Aggregates Manager October 2019 by Sandy Turner Jr

Abrasive material PG19

Your guide to profitable production

Classification systems PG24

CERCLA bonding PG28

October 2019 | www.AggMan.com

Aggregate Resource Industries

takes on remote-control drilling

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John Deere’s new L-Series wheel loaders offer upgrades in operator comfort and horsepower while reducing fuel consumption.

PAGE 7

On Our Cover: Kris and Katie Jeremiah put remote control drilling to the test in North America. Cover photo courtesy of Epiroc.

An automated classification system such as this one has no moving parts and requires minimal maintenance.

PAGE 23

TABLE OF CONTENTS OCTOBER 2019 |

VOLUME 24, NUMBER 10

FEATURE ARTICLES

12 Predictable Productivity

Smart drilling sets a benchmark in safety while providing data key to success for Aggregate Resource Industries.

23 Does Your Classification System Make the Cut? Classification systems pose a challenge for predictive maintenance. This primer explains how to keep materials in spec with both wet and dry processing.

COLUMNS & DEPARTMENTS 3 Editorial Do penalties improve safety? 4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook. 7 RollOuts Powerscreen launches the Premiertrak 330, and other new equipment for the aggregates market. 28 Rock Law A decade after being pushed to propose a bonding rule, EPA wins the right to stay out of the hard rock mining business. 30 Advertiser Index See who’s who and where to find their products.

OPERATIONS ILLUSTRATED

Design for Durability

When working in abrasive stone, special consideration must be given to stationary and mobile equipment alike.

31 Classified Ads Aggregates industry classifieds. 32 Carved in Stone Got rocks in your head? Trace minerals such as iodine, zinc, and boron ensure essential brain functions.

THE RIGHT CRUSHER FOR YOUR OPERATION.

From Reduction to Shaping Your ability to turn virgin material and waste product into high quality aggregates requires equipment with unmatched power and precision. From reducing shot rock to sizing and shaping fine sand, we design and manufacture the most versatile and efficient crushers. Not sure what you need? Let our experts partner with you to apply the ideal solution.

Visit kpijci.com to learn more.

Let legislators know you support increased highway spending. Send them a letter at dontletamericadeadend.us KPI-JCI and Astec Mobile Screens

Astec Industries Companies

700 WEST 21ST STREET • YANKTON, SD 57078 USA • 800.542.9311 • FAX 605.665.8858 • kpijci.com

October 2019

EDITORIAL

Vol. 24, 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

Do Penalties Improve Safety?

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, Audience: Linda Longton Senior Vice President, Acquisitions & Business Development: Robert Lake 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 2019. 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.

hroughout my years covering the industry, I’ve seen a number of variations of the carrot and the stick approach to safety. Some Mine Safety and Health Administration (MSHA) leaders have opted to denigrate the validity of safety training in the industry. Others have improved partnership programs and educational programs to help operators improve safety. In recent years, the Civil Monetary Penalties (CMP) program has been used to financially penalize operators for safety hazards. From 2000 to 2017, more than $1 billion in violation penalties have been issued, and the agency has collected approximately 90 percent of those penalties. What hasn’t been known, until recent weeks, was whether those financial disincentives had any impact on operator behavior. A new report from the Office of the Inspector General (OIG) sheds light on this question. “Our data analysis showed no correlation between penalties paid and the safety of mine operations. Specifically, the data revealed most fatal or permanent injury accidents occurred at mines where operators paid almost all of their penalties assessed,” the Aug. 16 OIG audit reports. “Additionally, we found no correlation between the percentage of penalties paid and the average number of fatal or permanent injury accidents. Further, the frequency of severe violation recurrence was very similar whether or not violation penalties were paid. “The CMP program is intended to protect miners by financially penalizing mine operators for safety hazards found during inspections… Without metrics, MSHA has not been able to ensure CMP was achieving its intended purpose.” I find it particularly interesting that the OIG report notes that the highest average number of severe accidents occurred at mines where operators paid more than 99 percent, but less than 100 percent of their penalties. It’s also worth emphasizing that a comparison of repeated severe violations showed nearly even results between operators who did and did not pay the penalties (see bar chart). It’s difficult to review this data and believe that punitive penalties are having the desired effect. As it reviews its approach to safety, perhaps carrots should be a larger part of MSHA’s mix, with a greater focus on training and education. And perhaps, rather than pocketing unproven financial penalties, the agency should direct operators to invest some of those dollars in safety programs. AM AGGREGATES MANAGER / October 2019

mining

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

Diesel Fuel

Prices 9/9/19

United States $2.971 One Week -0.005  One Year -0.287

New England $3.022 One Week +0.005  One Year -0.233 

Central Atlantic $3.161 One Week -0.017  One Year -0.246 

Lower Atlantic $2.871 One Week -0.003  One Year -0.260 

Midwest $2.864 One Week -0.010  One Year -0.330 

Gulf Coast $2.745 One Week +0.005  One Year -0.294 

Rocky Mountain $2.933 One Week +0.009  One Year -0.434 

West Coast $3.548 One Week -0.007  One Year -0.198 

West Coast less California $3.131 One Week -0.008  One Year -0.334

California $3.878 One Week -0.007  One Year -0.091  Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).

52-Week High

$3.95 

$2.82

$7.32

CRG

$33.71 

$23.98

$34.29

EXP

$84.64 

$57.00

$93.18

Granite Construction Inc.

GVA

$29.29 

$26.57

$58.93

HEI

$73.81 

$57.27

$81.21

HCMLY

$9.59 

$7.96

$10.63

Martin Marietta Materials, Inc.

MLM

$253.10 

$150.75

$264.39

MDU Resources Group, Inc.

MDU

$27.53 

$22.73

$27.82

Summit Materials

SUM

$22.08 

$11.25

$22.50

United States Lime & Minerals, Inc.

USLM

$74.13 

$68.20

$85.85

U.S. Concrete

USCR

$46.61 

$27.68

$54.95

Vulcan Materials Co.

VMC

$142.06 

$82.52

$145.53

Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 9/9/19.

COMPANY SPOTLIGHT

East Coast $2.992 One Week -0.008  One Year -0.254 

52-Week Low

Eagle Materials Inc. HeidelbergCement AG

U.S.

Current Value

CRH plc

LafargeHolcim Ltd. ADR

On-Highway

Ticker

ulcan Materials Co. (VMC) reported revenue of $1.3 billion, a 10.6-percent increase, for the second quarter ended June 30, 2019, compared to the second quarter of 2018. Net earnings were $198 million, up 24 percent from the prior year. Double-digit growth was driven primarily by a 16-percent increase in the gross profit of the Aggregates segment. “We continued to execute well. Our industry-leading unit profitability in aggregates increased from $5.16 to $5.74 per ton, an 11-percent increase compared to the prior year’s second quarter,” said Chairman and CEO Tom Hill, in a news release. “We remain keenly focused on creating long-term value by compounding our aggregates unit margins, while continuing to operate safely. Shipment growth in the quarter was solid and consistent with full-year expectations. Importantly, price improvements were widespread.” Second quarter segment Vulcan Materials Co. (VMC) sales increased 11 percent, and gross profit increased 16 percent to $329 million. For the quarter, aggregates shipments increased 4 percent year-over-year, and freight-adjusted aggregates pricing increased 5.9 percent. All of the company’s key markets reported yearover-year price growth. According to Vulcan, underlying fundamentals of increased public funding for highways, along with employment and population growth, helped drive shipment strength across its footprint, particularly in the Southeast and Mid-Atlantic. Weather delayed shipments in Illinois, Tennessee, and Texas, while California overcame wet weather to achieve shipment growth compared to the prior year. During the quarter, Vulcan made capital expenditures of $64 million of core operating and maintenance capital to improve or replace existing property, plants, and equipment. It invested an additional $40 million in internal growth projects to secure reserves, develop new production sites, and enhance its distribution capabilities. Its full year expectations are to invest $250 million on maintenance capital and $200 million on internal growth projects. “Overall demand growth in Vulcan markets remains healthy,” Hill said, noting that state-level transportation funding increases signed into law during recent years have led to new highway construction starts that are 21 percent higher than two years ago. “Public demand, led by highways, continues to be robust across our footprint. Current shipments into private construction end markets continue to benefit from the ongoing economic recovery.” Source: Market Watch

Data

STOCK REPORT

AGGREGATES INDUSTRY OUTLOOK The Aggregates Industry Outlook results plunged in September to an overall score of 125.56, even as the stock prices of many publicly held companies bounced back from August setbacks. Near-term sales seem to be the underlying cause: the most significant drop in this month’s results is seen in quarterly sales expectations, which are down 12.2 percent compared to August results. Monthly sales trail just behind, down 11.4 percent compared to August.

Aggregates Industry Outlook 150 138.10

145 140

130.68

135 130

137.57

136.42 143.33

127.22 136.65

136.11

125

132.64

120

125.56

125.00

115

120.20

110 105 100 Oct. 2018

Nov. 2018

Dec. 2018

Jan. 2019

Feb. 2019

Mar. 2019

Apr. 2019

May 2019

June 2019

July 2019

Aug 2019

Sep. 2019

While current sales remain steady, customers are reporting the market for sand, road base, and asphalt is starting to soften with variation of “soften” by region. — 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 Type of Construction (Private)

% change July 2019- June 2019

% change July 2019- July 2018

7/1/2019

6/1/2019

Residential

512,777

509,560

0.6

-6.6

Non-residential

776,017

778,511

-0.3

0.1

Office

78,943

78,862

0.1

6.0

Commercial

82,552

85,070

-3.0

-16.5

Health Care

44,761

44,278

1.1

5.5

Educational

90,845

89,878

1.1

-4.6

Transportation

56,179

56,755

-1.0

5.2

Power

99,518

99,235

0.3

0.1

Highway and Street

97,314

100,037

-2.7

2.3

Sewage and Waste Disposal

27,848

27,253

2.2

19.2

Manufacturing

72,491

71,149

1.9

3.3

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

Loader increases operator comfort, seat belt alerts John Deere’s new L-Series wheel loaders, including the 744L, 824L, and 844L, offer an upgrade in operator comfort, higher horsepower, and reduced fuel consumption. The standard premium cab offers 3 more inches of legroom and storage space behind and next to the seat, compared to the K-Series. The new seat has heating and ventilation, as well as seat pan and tilt adjustment. The cab door is 79 percent wider at the floor compared to previous models, allowing for easier entrance and exit. Standard joystick steering helps to improve cab room (a steering wheel is available as a field kit). A dedicated steering pump provides quicker hydraulic cycle times for combined functions. All new electrohydraulic controls include several new features: a soft stop feature allows the boom or bucket to gradually stop, cylinder snubbing gradually slows cylinders near the end of stroke, and programmable return to dig can be activated with the bucket dumped out or rolled back. The new machines have up to 9 percent more horsepower and lower fuel consumption than their predecessor. For example, the 844L Aggregate Handler boasts 429 horsepower with a 7-percent reduction in fuel consumption. A new seat belt minder system sets off a Diagnostic Trouble Code if the operator fails to use the seat belt for 60 seconds, with an alert sent to the machine owner. Finally, a factory-installed auto-lube system ensures automatic greasing takes place while the machine is in operation for more effective grease distribution.

John Deere | www.johndeere.com

Crusher designed to minimize material build-up Powerscreen launches the newest addition to its range of crushers, the Powerscreen Premiertrak 330. Fitted with a large, fixed hopper and manufactured with a 5/16-inch wear plate, it is designed to improve set-up time, reduce pegging, and increase the life of wear parts. The hydrostatic drive allows reversibility of the chamber, meaning the machine can unblock and run in reverse, allowing easier crushing of certain materials. In addition, a low engine speed improves fuel consumption and lowers noise emissions. A two-piece grizzly feeder, with angled second section, is said to create a better material flow toward the crushing chamber and prevent bridging. The 40- by 24-inch jaw chamber can produce up to 308 tons per hour. The unit comes with the Pulse Intelligence system, a remote monitoring and fleet management system, as standard. Powerscreen | www.powerscreen.comm

Sensor monitors condition of bearings ABB introduces the ABB Ability Smart Sensor for Dodge mounted bearings to enable ‘health checks’ for bearings. The smart sensor technology provides an early indicator of any potential problems by assessing the condition of bearings from vibration and temperature information, helping to reduce downtime on conveying applications. Approximately 80 percent of bearing failures are lubrication related, which is expressed in them ‘running hot.’ The monitoring system is said to offer a simple way to monitor potential system problems. The smart sensor mounts to the bearing and communicates wirelessly via a smart phone or other device. ABB | www.new.abb.com

AGGREGATES MANAGER / October 2019

ROLLOUTS Haul truck boosts production, fuel efficiency The redesigned Cat 777G, powered by a Tier 4 Final engine that delivers 1,025 gross horsepower, offers several fuelconservation features. Auto Neutral Idle allows the transmission to intermittently shift to neutral when the truck is idling in a forward gear to avoid stalling the torque converter and increasing engine speed. Engine Idle Shutdown, an operatorselected feature, stops the engine when the truck idles in park for more than a preset interval. Speed Limiting provides an alternative to gear-limiting the truck by allowing it to travel at a more fuel-efficient speed and in a more efficient transmission gear. Advanced Productivity Electronic Control Strategy (APECS) transmission controls boost fuel efficiency by maintaining momentum and speed on uphill grades. Two operating modes, Standard Economy and Adaptive Economy, offer fuel savings of 0.5 to 15 percent based on the fleet and economic conditions at a particular site. The redesigned cab is easier to enter and exit, while the truck’s new design improves visibility. The 777G’s major structures are designed to last through more than one power-train life cycle. Box-section castings are used in high-stress areas, while a new front frame design increases the approach angle on ramps and grades, and a heavy-duty rearaxle housing allows increased lubrication and filtration of critical components. The Dual Slope Body, with a heaped capacity of 78.8 cubic yards, is designed to carry material low and centered for stability.

Caterpillar | www.cat.com

Online filter search tool Luber-finer expands its Digital Advantage Program with what it describes as the first online Vehicle Identification Number (VIN) search tool in the heavy-duty filtration market. Users can enter the 17 digits of a vehicle’s VIN into a search field and receive a list of the specific filters that are required to service that exact vehicle. Additional features include VIN search capability for light- and mediumduty vehicles, as well as the ability to upload multiple VINs at once from an Excel spreadsheet. The tool also generates a downloadable PDF packet of all search results for future reference.

Luber-finer | www.luberfiner.com

Screen boasts robust design Terex Minerals Processing Systems (MPS) rolls out a new series of Simplicity Standard Incline (SI) screens for heavy-duty, medium, and fine screening applications. The screens are built with a robust drive mechanism and oversized bearings to handle large tonnages. The units, which can be used as wet or dry screens, have adjustable stroke and speed combinations and are available in two- or three-deck configurations. They are fitted with woven wire media, but can be converted into modular media with polyurethane, rubber media, or steel plate without any cutting or welding. The screens have the option of operating with grease or oil lubrication, with an auto-lubrication system available with grease lubrication. Feed tray and discharge lips are provided with abrasionresistant liners, while the screen box is made of weld-free construction to reduce stress concentration.

Terex MPS | www.terexmps.com

AGGREGATES MANAGER / October 2019

Mobile app works with or without connectivity B2W Softwareâ&#x20AC;&#x2122;s B2W Inform mobile app allows operators to use the electronic forms and reporting solution in both offline and online modes. The mobile app was designed to address the fact that wifi and cellular connectivity is not available at all sites. It allows operators to use forms for safety, inspections, training, and more by downloading them in advance, along with operational data, such as employee, job, and equipment lists. Forms can then be completed in the offline mode and synched back when a connection is established.

B2W Software | www.b2wsoftware.com

Surface mine tire available in new size Michelin North America introduces a new size of the Michelin XDR 3 surface-mine haul tire: 37.00R57. Addressing the productivity and endurance issues found in surface mines, the tire was developed for a range of rigid dump trucks with a payload capacity of up to 400 tons. Its tread pattern provides excellent load distribution across the contact patch, which is said to lower contact pressure, improve wear, and increase tire life by a minimum of 8 percent. Interlocking blocks of rubber on the shoulder are designed to reduce wear. The tire is MEMS-ready to capture and transmit temperature and pressure information in real time. In addition, 10-percent stronger corrosion-proof cables are incorporated into the tireâ&#x20AC;&#x2122;s structure.

Michelin North America | www.michelinman.com

Pumpable resin system for rock bolting Epiroc, with partner LKAB, introduces a new solution for the installation of rock bolts in poor rock conditions. Typically, blocky or friable ground leaves drilled bolt holes either partially or totally blocked, slowing down or preventing the introduction of bonding agents, such as cement grout or resin cartridges, in the bolt hole. The partners developed an integrated pumpable two-component resin system that can be used with a self-drilling anchorstyle bolt in tougher ground or a two-step hollow bolt in more moderate ground conditions. The integrated pumpable resin system is designed to be used on the mechanized bolting machines Boltec M and Boltec E models.

Epiroc | www.epiroc.com

Adapter improves screen media performance Major offers a new crown curve calculation and updated crown curve adapters, which are said to improve performance of tensioned screen media, such as Flex-Mat, on screen decks originally designed for modular panels. A proper curve on the screen deck will allow producers to tension the screen media correctly, which is essential to maximum performance and wear life. The crown curve adapters allow producers to modify a flat vibrating screen deck for use with tensioned screen media and try tensioned media at their site without the time or expense of a deck conversion.

Major | www.majorflexmat.com

AGGREGATES MANAGER / October 2019

PA R T N E R S O L U T I O N S / M O T I O N I N D U S T R I E S

Beneﬁts of comprehensive plant surveys

Discovered during a plant survey, this return idler is worn all the way through. If not replaced, it could have caused continued damage to related machinery components. Photo: Motion Industries

t’s the middle of the night and halfway through Joe’s shift, he hears a loud bang echoing through the darkness. Upon further inspection, he notices that the drive pulley shaft on his stacker conveyor has snapped – resulting in a catastrophic plant shutdown. He races to find his PPE, flashlight, tools and manlift to identify the components needed to get the plant running. It takes him precious minutes or even hours to make his way up to the head section of the conveyor only to find that none of the components are labeled. He then has to take accurate measurements and find a supplier with adequate stock of materials needed to get the conveyor up and running again. If only Joe had access to a comprehensive plant survey to quickly identify these critical components, he could have saved the company valuable downtime, money and even potential inaccuracies of product identification. Let’s face it: It’s not easy to measure components in low light, particularly when they’re covered in debris.

Accurate plant surveys conducted by a qualiﬁed supplier provide the end user with critical information that is not otherwise always easy to get, and eliminates the guesswork on accurately identifying products. It also gives the supplier a detailed list of components in order to provide less downtime, faster delivery and a detailed overview of the plant. Site mapping Most aggregate plants are extremely good at labeling their conveyors, crushers and shaker screens, but that can get confusing when equipment gets moved or when additional equipment is installed and new labels are made. Providing, maintaining and updating the plant surveys makes it easier for the end user and supplier to keep accurate and current information. It is always a good idea for a supplier, as well as the end user, to know the site layout. Plant surveys also allow the supplier to provide detailed information to contractors hired to install conveyor belts and heavy equipment. This data includes optimal

supplier can also provide cost-effective interchanges for the products identiﬁed within the surveys, giving the end user more viable options. Training Being intimately involved in the surveying process presents opportunities for the supplier to assist in identifying the right components for the application. This helps to educate the end user on how to improve production by selecting a product better suited for a particular application. It also allows the supplier to train employees on the do’s and don’ts when identifying and installing these components. This belt’s broken mechanical fasteners were in such bad shape they could have potentially caused a lengthy plant shutdown. The mechanical splice was immediately replaced and the conveyor belt was running again, within an hour. The broken fasteners were also identiﬁed during a plant survey. Photo: Motion Industries

installation locations, potential hazards and critical dimensional information. Preventative maintenance Plant surveys allow the supplier to inspect and identify potential hazards or component failures within the plant. In most cases, suppliers can identify areas causing premature failures, and provide alternative products for that application, saving the end user time and money. It is always a good idea to carry a separate preventive maintenance sheet to list any worn parts or potential failures that might become serious issues if not addressed quickly. A numbering or color-coded system could be used to identify critical versus noncritical potential failures. Inventory management A comprehensive plant survey provides the end user a detailed list of critical parts and components to help manage their inventory. Usage reports provided by the supplier can help reduce inventory, which has the bonus of ensuring the supplier keeps adequate inventory at a branch level. Cost savings Those crucial hours during downtime can cost a plant thousands of dollars per hour. Plant surveys provide end users the information they need to effectively and efﬁciently get the plant up and running again. In some cases, the

Communication None of this can be done without open communication and a strong relationship between the end user and supplier. Plant surveys make the supplier a critical part of the plant production process and allow them to become a trusted member of the team. As part of that team, the end user needs to update the supplier with any changes made to plant equipment or components, so survey adjustments can be made to keep everything up-to-date. Comprehensive plant surveys take an extensive amount of patience. They must be extremely detailed so that a supplier can accurately identify every part and component at an end user’s plant. Surveys should be maintained and updated upon any changes to equipment and reevaluated every couple of years. It is one of the hardest processes to accurately complete, and usually is only done during afterhours, weekends or winter maintenance outages. If done correctly, it provides both supplier and end user everything they need to effectively maintain a productive and proﬁtable aggregate processing plant. In a world where knowledge is king and time is a precious commodity, plant surveys will always be the most valuable tool to keep your plant in uptime.

Jeremiah Newton is an Aggregate Specialist/ Conveyor Belt Specialist at Motion Industries, and specializes in aggregate sales support, product identiﬁcation and plant surveys. He has over 15 years in the industrial and power transmission industry, with 10 of those years as an industrial conveyor belt technician focusing on heavy-duty black belt/lightweight belting installations and vulcanization.

For more information, visit MotionIndustries.com/aggman and Mi On-site Solutions (https://tinyurl.com/yxe43jm7).

APPLICATIONS

Predictable

Productivity Smart drilling sets a benchmark in safety while providing data key to success for Aggregate Resource Industries.

AGGREGATES MANAGER / October 2019

ision, industry savvy, and leadership of the brother-sister executive team, President Kris Jeremiah and Chief Executive Officer Katie Jeremiah, have made Aggregate Resource Industries (ARI) the largest drill and blast company in the Pacific Northwest. They’ve earned awards along the way, such as the Medium-Sized Family Business of the Year and Oregon Stater Engineering Award. Before joining the family business, Katie worked in construction management, then construction law, representing mine operators and contractors. She is still involved with law as a special counsel and was appointed to the board of the Oregon Department of Geology and Mineral Industries. Katie designed a user-friendly, intuitive app that ensures standard, easily accessed protocols and documentation between ARI employees — from mechanic to operator and more. ARI was the first to introduce the region to the efficiencies of down-the-hole (DTH) drilling. Now, ARI has become the first company in the nation to incorporate remote drilling capabilities — enhancing not only operational productivity but also safety. Kris Jeremiah says being first to explore innovative technology helps ARI remain ahead of its competition. “At first, they tell us that we’re crazy,” he says. “A few years later, seeing our success with it, they are following in our footsteps.”

Embracing new technology

ARI regularly embraces the use of cutting-edge technology for its drilling and blasting operations. It was an early adopter of down-the-hole drilling and recently became the first company in the United States to implement remote drilling capabilities.

ARI has always embraced cutting-edge technology for its drilling and blasting operations. While getting boots dirty will always be a part of the job description for ARI drill rig operators, company co-managers Kris and Katie Jeremiah say they firmly believe that technology leads to safer workers, more profitable customers, and a lower environmental impact. The brother-and-sister team recently explored an increase in automation technology with remote drilling that would help them pursue their lofty goals AGGREGATES MANAGER / October 2019

APPLICATIONS

Jay Lawhon operates two rigs from a single operator station set up inside a van. He can drill with the van doors shut for extra noise reduction and protection from elements.

for the family business. After putting a semi-autonomous dozer into service, they looked to further expand the technological capabilities of their fleet and chose to partner with Epiroc. Epiroc offers BenchREMOTE, a unique remote operator station, on SmartROC D65 and SmartROC T45 drill rigs. ARI is successfully using the remote operator station — becoming the first in the U.S. to do so on a surface crawler rig. The company set it up in a van for the best mobility on site and across its large service territory. “We’ve chased technology all along the way,” Kris says. “We started with an air-track drill, then we went to hydraulic, then electric over hydraulic. Then we went to high pressure down-the-hole drilling, which was great for production, but also meant high fuel consumption. Now, fuel consumption has become more important to us.”

“New technology has allowed us to provide better service to our customers,” Katie adds. “It’s also allowed us to attract the new wave of workforce that’s coming in.” The remote operator station can operate up to three rigs from up to 320 feet away. Advantages include increased productivity and efficiency, enhanced safety, and an improved operator working environment. “The remote drilling has allowed us to leverage our experienced, qualified operators to be able to run multiple drill rigs at the same time on job sites,” Kris says. “It keeps our operators a safe distance away from high walls and faces, while giving additional production to our fleet.”

According to plan The Jeremiahs are quick to spot advantages of high-tech solutions, especially those that integrate well with others.

Aggregate Resource Industries (ARI) At a Glance Founded by Bob “BJ” Jeremiah in 1978, Aggregate Resource Industries is headquartered in Eugene, Ore., and works across a nine-state region. It owns quarries and offers contract drilling. Employees: 54 Fleet size: 100+ Drill rigs: 30+

AGGREGATES MANAGER / October 2019

Katie prides herself on taking a specific project challenge and finding the right technology solution. Government work, for instance, often demands 3D blasting plans, which ARI now gets through computer-analyzed photographic surveys using drones. “I’ve always been accused of being a tech nerd,” Katie says. “Now, it’s paying off.” High-tech drilling with the SmartROC D65 starts with Epiroc’s Hole Navigation System (HNS), which makes setup and planning faster and more precise. Operators and surveyors don’t have to work outside in potentially dangerous areas because the site has been pre-planned. A blasting engineer plans the site based on photos and a Global Navigation Satellite System (GNSS). The plan is sent right to the drill. The drill also comes with a Trimble system, a high-accuracy GNSS correction technology. “We are running on CenterPoint RTX from Trimble with very high accuracy,” says Troy Thiel, ARI’s Epiroc contact for sales and a former expert service tech. “This is a great option for machines that move a lot.” Epiroc’s SmartROC D65 adds rods and extracts them automatically when it reaches depth. The rig adjusts drilling parameters to changes in conditions as formations change gradually or even suddenly, as in an encounter with a void. Reduced deviation is easier on both tooling and the rig. It ensures parallel holes within the pattern for better blasting control. ARI’s blasting crew reports that the Epiroc rigs have changed their results dramatically for the better. “This is 100 percent better than anything I’ve run in the past,” says operator Jay Lawhon, after spending a few months behind the BenchREMOTE. “I’ve run faster drills, but they used a lot more fuel. The D65 is up for anything that we can do with it, technology-wise.” The drill uses intelligent control of compressor load and engine rpm for fuel savings. Lawhon says transitioning to operating two rigs from a distance wasn’t difficult. “I’ll try anything to make my job more efficient,” he explains. “Once you get your timing down, it is easy. While one rig is drilling the hole, I move the second drill

The operator station controls and displays are identical to those in the rig so it is an easy transition for drillers already using Epiroc. The station also includes a live-feed camera display to keep the operator well informed during all steps of drilling.

to the next spot and get that one started. Then the process starts again.” The operator confirms he has nearly doubled feet drilled per day with the two rigs at all the sites he’s taken the rig to. He prefers to run the operator station on the same level as the rigs rather than rely solely on cameras and an automated site plan. That way he can see the contour of

the land and obstructions like a boulder or other obstacle. Lawhon appreciates the noise reduction when working from the remote station in the van with the doors shut. “And I’m out of the elements for longer periods, so that’s a big plus,” he says. Keeping employees happy was a part of looking toward the latest technology.

“Drillers are embracing the technology,” Katie says. “When they learn it, it becomes pushbutton. The drill technology takes an inexperienced driller and makes him proficient in a short period of time. Getting the right operators and training them, then giving them the tools to do their best, helps us with employee retention.”

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APPLICATIONS “Technology will simplify an operation, and automation is the future of managing a modern fleet,” says Modern Machinery Branch Manager Jason Vaughn, who supports Epiroc products for ARI. “An operator is human and has limitations and good and bad days. The automatic drill doesn’t have those same days,” adds Kris. “Get on the pattern and automation can work all day. It comes back to our bidding and how we can be predictable and, therefore, profitable.” Looking into the future, ARI anticipates a work environment where people with advanced video gaming skills will make ideal drill rig operators. “It’s no longer about being out on site all day,” Katie says. “You come in to work, work behind a screen, and still get improved results.”

Leveraging data insights When drilling and blasting is completed, and even during its process, data tracking is a key part of ARI strategy. Their customers, their equipment managers, and even the operators themselves want to see results. Certiq is a telematics solution that comes on some Epiroc rigs. “What’s good about Certiq is it can simplify your analysis. You don’t want to spend more time going over numbers than you actually spend drilling or working on your business,” Thiel says. “Kris and Katie are most concerned about their customers, and they use good information to take care of them.” “With Certiq, if there’s an issue, we can troubleshoot remotely, which is great for the size of territory that we cover,” Kris says. Telematics allow

Thiel and ARI to log in at any time and check on productivity. “It may show settings that are off,” Kris adds. “It can reveal a minor maintenance issue if fuel consumption seems off. Or there may be problems with a bit.” As the rig ages, telematics will help ARI plan for downtime or maintenance rather than deal with problems as they start. People just can’t keep records as accurately or quickly as a computer system, Kris notes. Automation technology has increased his efficiency for billing and for reconciling projects with the plans on any number of data points. “Automation is important for consistency and smart planning, but we’ll always have a personal touch,” Katie says. “Every evolution in technology has helped us hone in on the standards we want to keep. We want to remove uncertainties and limitations. We want our customers to say we are the best — whether they measure that by meeting their deadline or their cost — and we want our employees to say we are the best.” While remote drilling has been a focus of attention lately, the Jeremiahs are already thinking of even greater automation — and fully autonomous drilling is not out of the question. It will come in steps. The first step is line-of-sight, multirig, BenchREMOTE drilling. The next is off-site teleremote drilling operations from a control station anywhere in the world. For ARI, the current state of the art is a moving target. And they will be happy to sit at the controllers. AM Article courtesy of Epiroc.

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OPERATIONS ILLUSTRATED By Therese Dunphy, Editor-in-Chief

Design for Durability

Line chutes to protect the structure.

Use bed liners to protect the body of haul trucks.

Minimize the number of transfer points.

OUR EXPERTS

Ensure parts availability for repairs.

Mark Krause is the managing director, North America, for McLanahan Corp. He has worked in the aggregates industry for more than 40 years, as a manufacturer, dealer, and producer. Krause has a bachelor’s degree in finance from the University of Wisconsin.

Jason Hurdis is the global market professional, quarry and aggregates, Caterpillar Inc. He has served the market for more than 25 years. Hurdis has a bachelor’s degree in engineering from the Milwaukee School of Engineering.

Steve Mitchell is the operations manager for GW Systems. He has been with the company for more than 13 years and has a background in construction project management that spans more than three decades.

Eric Work is a designer in GW Systems’ engineering department. He joined the company 31 years ago and started out as a detailer before working his way into design work.

AGGREGATES MANAGER / October 2019

Tips for processing abrasive stone

brasive material is naturally harsh on equipment. Decisions made during plant design, including equipment and component selection, can make a significant impact on operation uptime and ease of maintenance. As with many financial decisions, there are tradeoffs between initial capital expenditure and ongoing operating costs. “Any time you’re working with granite versus limestone, it’s a lot more abrasive, so you have to take that into consideration,” explains Eric Work, a designer with GW Systems’ engineering department. Crusher selection, for example, must suit the material being processed. “Obviously, abrasive material is going to dictate that certain types of machines can’t be used,” notes Mark Krause, managing director, North America, McLanahan Corp., explaining that compression crushing offers lower operating and maintenance costs for abrasive materials. Building in rock boxes and minimizing transfer points helps reduce wear and maintenance throughout the plant. From an engineering standpoint, the goal is to ensure as much rock-on-rock contact as possible. When rock-on-steel can’t be avoided, however, material selection for liners has a significant impact on its lifespan. “My recommendation would be to think more about long-term costs rather than just the upfront capital cost when purchasing equipment,” says Steve Mitchell, operations manager for GW Systems. For example, abrasion-resistant materials, ceramic, and rubber can improve the life of liners in the appropriate application.

“It does cost more than normal steel, but — long-term — it’s much better for the product and much better for the equipment,” he adds. In addition to robust design, rigorous inspection and maintenance is essential in these operations, and, during a time when skilled labor is difficult to find, some operators are eying new options for how to ensure timely maintenance. “There’s this whole idea of what should your maintenance program look like,” Krause says. “Are you going to do it yourself or outsource? What parts are you going to choose to do and not do?” When factoring considerations such as salary, benefits, and training of staff employees versus having a fixed maintenance cost and schedule, service contracts make financial sense for some operations. While site personnel continue to walk the plant and perform daily inspections, many are turning to outside options for maintenance items such as liner changes and chute work. Krause says the outsourcing of these jobs seems to be on the rise. Mobile equipment maintenance needs also need special consideration. “When working in abrasive materials, maintenance costs can generally be higher than when working with softer materials due to wear on ground engaging tools, beds, bed liners, undercarriage, and linkage,” notes Jason Hurdis, global market professional, quarry and aggregates, Caterpillar Inc. “Tires such as on a wheel loader will also see a higher maintenance cost due to sidewall cuts and damage.”

Reinforce structures

Abrasive material can damage structures. Liners, such as the AR liner in this crusher, take the abuse and protect the overall structure. Liners are available in various materials and price points with harder materials generally being more expensive, but also more durable. The best liner for the application is generally based not only on material hardness, but also size.

AGGREGATES MANAGER / October 2019

Create rock-on-rock contact

Rock ledges, shown in blue, help retain material within each stairstep of the chute. This promotes rock-on-rock material flow, which protects the structure of the chute. Ceramic liners, shown in green, protect the sidewalls from material impact.

Minimize transfer points

Minimize the number of transfer points by using fewer and longer conveyors. This not only reduces the stress to the belt of material transfer, but also reduces the number of drives, motors, bearing shafts, and pulleys that must be maintained.

Get the right gear

Pay particular attention to the bucket and ground engaging tools on mobile equipment. High abrasion tips and teeth, mechanically attached wear plates, edge protection, and bucket liners can protect the machineâ&#x20AC;&#x2122;s working tool. Careful loading technique can minimize exposure of the tire sidewall to abrasive material, and tire chains can be used, if necessary.

AGGREGATES MANAGER / October 2019

Voices of Experience Mark Krause

hen designing and operating a plant to process abrasive material, experience matters. And as the industry operates with fewer people and many of the old guard begin to retire, operators must develop ways to supplement knowledge gaps. “If you don’t have the experience on that basic design, talk to somebody,” says Mark Krause, managing director, North America, McLanahan Corp. “Take the time and make sure that you’ve thought it through.” A mix of automation and asset tracking can help operators improve maintenance. For example, monitors for bearing temperatures and vibration analysis of screens can provide early warning signals of equipment problems. Telematics provide detailed information on mobile equipment. And, where technology is not an option, operators can track the average life span of liners and other wear materials. “I’d say it’s gotten a little more sophisticated these days, with operators using historical data as to how long things will last,” Krause says. “The mobile world used that for a long time: how long did the transmission last, how long did the brakes last? It’s taking that idea and applying it to fixed equipment.” By tracking average life of items and documenting that data, operators are able to fine-tune their maintenance routine by building it into their schedules and budgets. This proactive approach to parts management goes hand in hand with preventive maintenance. “We’re seeing a lot less of that ‘I’ll wait until the last minute and then try to find it before breakfast mentality,’” Krause says. Rather, he is seeing operators implement a planning program where they plan not only the downtime for maintenance, but also ensure timely access to all the necessary parts to do the job. “The better operations are working with their manufacturer or dealer so the parts are always there,” he says. “It isn’t a fire drill every time.”

AGGREGATES MANAGER / October 2019

Jason Hurdis

perators of mobile equipment in sites with abrasive stone should pay particular attention to their equipment’s working tools, as well as tires, tracks, and truck beds. “Abrasive stone, such as granite and similar materials, require special attention to both the bucket and ground engaging tools (GET),” notes Jason Hurdis, global market professional, quarry and aggregates, Caterpillar Inc. “Manufacturers offer a range of GET that typically includes high abrasion tips and teeth, as well as mechanically attached wear plates, edge protection, and additional bucket liners to help control operating and repair costs in abrasive materials.” During loading, the operator should avoid dragging the heel of the bucket on the ground or across abrasive material. Proper alignment, with the base edge of the bucket running parallel to the ground, reduces stress on the bucket. To reduce tire cuts and damage on front tires, Hurdis suggests using tire chains on wheel loaders, while careful truck loading techniques should be used to minimize exposure of the tire sidewall to abrasive material. Track selection on excavators and dozers is also important. “The rule of thumb is narrower track shoes for rock or abrasive materials and wider shoes for flotation,” he explains. “A heavy-duty track shoe for excavators or dozers is the best selection for abrasive materials. Depending on the machine, track guards may be a valuable addition to minimize material track intrusion.” And, equipment operators should avoid or minimize counterrotation movements and reduce travel speed in these conditions. For haul trucks, choosing the right bed liner is important to optimizing the life of the body system, Hurdis says. Heavy-duty steel and rubber liners offer greater protection in highly abrasive material conditions. “Good operating techniques of placing softer or finely shot material in the bed on the first pass will help reduce impact, wear, and maintenance costs,” he adds.

Steve Mitchell and Eric Work

hen designing a plant that will process abrasive material, the plant design should alleviate as many stress spots as possible to ensure smooth day-to-day operations and ease of maintenance. “We can influence that heavily in our design by creating what we call rockon-rock,” says Steve Mitchell, operations manager, GW Systems. With material-on-material transfer, material build up can be created at a stress point so the abrasive material hits stone rather than steel and protects these points. “Whenever we have a material that is not a blended product, we use a lot of rock-on-rock,” adds Eric Work, designer, GW Systems. “It’s really preferred because the wear is so much lower when you have material on material.” Sometimes, it’s not possible to eliminate all rock-on-steel transfers. When that is the case, they design in ceramic coatings, rubber liners, or AR plate. “You need a good design on transfers with the rock ledges properly located,” Work says. “Along with rock ledges, you need liners on the side of the chute, anywhere the material is traveling down the chute and rubbing along the sides. If you don’t have some sort of liner, like AR, it will just wear a hole right through.” Many ledges are designed with a V to keep material toward the middle of the chute and off the sides. Reducing the number of conveyors is another way to reduce the wear on systems operating in harsh conditions. With fewer components such as drives, motors, bearing shafts, and pulleys to worry about, this usually streamlines maintenance. While many operators are concerned with the upfront cost rather than longterm maintenance, cutting corners doesn’t always pay. “Some companies that have in-house engineering capabilities will work with us to develop a design that’s good long-term, but also economical,” Mitchells says. “It really just depends on the corporate mentality of the operator.”

EQUIPMENT MANAGEMENT by Clarence Kreiser and Jim Miller

Does Your

Classification System Make the

Cut?

Classification systems pose a challenge for predictive maintenance. This primer explains how to keep material in spec with both wet and dry processing.

veryone dreads the message from quality control that product has become out of spec. The line shutdown, lost production, hunt for the culprit, and eventual equipment repairs or adjustments can translate to many thousands of dollars in lost time and potentially lost business. Given that many of these changes in product quality can be attributed to the classification step in the process, paying attention to maintaining the equipment involved in screening, separating, and classifying material can help keep production moving and avoid these costly stoppages.

AGGREGATES MANAGER / October 2019

Wet processing plants While maintaining todayâ&#x20AC;&#x2122;s trucks, loaders, and other vehicles often involves using high-tech computer diagnostics to prevent problems before they occur, most classification equipment remains unaffected by the latest technology. Maintaining these particle sizing screens and other separators remains a decidedly low-tech procedure that does not easily lend itself to preventive maintenance. In a traditional wet processing plant for manufactured sand and aggregate washing, for example, classification is typically done by screening the material through a wire mesh.

Maintenance in a dry process eliminates the need for the dewatering equipment, classifying tanks, and settling ponds typical of a wet process. This opens space for storing material.

At Luck Stoneâ&#x20AC;&#x2122;s Goose Creek Plant in Leesburg, Va., an automated classification system with no moving parts keeps maintenance needs to a minimum.

But these screens, in non-stop contact with tough materials, suffer constant wear and tear. Processing high-density, abrasive materials and using high throughput rates will only speed this rate of wear. The first step in minimizing wear is to specify the proper screen for the application. Stainless steel, high carbon, oil-tempered, and other materials and coatings are available to align the screen with the properties of the material. Using an incompatible type of screen material will increase the frequency of screen failure and replacement. Similarly, properly calculating

the mesh size based on the incoming particle size and throughput rate is critical for long screen life. Preventive maintenance is typically impractical, given that it requires a complete shutdown to safely allow human inspection. If the process must be shutdown, it simply makes practical sense to wait until the material has tested out of spec and then inspect the screen for material blinding, breaks in the mesh, and other causes of failure. By keeping these screen failures and repairs in a maintenance log, processors can track screen life and determine approximately when to replace the screens, ideally just before a screen failure is likely to cause the product to go off spec. Of course, timing the rate of wear to get the maximum screen life possible can be a challenge. Purchasing an inventory of replacement screens to keep on hand and talking with the screen manufacturer at the outset are recommended. Conveyors that transport the screened product also need to be monitored for belt wear since a failure stops production until new belting is spliced or otherwise replaced. Similarly, fines that do not meet the spec are typically conveyed to settling ponds and any failure could be catastrophic. The sludge levels need to be carefully monitored, and any berms need to be checked daily to detect structural weaknesses before they become problematic.

Dry processing plants Separating particles without water via air classification eliminates a number of potential maintenance headaches simply by eliminating the dewaterers, dryers, classifying tanks, settling ponds, and other auxiliary equipment involved in adding and then removing water from the process. Instead of screening to remove fine particles from the product, this dry process first became popular for its ability to separate materials at finer cut points and at higher throughput rates than screening. More recently, pneumatic, dry classification has drawn renewed interest as a green, environmentally friendly solution for water conservation, water quality protection, and energy savings that also converts fines into saleable product and helps ease the permitting process when siting facilities. Though the process is AGGREGATES MANAGER / October 2019

EQUIPMENT MANAGEMENT

These dual Gravitational-Inertial Classifiers at Luck Stoneâ&#x20AC;&#x2122;s Goose Creek Plant process 60 tons per hour of #10 screenings, 24/7, yet may run for several years without maintenance before product tests out of spec.

streamlined versus the wet process, a line shutdown presents comparable risk of loss and costly repair, so maintenance needs still must be considered.

AGGREGATES MANAGER / October 2019

Rotary classifiers â&#x20AC;&#x201C; As the entry level air classification device for many producers, rotary classifiers rely on a circular disc that rotates at high speeds. Centrifugal

force pushes material to the outer edge through a series of blades, while a fan directs an airstream through the material. Coarse particles drop into a hopper while fine particles are discharged with the airstream and collected separately. These rotary blades come into constant contact with the material and are subject to significant wear. Though operators know and understand how rotary classifiers eventually fail to properly separate materials, their design makes it difficult to monitor and inspect. Until the material tests out of spec, there is no practical way to assess the condition of the equipment. In a sand plant operating 24/7, the rotary wheel may require replacement due to wear approximately every two years. Replacement is a demanding, four-person job that costs upwards of $10,000 and takes the system offline for a week or more. Gravitational-inertial classifiers - For producers interested in reducing maintenance from the classification step in the process, gravitational-inertial classifiers

EQUIPMENT MANAGEMENT

Safe, easy access to classification equipment saves time during maintenance, lowers costs, and minimizes downtime.

(GIC) offer a track record spanning more than 20 years of non-stop operation. For example, Van Tongeren’s proprietary design automatically removes fine particles from saleable product using only ambient air and gravity. Since its design has zero moving parts, there is very little that can go wrong. Loose, dry material is conveyed to a gravity feed distribution box that forms the product stream into a uniform curtain of falling material. As the material falls, a fan directs air into this curtain at velocities ranging from 3,500 to 6,000 feet per minute and forms an eddy current. The eddy current directs the rotating mixture toward a series of classifying vanes that are carefully set based on the material and cut point to direct the airflow and fine material through the vanes for collection via a cyclone or baghouse dust collector. Particles that escape the classifying vanes are returned into the eddy current until they are discharged either through the fines outlet or through the coarse discharge outlet at the bottom

onto a conveyor as air-scrubbed, on-spec manufactured sand or aggregate. The classifying vanes eventually wear due to material contact, but this may take three or more years before testing reveals the product as out of spec. When needed, two people can replace the entire vane rack in a half-day, returning the classifier to service for less than $5,000 without significant line downtime. Many of the maintenance headaches involved in processing sand and aggregates may be eliminated at the outset by using a dry process with a classification system custom-engineered based on the material and target cut points. AM

Clarence Kreiser is a consultant and Jim Miller is vice president, engineering and design, for Lebanon, Pa.-based Van Tongeren.

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by Karl F. Kumli

ROCKLAW CERCLA Bonding Put to Rest A decade after being pushed to propose a bonding rule, EPA wins the right to stay out of the hard rock mining business.

he final chapter has closed on the Environmental Protection Agency’s (EPA) decision to stay out of the business of bonding hard rock mines after a decision by the U.S. Circuit Court of Appeals for the District of Columbia affirmed the EPA’s authority to not promulgate new bonding requirements. Now you might reasonably wonder, dear reader, why the EPA had to get a court order to decide not to do something. Such is the tangled web of environmental regulation and the extent of litigation surrounding a little law known as 1980’s Comprehensive Environmental Response, Compensation, and Liability Act or CERCLA.

The proposed rule

Karl F. Kumli is an associate in Jackson Kelly PLLC’s Denver, Colo., office where he practices in the Energy, Manufacturing, and Mining Law industry groups, focusing primarily on workplace health and safety and litigation. He can be reached at 303390-0026 or karl.kumli@ jacksonkelly.com.

The EPA is tasked with ensuring the cleanup of sites contaminated by hazardous waste. Under this mandate, the EPA was given two ways to ensure that the money is available to restore contaminated sites. The EPA can take “response actions” to clean up past or impending releases of hazardous substances. These response actions are paid for through the EPA’s Hazardous Substance Superfund (hence, the infamous Superfund sites). Once the response action is underway, the EPA can take cost recovery actions, a fancy term for lawsuits, against the companies responsible for the release. Alternatively, the EPA can compel responsible parties, through citation or court order, to finance response actions directly. Responsible parties can include generators, transporters, and facility operators, and finding the money to pay for cleanup can be a long and expensive process for both sides. To avoid some of the time and cost, the

AGGREGATES MANAGER / October 2019

CERCLA mandates that the EPA require certain types of facilities to ensure that the money for cleanup is available if it is needed. This can be done through insurance, surety bonds, or letters of credit from a bank guaranteeing the agency that the clean up money is in place prior to the facility being approved for operation (i.e., CERCLA Bonding). The amount of money set aside and the industries required to set money aside are determined based on the EPA’s assessment of cleanup costs and what industries present the greatest risk for a spill or contamination. In 2009, environmental groups sought a court order to force the EPA to address hard rock mines under the CERCLA Bonding requirement. The EPA agreed to propose a bonding rule for the hard rock mining industry. In January 2017, the EPA published the proposed rule and sought public comment.

The decision not to promulgate a rule Before issuing the January 2017 proposed rule, the EPA looked at several reports on “recently or currently operating mines.” Based on these reports, the EPA determined that hard rock mining facilities continue to pose an environmental risk based on the handling of hazardous substances at mine sites. However, when the rule was published, the EPA got an earful from state and federal agencies with a bit more experience with mines. The U.S. Department of the Interior’s Bureau of Land Management and the U.S. Forest Service both submitted comments opposing the EPA rule. Additionally, a number of state agencies charged with regulating mines at the state level also

submitted opposing commentary on the rule. Along with industry, these comments focused on the EPA’s “inappropriate evidence… not relevant to the facilities to be regulated” and its failure to give credit to existing federal and state regulatory programs and voluntary industry practices in reducing risk and providing financial responsibility requirements. The EPA was convinced by this information and, in February 2018, announced that it would not issue financial responsibility requirements for the hard rock mining industry.

The lawsuit

rule were the Attorneys or Solicitors General for 15 states, as well as the Alaska Mining Association on behalf of industry groups and a number of industry intervenors. The environmental groups argued that proposing a rule meant that the EPA should make a new rule, that the agency did not assess risk properly, and that the economic analysis was arbitrary. The court addressed each of these arguments and found them wanting. The court, in rejecting the environmental groups’ arguments, took care to specifically state that a notice of a potential rulemaking, by the nature of being potential, might not become a final rule. The EPA decision not to require CERCLA Bonds at hard rock mines was affirmed.

Shortly after the EPA announced its decision not to place the new requirements on the industry, environmental groups took the agency to court in an effort to force it to issue hard rock mine bond regulation. Six environmental groups filed a lawsuit claiming that the EPA’s stated reasons for finding the bonding requirement unnecessary were contrary to the law, arbitrary and capricious, and defective on procedural grounds. The EPA had stated that, in evaluating the comments, it had found that many mines where costly cleanup occurred had operated prior to modern state and federal regulation and that current regulation and bonding was sufficient to limit the risk and pay for potential cleanup. The groups disagreed. Joining the EPA in defending the decision not to make a new

So, what does this mean? It would be easy to say nothing has changed or to ask what is the big deal? But the D.C. Circuit Court is the final decision maker in most situations where a federal agency has been sued. In throwing out the environmental groups’ case, the court put the issue to bed. Ten years after the EPA first agreed to regulate hard rock mines, two and one half years after the proposed rule, and more than a year after the decision not to make the rule, hard rock mine operators can finally rely on the fact that the EPA will not be adding one more bond requirement to their operating costs. And that’s a good thing, as we could all use a little more certainty in these times. AM

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Contact Person JULIE PUCKETT Telephone (224) 577-6882

8. Complete Mailing Address of Headquarters or General Business Office of Publisher 3200 RICE MINE RD NE TUSCALOOSA, AL 35406-1510 9. Full Names and Complete Mailing Addresses of Publisher, Editor, and Managing Editor Publisher (Name and complete mailing address) Michael Newman 3200 RICE MINE RD NE TUSCALOOSA, AL 35406-1510 Editor (Name and complete mailing address) Therese Dunphy 2849 LEE RD SILVER LAKE, OH 44224-3715

Experience: Retired November 2011 following 41 years with the U.S. Geological Survey

Managing Editor (Name and complete mailing address) Marcia Gruver Doyle 3200 RICE MINE RD NE TUSCALOOSA, AL 35406-1510 10. Owner (Do not leave blank. If the publication is owned by a corporation, give the name and address of the corporation immediately followed by the names and addresses of all stockholders owning or holding 1 percent or more of the total amount of stock. If not owned by a corporation, give names and addresses of the individual owners. If owned by a partnership or other unincorporated firm, give its name and address as well as those of each individual owner. If the publication is published by a nonprofit organization, give its name and address.) Full Name

Complete Mailing Address

Randall-Reilly Holding Co, LLC

3200 RICE MINE RD NE, TUSCALOOSA, AL 35406-1510

11. Known Bondholders, Mortgagees, and Other Security Holders Owning or Hoding 1 Percent or More of Total Amount of Bonds. Mortgages, or Other Securities. If none, check box Full Name Complete Mailing Address GE Capital

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

None

11175 Cicero Drive, Suite 600, Alpharetta, GA 30022-1167

PS Form 3526-R, September 2007 (Page 1)

• 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

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• Resource evaluation • Expert testimony

• Technical writing and review • Lecturer

Contact me at: 13. Publication Title

14. Issue Date for Circulation Data Below

RANDALL REILLY PUBLISHING/AGGREGATES MANAGER 15. Extend and Nature of Circulation

08/01/2019 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)

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 and Requests including Association Requests, (By Mail 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

19595

11999

11136

199

198

12198

11334

7138

7792

259

7397

7834

19595

19168

120

427

19715

19595

62.25 %

59.13 %

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

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

Total Requested Copy Distribution(Line 15f)+ Requested/Paid c. 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 10/01/2019 issue of this publication.

18. Signature and Title of Editor, Publisher, Business Manager, or Owner Title Julie Puckett

Date Aud Dev Dir

08/26/2019 13:51:14 PM

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)

BillLanger_AGRM0115.indd 1

12/14/16 8:54 AM

To advertise here call

Copies Distributed by Other Mail Classes (4) Requested Through the USPS (e.g. First-Class Mail)

19714

Pete Austin (205)248-1258

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

Bill-Langer@researchgeologist.com www.researchgeologist.com

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AGGREGATES MANAGER / October 2019

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

Hey! You got rocks in your head? Trace minerals such as iodine, zinc, and boron ensure essential brain functions.

ometimes when I was a kid and I did something stupid, my dad would ask me, “Hey! You got rocks in your head?” I should have replied, “Absolutely. That’s why I am so smart!” That would not have gone over too well, but it is true — at least the rocksin-my-head part. There are numerous elements that are critical to a healthy brain, most of which come from rocks. People used to think that the brain cells we were born with are the only brain cells we will ever have and that, when they die, they’re kaput. However, recent research suggests that at least one part of the brain, the hippocampus, continues to create new cells throughout a person’s lifespan. The hippocampus is involved in the formation of memories, with learning, and with emotions, so you want to keep it healthy. This cellular regrowth, as well as other brain functions, requires a lot of energy. (When we are resting, the brain uses about 20 percent of our calories.) Most of our energy comes from eating carbohydrates, which are composed of carbon (C), hydrogen (H), and oxygen (O). If the brain does not get enough energy (calories) we can experience confusion, irritability, forgetfulness, and even blackouts. Okay — C, H, and O come from the atmosphere, but the brain relies on many The hippocampus, shown in blue, creates new cells trace elements that come from rocks. Different elements occupy different parts of the brain and, if those elements are not present in the right amount, a men- throughout a person’s lifespan. Illustration courtesy Jay Leek, UC Davis. tal weakening occurs that affects memory, concentration, alertness, ability to learn, and ultimately the quality of life. For example, a deficiency in iodine can lead to brain damage. Iodine is the 61st element in terms of abundance, making it one of the rarest elements needed for life. Fortunately, iodine can be found nearly everywhere in trace amounts in water, soil, and rocks. Iodine is taken up from the soil by plants and from seawater by algae, seaweed, and other sea vegetables and is then propagated through the food chain to humans. Fish (such as cod and tuna), seaweed, shrimp, animals, fowl, as well as dairy products and eggs, are generally rich in iodine. The brain also needs zinc, the 24th most abundant element in the earth’s crust. Zinc is one of the eight essential micronutrients crucial to plant development, so when you eat a plant you probably are consuming some zinc. But beware; brain performance drops significantly when the diet is poor in zinc, so eat your veggies. Another critical element, boron, is believed to be important for attention, perception, and short- and long-term memory. Boron is another of those micronutrients that are essential for plant growth. However, unlike iodine and zinc, boron has more limited distribution, and there are many areas where plants suffer from boron deficiency. But never fear; you can get your boron from dried fruit, nuts, and — get this — from wine. Our brain’s health relies on maintaining a delicate balance between too little and too much of the elements in our brains. Too little calcium and magnesium can lead to diminished awareness and mental fatigue. Too much metal like copper, iron, chromium, and manganese can cause brain fog, mood swings, confusion, and excess emotions. Metals such as lead, mercury, cadmium, arsenic, nickel, aluminum, and beryllium can also be neurotoxins. So maybe when I did something stupid, I should have told my dad that I didn’t have enough rocks in my head. AM

AGGREGATES MANAGER / October 2019

MAXIMUM FINES RECOVERYIT TAKES MORE THAN A PIECE OF EQUIPMENT

With a McLanahan Ultra Fines Recovery System you can keep 30,000 tons or more from going to the pond, giving you more usable product. The Ultra Fines Recovery System includes dewatering screens, cyclones, sumps, pumps and a structure all engineered to your specifications by McLanahan. With McLanahan, you get years of experienced process engineering coupled with an analytical lab, all supported by a dealer network to provide local parts and service.

mclanahan.com

EVOLUTION ON THE OUTSIDE REVOLUTION ON THE INSIDE THE NEW SANDVIK 800i CONNECTED CONE CRUSHER SERIES

These eight crushers maximize uptime and offer you the best possible solution for any mining or aggregate application. Connected 24/7 to the My Sandvik portal, and with the new generation Automation and Connectivity System (ACS) as standard, they boost productivity and help you predict performance. And with the option of Sandvik Reborn and overhaul kits, crushing has never been easier to upgrade, or as cost-efficient to operate.

Join the crusher revolution. info.mining@sandvik.com ROCKTECHNOLOGY.SANDVIK /800i