Aggregates Manager 1114 issuu by Sandy Turner Jr

Whites Creek Quarry Marks

10 Years

with November 2014

Zero Injuries www.AggMan.com

21 30 40

Crushing circuits that yield cubical material Manage conveyor maintenance MSHA uses non-ďŹ nal violations in POV determinations

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On Our Cover: Rogers Group, Inc.’s Whites Creek quarry marks a milestone. Cover photo courtesy of Rogers Group, Inc.

Fixing a problem with belt carryback may be as simple as adjusting the tension on your cleaners.

Volvo’s new L110H and L120H Tier 4 Final loaders focus on fuel efficiency and performance.

CONTENTS NOVEMBER 2014

FEATURE ARTICLES

14 30 37 38

Tennessee Treasure

Whites Creek Quarry recently celebrated a milestone — 10 years of zero injuries.

COLUMNS & DEPARTMENTS

Conveyor Maintenance: Safety First

Like a Well-Oiled Machine

AND PROVINCE NEWS A roundup of the latest news in North 4 STATE America.

Stuck in the Middle?

Cat’s new 824K wheel dozer, and other new equipment for the aggregate 7 ROLLOUTS market.

Put your workers first when performing belt maintenance.

When it comes to protecting your equipment investment, oils and lubricants play a critical role. Don’t underestimate the importance of middle management; it puts ideas into action.

CRUSHING SUPPLEMENT

27 28

VOLUME 19, NUMBER 11

Crushers: by the Numbers

When it comes to units financed, find out which new and used units are the best sellers. Stationary and portable crushers for the aggregates market.

OPERATIONS ILLUSTRATED

21Crushing for Particle Shape

Whether aggregate is destined for concrete or asphalt, cubical stone is considered ideal. Our experts share how they achieve the optimal shape.

EDITORIAL Hitting a safety milestone.

MINING The latest financial analysis 13 DATA of issues impacting in the industry. LAW The Federal Mine Safety and Health Review Commission upholds MSHA’s 40 ROCK use of non-final violations in Pattern of Violation determinations.

INDEX See who’s who and where to find their products. 42 ADVERTISER ADS Aggregate industry classifieds. 43 CLASSIFIED IN STONE Route 66 winds through the ghost town of Calico, Calif., where silver 44 CARVED and borax mining led to its boom and bust.

Precisely the right tire

ENGINEERED FOR YOUR WORLD. Wherever you roll, whatever the work, Bridgestone off-the-road tires are engineered to tackle the toughest jobs. See our innovative thinking at bridgestoneminingsolutions.com. Or visit a local dealer.

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

November 2014

Vol. 19, No. 11

aggman.com /AggregatesManager @AggMan_editor

Editorial Editor-in-Chief: Therese Dunphy Editorial Director: Marcia Gruver Doyle Online Editor: Wayne Grayson Online Managing Editor: Brian Ethridge editorial@aggman.com

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

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Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly Publishing Company copyright 2014. 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.

Hitting a

SAFETY MILESTONE

artin Marietta’s Beckmann Quarry recently achieved a remarkable milestone — 2 million consecutive employee hours without a reportable incident. The operation’s safety track record extends back to 2007 when it set its sights on becoming a world-class operation in terms of safety metrics (it’s already one of the largest production quarries in the United States). The achievement is one worth celebrating, but, even more importantly, worth sharing. In 2007, the management and staff set an ambitious goal for themselves: to record 1 million employee hours without a reportable injury. “It’s really critical to set goals and to push ourselves to hit new milestones,” says Chance Allen, regional vice president of Martin Marietta – Central Texas Aggregates. “It’s part of the journey for us: knowing what the next goal is and that it’s achievable.” The first step was to empower employees at all levels to stop, correct, and fix any unsafe act. Through the Guardian Angel program, managers gave the staff not only the right, but also the responsibility to control their own safety program. Allen says behavior-based safety fosters trust among the staff so they can share information openly and correct one another’s behaviors. Next, company leaders ensured that people in leadership positions believed in and supported the goals. Numerous longtime employees Martin Marietta’s Beckmann Quarry surpasses 2 million hours of safe operation. embrace the culture and have built the trust needed to make behavior-based safety effective. But, the operation also diligently educates new hires, recognizing that it takes approximately a full year for new employees to become truly immersed in the operation’s safety culture. Another element to its success is understanding what Allen calls “the risks on the safety battlefield.” For example, new hires pose one such risk because they aren’t as familiar with the site, best practices, or fellow workers. In the first 90 days on the operation, they wear a different colored hardhat in recognition of that risk. It helps co-workers quickly identify them and pay particular attention to their safety. Finally, safety is a family affair at Beckmann Quarry. Because employees become immersed in the safety culture, they continue to use safety principles even after hours. Family members are encouraged to write up and share safe behaviors that happen at home. “This program has really allowed people to take ownership of the program,” Allen says. “In past incidents, there were key safety elements that were not followed. The big change that I see is that we’re not doing those things in off hours or when no one is looking. It’s not because we’re afraid of getting caught, it’s because we really believe in the program.” For more ideas on safety from Rogers Group, Inc.’s Whites Creek Quarry, turn to page 14. AGGREGATES MANAGER November 2014

State & Province

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

California

The Humboldt County Board of Supervisors straw voted through the draft General Plan’s Mineral Resources section during a review meeting, discussed the environmental impacts of mining on riverbeds, and laid the groundwork for extending the time period between mining permit renewals. The Redwood Times reports that there was some discussion from the County Planning and Building Department staff to include specific information on in-stream mining operations’ environmental impact on endangered and threatened species, but an attorney for local mining companies pointed out that they already work with the County of Humboldt Extraction Review Team (CHERT) on these issues. The board approved the addition of language that would allow mines that extract consistent volumes of materials to be extended beyond the current 15-year limit.

Louisiana

The Livingston Parish Council’s ordinance committee voted 4-0 to recommend the Parish Council table proposed sand and gravel regulations following pushback from the mining industry that said compliance costs could put them out of business. According to The Advocate, the proposed regulations — drafted by a councilman who lives next to a 238-acre planned mining operation — included a $3,000 annual permit, 8-foot perimeter fence, increased buffer zones, and restricted hours of operation, among other requirements. The committee chairman noted that, by the councilman’s own estimates, the regulations would increase a mine’s start-up costs by $300,000 to $400,000. Other council members noted that the ordinances were “drafted too hastily, amended too late in the process, and were causing considerable confusion.”

AGGREGATES MANAGER November 2014

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

Maine

At Aggregates Manager’s press time, a town meeting was being held in Eddington to determine if a six-month moratorium on mining would be extended. The Bangor Daily News reports that the moratorium was approved in April by voters and intended to give town leaders time to develop new regulations. Town Manager Russell Smith said the regulations were “almost done, but not quite.” He talked about the possibility of a three- to six-month extension so the rules could be finalized and reviewed by the town attorney. The planning board would then hold public hearings and vote on them.

New Jersey

In late September, visitors to a Mantua quarry got to play paleontologists and see a new dinosaur species, the Dreadnoughtus schrani. According to the Courier-Post, more than 1,200 people attended the event. A Drexel University paleontologist and his team have scoured the site for years to find evidence that ties fossils in a 6-inch layer of dirt to when an asteroid struck the planet and sent dinosaurs toward extinction. The professor noted that a high proportion of articulated specimens in the quarry point to a mass death event.

New York

A pair of neighbors have spent four years trying to block the Department of Environmental Conservation from approving a permit that would triple the size of the 25-acre Kinsella gravel quarry near Highland Forest in Fabius. CNYCentral.com reports that they have collected hundreds of documents, including one noting that the town banned gravel mines in 2007. The mine owner, Tom Kinsella, told the news agency that he understood their concerns, but the operation is grandfathered since the quarry began in the 1950s. He also pointed out that gravel from his quarry is needed for bridges and roads throughout the region.

Pennsylvania

In mid-September, emergency responders from Eastern Berks Fire, Boyertown Area Fire and Rescue, and Gilbertsville Fire and Rescue, as well as EMS personnel from Boyertown, Bally, and Gilbertsville, took a guided tour of the Martin Stone Quarry in Colebrookdale Township. According to The Berks-Mont News, the tour was organized by Bruce Hoffman, an employee who has served with EMS and fire units. He showed responders the layout, potential hazards, and safety features of the mine. Safety Director Anne Kelhart provided an overview of emergency procedures in case of an incident at the quarry.

Rhode Island

As town officials in Charlestown are crafting a proposed ordinance on sand and gravel operations, local operator Roland Fiore invited Rhode Island Public Radio to visit one of his operations. He told NPR that it is not difficult to be a good operator and pointed to the trees planted around his operation to buffer noise. He shared that his staff waters down the trucks and roads to prevent dust from traveling. He talked about the stringent standards used to build his diesel trucks. He outlined his operating hours, noting that crushing ended by 5 p.m. or earlier. Fiore also shared that the proposed ordinances will make it more difficult for sand and gravel operators to stay in business and furnish the sand needed for beach restoration and roads.

Texas

After 65 years of service, the Martin Martietta (formerly TXI) Midlothian Cement Plant’s locomotive #2447 will become an educational resource at its new home in the Museum of the American Railroad. According to the Frisco Enterprise, a local metal recycler notified the museum that the locomotive was heading for the scraper. The museum team and Martin Marietta management worked together to relocate the engine to Frisco, which was 60 miles from its location. BNSF railroad donated transportation of the engine. TXI purchased the engine in 1984 and used it to switch 100-ton rail cars of raw material and finished product in and out of the Midlothian plant. The engine will be used as a learning tool in the museum’s new STEM-based educational programs.

Virginia

In September, three public officials — Pat Weiler, Powhatan County administrator; March Altman, deputy county administrator-community development; and Carson Tucker, chairman of the Powhatan County Board of Supervisors — watched a blast at Luck Stone Corp.’s Powhatan quarry. Blastholes were loaded with 9,000 pounds of ammonium nitrate and yielded about 22,000 tons of granite. Powhatan Today reports that the visit was part of the Board of Supervisors’ Vision 2030 program, which encourages a strong economy, in part, by being probusiness. Weiler described the blast as “very unimpressive, which is a good thing.” She also noted how neat and clean the operation was. “What I saw was controlled and directed,” Tucker added.

Washington

Snohomish County approved Aggregates West’s request for extended hours at its Green Mountain Mine for an unusual construction project. According to The Bellingham Herald, the operator can transport aggregates every night until 3 a.m. to keep up with the needs of contractors building the new Boeing 777X factory in Everett.

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For

FREE Product Information Text INFO to

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

or visit

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

Versatile loader The WA200-7 wheel loader, from Komatsu America Corp., features 126 net horsepower and is powered by a Tier 4 Interim Komatsu engine. It has 3-percent lower fuel consumption than the WA200-6 it replaces. Parallel Z-bar loader linkage gives the loader large breakout and lift force, for quick bucket loads and digging performance. A secondgeneration hydrostatic drivetrain features large pump capacity for high efficiency and responsiveness, giving the loader sure footing in soft or slippery conditions. Komatsu America Corp. | www.komatsuamerica.com

Next generation dozer Self-adjusting belt skirting Martin Self Adjusting Skirting is designed to fit any conveyor while reducing maintenance and increasing efficiency. By creating a tight seal to the belt, it prevents spillage and equipment breakdown caused by fugitive material. The skirt requires only 1.25 inches of free belt area, making it suitable for conveyors with chutes close to the belt edge. The rubber sealing strip is 0.75 inches wide and provides 2 inches of wear life, at speeds of up to 700 feet per minute. The sealing strip is available in continuous lengths of up to 100 feet. Maintenance is streamlined with a simple rubber clamp so that no tools are required for assembly. Martin Engineering | www.martin-eng.com

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The Cat 824K Wheel Dozer builds on its predecessors with engineering refinements in its powertrain, operator station, and structures. With a new power rating of 405 horsepower and maximum operating weight of 74,966 pounds, the unit is available with six blade configurations ranging in capacity from 6.6 to 21.1 cubic yards to customize it for production dozing, stockpile dozing, or cleanup work. The Cat C15 Acert engine features an electronically controlled fuel delivery system, an engine idle shutdown system to conserve fuel, and a delayed shutdown feature to ensure the engine is not stopped until operating temperatures have stabilized. For drivetrain efficiency and smooth shifting, the 4F/4R Cat power shift transmission can be set by the operator to automatically upshift or downshift based on machine speed, while the single clutch speed shifting controls allow the dozer to carry momentum through a range of shifts for high productivity and fuel savings. Caterpillar | www.cat.com AGGREGATES MANAGER November 2014

ROLLOUTS

Heavy duty conveyor pulleys Baldor Electric Co. introduced conveyor pulleys with XT hubs and bushings. The XT conveyor pulleys are available in heavy duty, mine duty, and mine duty extra construction, in both drum pulley and wing pulley design. The pulleys feature thicker end discs, which means they can power through tough conditions. Baldor Electric Co. | www.baldor.com

Tier 4 Final loaders Mobile plant monitoring Metso now offers fleet management systems for its Lokotrack mobile applications. Metso Fleet Management system consists of an IC process control system, a satellite uplink, and a Metso DNA Report portal. The system collects and presents a daily overview of the operating fleet, including effective operating hours, fuel consumption, location of the units, alarms, and parameter changes. With the new fleet management tool, information collected by the Metso IC process control system is sent from the crushing units via satellite to an internet portal. Data can be compared between units, days, or weeks. Metso Mining and Construction | www.metso.com

The Volvo L110H and L120H are said to be among the manufacturer’s most environmentally friendly and fuel-efficient machines to date. The latest generation of machines in the 18- to 22-ton class is powered by an 8-liter tier 4 Final engine with fully automatic regeneration that combines high performance with low emissions and low fuel consumption. The powertrain and intelligent hydraulics, which supply power on demand, supplement the engine’s efficiency. Load-sensing hydraulics offer faster response for control over the load and shorter cycle times. The Reverse-ByBraking function automatically reduces engine rpm and applies the service brakes when the operator changes the direction of the machine, which not only conserves fuel, but also reduces stress on the drivetrain. OptiShift technology combines the braking function with a lock-up torque converter to create a direct drive between the engine and transmission, eliminating power losses in the torque converter and reducing fuel consumption by up to 18 percent. Volvo Construction Equipment | www.volvoce.com

Ceramic pulley lagging Flexco introduces its Flex-Lag Medium Ceramic Pulley Lagging, which features 39-percent tile coverage and complements its Full Ceramic and Diamond Ceramic lines. The pulley lagging can be used in dry, wet, or muddy applications where slippage can occur. Horizontal grooves in the lagging trap and deflect water and debris, while the molded ceramic buttons grip the belt’s underside for positive traction and no slippage. The lagging comes in strip widths ranging from 35 to 101 inches to match pulley face widths or 18 to 84 inches to match belt widths. It works with pulley diameters over 12.6 inches and is also available in SBR or FRAS rubber. Flexco | www.flexco.com

AGGREGATES MANAGER November 2014

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MAXIMIZE UPTIME because results drive business Telsmith T-Series™ Cone Crushers are engineered to deliver un-compromising productivity, safety and ease of maintenance for maximum uptime in tough, abrasive aggregate and mining applications. The Telsmith T-Series™ line-up of cone crushers delivers the reliability, productivity, and safety needed for your bottom line.

HYDRAULIC RELIEF AND CLEARING • Top-service for tramp cylinder maintenance • Fewer cylinders help reduce maintenance costs • Largest in-class clearing stroke

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ROLLOUTS

Artic with larger payload Komatsu America Corp.’s HM300-5 articulated dump truck boasts 324 net horsepower and is powered by a Tier 4 Final Komatsu SAA6D125E-7 engine. The new truck delivers high levels of performance while reducing fuel and operating costs, Komatsu says. It has a 30.9-ton payload and a gross vehicle weight of 117,892 pounds. Through body design optimization, the truck has increased body capacity and payload. The low 9-foot, 2-inch loading height matches with 30- to 60-ton excavators or 5- to 7.5-cubic-yard wheel loaders. Two single-staged body lift cylinders provide a 70-degree dump angle. Economy and Power modes allow the operator to tailor machine performance to work conditions. Komatsu Advanced Transmission with Optimum Modulation Control System (K-ATOMiCS) offers a six-speed, fully automatic transmission that uses an advanced electronic system to shift shock and torque cutoff to improve operator and engine efficiency. It automatically selects the ideal gear based on vehicle speed, engine rpm, and the shift position chosen. Komatsu | www.komatsuamerica.com

Longer radial stacker KPI-JCI and Astec Mobile Screens offers a 170-foot long SuperStacker, its latest model of telescoping stackers designed to minimize stockpile segregation and increase stockpile capacity. The unit is an addition to the new generation SuperStacker product line and provides a longer length for additional stockpiling capacity, while still being road portable. The new generation eliminates the echain, reducing field maintenance and providing smoother operation. It also features an updated Wizard Touch automation control system, which is said to be more user friendly. KPI-JCI and Astec Mobile Screens | www.kpijci.com

WITH GREAT POWER,

COMES GREAT VERSATILITY

Topcon’s new GLS-2000 is equipped with ultra high speed scanning that provides time saving benefits without compromising accuracy. With a scan range of over 350 meters, a full-dome 360° x 270° field-of-view, and a simple one-touch operation, the GLS-2000 is a rugged and versatile tool that enables you to capture accurate 3D data in all your challenging work environments, across all your applications. The GLS-2000 is an industry-leading scanner that no serious practitioner should be without. topconpositioning.com/scanning Text INFO to 205-289-3782 or visit www.aggman.com/info

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AGGREGATES MANAGER 10/21/14 November 8:39 2014AM

Be Concrete 20-25 April 2015 Paris-Nord Villepinte - France

In t er n a t ion al E x h ib it io n fo r Equipm e nt a nd Te chnique s f or C on st r u c t ion a nd Ma te ria ls Indus trie s .

an event by

INTERMAT c/o IMEX Management, Inc. Tel: 704.365.0041 - Fax: 704.365.8426 Email: rebeccaj@imexmanagement.com Text INFO to 205-289-3782 or visit www.aggman.com/info

w w w. i n t e r m a t c o n s t r u c t i o n . c o m BLOG

#intermatparis

Data Stock Report Company

U.S. On-Highway Diesel Fuel Prices Ticker

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

CRH plc

CRG

Eagle Materials, Inc. Granite Construction, Inc.

Current Value

52-Week 52-Week High Low

$12.65 q

$13.81

$9.43

10/6/2014

One Week

One Year

United States

$3.733

-0.022 q

-0.164 q

East Coast

$3.755

-0.023 q

-0.153 q

$22.54 p

$27.60

$21.03

EXP

$93.04 q

$105.69

$69.18

New England

$3.848

-0.032 q

-0.192 q

GVA

$31.50 q

$40.55

$28.35

Central Atlantic

$3.830

-0.027 q

-0.137 q

$64.91

Lower Atlantic

$3.678

-0.016 q

-0.160 q

Heidelberg Cement AG

HEI

Holcim Ltd.

HOLN

$69.83 q

$89.61

$65.50

Midwest

$3.670

-0.024 q

-0.206 q

Martin Marietta Materials, Inc.

MLM

$120.92 q

$136.36

$94.01

Gulf Coast

$3.662

-0.023 q

-0.143 q

$27.03

Rocky Mountain

$3.787

-0.019 q

-0.128 q

$52.53

West Coast

$3.855

-0.015 q

-0.119 q

MDU Resources Group, Inc.

MDU

$66.63 q

$27.46 q

$86.89

$36.05

United States Lime & Minerals, Inc. USLM

$60.07 q

$68.50

U.S. Concrete

USCR

$25.52 q

$28.64

$18.78

West Coast less California

$3.998

-0.021 q

-0.081 q

Vulcan Materials Co.

VMC

$58.51 q

$69.50

$50.32

California

$4.079

0.009 q

-0.152 q

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 10/6/14.

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

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Whites Creek Quarry, within the city Teichert’s Hallwood Plantlocated is located on 711 acres of limits of Nashville, Tenn., recently celebrated the Yuba Goldfields in northern California. 10 years of operation with no injuries.

Tennessee

Treasure Whites Creek Quarry recently celebrated a milestone — 10 years of zero injuries. by Kerry Clines, Contributing Editor

hites Creek Quarry, a Rogers Group, Inc. operation, sits inside the city limits of Nashville, Tenn. Though the quarry has been in that location since the early 1950s when there was nothing nearby, it eventually found itself in the midst of civilization as homes, schools, and churches crept closer until finally coming to a halt right across the street. Those were the circumstances when Rogers Group acquired the quarry from Martin Marietta in 2004.

AGGREGATES MANAGER November 2014

“When we picked up the new quarry, everything was in limbo,” says Russ Matthews, plant manager, explaining that there was just a foreman at the quarry during the first six months until he took over as plant manager. “I’ve been there going on 10 years now.” Last year, Whites Creek took on a major project to improve the appearance of the plant entrance by investing time and money in landscaping and beautification. “Our road frontage was sort of a mess, so we cleaned up about half a mile along the road around the entrance,” Matthews explains,

PLANT PROFILE

adding that more than $100,000 in landscaping materials, plants, and labor, as well as equipment use, were invested in the project. “We took out all the debris and planted plants, shrubbery, and trees to dress up the road frontage.”

Making little rock

The deposit at Whites Creek is limestone. Blasting takes place once every two weeks, at which time about 30,000 to 35,000 tons

of rock is put on the ground for mucking and processing. “We have two 65-ton haul trucks that haul the shot rock to the primary crusher,” Matthews says. “The material goes through the primary crusher, then travels up a conveyor to the secondary plant that contains two smaller crushers. The products are screened out, washed, graded, and stockpiled. We make 11 different rock products that are used for a variety of

different things — roadwork, concrete, asphalt, construction, under base, and such.” Once the material is stockpiled, a yard loader takes care of loading customer trucks, which range in size from pickups to large rock trucks. If the customer doesn’t have its own truck, the quarry arranges for delivery. Rather than dealing with the upkeep of its own trucks, Whites Creek sub-contracts with two trucking companies to make all of its deliveries to AGGREGATES MANAGER November 2014

Photo courtesy of Rogers Group Inc.

Material is hauled up from the pit floor and dumped into the primary crusher. Once crushed, it travels up a conveyor to the processing plant for secondary crushing and screening.

CUSTOM LUBE TRUCKS

BECAUSE NOT EVERY JOB SITE IS THE SAME. Text INFO to 205-289-3782 or visit www.aggman.com/info

AGGREGATES MANAGER November 2014

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PLANT PROFILE

customers who need that service. The companies have a variety of trucks to suit any type of delivery. “Eight to 10 trucks sit at the plant all the time, so when our customers call in an order, we put a truck on it,” Matthews explains. “We have a good relationship with the truckers. It’s their responsibility to go out and serve our customers, as far as doing a good job by spreading the material or putting the material where the customer wants it. The truckers know that our customers are the ones who pay the bills, and they do all they can to make sure the customer is happy. This arrangement works out well.”

Safety

In a year when quarry accidents and fatalities are on track to possibly outpace

the past few years, Whites Creek is setting a new safety record, one day at a time. A sign hangs on the outside of its service building showing how many days the plant has been accident free. At the end of September, it read 3,731 days…and counting. “Our goal for safety is zero injuries,” Matthews says. “On Sept. 25, I had a steak dinner for all of my guys here, along with about 15 people from the corporate office. We celebrated 10 years injury free — no accidents and no injuries — at Whites Creek Quarry. That’s a pretty good milestone for Rogers Group, for a quarry of this size. “I do something special for my employees every 500 days that we go accident free,” Matthews continues. “I usually buy them a jacket, sweatshirt, or duffle bag

and personalize it by putting their names on it. I want them to know that they aren’t just an employee, they are a person. We treat all our employees as if they are family.” Three of the employees at Whites Creek have been with the quarry since it was acquired by Rogers Group. They transferred over with the quarry when it was purchased from Martin Marietta, so they have more than 10 years of experience. However, zero injuries is quite an accomplishment considering the fact that four of the employees at the quarry are recent hires with less than a year of experience. “I’m trying to take care of the new hires and keep them safe by teaching them the right thing,” Matthews says. “We want to keep that 10-year safety record going.

Introducing the new Nordberg NP15 impact crusher Metso’s new Nordberg NP15 impact crusher takes you 3 steps forward:

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AGGREGATES MANAGER November 2014

Photo courtesy of Rogers Group Inc.

A wheel loader handles the loading of all customer trucks, which range in size from pickups to large rock trucks.

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AGGREGATES MANAGER November 2014

That’s our biggest challenge right now, but the employees that we hire are really intelligent. Once we instruct them on how to do something, they pick up on it pretty quick, so it’s easy to train them. I made a point of telling them at the dinner that it’s all about how they perform their jobs. I can’t be there with them every second of the day, so I try to train them properly, then it’s up to them to do things the way they were trained to keep them from getting hurt.” “Russ takes his job very seriously,” says Tom Kenley, community and media relations, Rogers Group. “He has a commitment to safety that translates into how the people working at that plant are committed to safety. They have safety meetings at the beginning of every single shift. They discuss company memos addressing injury alerts and near misses at other plants. Those are reviewed face to face with the employees. They also discuss what’s going on at the plant that day. If anyone will be visiting, they discuss where that person will be, the time frame, and things to look out for. If they are expecting any unusual activity, they will review that so that everyone is aware of what’s going on.” One way Whites Creek has continued to maintain its safety record is through the use of safety audits. Rogers Group put together a safety committee formed of hourly employees from all the quarries in the region. The committee gathers at one quarry location each month to walk the whole plant. They look for anything that might cause an accident or allow someone to get hurt and take a picture of it. Once the audit is finished, the committee sits down with the corporate safety manager, the plant

PLANT PROFILE

manager, and the production manager and goes over the pictures to determine what needs to be fixed and prioritize the items according to what should be fixed first. “At a later date, the committee comes back for a review and to make sure everything on the list was taken care of,” Matthews adds. “It’s pretty good to get a different set of eyes on what you see every day. It really helps in the long run.” The great safety record at Whites Creek helped Rogers Group garner recognition from the National Stone, Sand and Gravel Association (NSSGA) in the form of an award two years ago. The company received the NSSGA Sterling Safety Award, which is given to the NSSGA member company that maintains the lowest accident incidence rate based on Mine Safety and Health Administration data. AM

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

Volvo 220-E loader Caterpillar 988-B loader Caterpillar 988-F loader Caterpillar 769 haul truck Komatsu HD-465 haul trucks (2) Caterpillar 613-B all-terrain water truck Bobcat S-185 dozer Caterpillar D-7 dozer Volvo 460 track hoe Pioneer 42-48 jaw crusher Symons 5 1Z2 cone crusher Symons 77 vertical shaft impact crusher 6x16 Deister scalping screen 8x20 Deister finish screen 6x16 Deister wash screen

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AGGREGATES MANAGER November 2014

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PULL-OUT GUIDE

OPERATIONS ILLUSTRATED Crushing for Particle Shape

Crushing for shape typically takes place at the tertiary and quaternary stages.

A lower reduction ratio will result in a better particle shape.

Geology plays a part in crusher choices.

High-speed cones and VSIs will produce cubical products.

OPERAT 1

The quest for cubicity

Crushing For Cubicity

ost crushed stone and sand is produced for use in concrete and asphalt, and there is general agreement that a cubical stone is ideal for use in these products. “The more elongated and flaky the material is, the more water, cement or binder you require,” says George Fensome, area manager, Americas, for Sandvik Construction’s crusher product line. “A cubical aggregate allows you to reduce the amount of cement and water, while still producing a strong concrete product, so it is better. The benefit is similar for asphalt,” he adds. According to Bradly Estes, plants manager, Western Region, for Granite Construction Co., natural sand is cubical in nature. When it comes to crushing aggregate to form a cubical particle, the geologic makeup, crushing stage, and type of crusher all play a part in producing the desired end product, he says. For instance, in a sedimentary deposit such as limestone, the strength of some rock is lower in one direction than in another due to mineral cleavage and other weak layers that occur in the parallel planes. Rocks with these characteristics tend to become flat and elongated when crushed — especially with compression crushing. “Impact crushing, AGGREGATES MANAGER

more specifically with rock-on-rock action, helps such stone to break along its natural lines, rounding off weak edges and sharp angles so that the particle more closely resembles natural sand,” notes Estes. The goal with primary crushing is to reduce the particle size. Some refining of shape may take place in the secondary stage, but most particle refinement for shape takes place in the tertiary and even the quaternary stages. “Many operators will try to crush with only two stages, but you usually need at least three stages,” Fensome says, explaining that feed size plays into this. A primary jaw or impact crusher may take a feed with a top size of 39 inches. The secondary crusher could take an 8-inch to 10-inch feed. The top size feed for the tertiary crusher may be 4 inches, but typically it is 2 inches. “If you have a jaw, and you’re going for a 2:1 or 3:1 ratio, a 36-inch rock suddenly goes to a minimum of 12 inches,” Fensome continues. “That means you’re feeding a 12-inch rock at the secondary stage to a crusher that may accept a top size of only 8 inches because you’re trying to reduce it too quickly. “People often try to save a penny at the start of the process, and it ends up costing them a dollar more in the end. You can’t cut corners,” he adds.

Typically, when crushing aggregates for particle shape, the desired output is a cubical product. In concrete production, a cubical aggregate product requires less water and cement than a flat and elongated product. Similarly, with asphalt production, cubical aggregate requires less asphalt binder. One difference is production of aggregate for Superpave, which does specify a more angular product.

More about crusher choices

It has been argued that rock-on-rock crushing produces the most cubical product. The graph shows the ideal crusher type for aggregate refinement, based on hardness and abrasion. HSIs and shoe-and-anvil vertical shaft impact crushers (VSIs) are preferred for softer, less abrasive stone. Autogenous VSIs and cone crushers are better with more abrasive, harder stone. Ultimately, for product shape, an autogenous VSI will produce the best quality product.

TIONS ILLUSTRATED Crushing for Particle Shape 2

Setting the stage

Geology plays a part

The main job of the primary crusher is to reduce the particle size, with product shaping taking place at the secondary or tertiary stages. Some operations may finish the product at the secondary stage, but most will require at least three stages of crushing. Closing the circuit at the third or fourth stage also will help to refine particle shape because it allows for crushing at a lower reduction ratio, which improves shape.

To a degree, geology dictates the type of crusher required to produce cubical aggregate products. For instance, limestone has lower abrasion characteristics and is softer than granite or basalt. For limestone production, primary and secondary horizontal shaft impact (HSI) crushers will help produce cubical product. With granite and basalt, compression crushing through a primary jaw and secondary cone is often required.

A few thoughts on cones

Modern, high-speed cones can produce a cubical product, where their older-style counterparts cannot, due to the fact that they create rock-on-rock crushing within the chamber. The key to success is to ensure the cone is consistently choke fed, with an aim toward a lower reduction ratio. A benefit is that a modern cone crusher also is economical to operate over time because wear costs are typically low.

Success with a VSI

OUR EXPERTS Bradly Estes is the plants manager for the Western Region of Granite Construction. Based in the Seattle, Wash., area, he oversees the materials business for Granite’s Washington region, including numerous aggregate, recycle, and HMA facilities. Estes started with Granite in June 2003 and has held positions in engineering, plant management, and materials management over the past 11 years. He holds a bachelor’s degree in mining and mineral engineering from Montana Tech, of the University of Montana.

George Fensome is the area manager, Americas, for Sandvik Construction’s crusher product line. He is based in Chilcompton, United Kingdom. Fensome has more than 23 years in the crushing and screening industry. His experience within Sandvik goes back to 1991, when he joined Svedala, a company later acquired by Sandvik, and has included several positions in product line and sales management. During this time, he has also been involved in the development of several crusher components patented by Sandvik.

It may seem counterintuitive, but the faster the speed with a VSI, the lower the throughput — with greater production of undesirable crusher fines. Every crushing chamber has an ideal speed at which it produces the best mix of product quality and production rates. Slowing a VSI crusher will improve product shape while producing fewer minus-200s and providing greater tonnage per hour.

November 2014

OPERATIONS ILLUSTRATED Voices of Experience Bradly Estes

“T

ypically, a cubical aggregate product is what you want in the end,” says Bradly Estes, plants manager, Western Region, for Granite Construction Co. “But sometimes certain specs, such as Washington DOT Superpave, require a minimum angularity for your fine aggregate that pushes you away from cubical.” That said, Estes says that the geologic characteristics of a deposit will dictate what effort is required to make a cubical or angular product. “You look at the finished product you want to make and the aggregate material that is available, and select your crusher for each stage based on those parameters,” he says. If a deposit tends to produce an end material that is flat and elongated, compression crushing may exacerbate the problem by creating a more angular particle. A higher reduction ratio also will produce a more angular aggregate product. “Some form of rock-on-rock crushing is usually required to make a cubical product,” Estes notes. “With rock-on-rock, the aggregate will break along the natural lines and round off the weak edges for a smoother particle that is similar to natural sand.” Impact crushers are the first crusher types that come to mind for rock-on-rock crushing, whether they are horizontal shaft impact crushers (HSIs) or vertical shaft impact crushers (VSIs). Modern, high-speed cone crushers using a fine cone liner configuration also will provide some rock-on-rock crushing , as long as they are kept choke-fed. “Most producers are familiar with a jaw-cone-cone configuration,” Estes says. “And most times, a cone is the cheapest way to go over the long haul. Wear costs are low over time with the modern cones, and you do get a good particle shape. But if you’re looking purely at particle shape, an autogenous (rock-on-rock) VSI is best. The modern cones still cannot produce a particle shape that is as good as what you can get from an autogenous VSI.” Coming from the West Coast, Estes says that many alluvial sand and gravel deposits in his region yield pea gravel that is difficult to crush with a cone. “In order to create the high-fracture aggregate we need for asphalt, we often need a VSI that will nick and fracture the gravel, versus a cone that has a harder time breaking it,” he says. Estes offers some additional tips for achieving a desired particle shape in crushing. • A lower reduction ratio will yield a better product shape than a larger reduction ratio in one stage. • A closed circuit allows the machine to be consistently choke fed. • Choke feeding a cone increases the rock-on-rock crushing action. • Slowing a cone crusher allows more throughput and less reduction, but produces a coarser product. • Slowing a VSI reduces the fracture count for better product shape, while producing fewer minus-200 fines. AGGREGATES MANAGER

George Fensome

eological characteristics will dictate many of the considerations for crusher type. According to George Fensome, area manager, Americas, for Sandvik Construction’s Crusher Product Line, a softer rock that has low abrasion characteristics, such as limestone, may call for a horizontal shaft impact (HSI) crusher at the primary and secondary stages. “For basalt and granite, a jaw and cone may be the best choice for the primary and secondary stages,” he says. When you get to the tertiary stage, especially with a harder and more abrasive material, if you want a cubical fine aggregate product, your best choice is an autogenous VSI (rock-on-rock vertical shaft impact crusher). What Mother Nature achieves over millions of years to make cubical sand – through weathering, erosion, glacial deposits, and so on — a VSI crusher can accomplish in seconds.” Fensome explains that producers and manufacturers are more familiar and more comfortable with cone crushers than VSIs. VSI crushers gained some popularity in the 1990s with the advancement of asphalt pavement technology, but they also have a reputation for being high-maintenance. “It’s true that a VSI will take more looking after than a cone, but the product you get out of a VSI is better quality,” says Fensome. “As the mantle and bowl liners wear on a cone, and you continue to tighten it down, eventually you are going to get material that is out of spec. With a VSI, even when your wear parts become more worn, the product gradation never changes,” he adds. Feed size and reduction ratio are critical at any stage, says Fensome. For a tertiary VSI, the maximum feed will be approximately 2 inches. For this reason, a VSI will never be suitable as a primary crusher. A primary jaw or HSI must reduce material quickly. The secondary crusher reduces the material even more. At the tertiary stage, refinement for shape begins to take place. “Every crusher has its ideal application dictated by physics. When you try to use a crusher outside of the boundaries it’s capable of, you’re going to have problems,” Fensome says. He adds that every crushing chamber is designed to operate optimally at a certain speed, and VSIs are no different. “The faster your speed with a VSI, the lower your throughput and the lower your product quality,” Fensome notes. “It is the rockon-rock action that gives you the correct fracturing to produce a cubical product from rock all the way down to sand, and 51m to 55m per second is ideal for that. At 65m per second, the crusher becomes inefficient. By slowing it down and introducing the proper feed, you will hit that sweet spot where the material impacts correctly.”

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Cutting-Edge Components To achieve peak performance, conveyor owners need to ensure their idlers, pulleys and accessories are properly maintained. Historically, that meant countless hours of expensive maintenance and exhausting repair. That was before wing pulleys that reject wedged rocks, training idlers to straighten crooked belts and single-mount scraping systems that automatically maintain tension. Stay tuned, we’re not done inventing yet...

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

Top financed crusher brands

Top financed new crusher

Cedarapids, 24 units Metso, 16 units KPI, 13 units BL-Pegson, 13 units

Sandvik QJ-341 (8 plants)

Top financed used crusher - tie

Top three states for crushing buyers* Texas: 17 units Michigan: 10 units Washington: 8 units

*Oct. 1, 2013 to Sept. 30, 2014, includes both new and used financial sales, includes crushers and crushing plants.

BL-Pegson N/A (3 units) BL-Pegson Premiertrak (3 units)

Crusher buying patterns

*Jan. 1- Sept. 30, 2014

New

250

Top financed new crushing plant - tie

200

Used: high 215 in 2011

Used: low 135 in 2009

150

Inertia 5066-Hawk (3 plants) Lippmann 6224 (3 plants)

100

Used

New: high 76 in 2011 New: low 41 in 2009

New, used crushing equipment year-over-year change*

Oct. 1, 2013 to Sept. 30, 2014 Source: EDA, edadata.com (Note: EDA reports are continually updated.)

New: 2014: Increase of

2014*

2013

2012

KPI FT-4250-CC (9 units)

2011

2010

Top financed used crushing plant

2009

Used: 2014: Decrease of

37%

*Comparison of number of crushers and crushing plants financed Oct. 1, 2013 - Sept. 30, 2014 and Oct. 1, 2012 - Sept. 30, 2013.

Stationary Crushers

Sponsored Information

Mobile Tier 4 Final cone crusher

Kleemann says its new Mobicone MCO 9i EVO/MCO 9i S EVO mobile cone crushers offer high-productivity secondary or tertiary crushing in a fuel-efficient, Tier 4 Final emissions-compliant machine. The S-version provides a discharge conveyor-mounted final classifying screen with oversized aggregate return conveyor that permits a closed material cycle and production of final particle sizes without a standalone screen. The oversize can also be discharged via the swivel-mounted return conveyor at the side. The unitâ&#x20AC;&#x2122;s diesel-electric drive provides low fuel consumption in a compact design. Optional crusher anti-spin and automatic lubrication functions make for high crushing capacities and durability. Its power plant generates 332 horsepower at 1,500 rpm, and the optimized crusher housing design permits more than 287 horsepower to be continuously available to the crusher. The cone diameter permits a raw feed capacity of 287 tons per hour, with a feed size maximum of 8 1/4 inches. Kleemann | www.wirtgenamerica.com

Cost-effective tracked impactor

KPI-JCI and Astec Mobile Screens offer its new GT440 Horizontal Shaft Impact Crusher. The track-mounted crusher features an Andreas 4240 HSI crusher, which includes a threeor four-bar rotor configuration, allowing the end user to select the best solution for the application. The unit uses a vibrating grizzly feeder with a large hopper and an optional grizzly pre-screen designed to keep the crusher fed and operating efficiently. The pre-screen consists of independent vibrating fingers that resist blinding and plugging. The replaceable pre-screen module provides multiple settings for scalping unwanted material. The crusherâ&#x20AC;&#x2122;s hydraulic drive optimizes crusher capacity without sacrificing blow bar wear. The 5- by 10-foot, two-deck screen offers 100 square feet of screen area and provides quick, thorough screening. KPI-JCI and Astec Mobile Screens | www.kpijci.com

High-production portable plant

Terex Minerals Processing Systems introduces the Terex Cedarapids CFJ3750 plant, which combines a JS Series jaw crusher with a high stroke, 52-inch by 20-foot vibrating grizzler feeder to create a high-production portable crushing machine. The system boasts a new hopper design to handle severe primary applications, while the jaw crusher features improvements such as wedge release jaw dies and hydraulic-assist crusher settings. Isolation of the jaw reduces plant vibration, while the tail of the product conveyor lowers for operation, maximizing clearance under the crusher. The conveyor discharge adjusts to reduce material impact on the receiving conveyor. Terex Minerals Processing Systems | www.terex.com

Hydraulic breakers should be properly sized for the carrier.

Spillage in the load zone can not only be costly, but dangerous.

Conveyor

Maintenance:

Safety First

Put your workers first when performing belt maintenance. by Ryan Grevenstuk

here are two main types of belt maintenance: reactive maintenance and proactive maintenance. The first, reactive maintenance, involves a problem that occurs on your beltline that needs to be fi xed to avoid extended downtime. The second type, proactive maintenance, involves assessing your system and determining what needs to be addressed before a problem occurs. When it comes to belt maintenance, however, worker safety is anything but routine. Safety is of utmost importance on the job site every day. Workplace accidents are painful to both workers and the bottom line. Even one small injury can not only affect productivity, but can also result in medical bills and a workersâ&#x20AC;&#x2122; compensation claim. Whether you are performing proactive main-

AGGREGATES MANAGER November 2014

tenance or reacting to a repair need, preparing to work safely is key. In addition to wearing personal protective equipment, using appropriate lock out/ tag out procedures, and making sure youâ&#x20AC;&#x2122;re secured to a sturdy structure, following the proper procedures and using the right products is an essential part of safe and successful belt maintenance.

Proper lifting

When conducting maintenance that involves lifting a belt, using the proper equipment is paramount to safety and success. Lifting a tensioned conveyor belt out of the way to perform maintenance work is a difficult job. It can not only be time consuming, but extremely dangerous if not done correctly. Easy-touse belt lifters can help make the job safer and easier.

EQUIPMENT MANAGEMENT

The right belt lifter can raise a belt even when it is tensioned up to the stated ratings, and some are adjustable to lift troughed or flat topside belts. Choose one that lifts the belt from underneath instead of clamping onto the belt’s edges or cover.

Safe splice installation

One of the most common maintenance tasks involves replacing worn or damaged belting. In this case, installing mechanical belt fasteners is a quick and easy way to get the belt back up and running. There are a few safe maintenance tips to remember when installing a splice. These tips not only keep workers safe, but also ensure that you have achieved a proper splice. • Clamp the belt. This is a necessity every time you repair a belt. Serious injuries are possible when clamping is done without using the proper tools and products. Choose belt clamps that have been designed specifically for work on conveyor belts. Made with durable materials, these belt clamps are more reliable than a piece of lumber that can easily snap under pressure. The best belt clamps provide even tensioning across the entire belt width and are typically available in a variety of sizes. Finally, many quality belt clamps now feature “safety pins” — retaining pins that prevent the scissors from slipping off of the clamp bar — which are an added layer of security. • Square the belt. An accurate, squared cut will enhance belt and splice performance and ensure that the belt tension is distributed evenly across the belt. It also discourages mistracking, which can occur when a cut is made on an angle, causing the belt to wander. While the utility knife is an attractive option because it is readily available and inexpensive, it can be a safety and accuracy nightmare. Working with an exposed blade always presents a safety hazard, and when you pair that with the several passes it takes to complete the cut, it increases the risk of injury and decreases the chances that you will have a straight and accurate cut. There are two main options when it comes to belt cutters — hand-powered and electric. Finally, finding a belt cutter with an enclosed blade is a big safety advantage, as any exposed blades are inherently dangerous. • Skive the belt. While skiving isn’t a necessity in terms of safety, it is a necessity in terms of maintenance. Skiving the belt reduces the splice profile for better interaction with belt cleaners and the rest of the conveyor system. When choosing a skiver, look for a compact, lightweight model for working in cramped spaces with an enclosed blade for safety pur-

If a belt is constantly hitting a structure, it could shave layers off the belt until there is little left, resulting in material spillage. poses. In addition, it is important to measure the cut from the most worn part of the belt, as removing the top cover of the belt does not compromise the strength of the belt, but cutting the carcass will. • Choose the right fastener. Depending on the type of belt you are running and the materials you are conveying, you’ll want to make sure you choose the correct fasteners for the job. Selecting the proper fastener involves taking three primary factors into consideration — belt tension, belt thickness, and pulley diameter. That isn’t to say these are the only things that should be taken into account. The type of material that is being conveyed and other important applicationspecific details should also be considered. Matching the fastener to the application helps ensure a strong, long-lasting splice. This means less of a chance of sudden failures that can put workers at risk.

When you perform proactive maintenance, issues such as mistracking can be identified and fixed with products like this belt positioner. AGGREGATES MANAGER November 2014

your maintenance team follow in order to ensure that all parts of the system, components, and even the conveyor structure are working correctly. Some of the most obvious assessment duties involve splice inspection, gauging your belt and idler wear, looking for any signs of mistracking and material spillage, checking for belt slippage, and evaluating carryback.

Maintaining your belt cleaners Inspecting the belt cleaner is just one of the steps you can go through when evaluating their performance.

Proactive maintenance is key

If you periodically assess your system, you can detect potential problems before they lead to costly repairs, unscheduled downtime, and potential worker safety issues. These assessments should be done daily by your maintenance crew and once or twice a year by a third party for maximum effect. Daily assessments should include a checklist that members of

Carryback is a major contributor to the cost of maintaining the system. Proactive maintenance on belt cleaners can be just the answer for any carryback problems that may be occurring on your system, all the while extending the life of your other components. Properly maintained cleaners are less likely to cause damage to belts and fasteners in comparison to cleaners that are installed and ignored until it’s time to replace them. When approaching cleaner maintenance, there are three simple principles to remember: Clean it. Inspect it. Tension it. • Clean it. It may sound obvious, but the first rule of thumb with cleaners is to remove any debris from the blade and tension springs. Tensioners can’t do their jobs with debris stuck in them, and removing material build up from blades will make

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“The Story of Cubee the Aggregate” Coloring Book Cubee and his aggregate friends take children on a magical journey from the quarry to the community to see how aggregates are used in our schools, roads, and structures. It’s a great story combined with 20 pages of coloring fun. For students in grades K-3. Prices range from $1.20-$1.85 per book, based on quantity. Customize books with your company logo!

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EQUIPMENT MANAGEMENT close you are to complete wear and the approximate amount of time it took to get to that point. • Tension it. Tension the blade to accommodate the blade wear. In most cases, this is done quickly and easily by referencing the tension check decal on your cleaner or the operations manual and measuring the tension spring to ensure the blade is properly tensioned.

Identifying and addressing mistracking Fixing a problem with carryback may be as simple as adjusting the tension on your cleaners for a safer, more productive operation. them much more effective. Plus, a dirt-free cleaner is much easier to inspect. • Inspect it. A simple visual inspection can do wonders for a cleaner. You can check to see that everything is in working order and replace any damaged components. When it comes to blades, inspect the visual wear lines to ensure that the blades have not reached the end of their lives, and make note of how

Mistracking is a maintenance issue that can be handled reactively or proactively. If you are experiencing spillage of large amounts of material that can injure a worker either by falling on them or presenting a slipping hazard, it is reactive maintenance. If you notice your belt is mistracking a bit during a routine assessment and can fix it before it becomes a major problem and lost revenue, it is proactive maintenance. Belt mistracking can cause damage to your belt and conveyor structure that could lead to serious problems. In some cases, layers of the belt can be shaved off the sides, which can spill material off the topside onto the area, as well as onto workers around it.

CRUSH. FEED. PROCESS. CONVEY. STORE. Jeffrey Rader ®, a brand of TerraSource Global, is a leading manufacturer of crushers, feeders, conveyors and other equipment for the aggregates, coal and mining industries. Our line of electromagnetic and electromechanical vibratory feeders are unsurpassed in quality, durability and output. With unit capacities of up to 2,500 TPH and one of the quickest delivery schedules in the industry, we can build and ship your equipment when you need it and guarantee it to work. Contact us today for more information. We also offer market-leading equipment and systems for ... Screening & Processing Size Reduction Material Handling Storage & Reclaim Pneumatic Feeding

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Handling a World of Materials

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Printed version of the Aggregates Manager 2014 Aggregates Industry Atlas

not enough for Then you’ll want you? its companion… Atlas on CD

While the printed version of the Aggregates Manager 2014 Aggregates Industry Atlas, will become an integral part of doing your job, perhaps you’ll need additional information about companies listed in the atlas.

If so, we have the perfect companion, the Atlas on CD, which contains information about mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more. The Atlas on CD, which contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2014 Aggregates Industry Atlas in pdf format. Order additional copies of the Aggregates Manager 2014 Aggregates Industry Atlas on CD or the printed version of the Atlas today!

Atlas 1-5 copies 6-20 copies 21-49 copies 50 copies or more

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EQUIPMENT MANAGEMENT Before finding a device that can help solve your problem, you and downtime, so minimizing that time with proactive maintemust first identify what type of mistracking you are experiencnance inherently limits the opportunity for injury. Routine maining. If your belt is constantly moving back and forth, you are tenance of your system and components is the hallmark of any experiencing wander. If your belt runs to one side constantly, it great safety program — saving you time, money, and injury. AM is simply mistracking. The device you choose depends on which type of mistracking is occurring, along with the belt tension, belt Ryan Grevenstuk is Flexco’s senior product manager. speed, thickness, width, and whether the belt reverses. • Belt positioners — A proper belt positioner is the simple, reliable solution for problem belts that consistently mistrack to one side of the conveyor. A belt positioner works on the return side belt, using simple angled rollers mounted YOUR Rock, Any Size, Any Tonnage, Anywhere… in a fixed position to quickly and continuously funnel the belt into the correct path. This is a quick, simple solution for belt tracking problems caused by conveyor misalignment mishaps, ground shifts, or on temporary systems. • Belt trackers — For top side or return side belts that wander from side to side, it is best to choose an active belt tracking device that adjusts based on the movement of the belt. An active belt tracking device that affects both friction and the belt tension will most effectively track w Oja PR the belt. Many of these belt tracking one Oc PR devices will also have guide rollers that een scr RO P help actuate the movement of the belt ax kM Roc x tracking device. Ma and S • Reversing belt trainers — Reversing Box ts ar t m lan S belts typically need a different style of eP l b ta rk for Por t. belt tracking device designed to work to wo Wear Cos d e e t d n n a a r in both directions. Before putting a belt Gua rmance rfo cts… r’s st Pe e rodu B tracking device on your belt, clarify that the est P nufacture B e h a T est M ranty it will work on reversing belts if the apr the B with 5 year wa plication warrants, otherwise, it may do more harm than good.

GOT HARD ROCK? ! T S E B T THE

All Dealer and Manufacturer Representative Inquiries welcome.

General safety

When it comes to safety, it is important to receive proper training and follow the suggested guidelines outlined by health and safety administrations in your area. Many injuries occur during times of maintenance Untitled-1 1

Rock Engineered Machinery Co. Inc. 263 S. Vasco Road • Livermore, CA 94551 • USA Tel (925) 447-0805 • Fax (925) 447-7038 Email: crush@remcovsi.com • Website: www.remcovsi.com Worldwide Products of REMco

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10/20/14 11:03 AM AGGREGATES MANAGER November 2014

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Come to World of Concrete, roll up your sleeves and try your hand at the year’s newest products, equipment and services. Technology, training, resources and ideas—zoom in at the industry’s only annual international event designed specifically for commercial concrete and masonry professionals.

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

LIKE A WELL-OILED MACHINE When it comes to protecting equipment, oils and lubricants play a critical role.

New category of severe-duty motor oil Chevron Products Co. unveiled a new category of motor oil. Delo 400 SD SAE 15W-30 is an API CJ-4 heavy-duty diesel engine oil formulated using a new patent-pending technology to provide benefits for engines with “severe duty” cycles in on- and off-highway applications. Key benefits include engine protection in severe applications, maximum vehicle utilization and minimal downtime resulting from oxidation stability and deposit control, and improved fuel economy compared to conventional oils in its class. It is formulated for use in Tier 4 compliant low-emission diesel engines with Selective Catalytic Reduction (SCR), Diesel Particulate Filter (DPF), and Exhaust Gas Recirculation (EGR). Chevron Products Co. | www.chevron.com

High-pressure delivery filters Filtering oil prior to dispensing it into equipment is critical to meet the ISO cleanliness specifications demanded by today’s OEMs. Donaldson says its Bulk hP filters provide high-efficiency filtration in a single pass, at system pressures up to 1,000 psi (69 bar). The filters remove contaminants delivered in oil and picked up in storage or delivery lines during final transfer and help to ensure the required ISO cleanliness level is met. Donaldson | www.mycleandiesel.com

Oil analysis management system Analysts, Inc. released version 1.2 of is Lube Oil Analysis Management System, which is said to be a user-friendly, cloud-based customer interface. The application gives users the control to keep lists clean and sampling histories intact along with the ability to add, delete, update, merge, and move units between locations. Users can register samples online and print bar-coded sample jar labels, which allows them to maintain scheduled sampling intervals and track samples. The application’s search and filter capabilities are also more robust. Analysts, Inc. | www.analystsinc.com AGGREGATES MANAGER November 2014

Stuck in the

Middle? Don’t underestimate the importance of middle management; it puts ideas into action.

by Zach Knoop

s it logical to think that one level in the organization holds the key to safety performance? Often times, we speak of the importance of top management in setting the “tone from the top” and supervisors leading the daily charge in ensuring safe work conditions and safe employee behavior. There is no doubt that top management and supervisors play a key role in an effective safety system, but are they the “key?” Who is responsible for restating and putting top management’s commitment into action? Who is responsible for holding supervisors accountable for leading the daily charge in safety? The answer is middle management. A glaring problem with most traditional safety systems is that they ignore the role of middle management within the system. This group tends to be absent from the process, so the work of managing safety is left to the safety director or supervisors, who do what they can and hope for the best. “You do not produce safety with middle management, but you cannot produce safety without it,”

AGGREGATES MANAGER November 2014

said Dr. Dan Petersen, who established the Six Criteria for Safety Excellence. In other words, middle managers are a key component of a successful safety system. It is quite simple; supervisors will do what they believe is important to their boss — “they will react and respond to the priorities, the wishes, the measures, and rewards,” as defined by their boss. The company safety director is typically not the boss of your front-line supervisors and foremen, and, therefore, will be more challenged in influencing supervisory safety performance without the active involvement of middle management. So what is the role of middle management in establishing safety as an organizational value and in driving safety performance? In Petersen’s Six Criteria, the second criterion dictates that middle management be actively involved. According to Petersen, the role of middle managers in actively demonstrating their commitment to safety is threefold and should be no different from how they manage quality and production. The three requirements of middle managers are:

SAFETY EXCELLENCE

Ensure supervisory performance of safety-related activities. Supervisors have to understand that safety is part of their scorecard. If not, they are less likely to demand safe production from their employees. Middle managers can ensure supervisory performance by requiring, reviewing, and responding to safety reports from supervisors on their defined safety activities, and by participating in various safety activities with their supervisor.

Ensure the quality of supervisory performance of safety-related activities. Performance measurements have to go beyond looking only at lagging indicators (injury statistics) and reports that indicate whether supervisors are completing safety tasks (quantity). There must be a quality check by the manager to determine how well the safety activities are being executed. An ineffective safety meeting with employees does nothing to improve safety. The role of the manager is then to periodically conduct spot checks on the defined safety activities and measure them against the quality standards. Where performance issues are noted, the manager can help to improve the skills necessary to meet the desired expectations. Managers can also inspire the continuation of performing quality safety activities by recognizing supervisors when they do a good job.

Demonstrate your belief that safety is important. There are many activities that middle management can perform to achieve this.

Six Criteria for Safety Excellence Top management is visibly committed. Middle management is actively involved. Front-line supervision is performance-focused. Employees are actively participating. System is flexible to accommodate the culture. Safety system is positively perceived by the workforce. Here are a few to consider: a. MBWA, or Management By Walking Around â&#x20AC;&#x201D; make yourself visible to the workforce and model safe behavior. Spend time talking to employees about safety and focus on being positive and catching people doing things right. b. Participate as often as you can in safety meetings, workplace examinations, and other safety activities. c. Hold one-on-one meetings with your supervisors to discuss safety and how you can support them. d. Provide your supervisors with the necessary time to complete their safety activities and provide ongoing safety training to their employees. e. Prepare a routine safety report for your boss based on safety reports from your supervisors. The Six Criteria suggest there isnâ&#x20AC;&#x2122;t a singular key to safety performance, or an individual group within an organization whose involvement makes or breaks the

culture. Rather, we could liken the criteria to a combination lock in which the alignment of multiple digits grants access to peak performance. In the October issue, I explained how top management aligns itself with the goal through visible commitment. Now, we know how middle managers can lock into the effort. In next monthâ&#x20AC;&#x2122;s issue, we will look at the critical role supervisors play in a culture of safety excellence. AM

Zach Knoop is a senior safety consultant and project manager for Caterpillar Safety Services. He works with Caterpillar customers in the aggregates and construction industries to coach leaders, train supervisors, and engage employees in building cultures of safety excellence. He can be reached at SafetyServices@cat.com. AGGREGATES MANAGER November 2014

by K. Brad Oakley

Rock Commission upholds MSHA’s use of non-final violations in POV determinations.

CHALLENGES Continue on POV Rule I

K. Brad Oakley is a member in Jackson Kelly PLLC’s Lexington, Ky. office, where he practices with the Occupational Safety and Health Practice Group. He can be reached at 859-288-2835 or via email at kboakley@jacksonkelly.com.

n January 2013, the final Pattern of Violations (POV) rule was announced by the Mine Safety and Health Administration (MSHA). MSHA amended the POV rule by making two significant changes: it eliminated the preliminary Potential Pattern of Violations (PPOV) notice and review process and the requirement that only violations becoming final orders be used for POV determination. The rule also states that MSHA will review certain data each year to determine if mines meet specific POV “pattern criteria,” which are to be posted on MSHA’s website. MSHA enforced the POV rule (30 C.F.R. Part 104) for the first time in October 2013, placing four mine operators on its POV list. National trade associations and a few mine operators challenged the rule in federal court. On Aug. 19, 2014, the Sixth Circuit Court of Appeals held that it lacked jurisdiction to review this challenge. Nat’l Mining Ass’n et al. v. Sec’y of Labor, Docket Nos. 133324/3325, 2014 WL 4067867 (6th Cir. Aug. 19, 2014). Brody Mining recently brought a facial challenge to the POV rule in front of the Federal Mine Safety and Health Review Commission (Commission). A 4-1 majority held that the rule is facially valid and that it was not applied in an impermissibly retroactive manner to Brody. Brody Mining, LLC v. Sec’y of Labor, WEVA 2014-82-R et al., 2014 WL 4491147 (Aug. 28, 2014).

AGGREGATES MANAGER November 2014

The Commission upheld the use of non-final violations in making the POV determination. Finding the term “violation” in § 104(d) to be ambiguous, the Commission deferred to the Secretary’s interpretation. It noted that the POV provisions of § 104(d) parallel the unwarrantable failure provisions of § 104(e), which do not condition enforcement on having a final order. The majority ultimately found the Secretary’s interpretation to be consistent with the language, structure, and history of the Mine Act. The Commission next rejected Brody’s assertion that the POV regulations were “arbitrary, capricious, an abuse of discretion, or otherwise not in accordance with law,” in violation of the Administrative Procedure Act. Brody argued that, in adopting a rule basing POV determinations on non-final S&S citations, MSHA failed to adequately consider that S&S citations are overturned at a significant rate upon review. However, the Commission found that MSHA expressly considered evidence that S&S citations may be subsequently changed or overturned, and that there was a rational connection between the facts considered and the policy choices made. It found that even if 20 to 30 percent of S&S citations were overturned, there could still be a significant number of violations on which to base a pattern determination. Furthermore, the prior rule requiring final orders resulted in substantial delay between the issuance of citations

ROCKLAW

and a possible POV determination. The majority found that this inhibited MSHA from effectively considering recent citation history in making POV determinations. Brody also argued that MSHA irrationally ignored the safety and compliance benefits of the PPOV process. However, the Commission found that the agency rationally concluded that PPOV failed to effect “systematic, long-term improvements,” and that the current rule provides “more sustained improvements” by placing more responsibility on mine operators to maintain compliance. The Commission unequivocally rejected Brody’s due process challenge to the rule. The Commission did find, contrary to the administrative law judge, that Brody had a strong private property interest in continuing its mining operations. However, the Commission determined that the government’s interest in basing POV determinations on non-final orders was strong. Furthermore, the final factor in the due process analysis — the risk of erroneous deprivation of property — was adequately addressed by the POV process and other post-deprivation procedures available to operators. For example, the Commission noted that the online monitoring tool provides operators with the opportunity to address errors before incurring a POV designation; operators can further address citations during closeout conferences and request expedited hearings for citation contests when nearing POV designation. The Commission also noted various “post-deprivation” (i.e., post-POV) litigation options, such as seeking expedited temporary relief under section § 105(b)(2) of the Mine Act or expedited proceedings on contests of withdrawal orders. Finally, the Commission rejected the argument that MSHA’s initial POV pattern criteria required notice-and-comment rulemaking. It found that the pattern criteria are a general statement of policy rather than a legislative rule, as they allow for sufficient agency discretion in their application. The Commission also held that the rule was not impermissibly retroactive and that the Secretary could consider citations before the effective date (March 25, 2013) in assessing POV status. Commissioner William I. Althen filed a dissent, finding the pattern criteria to constitute a binding norm requiring notice-and-comment rulemaking. Commissioner Althen pointed out that the revised rule does not even define the “pattern” that would result in POV status; yet, it instructs MSHA to create “arbitrary numerical criteria” to implement this vague statutory term. Commissioner Althen also found the POV procedures to

violate due process and would require MSHA to include a measure of pre-deprivation review into the lengthy POV determination process. He discounted the Secretary’s claim that the POV rule served any government interest in immediate correction of imminent health or safety hazards, calling POV “a long-term weapon aimed at culture rather than specific hazard.” The holdings and arguments outlined in this article may be scrutinized yet again, as the Brody decision has been appealed to the D.C. Circuit. Until review by a higher court, however, MSHA’s “criteria” approach to pattern determination remains the rule going forward and entrusts MSHA with significant discretion in determining which mines qualify for pattern designations. Consequently, mine operators must take all available precautions, including monitoring compliance performance, implementing specific compliance goals, and collecting as much evidence as possible regarding citations issued in order to maximize the likelihood of a successful outcome should a POV notice be issued. AM

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In Stone THE GHOST Sect TOWN ion

by Bill Langer

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

From the Amboy Crater to Calico, towns rose and fell with the fates of mining.

AGGREGATES MANAGER November 2014

Photo courtesy of the U.S. Geological Survey.

efore we leave Needles, Calif., on our westward trek along old Route 66, we stop and fill up our tank. West of Needles, historic Route 66 veers away from I-40; first to the north, then to the south. We face more than 150 miles of barren desert road littered with relics from the past along what some call the Ghost Town section of Route 66. Riding along this crusty path of road, we eventually come to Amboy. Two extinct volcanoes are located to the west of town. One of those, Amboy Crater, is a 6,000-year-old cinder cone volcano. Once an old Route 66 tourist attraction, the crater stands silent vigil to the small town. But Amboy Crater wasn’t always that way. One day, back in the 1950s, the crater spewed out a black cloud of smoke. Fearing an eruption, Route 66 and the Santa Fe railroad were shut down. A team of investigators was dispatched to investigate. To their surprise and relief, instead of billowing clouds of ash, redhot lava, and steam, they saw a fire of burning tires and trash; a hoax perpetrated by some kids from nearby Barstow! I do not know if this story is true or an urban legend, but it tickles my fancy. We continue westward through a few more old towns. Like many towns we have passed elsewhere in our journey along Historic Route Daggett, Calif., served as home base for a team of 20 mules that transported borax from a mine in Death Valley. 66, many of these desert towns got their start with the railroad, boomed with mining, blossomed while servicing traffic along Route 66, and withered away following the opening of Interstate 40. So it was with Daggett, one of the next towns we come upon. Originally founded in the 1860s, the town boomed when silver was discovered in the Calico Mountains to the north. Borax was also important to Daggett’s economy; for two years, Daggett was the terminal of the 20-mule team run from a borax mine near Furnace Creek in Death Valley. In 1883, the Furnace Creek mine was abandoned for a more favorable borax deposit in the Calico Mountains just east of the Silver Mining District of Calico. Initially, the ore was hauled to Daggett using the 20-mule teams and wagons once used in Death Valley. In 1894, the operators experimented with a steam tractor locally called “Old Dinah.” This experiment was a failure, and, in 1898, a narrow gauge railroad was constructed to ship ore to a calcining plant located just North of Daggett. From 1890 to 1907, these mines, with a total production valued at more than $9,000,000, were the largest producers of borax in the United States. But in 1907, the main borax operations were shifted to new mines back in the Death Valley region, causing Daggett to go into decline. Nevertheless, Daggett tenaciously survives. Before heading on down the Mother Road to Barstow, we take a side trip 7 miles north of Daggett to the historic ghost town of Calico; site of the silver and borax mines. During the late 1800s, while the country was switching from the silver standard to the gold standard, the price of silver plummeted. So did Calico’s population. Just after the turn of the century, the narrow-gauge Calico railroad was dismantled, borax mining ended, and the town slowly died. By 1935, the town was entirely abandoned and left to decay in the Mojave Desert. In 1950, Calico was restored by Knott’s Berry Farm and, subsequently, donated to the San Bernardino County Regional Parks. After catching a glimpse of life during the old mining days, we head to Barstow on our westward journey along Historic Route 66. AM

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