miller Senior Vice President, Editorial and Research: Linda Longton Senior Vice President, Acquisitions & Business Development: Robert Lake Vice President of Events: Stacy McCants Vice President, Audience Development: Prescott Shibles Vice President, Digital Services: Nick Reid Vice President, Marketing: Julie Arsenault

For change of address and other subscription inquiries, please contact: aggregatesmanager@halldata.com.

Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2018. 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.

Three Steps to Safer Operations

s this issue goes to press, safety is weighing a little more heavily than usual on the hearts of our editorial staff. An operation we visited earlier this year experienced a fatality in the days following that trip and, while each fatality hits hard, it’s different when it’s someone you may have seen working at a site. It’s more personal; much more personal. Simply put, it’s an experience each of us hopes never to have. From its perspective, the Mine Safety and Health Administration (MSHA) is working toward safer operations by tackling the issues it believes can have the greatest impact on safety. Anyone who has heard Assistant Secretary David Zatezalo speak in recent months recognizes that the agency has a laser-like focus on powered haulage accidents, which accounted for half of the fatalities in 2017 and two-thirds of the fatalities so far in 2018. In meetings with producers and industry associations, the agency is advocating for improvements in three areas: • Large vehicles hitting smaller vehicles; • Seat belt usage; and • Conveyor belt safety. In its proposed rulemaking, Safety Improvement Technologies for Mobile Equipment at Surface Mines, and for Belt Conveyors at Surface and Underground Mines, the agency is seeking feedback on how technology may improve safety in these three areas. Specifically, it is soliciting comments on various technologies and how they might create safer mine sites. Comments are due by Dec. 24. In terms of mobile equipment, which accounted for almost 40 percent of mining fatalities and more than 30 percent of injuries in 2017, engineering controls such as collision warning systems and collision avoidance systems are being explored. The agency is seeking feedback on the advantages and disadvantages of such systems, as well as — importantly — the associated costs and what types of mobile equipment might benefit most from the installation of such systems. MSHA studied 38 fatal accidents that occurred since 2007 involving mobile equipment in which the deceased did not wear a seatbelt. It determined that 35 of those people may have survived if they had been wearing their seatbelt, which was adequately functioning in 30 of those accidents. MSHA is considering engineering controls such as high-visibility seatbelts and warning devices that remind the operator to wear the seatbelt, among others. Finally, with belt conveyors, MSHA is studying items such as guards, number and location of crossovers, and lockout/tagout procedures for ways to improve safety. On a parallel path, NIOSH has released a beta version of its EXAMiner software, which is designed to help operators spot hazards in the field. It can be used as part of new miner training or Part 46 refresher training. Learn more about the software and the research behind its development on page 10. The path to safer operations may not be an easy or inexpensive one, but if it can help the industry avoid future fatalities, it is a path well worth taking. AGGREGATES MANAGER / October 2018

mining

Company Cemex, S.A.B. de C.V.

Diesel Fuel

Prices 9/10/18

United States $3.258 One Week +0.006  One Year +0.456 

New England $3.255 One Week -0.015  One Year +0.494 

Central Atlantic $3.407 One Week +0.008  One Year +0.485 

Lower Atlantic $3.131 One Week +0.017  One Year +0.355 

Midwest $3.194 One Week +0.003  One Year +0.441 

Gulf Coast $3.039 One Week +0.004  One Year +0.392 

Rocky Mountain $3.367 One Week +0.003  One Year +0.540 

West Coast $3.746 One Week +0.004  One Year +0.644 

West Coast less California $3.465 One Week -0.004  One Year +0.458 

California $3.969 One Week +0.010  One Year +0.790  Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).

$5.72

52-Week High $9.45

CRG

$33.24 

$30.46

$38.13

EXP

$86.64 

$85.84

$122.49

Granite Construction Inc.

GVA

$45.56 

$40.76

$68.58

HEI

$76.45 

$75.03

$111.48

$9.18 

$9.08

$12.59

HCMLY

Martin Marietta Materials, Inc.

MLM

$190.54 

$188.34

$241.33

MDU Resources Group, Inc.

MDU

$27.36 

$24.29

$29.62

Summit Materials

SUM

$19.04 

$18.81

$34.06

United States Lime & Minerals, Inc.

USLM

$76.94 

$70.56

$101.40

U.S. Concrete

USCR

$45.60 

$44.00

$86.35

Vulcan Materials Co.

VMC

$107.20 

$106.10

$141.20

Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 09/10/18.

COMPANY SPOTLIGHT

East Coast $3.246 One Week +0.011  One Year +0.417 

$6.79 

52-Week Low

Eagle Materials Inc.

LafargeHolcim Ltd. ADR

U.S.

Current Value

CRH plc

HeidelbergCement AG

On-Highway

Ticker

or the second quarter, ended June 30, Vulcan Materials Co. (VMC) reports net earnings of $160 million, up from $112 million in the second quarter of 2017. Adjusted earnings from continuing operations were $1.23 per diluted share versus $0.90 per share in the prior year’s second quarter. Adjusted EBITDA increased 13 percent to $325 million. “We remain on track with our full-year expectations. Vulcan-served markets are experiencing stronger growth in demand than other markets, and higher public funding for transportation infrastructure is now converting into higher shipments of aggregates,” says Tom Hill, chairman and CEO, in a press release. Vulcan Materials Co. (VMC) “Apart from geographic mix impacts, our pricing momentum continues to strengthen, including in our backlogged work. Our operating disciplines remain strong, and margins should continue to improve as we turn the corner on costs related to last year’s storms.” Aggregate segment sales increased $139 million to $956 million, and freight-adjusted revenues increased $99 million, or 16 percent, to $731 million. Shipments increased 7 million tons, or 15 percent, to 55 million tons. The segment’s gross profit increased 13 percent to $283 million or $5.16 per ton. In most Vulcan-served markets, the company notes the conversion of higher public funding for transportation into higher shipments of aggregates. A notable exception is in California, which does not “yet reflect the strength in highway construction activity we see building into 2019 and beyond.” For the quarter, freight-adjusted average sales price for aggregates increased by 1 percent versus the prior year quarter, with the rate negatively impacted by the faster growth in relatively lower-priced markets. Excluding that mix impact, aggregates price increased 3 percent. Higher price growth was realized in California, Georgia, and Virginia, while prices in Alabama, Arizona, and Illinois decreased modestly compared to the prior year. Fixed cost leverage and other operating efficiencies mostly offset the 30-percent increase in the unit cost for diesel fuel. During the quarter, the company also completed the dredging of its coastal Texas port facilities and took possession of a second new Panamax-class ship. “Our business is positioned for continued shipment growth, compounding pricing improvements, and further gains in unit profitability in the second half of the year and into 2019,” Hill says. “Public construction demand is beginning to join the sustained recovery in private demand, and Vulcan-served markets are benefitting disproportionally.”

Source: Market Watch

Data

STOCK REPORT

AGGREGATES INDUSTRY OUTLOOK The September Aggregates Industry Index fell 3.02 percent from August to 130.86, the index’s lowest point since January. A variety of factors seem to be in play with diesel fuel prices continuing to climb and a very wet end to the third quarter in many parts of the nation. Monthly aggregate sales demonstrated the greatest decline for the month, down 10.5 percent from August, with the outlook for the next three to six months also down by 5.5 to 5.7 percent, respectively. While some producers reported strong business conditions, many publicly held companies were trading near their 52week lows. It is worth noting that election cycles tend to drive down industry outlook responses.

Aggregates Industry Outlook 150 138.44

145 135

134.94

133.44

140

132.22

130.86

129.35

128.38

138.89

130

135.83

125

134.72

132.73

120 115

121.45

110 105 100 Oct. 2017

Nov. 2017

Dec. 2017

Jan. 2018

Feb. 2018

March 2018

April 2018

May 2018

June 2018

July 2018

Aug. 2018

Sept. 2018

Our outlook for the next six months or more is very positive. Our main concern at this point is the ability to manufacture enough stockpiles to meet demand through the winter months before we are forced to shut down when colder temperatures arrive!

Weather has greatly impacted projects in the Pennsylvania tri-state area. The last quarter should be very strong IF the weather cooperates. Future projects to be bid and current ones remain to be completed.

— Karen Hubacz-Kiley, Chief Operating Officer,

— Daryl Zeiner, Sales Manager, The H&K Group

Bond Construction Corp.

Permian Basin frac sand operations are coming on line, and sand is being moved via truck and rail. Highway work requiring aggregate materials is increasing in most states whether major road expansion or patch work. (We are) starting to see a slight increase in concrete materials as well; not sure what specific segment is driving it right now. — Jason Hurdis, Senior Market Professional, Caterpillar

Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at tdunphy@randallreilly.com.

VALUE OF CONSTRUCTION PUT IN PLACE, SEASONALLY ADJUSTED ANNUAL RATE 7/1/2018

6/1/2018

Residential

566,595

563,177

0.6

6.6

Non-residential

Type of Construction

% change July 2018 - June 2018

% change July 2018 - July 2017

748,847

751,058

-0.3

5.3

Office

72,545

72,543

0.1

8.7

Commercial

90,430

93,469

-3.3

1.3

Health Care

41,599

41,998

-1.0

0.1

Educational

91,964

9,183

1.0

2.7

52,646

52,619

0.1

20.5

102,676

103,238

-0.5

8.0

Highway and Street

94,358

93,980

0.4

3.9

Sewage and Waste Disposal

22,373

22,321

0.2

10.8

Manufacturing

62,417

62,129

0.5

-4.7

Transportation Power

Seasonally adjusted annual rate. (Millions of dollars. Not all sub-categories of non-residential construction are included.) Source: U.S. Census Bureau.

ROLLOUTS

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

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

Mastless grade control motor grader John Deere’s G-Series motor grader line features SmartGrade technology that delivers mastless Topcon 3D integrated grade control as a factory option on new machines and a field kit to retrofit equipment in the field. The system is fully incorporated into the machine’s structures and software, delivering grading performance while eliminating masts and cables. This protects the machine from possible theft or damage while also removing the need to climb on the machine each day to install blade-mounted sensors and components, making for shorter setup time. In the cab, the grade system interface is built into the Grade Pro controls available in the Deere fingertip or dual joystick design. An all-new automation suite is included with SmartGrade. It includes auto-articulation, blade flip, and operator-selectable machine presets. John Deere | www.johndeere.com

More fuel-efficient loader Komatsu America Corp. introduces the WA480-8 wheel loader. Equipped with a 299-horsepower, Tier 4 Final, SAA6D125E-7 engine, it uses up to 20 percent less fuel than its predecessor. Operator friendly design features include an optional advanced joystick steering system, eliminating the steering wheel, which may cause operator fatigue. The new “generous curves” bucket design fills and retains material, making the machine nearly 8 percent more productive than the previous model. A new auto dig system controls bucket tilt and lifting by sensing pressure applied to the work equipment, while a new swing-out rear door and standard auto-reversing fan allow easy access to the radiator for ease of cleaning. The loader is designed for three pass loading of on-highway trucks and hoppers.

Komatsu America Corp. | www.komatsuamerica.com

Off-road bus transportation option The world’s first heavy-duty, off-road bus, the Torsus Praetorian, is designed to transport personnel and equipment over rough terrain and tough conditions. Launched at Hillhead, the off-road bus features heavy-duty construction, 15.6 inches of ground clearance under the axles, and rugged off-road capability. It boasts a payload of up to 35 passengers and four-wheel drive as standard. Based on a MAN chassis, it’s powered by a six-cylinder MAN 6.9-liter diesel engine that produces 240 brake horsepower.

Torsus | www.torsus.eu

AGGREGATES MANAGER / October 2018

ROLLOUTS Dozer increases productivity, fuel efficiency Caterpillar’s new D8T dozer moves up to 18 percent more material than its predecessor, while using the same amount of fuel. Much of the fuel efficiency increase is due to its new, fully automatic, four-speed transmission. The powertrain continuously optimizes the dozer for maximum power and efficiency based on the load. Operators do not need to upshift or downshift, allowing operators of varying skill levels to efficiently use the machine. The Semi-Universal blade has also been upsized, with a capacity of 13.4 cubic yards, making it the largest SU blade in the size class. Optional performance cutting edges increase blade payload by up to 25 percent compared to standard cutting blades. The dozer is powered by a Cat C15 Acert engine, with a class-leading 354 net horsepower. Drawbar power is increased by up to 13 percent. A range of technology options, from simple grade indicators to full factory-integrated GPS, is available. Caterpillar | www.cat.com

Water management solution AquaClear, Terex Washing Systems’ new water management offering, delivers end-toend solutions for washing and water management from a single supplier. The range includes clarifying tanks, flocculent dosing systems, filter presses, and all associated equipment.

Terex Washing Systems www.terex.com

LOOKING BEYOND THE HORIZON BKT’s extensive product portfolio comprises specific cutting-edge tire ranges to cater for the most demanding needs in a variety of fields such as agriculture, construction, and OTR, as well as transport and agro-industrial applications.

BKT USA Inc. 2660 West Market St., Suite 100 Fairlawn (Akron) - OH 44333 Toll free: (+1) 888-660-0662 - Office: (+1) 330-836-1090 Fax: (+1) 330-836-1091

AGGREGATES MANAGER / October 2018

Electronic initiation system reduces blast delays Dyno Nobel launches the DigiShot Plus 4G electronic initiation system, said to be the most sophisticated addition to its electronic line. Developed with joint-venture partner DetNet, the system is designed to help reduce overall costs and increase productivity by reducing blasting delays and introducing programming speeds seven times faster than existing systems. The system has two robust downline wires with two deployment methods designed to improve safety by reducing time spent on the bench. The wire and detonator are packaged as coils or with spools. There are three types of wire: standard, deep hole, and XTM (extreme conditions). It contains the new 4G chip and is fully programmable with 15 times more memory for storing and tracking unique identification numbers, GPS coordinates, and time and date of blasting.

Dyno Nobel | www.dynonobel.com

Classifier separates dry particle sizes Van Tongeren America unveils a line of classifier systems that collect and separate dry particles by size range using only ambient air and gravity. Allowing the material to be kept dry upstream and downstream, it eliminates the use of water, as well as the use of settling ponds or drying equipment. The classifier line includes three different models using three different methods of classification, all custom designed and engineered based on specific production goals and product specs. The line operates entirely without moving parts for low maintenance. The classifiers may be used in series to split feed multiple products at different cut points and often include a cyclone or bag house dust collector.

Van Tongeren America, LLC | www.van-tongeren.com

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AGGREGATES MANAGER / October 2018

SPECIAL REPORT by Brianna M. Eiter, Ph.D., Jonathan Hrica, William Helfrich, Jennica Bellanca, Timothy Orr, Jason Navoyskim

New software from NIOSH, EXAMiner, helps mineworkers recognize hazards at their sites.

s the metal/non-metal (M/NM) mining industry prepares for the enforcement of the Mine Safety and Health Administration (MSHA) final rule on Examinations of Working Places (30 CFR Part 56/57.18002), researchers at the National Institute for Occupational Safety and Health (NIOSH) are developing programs designed to help mineworkers improve their hazard recognition abilities. Hazard recognition is critical for mineworkersâ&#x20AC;&#x2122; health and safety; however, recent laboratory research shows that mineworkers are not identifying a significant number of hazards.

recognition ability. Experienced and inexperienced mineworkers, mine safety professionals, and mining engineering students performed a simulated workplace examination by searching through 32 true-to-life-size panoramic pictures of typical locations (e.g., pit, plant, haul roads, and shop) at a surface limestone mine for hazards. This simulated workplace examination took place at NIOSHâ&#x20AC;&#x2122;s Virtual Immersion and Simulation Laboratory (VISLab). Study results show that even the most experienced mine safety professionals were only able to accurately identify 61 percent of the hazards included in the images, which is well below the 90 percent standard for mastery.

Hazard recognition in the laboratory NIOSH researchers conducted a laboratory study to identify the impact of mineworker experience on hazard

AGGREGATES MANAGER / October 2018

EXAMiner: Moving from laboratory to field In order to address potential deficiencies in hazard rec-

Figure 1 shows a potential slip, trip, and fall (STF) hazard identified in EXAMiner software. The mineworker does not have three points of contact while climbing the front-end loader.

ognition ability within the mining industry, NIOSH researchers focused efforts on developing practical solutions from NIOSHâ&#x20AC;&#x2122;s research findings. One practical solution is EXAMiner â&#x20AC;&#x201D; software that gives mineworkers the opportunity to perform a simulated workplace examination, in much the same way participants in the NIOSH laboratory study performed workplace examinations in the VISLab. There are several proven training strategies incorporated into EXAMiner. The first is to provide mineworkers with a simulated task that is immersive and recreates part of the mining work experience. Within EXAMiner, mineworkers perform a simulated workplace examination by searching high-fidelity panoramic pictures for hazards as if they were at a mine site. NIOSH researchers created this simulated task with the aim of improving information retention and enhancing transfer of knowledge from training to application in the workplace. A second training strategy included in EXAMiner is practice. EXAMiner gives mineworkers the opportunity to practice searching for and finding hazards in the panoramic pictures. Figure 1 shows a panoramic photo from the software. Using a keyboard and mouse, mineworkers can identify the hazards by clicking on them. Previous research shows that realistic and relevant practice increases the likelihood that critical skills and concepts will transfer to the job. A third training strategy is to provide mineworkers with feedback about their performance on the hazard recognition search task. EXAMiner provides a debrief session where mineworkers receive accuracy scores as well as specific information about hazards, including a brief description, accident and injury statistics, and information from the Code of Federal Regulations. Debrief sessions are critical during training because

feedback increases the impact of simulation and practice on learning.

Critical hazard recognition competencies EXAMiner addresses four competencies critical for hazard recognition ability. These competencies were chosen because they are important basic competencies that all mineworkers should have. General hazard recognition knowledge in mining is the knowledge of hazards found at most mine sites. For example, mineworkers have to be knowledgeable that slip, trip, and fall (STF) hazards can be caused by the build-up of material on a stairwell or catwalk. STF hazards have the potential to occur at most mine sites, regardless of the type of material mined. Site-specific hazard knowledge is knowledge of hazards that are unique to mining operations. For instance, mineworkers operating front-end loaders and haul trucks in quarries and pits have to be knowledgeable about the unique geological characteristics of the material they are mining at their site. Improving general and site-specific hazard knowledge will better prepare mineworkers to recognize hazards when they are present. Both general and site-specific hazard knowledge is represented in EXAMiner by the hazards chosen to be included in the panoramic pictures. These competencies are also reinforced during the debrief session with information about the specifics of the hazards. Visual search skills are critical contributors to hazard recognition ability because mineworkers must also be able to efficiently and effectively search their workplace and surroundings. To address this competency, EXAMiner gives mineworkers the opportunity to practice searching for hazards using panoramic pictures. AGGREGATES MANAGER / October 2018

SPECIAL REPORT

Figure 2 shows a larger, more noticeable hazard of a mineworker walking under an unsecured toolbox and a smaller, less obvious hazard of a broken step. The larger hazard was correctly identified 93 percent of the time during the NIOSH laboratory study while the smaller hazard was only identified 20 percent of the time.

Finally, EXAMiner targets pattern recognition because mineworkers must also be able to recognize patterns and changes in normal operation patterns that reflect normal activities or are an abnormality. For instance, there are safe and acceptable locations of equipment or personnel during operations, and there are typical cycles of changes in a mine environment over time. Changes to these patterns can signify when something is out of place or â&#x20AC;&#x153;does not look right,â&#x20AC;? which may trigger the mineworker to recognize a hazard. To address this competency, the panoramic pictures include multiple examples of the same hazard. For instance, there are several different hazards related to fire extinguishers, including missing extinguishers where there is signage present, but the fire extinguisher is missing, blocked, or obstructed. This approach should increase the likelihood that a mineworker will be able to recognize a fire extinguisher hazard in the future, even if it was not specifically included in a training session.

Considering mining industry training needs NIOSH researchers designed EXAMiner so that users can easily adopt it into current training programs. EXAMiner will be available as downloadable software that, once installed, will not require an internet connection and can be used with any device running the Windows 10 operating system. EXAMiner was designed to be used during an instructor-led Part 46 annual refresher or new miner training held in a classroom setting and can be used during other training situations as well (e.g., during monthly training meetings or toolbox talks). EXAMiner gives trainers the ability to customize training scenarios either by creating their own training scenarios or by choosing to create random scenarios from the panoramic images included with the software. Finally, EXAMiner includes

AGGREGATES MANAGER / October 2018

scenarios focused on specific types of hazards (e.g., electrical or slip, trip, fall) and enough content to last for Part 46 annual refresher and new mining training classes for several years.

EXAMiner in the field NIOSH provided several trainers who are leading MSHA Part 46 annual refresher training with a beta version of EXAMiner to gain preliminary industry feedback on the usability of the software and identify ways that trainers could incorporate EXAMiner into their training plans. Overall, feedback on software usability has been positive, and NIOSH researchers have observed trainers using EXAMiner in a variety of ways with their training classes. Trainers allocated between 30 and 45 minutes of their 8-hour training sessions to using EXAMiner. Trainers used the software with groups that range from five to 25 mineworkers. These classes were held in conference rooms with integrated projector systems and mechanical shops with a portable projector and screen. Trainers used EXAMiner either in conjunction with a review of hazard recognition and the current workplace examination rule, or at the end of their training day as an evaluation tool. Using EXAMiner as an evaluation tool gives trainers a means to assess mineworker knowledge of the training they just completed and to identify any potential gaps in mineworker hazard knowledge that can be addressed during future training (e.g., monthly safety meetings or toolbox talks). It also gives mineworkers the opportunity to put their Part 46 annual refresher training into practice, which is critical for transferring knowledge from the classroom to implementation in the workplace. Feedback from both trainers and mineworkers is that EXAMiner provides an opportunity for interaction and discussion,

— Dodge® bearings and power transmission Local manufacturing Global support

For 140 years, we’ve focused on providing industry-leading products that reduce your total cost of ownership. Every day we produce the mounted bearings, enclosed gearing and PT components you trust and prefer from Tennessee, North Carolina, and South Carolina. We are proud to continue to offer the same products and service you prefer with the global ABB technologies and innovation you deserve.

479-646-4711 Baldor.com

Lower Cost per Ton – Automatic Lubrication Systems

o maintain competitiveness, aggregate quarries must maximize production output while minimizing long-term operating costs. A key component to achieve this is the implementation of preventative maintenance strategies, which extend equipment service life and minimize the downtime required for maintenance, repair and operation (MRO). Success in this area reduces the total cost of production assets, and ultimately improves business performance. Cost and downtime due to premature wear is significant. For grease-lubricated bearings, well-considered lubrication strategies have a dramatic effect on extending bearing service life and therefore reducing costs and improving equipment reliability. The chart (Image 1) provides proportion estimates of premature bearing failure causes. Major causes are poor lubrication practices and contamination.

Factors which reduce the service life of grease include high speeds, elevated operating temperatures, vibration and high loads. When operating conditions such as these prevail, the benefits of delivering small amounts of grease at short time intervals are at their greatest. Image 2 demonstrates the differences between re-lubrication methods which deliver small amounts of grease at short intervals and those which deliver large amounts at extended intervals.

Premature bearing failure causes. Red (55%) indicates poor lubrication practices, which can be solved via automatic lubrication. IMAGE 1

In recognition of this, leading construction-industry businesses invest in automatic lubrication systems for the purpose of bearing re-lubrication and contaminant exclusion, because these systems deliver superior reliability results compared to manual lubrication. Reliability results such as: • Continuous production processes and predictable maintenance intervals • Continuous, low-maintenance, long-term lubrication • Permanent supply of lube-points with fresh lubricant • Consistently high lubricant quality guarantees • High equipment availability • Energy cost reduction Bearing re-lubrication addresses the need to maintain sufficient fresh grease around the working components of bearings as they rotate. Insufficient or infrequent re-lubrication leads to deterioration of lubrication conditions, lubricant starvation, and premature wear. Meanwhile, for high-speed bearings, the rapid supply of excessive amounts of grease can cause over-lubrication, which leads to degradation of grease condition and threatens the service life of bearings. The longest bearing service life is achieved when grease is added in small amounts at short intervals. When implemented correctly, this regime of grease delivery maintains a steady state of lubrication protection where over-lubrication and lubricant starvation do not occur.

IMAGE 2

Too much grease • Potential for elevated operating temperature and rapid degradation of grease for high speed bearings • Less efficient use of fresh grease • Potential to damage contact type seals Too little grease • Starvation causing premature wear • Accelerated degradation of remaining grease • Increased potential for contamination entry due to lack of lubricant purge To determine if automated grease system could be a cost-saver for your aggregate site, engaging a qualified third party could help you get on track. For more information on automatic lubrication systems, contact your local Motion Industries servicing branch. A University of Tennessee graduate, Chad Schwender is Corporate Accounts Industry Segment Manager, Cement & Aggregate for Motion Industries. He has worked in the industry for 26 years, including 16 at Motion. For more information, visit Motion Industries.com and Mi On-site Solutions (https://bit. ly/2OqxTYf).

SPECIAL REPORT which can enhance the learning experience. In one class, mineworkers actually got out of their seats and approached the projector screen to physically point out hazards they identified to the instructor. This interaction led to in-depth discussions about hazards: What is the difference between a safety hazard and a situation that is a potential MSHA citation? What are our site-specific safety policies, and how do those policies potentially differ from those at other mine sites? In addition, trainers were typically able to incorporate points brought up during the hazard search task into the debrief sessions. In all the sessions NIOSH researchers observed, trainers using EXAMiner included debrief sessions and provided mineworkers with feedback on the hazards they found and those they missed. Interestingly, in a majority of the classes, mineworkers spent time during the debrief session discussing additional potential hazards found in the images, as well as their own site-specific safety policies. As one example, the mine site depicted in the panoramic pictures did not have a specific chocking policy or glove policy, but several of the mining companies NIOSH observed did. Trainers noted all of the instances where mineworkers identified missing chocks and gloves and hazards, then discussed their site-specific policies relative to MSHA regulations, reasons why mineworkers should chock vehicles, and the gloves that are required for different tasks.

workplace, because they will not find hazards if they do not take the time to search. • Remind mineworkers to look beyond the obvious. The EXAMiner software includes a variety of hazards in the panoramic pictures. Some of the hazards are large and easily noticeable. For instance, there are hazardous situations that include haul trucks and front-end loaders that should immediately pop out at the mineworker. There are also smaller, more obscure hazards such as a damaged or missing step or handrail. During the NIOSH laboratory research study, these smaller, obscure hazards were missed more often than the larger, more noticeable hazards (see Figure 2). It is important to remind mineworkers and workplace examiners to look beyond the obvious when inspecting their workplace, because there may be other less apparent hazards present that require mitigation.

Availability of EXAMiner A beta version of the EXAMiner software will be available on the NIOSH Mining website (www.cdc.gov/niosh/mining/) on Dec. 1. NIOSH researchers are also evaluating the effectiveness of EXAMiner as a training tool. For further information, contact Brianna Eiter at beiter@cdc.gov. AM

NIOSH Disclaimer The findings and conclusions in this paper are those of the authors and do not necessarily represent the official position of the National Institute for Occupational Safety and Health, Centers for Disease Control and Prevention.

Changes you can make now

Based on observations of the use of EXAMiner in its beta version, we suggest the following when discussing what mineworkers and workplace examiners should keep in mind when searching their workplace for hazards. • Encourage mineworkers to slow down and take their time. EXAMiner keeps track of the time spent searching for hazards for each panoramic picture as feedback during the training session debrief. NIOSH chose to include search time with other feedback variables because the amount of time spent searching can have an impact on the number of hazards mineworkers and workplace examiners find during inspections. As ovation • Service • Customizat an example, NIOSH laboratory research ent • Quality • Inn i on Commitm study showed that less experienced mineworkers and mining engineer• Customizable to your exact aggregates dredge@dscdredge.com ing students searched for hazards 156 Airport Rd application and production requirements. for significantly less time than safety Reserve, LA 70084 • Outstanding service after the sale with +1-985-479-1355 professionals and found significantly www.dscdredge.com 24/7 technical support. fewer hazards. Therefore, it is importContact DSC Dredge to help you Follow us on: ant to remind mineworkers, especially make THE RIGHT CHOICE. those who are new and inexperienced, to take their time while inspecting their

CSC Dredge_AGRM1018pg15.indd 1

AGGREGATES MANAGER / October 2018

9/19/18 3:58 PM

EQUIPMENT MANAGEMENT by Debbie Townsley

Keep Your Skid Steer Rolling

Time spent on pre- and post-shift inspections reduces the likelihood of unplanned downtime.

Reduce downtime and maximize productivity with daily maintenance.

odayâ&#x20AC;&#x2122;s high-performance skid steer loaders can provide several productivity advantages on nearly any jobsite. However, these competitive advantages can be lost if a skid steer isnâ&#x20AC;&#x2122;t running at peak performance, and there are several things that equipment owners can do to improve productivity and extend service life. By taking the following steps each day during pre- and post-operation, equipment owners and operators can help to prevent bad things from happening,

AGGREGATES MANAGER / October 2018

reduce the likelihood they turn into costly downtime events, and ensure that fleet managers can address concerns in equipment health and upkeep at times throughout the day with the least impact on productivity.

Tires Tires are one of the most costly consumable components on a skid steer. There are, however, several basic maintenance items that can help fleet managers and equipment owners maximize tire life.

Check tread depth and work with your dealer to determine when the tires need to be replaced. Check the tires and rims, looking for any cuts, cracks, abrasions, or uneven wear on the tires. Improperly inflated tires can cause unnecessary wear and damage and can wreak havoc on total cost of ownership (TCO), so tire pressure should be checked daily. Tires should also be cleaned regularly, and any debris should be removed from the tread whenever possible/practical. It is often much easier to remove mud from

Checking filters and fluids are two simple ways to keep machines running efficiently.

the wheels, tires, and the skid steer frame right after operation rather than waiting until the next day. Irregular wear can be present for a variety of reasons, and the best way to minimize it is to follow the manufacturer-recommended rotation intervals.

compartment require room to breathe. It’s important to check and remove any clutter or jobsite material that may have found its way into the engine compartment. Allowing debris to build up in the engine compartment can cause overheating and other issues.

Fluid levels

Filters

Check fluid levels — engine and hydraulic oil, diesel and diesel exhaust fluid (DEF), and coolant. Fluids are the lifeblood of each machine and require specified levels to operate properly. A sudden drop in fluid levels may point to any number of problems with the machine that require immediate attention (blown hoses, leaking filter, etc.). Using OEM-spec engine oils helps to ensure that a machine will operate as efficiently as possible throughout its lifetime. It also ensures that the machine stays on the proper maintenance schedule for which it was designed.

Check the fuel, oil, air, and other filters for signs of damage or leaking. Filters are often a quick and easy item to replace — and operating with properly working filters can prevent any number of problems with the machine. Today’s machines are engineered to the highest performance standards — each machine is a highly engineered system of complex working parts, which should be maintained by only using genuine filters and lubricants to ensure continued optimal performance. Using non-OEM-specified filters creates a weak link in the system and can compromise the performance of a machine.

before it fails, the operator can communicate with the maintenance team to replace during scheduled downtime or the next preventive maintenance to ensure it doesn’t create unplanned downtime during the course of the work day.

Grease points

Engine compartment Clear any accumulated debris from around the radiator and other engine components. The engine is made of moving parts and belts that generate heat and friction — and systems designed to cool the engine

Identify greasing points and frequency. Every machine and every OEM is different — and keeping the machine properly greased is critical considering the power and friction created by these giant pieces of steel working together. It can also help keep out moisture and abrasive materials from the jobsite that can work into joints and friction points if not properly greased.

Check for leaks Check for leaking or pooled fluid around and under the machine. This is an easy indicator that something isn’t right. The source of that fluid should be identified and addressed/fixed before operation, and those fluids should be replaced.

Belts

Hydraulics

Check belts (alternator, fan, etc.). A worn and frayed belt is another wear item that is relatively easy to replace. If noticed

Check auxiliary hydraulic connections and pressure. Simply check the integrity of the coupling structure and that it hasn’t AGGREGATES MANAGER / October 2018

EQUIPMENT MANAGEMENT to use the control pattern that they are most familiar with. This will lead to greater productivity and greater operator comfort and satisfaction. Identify auxiliary/attachment controls. Each type and style of machine controls attachments differently — operators should identify how to properly work their attachment prior to attempting to use it.

Check console indicators/cameras

Post-shift inspections allow service crews to make any necessary repairs prior to the next shift.

been damaged. Newer equipment often includes pressure relieving quick disconnects — take the time to relieve the pressure when disconnecting attachments.

Structural damage Check for new signs of structural damage, scratches, or dents on the machine. This is almost more important post-operation than it is pre-operation. Once done for the day, noticing and identifying any damage to the machine ensures that needed repairs are made before the next shift starts and also allows the operator to identify how that damage occurred. Is there another structure on site that the machine came into contact with? Is there damage elsewhere on site that needs to be addressed? Similarly, if damage is noticed before a shift starts and it was not there when the operator inspected it the day before, that pinpoints that something happened overnight or that there was possible unauthorized use of the machine.

Attachments Check for damage on ground engaging tools (buckets, teeth, etc.). A machine’s performance is affected greatly by the efficiency of how its working tools engage with the material it is digging into and

AGGREGATES MANAGER / October 2018

moving. Worn or broken buckets and teeth lead to inefficient operation, greater fuel use, and greater wear and tear to the machine as a whole. Identifying and addressing these elements of the machine before they become problematic will make the operator more productive and efficient. Inspect the attachment mount-up to ensure proper connection. This includes checking that the coupler is flush and fully engaged (either via manual or automatic/ hydraulic means), and that the hydraulic hoses (and electrical connections, if applicable) are properly connected.

Inside the cab Inspect the operator compartment and clear away any debris or obstructions. Clutter can be distracting — and anything in the cab that ultimately prevents the full range of controls from being engaged is a hazard to operation. Check and set mirrors. This might seem obvious, but visibility is critical to jobsite awareness, safety, and productivity. Having mirrors set to the operator’s preference will make them a better operator. Familiarize yourself with the control style and change as needed. Most of today’s machine’s come with rather simple pattern selectors that allow the operator

Start the engine and review console indicators and warnings. Today’s machines are built to give the operator more feedback on the workings of internal systems than ever previously available. Take note of any flashing symbols or warning lights, check the owner’s manual, and consult with maintenance staff prior to operation. If equipped, check the rearview camera. Again — jobsite awareness and safety is paramount. If that rearview camera is otherwise obstructed or disabled, it handicaps the operator’s ability to have full awareness of the worksite around him/her. Finally, review all external surroundings from the cab. Know your work site and the people and structures that exist inside your working envelope. This will ensure optimal jobsite safety and productivity.

Proper maintenance = profit Equipment manufacturers have introduced several innovations over the years to simplify maintenance procedures and extend the service life of skid steer loaders. However, the overall health and longevity of a machine often comes down to daily and weekly maintenance procedures. The operator and other jobsite personnel are often the first line of defense against costly equipment downtime, so it is critical for owners and operators to follow maintenance best practices to ensure that their skid steer loaders contribute to a safe and productive operation, and a strong bottom line. AM Debbie Townsley is product marketing manager, skid steer loaders and CTLs, for Case Construction Equipment.

OPERATIONS ILLUSTRATED By Nathan Medcalf, Contributing Editor

Process. Test. Repeat

Quality control trumps production.

Automation is a big part of a modern quarry’s quality control program.

OUR EXPERTS

Testing samples at different points of the operation strengthens total quality control.

John Crawley has spent the last 13 years in Quality Management with LafargeHolcim. As the technical services manager, aggregates, in the Great Lakes region, Crawley is responsible for the quality and material performance of approximately 14 million tons of aggregate annually.

Ensure aggregates meet product specs by employing rigorous quality control measures.

Dwayne McKenzie serves as director of sales for Nelson Aggregates. A 25-year industry veteran, he began his career with a familyowned company, learning the industry from the ground up, prior to moving to Walker Industries’ Aggregate division. McKenzie joined Nelson Aggregates five years ago.

Adrian Field is founder and president of Stonemont Solutions, Inc. The company develops quality control software for the construction materials industry that is widely used across North America. Field has a bachelor’s degree in geology from Bloomsburg University and a master’s degree in hydrogeology from Wright State University.

AGGREGATES MANAGER / October 2018

When it comes to production, quality is king

uarries only make money if they are producing material, so production only gets shut down for really important reasons, such as quality control. If a product is out of spec, it’s no longer marketable. Therefore, when a quarry is producing aggregate that doesn’t meet specifications, it’s no longer paying the input costs to make money from product sales, it’s paying to lose money. Depending on the product application and location, there are several specifying agencies that govern product quality, specifications, tests, and methods, including state departments of transportation, turnpike commissions, FAA, ASTM, and AASHTO. “Our laboratories perform quality control testing on both production and shipping materials at specific intervals. This process assures that materials being produced meet specification, or that materials not meeting specification are handled in a way that doesn’t impact the customer. Quality control testing also helps us identify potential changes we need to make to the production process to maintain product specifications,” says John Crawley, technical sales manager, aggregates, LafargeHolcim. “All quality assurance/quality control data is maintained in a central database. We perform regular statistical analysis of the test data to identify trends and provide customers with detailed information regarding the product we have supplied.” “Quality control trumps production,” says Dwayne

McKenzie, director of sales, Nelson Aggregates. “If production is out of spec, it gets shut down until we find out why aggregate is out of spec, whether there is a hole in a screen or the crusher needs to be tightened up or opened up a little more.” In this case, production and quality control work together to resolve the problem, and production resumes only once that happens. To improve its quality control program, the company recently upgraded its quality control technology by incorporating the StonemontQC software system. StonemontQC provides statistical summary and charting tools, which can be used to assess the performance of current results against historical data and detect potential issues before they become customer problems, as well as provide dynamic crusher modeling capabilities that can improve the ability to run “What If” scenarios, because the model isn’t limited to static gradations. “The ability to graph the results and look for trends over time to see how you are performing relative to targets/specifications is a very powerful tool,” says Adrian Field, founder and president, Stonemont Solutions, Inc. “You want to look to see if you are trending out of target/specification. For example, perhaps you are having a process change in the material that is causing your samples to trend away from target/specification. The sooner you can catch that the better. Graphs help you see these trends — before your product becomes a problem.”

Tweaking the system

Producers have a number of available options to impact the quality of the operation’s finished product. Everything from extraction to loadout can be tweaked to maintain a high level of quality and ensure that products are within specification. Is there a hole in the screen? Is the crusher overfed? Are machines set up properly? These are all questions that operations have to consider when quality control says product is out of specification.

AGGREGATES MANAGER / October 2018

Quality control is king

When quality control determines that a sample is not within specification, all of production shuts down until operations determine the cause of product being out of specification. Many variables can influence quality control, but quarries can turn to insights gained from their quality control department to determine the underlying reason why a product is out of specification.

Crushing to design

Designing to the crush means privileging the influences of circumstantial and environmental conditions over desired results. Crushing to the design means tweaking processes and equipment at the production stage so that your products are within specification. This allows for the best aggregate products imaginable.

Predictive problem solving

By charting results, an operation can see patterns and trends that will allow it to not only identify problems in product quality, but also to predict potential problems in the future. By automating certain features of quality control, such as report creation, quality control managers can spend more time on other tasks that improve aggregate quality.

AGGREGATES MANAGER / October 2018

Voices of Experience John Crawley

Dwayne McKenzie

Adrian Field

“O

ey to LafargeHolcim’s quality control strategy is to keep quality control in-house and to make it site-specific. “By maintaining internal quality management systems and site-specific quality control plans, we are able to address specific needs from both the quality assurance and control perspectives,” says John Crawley, technical sales manager, aggregates, LafargeHolcim. “Quality assurance occurs in the production process. Every aspect of production is performed in a manner which best assures the finished products will meet specifications.” All the data from tests adds up and can reveal trends and other long-term insights. “We perform regular statistical analysis of the test data to identify trends and provide customers with detailed information regarding the product we have supplied,” he explains, noting that testing samples at different intervals, including production and shipping, helps strengthen total quality control. “Quality control testing also helps us identify potential changes we need to make to the production process to maintain product specifications.” If quality control flags a sample as being out of specification, the production team can make changes to the equipment or the process to get back into spec. “Our crushed limestone plants have many levers available to them which impact the quality of the finished product at the site,” Crawley says. “Everything from extraction to load-out can be ‘tweaked’ to maintain a high level of quality. The fractionated plants have the great advantage of being able to blend individual fractions to satisfy a particular specification. Our natural sand and gravel sites have a different challenge, as they are often at the mercy of the natural deposit. However, these sites do a great job of blending and processing material, applying quality assurance and quality control standards to supply in-spec material to our customers.”

AGGREGATES MANAGER / September 2018

elson Aggregates maintains a certified lab staffed by certified lab technicians on site at each of its five quarries in order to ensure that all the aggregate being produced meets quality and regulatory specifications. “We take multiple production samples each day of everything that we do at each quarry,” says Dwayne McKenzie, director of sales, Nelson Aggregates. “Then we do shipping samples. So, as we are shipping the product, we take random samples to ensure shipping samples match production samples.” If there is any discrepancy between the two samples, the company has to investigate the cause of the discrepancy. “If a sample comes back out of spec in production, they shut it down and do a screen check or to see what the cause of the product being out of specifications,” Mckenzie says. “If we have an issue with oversize in a product, for example — let’s say all the aggregate is supposed to be 1-inch-minus, but aggregate 1.5 inches is found in the production, we would first look to see if there is a hole in the screen, because the sizing screen separates the material and only lets the right-sized material through. “Or, are we carrying too much on the screen deck, and it’s blinding because we are overfeeding it. There’s a bunch of different reasons you can be out of spec,” he says. “Our operation staff have a lot of experience and can easily determine the cause based on the information that quality control gives them.” Quality always takes precedence, McKenzie notes. When aggregate is found to be out of spec, production is shut down in order to determine the cause, whether it lies with a crusher setting or is due to a hole in the screen media. “Production works closely with quality control to get it back in spec, and production only proceeds once it gets a green light from quality control,” he says.

ur view is that, in order for a producer to have great quality control of their aggregates, they need a robust quality control management system that provides user-friendly data entry, and timely and easy access to information so that they can make informed decisions,” says Adrian Field, founder and president, Stonemont Solutions, Inc. Data must be able to be analyzed and presented in a variety of different ways, including different statistical, graphical, and reporting techniques. Automation, including interfaces to lab balances and other systems, email alerts, and automatic analysis and reporting improves the timeliness and ease of access to information. “Quality control data can represent a lot of different test results — and depending on where you’re located and what type of material you are producing — you will have a variety of different tests. Those tests may have different specifications or different targets, which are basically internal specifications set by the producer,” Field says. “If you are entering a result, you can get real-time feedback via an email alert as to whether that is meeting those targets/ specifications. A lot of our data, whether an individual test result — or a group of samples — get compared to targets/specifications, outlining how it performed, and then the software summarizes all that data into statistical summaries.” Another tool is the ability to graph the results and look for trends over time to see if an operation is performing relative to targets/specifications. The trend perspective allows an operation to see if it’s moving away from its specification goals and take action sooner rather than later. Observing such trends and making the appropriate operational changes needed allows an operation to avoid production of out-of-spec material all together, one of the most significant benefits to such analysis.

Get the the most current information with the 2018 Aggregates Industry Atlas and the Atlas Download. While the printed version of the Aggregates Manager 2018 Aggregates Industry Atlas will become an integral part of doing your job, donâ&#x20AC;&#x2122;t forget to order your copy of the Atlas Download to see additional information about companiesâ&#x20AC;&#x2122; mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more.

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Quarries and property values Equipment investment continues to climb The final Workplace Exam Rule

TECHNOLOGY by Jason Nichols

Drones and

Data Mining Operators are finding that use of drones can allow them to collect inventory data faster, more accurately, and more often.

Drone data can help operators overcome common challenges in three simple ways.

ouâ&#x20AC;&#x2122;d be hard-pressed to find an executive at an aggregates or mining company who is a stranger to the challenges of building an accurate forecast and managing inventory. Inaccurate or limited survey data is a common problem and could be a major hindrance to companies in what is otherwise looking to be a period of opportunity over the next few years. Inaccurate, limited data can restrain companies from achieving their maximum profit and delay forecasted company growth.

AGGREGATES MANAGER / October 2018

Market is poised for growth The U.S. aggregates market is expected to grow at a CAGR of 2.76 percent during the 2018-2022 period. This growth is largely being driven by an increase in housing construction, as the North American housing market continues to recover. These are very promising signs for aggregates companies, but this anticipated increase in demand means that companies will need to take proactive steps to best position themselves to take

full advantage of this opportunity. According to Ernst and Young, digital technology solutions are one important avenue that companies can take to overcome common challenges in the industry. But it’s also important for businesses to focus and prioritize so they are using new technologies to solve their most strategic challenges first.

some survey systems can require specialized training or take a lot of time to run, which only promotes even fewer inventory cycles each year. As a result, managers are left with a view into only small snapshots in time.

The technologydriven alternative

It’s clear that if aggregates companies want to address these challenges, they have to augment their traditional survey methods with new Strategic technologies that will challenges help them identify flawed Accurately assessUse of drones lowers the amount of foot traffic in dangerous areas, keeping workers safe. processes and potential ing production levels problems before they against forecast occur, not after. “That’s the nature of our business — always models is at the top of the challenge list for many aggregates trying to find the cutting-edge, to lower our cost at all times, businesses. With traditional survey methods, most forecasts and we want to do it in a safe manner,” says Murray Kline, vice rely on low visibility data with limited accuracy, and the conpresident of operations at APAC Central - Oldcastle. sequences can be significant. One promising solution is unmanned aerial systems, or Traditional surveys, often performed quarterly and drones. Drones are well suited to the dynamically changing sometimes even as infrequently as annually, tend to result in and dangerous environments often found in mines, allowing inaccurate and limited data. As a way to get more accurate, for more frequent and accurate collection of inventory data. companies will often deploy mixed survey methods, using a With drone technology, companies can gather larger datasets combination of manual, base/rover, and manned aerial flight surveys. This combination of approaches can add another layer faster and more often. This paves the way for managers to more easily identify trends and make decisions. of complexity and inconsistency when performing audits and regular inventory assessments. The manual methods used by aggregates companies norThree reasons why drones make sense mally consist of a worker (or several workers) physically walk1. Improves inventory data accuracy and reliability: First ing around a site to take measurements. It’s well documented and foremost, datasets gathered from drones are provthat accuracy suffers when using manual survey methods to en to be more accurate and reliable, providing busimeasure inventory volumes of complex stockpiles, often acnesses with a much clearer picture of actual inventory counting for just 75 to 85 percent of the true pile volume. and positioning managers to make informed decisions. When using manual survey methods, it’s not just project Drone platforms have been shown to deliver measuretimelines and profitability that are at stake. The aggregates ment accuracy of between 97 and 99 percent of true industry has inherent dangers, but the danger is increased volume, a level that traditional survey methods simply significantly when workers are walking around high-risk areas cannot consistently match. of the site such as highwalls, stockpiles, haul roads, and stockThe financial benefits of this level of accuracy are yards to perform surveys. The risks of potential litigation and clear. Companies will realize cost savings from less increasing insurance premiums are both higher, but manual material degradation by having a better pulse on their methods also put the company’s most valuable assets, their real inventory levels at any time. They can also reduce employees, at physical risk. labor costs, as they will no longer need to rely on In addition to risk, the sample sets produced by tedious, workers spending hours of time manually walking a time-consuming manual surveys produce limited data, making site to take measurements. Drone technology can be it a challenge to extrapolate out to the “big picture” and make operated by a single employee, and an entire 150-acre operational and financial decisions with confidence. Cumbersite can be scanned in just 30 minutes. AGGREGATES MANAGER / October 2018

TECHNOLOGY aggregates companies can forecast more accurately, as well as report against those forecast models to understand real performance. Drone technology can streamline the entire survey process, allowing companies to gather accurate inventory data more regularly and confidently report production levels to auditors and shareholders — all while keeping employees safe. Companies that are already deploying drone technology on-site say that they are realizing game-changing results. They report that they can make more strategic business decisions by having a more reliable, up-to-date picture of their inventory. “Bottom line, it’s just about getting the right information — and more information — just when we need it, instead of waiting for a manned aerial survey,” says Jim Gawthrop, vice president of York Building Products. These early adopters are maximizing profits and minimizing loss and risk in ways that are unprecedented with traditional survey methods. AM Drone platforms have been shown to deliver measurement accuracy of between 97 and 99 percent of true volume.

2. Increases frequency and consumption of data reporting: The ease of deploying and collecting measurements via a drone platform will mean that companies are no longer limited to painstakingly capturing data only a few times a year. Drones allow aggregates companies to collect data more regularly, while also gathering more robust inventory reports across multiple sites. Managers can easily capture accurate, reliable data often enough to identify patterns and make intelligent forecasts. This, in turn, helps companies eliminate missed revenue opportunities and improve customer relationships by increasing the percentage of properly-filled and on-time orders. With improved dataset consistency, aggregates companies will be able to identify inventory issues immediately, so they aren’t placing orders or making important decisions based on inaccurate inventory levels. And drone systems are easily scalable across an organization, providing a single source of standardized inventory information to be used by all divisions. 3. Protects workers: Worker safety is also greatly improved through the use of drones. By using unmanned aerial systems, companies reduce on-site foot traffic, especially in dangerous areas, so risk to workers — and the insurance premiums that accompany high-risk job sites — is reduced. Drones also allow for better site planning, meaning that traffic routes can be improved, haul roads and stockpile locations can be optimized, and emergency egress routes can be planned efficiently. Companies can use drone survey data to identify hazardous areas before they become a problem, reducing liabilities and creating a safer work environment in an already-tough industry. Drone technology has the ability to provide fast, safe, and deep insights into real-time inventory levels, so that

Jason Nichols is a product marketing manager at Kespry. Prior to joining Kespry in 2016, he worked as a product specialist for Topcon Positioning Systems. Nichols is also a professional geologist in the state of California and worked for 10 years as an engineering geologist, where he performed geologic surveys and generated topographic maps for quarries, mines, and construction sites.

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

Services Offered: Applied geology and geological research for construction rocks and minerals, with an emphasis on aggregates. • Resource evaluation • Expert testimony

• Technical writing and review • Lecturer

Contact me at:

Bill-Langer@researchgeologist.com www.researchgeologist.com AGGREGATES MANAGER / October 2018

BillLanger_AGRM0115.indd 1

12/14/16 8:54 AM

by Benjamin Ross Patrick W.J.Dennison

ROCKLAW ALJ Appointment Errors and Opportunities Lucia and Jones Brothers indicate rehearings are possible, but are they worthwhile?

Benjamin J. Ross is an associate in Jackson Kelly PLLC’s Denver office where he practices in the Mining Law industry group, focusing primarily on litigation and workplace safety and health. He can be reached at 303-390-0026 or bross@ jacksonkelly.com.

ecent decisions issued by the United States Supreme Court in Lucia v. SEC, No. 17-130, 2018 WL 3057893 (U.S. June 21, 2018) and the Sixth Circuit Court of Appeals in Jones Bros., Inc. v. Sec’y of Labor, No. 17-3483, 2018 WL 3629059, at *8 (6th Cir. July 31, 2018) have held that administrative law judges (ALJs) in the Securities and Exchange Commission (Lucia) and the Federal Mine Safety and Health Review Commission (FMSHRC) (Jones Brothers) were originally appointed incorrectly under the appointments clause of the Constitution. The courts found that the remedy for parties with cases decided by these ALJs was a new hearing before a different, properly appointed ALJ. On April 3, 2018 (after Lucia but before Jones Brothers), the FMSHRC released a notice that the entire Commission had properly ratified the appointment of all its ALJs. Commission Ratification Notice, https://www.fmshrc.gov/about/news/ commission-ratification-notice (Apr. 3, 2018). Although Lucia and Jones Brothers may suggest an interesting opportunity to challenge past decisions that a mine operator disagrees with, this opportunity has a potentially rocky and costly path which may not net significant gain and could present the potential for greater loss. An operator can challenge the proper appointment of a FMSHRC ALJ in any case that was heard before the April 3, 2018, ratification and is presently on review before the FMSHRC. Of the 15 cases currently on review before the FMSHRC, ALJs decided 13 of those cases before

AGGREGATES MANAGER / October 2018

the FMSHRC ratified their appointments. The FMSHRC may refuse to hear the issue if it was not preserved in the proceeding before the ALJ. However, the mine operator in Jones Brothers did not raise the issue before the ALJ, nor did it fully brief the issue before the FMSHRC. Notwithstanding, the Sixth Circuit excused the forfeiture of the argument given its novelty and lack of case law on the appropriate court to hear the argument. If a case is pending review before a U.S. Circuit Court of Appeals and was decided prior to April 3, 2018, the appellant may attempt to raise the argument before the court. However, another Court of Appeals may decide differently than the Sixth Circuit and may fail to excuse any forfeiture of the issue if it was not raised below. In cases already decided that have become final, the opportunity for a new hearing narrows unless the operator can convince the FMSHRC or a Circuit Court of Appeals to reopen the case based upon an appropriate basis for relief from a final order, such as an argument that the judgement is void or because of mistake, surprise, or excusable neglect. For a case heard after the April 3, 2018, ratification, an operator can only assert a challenge if it convinces a court that the FMSHRC’s ratification was invalid (Jones Brothers did not suggest this) or that the assigned ALJ issued an order before April 3, 2018 (this may include an order on a motion for summary decision or even a prehearing order) that allows an appointments clause claim.

In the interim between the Supreme Court’s decision in Lucia and the Sixth Circuit’s Jones Brothers decision, the Solicitor General issued guidance regarding appointments clause claims and appointments of ALJs, setting forth recommendations for handling pending proceedings. Guidance on Administrative Law Judges after Lucia v. SEC (S. Ct.), https://static. reuters.com/resources/media/editorial/20180723/ALJ--SGMEMO. pdf. The undated memorandum advises that the Department of Justice “will seek voluntary remands of matters pending in federal court in which an invalidly appointed ALJ participated.” The Department of Justice, however, will only seek a request for remand in pending matters where the appointments clause challenge to the ALJ was timely raised in accordance with agency procedure. Under FMSHRC procedure, the issue must be raised before the ALJ. It is within the FMSHRC’s discretion whether to follow this guidance. Ultimately, if the FMSHRC finds that Jones Brothers allows mine operators to preserve a late challenge to an improperly appointed ALJ, it may order a new hearing before a different ALJ for those cases on review. The process that ALJs must follow in a new hearing is unclear. Agencies may order that the new ALJ conduct an entirely new hearing or require the ALJ to rule upon the record previously developed before the improperly appointed ALJ. Alternatively, the FMSHRC may consider the parties’ arguments as to what

procedure is appropriate. If the FMSHRC does not specify a process on remand, the ALJ may simply decide how to proceed. A mine operator considering such a challenge should be aware that each of the avenues discussed above requires the cost and effort of filing motions and arguing issues of law before the FMSHRC or the appellate court. If a mine operator’s challenge is successful, it will then possibly incur costs to conduct a new hearing. Numerous challenges come with a new hearing, including the cost associated with legal fees, witnesses not being available or missing work for hearing, and the possibility that the new ALJ issues the same or worse decision. As well, during a new hearing, witnesses’ memories may have deteriorated, and the case could be difficult to retry. Although Lucia and Jones Brothers offer novel theories to explore, they do not guarantee success to a mine operator, and they certainly will require effort on the part of the mine operator. Moreover, it is unclear when mine operators will have the opportunity to resolve their claims. The terms of Acting Chairman Althen and Commissioner Cohen expired at the end of August 2018. Their departures leave the FMSHRC without the necessary quorum to decide cases. Thus, after August 2018, the FMSHRC cannot decide cases until the President properly appoints, and the Senate confirms, at least one new Commissioner. AM

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ADINDEX October 2018 Advertiser

Web

ABB Motors & Mechanical

baldor.com

Atlas

store.randallreilly.com

BKT USA Inc.

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DSC Dredge

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Elrus Aggregate Systems

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IFC

HCEA

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Hyundai

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Kruse Integration

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Motion Industries

motionindustries.com

NAI CIR

naicir.com

Progressive Commercial

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Rice Lake

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Statement of Ownership topbid.com

Trimble

trimbledimensions.com

World of Asphalt

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9 BC 31

Top Bid

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Page

26 IBC 7

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NAI CIR_AGM1018_PG.indd 1 PS Form 3526-R, September 2007 (Page 1)

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19649

19298

12417

12551

198

207

12615

12758

6456

6051

294

6750

6115

19365

18873

285

425

19650

19298

65.14 %

67.60 %

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

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

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

0.00 %

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d. Percent Paid and/or Requested Circulation (Both print and Electronic Copies) I Certify that 50% of all my distributed copies (Electronic & Print) are legitimate requests.

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CARVED IN STONE

Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at Bill_Langer@hotmail.com

Rocks – The Oldest Storytellers Dating back to the Miocene age, these rocks tell the story of how they were made.

en years ago, I wrote a series of articles about Rocky, a gneiss (pronounced nice) from a quarry near Morrison, Colo. Two of those articles (Rocky VII and Rocky XII) were written by Rocky himself. I still listen to stories the rocks tell. The exit from the Interstate to our neighborhood cuts through a rocky knob and exposes a very interesting sequence of rocks. Cars zoom along the exit ramp, so I have never stopped to closely study the rocks. Even so, the rocks tell me their story as I drive by. The rocks are Miocene age — in this area probably 15 to 25 million years old. The rocks say that, back in the Miocene, the landscape looked like a lush East African savanna. Various mammals including prehistoric dogs, camels, horses, deer, and giant rhino-like critters wandered the landscape, and a variety of snakes, turtles, and lizards slithered around. The light-colored rocks at the bottom of the road cut tell me they are volcanic rocks, referred to in general as felsic rocks. They say that, more specifically, they prefer to be called tuff. (To explain, saying felsic is like saying fruit; saying tuff is like saying apple or banana.) The tuff rocks were made from magma (molten rock) ejected from a volcano as ash, like what came from Mount St. Helens in 1980. The dark-colored volcanic rocks overlying the tuff say they are referred to, in general, as mafic rocks. They add that, more specifically, they are basalt made from magma ejected as lava, like that currently flowing out of Kilauea Volcano on Hawaii. In addition to color, the words felsic and mafic describe the minerals in the rock. Felsic rocks contain light-colored and light-weight minerals rich in feldspar (fel) and silica (si); hence the name felsic. Mafic magmas are rich in dark-colored, heavy minerals containing magnesium (Ma) and iron (Fe); hence the name mafic. Viscosity, a liquid’s resistance to flow, determines how magma will behave during an eruption. The more silica in the magma, the higher is its viscosity. Felsic (silica-rich) magma is viscous and does not flow easily. When it rises into a magma chamber, it may be too viscous to move and plugs the chamber vent. Dissolved gases become trapped by the magma and pressure builds up. Eventually, the pressure becomes so great that the magma chamber explodes. Magma, rock, and ash erupt, creating a cloud of volcanic ash. The ash falls to the ground and cools into a rock called tuff. That is how the white rock in my road cut says it was formed. In contrast to felsic magma, mafic magma is not viscous and will flow easily to the surface through volcanic vents. From there, the lava flows across the land surface and cools to become basalt. So, the story the rocks tell me is that, back in the Miocene, lighter weight, viscous felsic magma floated to the top of a magma chamber. Pressure built up, and the magma exploded, spewing ash into the air. That ash fell to the earth and cooled into tuff. With the light-weight felsic magma being gone, the heavier mafic magma rose to the surface and oozed out as lava and cooled into basalt. Someday, you should listen to the rocks in your quarry, pit, or nearby road cut. What you hear might be wrong, just like the story I heard from the rocks at 60 miles per hour might be wrong. But who cares. There’s no harm in story-telling! AM

AGGREGATES MANAGER / October 2018

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