Aggregates Manager December 2015

Top Rollouts 2015

Check out our picks for the year’s best equipment introductions.

December 2015

www.AggMan.com

10 29 44

AggMan of the Year 2015: Kelly Bailey Cut costs with overland conveyors Tips for maintaining your cone crusher

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On Our Cover: Review our top picks for new equipment.

Cover photo courtesy of Case Construction Equipment.

44

As the aggregates industry’s first industrial hygienist, this year’s AggMan of the Year, Kelly Bailey, has spearheaded health and safety practices throughout Vulcan Materials Co. and the aggregates industry.

More and more companies are sending operators for training to ensure the best performance from their crushers.

CONTENTS FEATURE ARTICLES

10 23 34 44 48 50 53

DECEMBER 2015 VOLUME 20, NUMBER 12

AggMan of the Year 2015 An advocate for health and safety, Kelly Bailey leverages science and data to influence how the industry — and regulators — approach worker health issues..

Tennessee Pride Mom and pop company builds its business with a focus on its fleet and taking pride in its work.

Top RollOuts of 2015 It was a big year for big iron with many equipment introductions focusing on fuel efficiency and productivity.

Caring for Your Cone Crusher Understand how training, maintenance, and the right operation tips can maximize their performance.

First Look: Liebherr’s XPower Wheel Loaders Their standard power-split transmission is expected to improve fuel efficiency by up to 30 percent compared to conventional drive loaders.

Better Breakers With features that allow for recycled recoil energy, shock absorption, and elimination of blank firing, today’s breakers are better than ever.

Boy Scouts and Merit Badges Following the introduction of the Boy Scouts’ new Mining in Society merit badge, Cemex offered a one-day camp to help Scouts learn about mining and earn the badge.

OPERATIONS ILLUSTRATED Smooth Conveying

29

Swapping mobile equipment for overland conveyors can reduce overall cost per ton and ease maintenance concerns.

COLUMNS & DEPARTMENTS

3

EDITORIAL Contending with confined spaces.

MINING The latest financial analysis of issues impacting in the 5 DATA industry and Aggregates Manager’s

exclusive aggregates industry outlook.

AND PROVINCE NEWS A roundup of the latest news in North 8 STATE America.

LAW Review Commission determines that the ALJ erred in 56 ROCK invalidating Brody POV notice prior to hearing.

INDEX See who’s who and where to find their products.

58 ADVERTISER ADS Aggregates industry classifieds.

59 CLASSIFIED IN STONE Bill Langer goes straight to the source for a historical 60 CARVED perspective on the Barre granite industry in a one-on-one interview with Toobig Uglyrock.

“With the roller bearing crushers, we don’t pour that steady stream of money into the crusher.”

Kevin Storedahl J.L. Storedahl & Sons

Kodiak® Plus roller bearings reduce operating expenses by up to 50%.

Patented Tramp Iron Relief System significantly reduces stress.

Patented internal counterweights maintain true balance.

Anti-spin cone brake extends manganese wear life.

TOUGHNESS REFINED.

Aggregate

Recycle

Construction

Infrastructure

Mining

Loading/Unloading

Energy

www.kpijci.com

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

December 2015

Vol. 20, No. 12

aggman.com

CONTENDING with Confined Spaces

/AggregatesManager @AggMan_editor

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

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

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

T

he Mine Safety and Health Administration (MSHA) recently issued an alert regarding deaths and injuries related to confined spaces. One recent fatality occurred when a miner was cleaning the inside of a tanker railcar.

Another miner was severely burned while performing maintenance inside

a baghouse screw conveyor hopper.

As a result of these injuries, MSHA will “be placing special emphasis on enforcing its standards related to entering bins, hoppers, silos, tanks, and surge piles.”

Regulations related to confined spaces include the following: • 30 CFR §§56/57.5001(a),

• 30 CFR §§56/57.14105,

• 30 CFR §§56/57.5002,

• 30 CFR §§56/57.15005, and

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

• 30 CFR §§56/57.5005(c),

• 30 CFR §§56/57.16002.

Corporate

that are not necessarily designed for people, but are large enough for workers

Chairman: Mike Reilly

to enter and perform certain jobs. Confined spaces also have limited or restricted

President and CEO: Brent Reilly Chief Operations Officer: Shane Elmore

• 30 CFR §57.5015, The agency also cautions that its definition of “confined spaces” includes areas

means for entry or exit and are not designed for continuous occupancy. Examples

Chief Financial Officer: Russell McEwen

include tanks, vessels, silos, storage bins, hoppers, vaults, pits, manholes, tunnels,

Senior Vice President, Sales: Scott Miller

equipment housings ductwork, and pipelines.

Senior Vice President, Editorial and Research: Linda Longton

Use the following best practices to avoid accidents in confined spaces:

Vice President of Events: Stacy McCants Vice President, Audience Development: Prescott Shibles Vice President, Digital Services: Nick Reid Vice President, Marketing: Julie Arsenault

•

Identify all possible confined spaces at a mine and associated hazards.

•

Inform miners by posting danger signs, and do not allow unauthorized entry.

•

Establish a written standard operating procedure that includes requiring permission to enter confined spaces, as well as communication and emergency

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

plans, and train the miners on the plan.

•

Identify authorized entrants.

•

Isolate the space, and ensure that energy sources are de-energized.

•

Conduct pre-entry testing for oxygen content, flammable gases and vapor, and toxic air contaminants.

Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2015. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406.

Subscription rates: $24 annually, Non-domestic $125 annually.

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

•

Monitor the atmosphere.

•

Assign an attendant to maintain contact with the miner working in a confined space.

•

Do not enter a confined space in an attempt to rescue a downed employee if you don’t know the atmospheric conditions or have special life-saving equipment.

Finally, remember that these rules apply to all miners, regardless of experience.

According to MSHA data, many experienced miners continue to fall victim to hazardous conditions. Use these best practices and stay safe while working in confined spaces.

AGGREGATES MANAGER December 2015

3

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DataMining Stock Report Company

Ticker

Cemex, S.A.B. de C.V. CRH plc Eagle Materials Inc. Granite Construction Inc. Heidelberg Cement AG LafargeHolcim Ltd. ADR Martin Marietta Materials, Inc. MDU Resources Group, Inc. Summit Materials United States Lime & Minerals, Inc. U.S. Concrete Vulcan Materials Co.

CX CRG EXP GVA HEI HCMLY MLM MDU SUM USLM USCR VMC

Current Value

$5.98 q $27.30 q $69.37 q $37.90 p $74.95 q $11.45 q $152.15 q $19.46 p $23.61 p $49.35 q $574.69 p $100.63 p

52-Week High

52-Week Low

$12.37 $30.25 $94.24 $39.09 $82.54 $15.49 $178.67 $28.51 $29.00 $76.98 $61.46 $103.44

$5.88 $18.02 $60.94 $28.45 $58.29 $10.09 $103.09 $16.15 $17.79 $45.56 $25.02 $61.45

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 11/9/15.

U.S. On-Highway Diesel Fuel Prices 11/9/15

One Week

One Year

United States

$2.502

+0.017 p

-1.175 q

East Coast

$2.513

+0.021 p

-1.055 q

New England

$2.549

+0.003 p

-1.110 q

Central Atlantic

$2.620

+0.016 p

-1.014 q

Lower Atlantic

$2.424

+0.028 p

-1.073 q

Midwest

$2.526

+0.010 p

-1.262 q

Gulf Coast

$2.317

+0.027 p

-1.245 q

Rocky Mountain

$2.488

-0.009 q

-1.308 q

West Coast

$2.716

+0.019 p

-1.066 q

West Coast less California

$2.607

+0.058 p

-1.105 q

California

$2.817

-0.014 q

-1.038 q

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

AGGREGATES MANAGER December 2015

5

In November, the Aggregates Industry Outlook (AIO) jumped nearly 7 percent 150 against October, to an overall score of 130.99. The increase came on 130.99 130.00 129.05 128.42 140 the heels of news that the House of 122.49 Representatives passed a six-year 130 bill to spend up to $325 billion on transportation projects. At press time, 120 the House and Senate had appointed 110 conferees from each chamber to reconcile the House bill (the Surface 100 July August September October November Transportation Reauthorization and Reform Act of 2015) and the Senate bill (the Developing a Reliable and Innovative Vision for the Economy Act). While operators are pleased to see both progress toward long-term transportation funding, lack of full funding continues to be a concern.

Aggregates Industry Outlook

Comments: While it is encouraging that the House has agreed on a highway bill, the fact that they are ignoring the long-term funding mechanism is disturbing.

— Bill Schmitz, Vice President, Quality Control and Sales, Gernatt Asphalt Product, Inc.

The weather has played a major contributor in production and sales the last few months, and with the very nice weather, sales have been going through the roof.

— Todd Whitehall, Performance Manager, Oldcastle Materials

(We) carry work from the year, with several new large projects in our area. The new six-year transportation bill has got to help.

— Elisha D. Hall, Jr., Drilling Superintendent, Boxley

Q 6

What’s the outlook for tons of aggregates sold in the next six months?

Looking ahead six months, operators reported the most buoyant expectations since the Aggregates Industry Outlook debuted in July, with an overall response of 4.00 on a 5-point scale.

AGGREGATES MANAGER December 2015

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State & Province

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

NEWS

Indiana

Students from South Putnam Middle School recently spent the day at DePauw Nature Park. According to the Banner Graphic, the field trip is hoped to be the first of many and was highlighted by trails, learning stations, and a dedicated park ecologist, Vanessa Fox. Fox and Park Superintendent Jeremiah Sutherlin have been conducting surveys regarding opening the park to the local community as the university studies usage, development, and management of the park. It consists of 520 acres of wilderness that formerly served as a Hanson Aggregates quarry. Opened in 1917, the land was donated in 2003 from Hanson Building Materials to DePauw University. Since then, the university has purchased adjacent land to form the current property, which includes man-made ponds and streams, as well as underground caves.

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

California

Blue Mountain Minerals recently enjoyed some positive mainstream press. The Modesto Bee reported that limestone quarried by Blue Mountain is spread on croplands to enrich the diets of poultry and cattle, as well as providing nutrients in grass plants that make up some California wine. The 46-employee company is the largest limestone producer in Northern California. It produces more than 500,000 tons per year, but the privately held company declined to cite more specific tonnages. The operation’s limestone is also used in emission controls on coal-fired power plants, glass plants, 35 feed mills, and more than 100 farm supply stores.

Georgia

Berry College reportedly purchased three land lots just north of Redmond Circle near a former Florida Rock Quarry from the Central of Georgia Railroad. According to the Rome News-Tribune, the land was purchased for $498,000.

Illinois

The Marengo City Council agreed to move forward with an annexation agreement and rezoning request for a proposed quarry. Northwest Herald reports that Jack Pease, owner of Super Aggregates, presented his plans to the city and asked for annexation of 80 acres, zoning of 255 acres for manufacturing, and a special-use permit for mining to develop a quarry.

The operator bought the 255-acre property earlier this year for $4.7 million. Pease told the council that the operation would function much like its neighbor, Prairie Material Aggregate. The matter will eventually proceed to council and be discussed at a public hearing.

8

AGGREGATES MANAGER December 2015

Kentucky

A lawsuit about a zoning change to allow an underground mine is headed to the Kentucky Court of Appeals, The Winchester Sun reports. The Southwest Clark Neighborhood Association filed notice it was appealing Clark Circuit Judge William Clouse’s last two decisions in the case. He previously ruled that the Clark County Fiscal Court acted properly in 2014 when it approved a zoning change request from the Allen Co. for 165 acres near the Kentucky River. He ruled that magistrates acted properly and reasonably, based on the information and evidence presented. He also denied the association’s claims that it was not afforded due process and that the fiscal court’s action was barred by the Planning Commission’s bylaws.

Pennsylvania

Mining consultant Meade Gunnell withdrew a petition to have a 132-acre property rezoned from office-institutional to a conditional use of general industrial. According to The Independent Tribune, public outcry against a proposed granite quarry and asphalt plant began after an Oct. 20 Harrisburg Planning and Zoning Board meeting. The following day, a Facebook page, entitled “No Mining in Harrisburg” was created and gained more than 1,700 members. The consultant had agreed to conditions on the property, including monitoring of air quality and providing the town with quarterly air quality reports; leaving 72 acres as a buffer zone; and providing an “impact fee” of a half cent in addition to the normal sales tax rate. Despite the conditions, the public voiced concerns about traffic impact and air quality.

Tennessee

Lt. Col. Stephen F. Murphy, commander, Nashville District, U.S. Army Corps of Engineers, penned a letter to The Tennessean, noting that he and the Corps take safety seriously with regards to a proposed limestone quarry and its impact on the adjacent Old Hickory Lock and Dam. Murphy notes that the Corps conducts an extensive annual inspection of the dam. He also explains that preliminary information provided to the Corps indicates that vibration levels coming from the quarry are within an acceptable range of what the dam was built to withstand. Finally, he notes that the Nashville District is reviewing any impacts to aquatic resources associated with the construction of the quarry.

Virginia

Luck Specialty Products has found a new use for waste material from its quarries in its Luck Ecosystems products, The Freelance-Star reports. Jimmy Rodgers, business development manager for Luck Specialty Products, told the newspaper that one product he’s particularly proud of is used in biofiltration for stormwater runoff from blacktop and parking lots. “It’s kind of a neat thing,” he says. “We’re helping to clean up the waterways with products that had been landfilled or wasted.” Luck Biofilter is a mix of sand, silt, and clay that comes from Luck’s Caroline County quarry. The company also uses sand from the Caroline and Green County quarries in its CourseScience Golf media, which are top dressings used to fill holes created through aeration, and Green Science, a premium topsoil made with the help of Virginia Tech scientists using overburden soil that’s blended with compost.

West Virginia

Inspectors with the West Virginia Department of Environmental Protection issued a violation notice to Essroc’s cement plant near Martinsburg at the end of October. According to Herald-Mail Media, the agency conducted visible emission observations on Oct. 27 in response to complaints of nearby residents. Inspectors found that the average amount of dust obscured by pollution in the air during six-minute blocks of time exceeded the plant’s permitted 10-percent emission limit, with the highest average reaching 40.4 percent. The notice said the company might be subject to civil and/or criminal penalties, including a civil penalty up to $10,000 per day, for each violation. An Essroc spokesperson outlined the steps the plant manager has taken to keep dust from leaving the plant, including a decision to stop a special operation to haul clinker to the company’s sister plant in Nazareth, Pa., which was believed to be causing extra dust “from loading of the trucks and transportation on the roads.”

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Wyoming

Sheridan County Commissioners approved permits for a quarry, The Sheridan Press reports. The 10-year quarry permit approved by commissioners will allow Eaton Brothers Inc. to mine sand and gravel on a 14-acre area of their ranch near Sheridan. According to the newspaper, dust control on the nearby County Road 89 would be paid in part by the county (with an annual limit of $12,500). The quarry will use approximately 6 miles of that road to haul material. The application notes that all homes within one-half mile of the quarry are owned by the Eaton family.

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www.flexco.com AD224_enUS_224_HPvert_Aggman_0615.indd 1 Untitled-4 1

AGGREGATES MANAGER December 2015

9

6/10/15 7:20 AM 6/15/15 1:32 PM

Kelly Bailey has spent more than 40 years improving worker health and safety.

10

AGGREGATES MANAGER December 2015

AGGMAN OF THE YEAR 2015

AggMan of the Year

2015

An advocate for health and safety, Kelly Bailey leverages science and data to influence how the industry — and regulators — approach worker health issues.

by Therese Dunphy, Editor-in-Chief

F

or more than 40 years, the 2015 AggMan of the Year, has worked diligently to protect worker health and safety. As the aggregates industry’s first industrial hygienist, he has pioneered the use of sound science

and data collection and analysis to develop — and share — programs that protect workers. Equally importantly, he has worked to hold government agencies accountable for using the same principals of sound science when developing regulations that impact the industry. For these reasons and more, we are proud to recognize Kelly Bailey as the 2015 AggMan of the Year.

“Kelly Bailey has worked tirelessly and has done an outstanding job for Vulcan and the aggregates industry for more than 35 years,” says Tom Hill, president and CEO of Vulcan Materials Co. “He has led the way in the development and implementation of world-class industrial hygiene programs to protect health and safety at Vulcan and throughout the industry. His contributions are deeply appreciated.”

“Kelly has spent his career relentlessly focused on protecting health and safety in the workplace,” adds David Donaldson, Vulcan’s vice president of governmental and community relations. “He has been equally focused on making sure that there is a strong voice for sound science in the regulatory arena. He is a nationally recognized leader in his field who enjoys the respect, admiration,

AGGREGATES MANAGER December 2015

11

AGGMAN OF THE YEAR 2015

and friendship of many people.”

It’s this kind of support from corporate leadership that has allowed Bailey to take the lead for the industry in a variety of safety and health issues throughout his career. “I’ve been re-

A career well spent

ally fortunate, as a health science professional, to work for Vulcan. I’ve gotten complete support from them, and I’ve been given a lot of latitude to do the right thing before it was required to be done,” Bailey says. “I’ve always believed that you do the right thing, and you don’t wait until you get booted in the fanny to do it.”

Growing health and safety programs Bailey joined Vulcan Materials Co. in 1979 as the senior industrial hygienist of what was then its Chemicals Division. His time was split between the Chemicals Division and corporate duties. In his early years with the company, he became involved with aggregates-related issues as he worked with Jim Christie and Will Lake to monitor noise and dust exposures of workers.

“We did a big study with Dr. Irving Tabershaw’s group,” he recalls. They performed chest x-rays and pulmonary functioning testing at some of the company’s quarries and used results from hearing testing, which Vulcan began in 1976. They worked with Tabershaw to correlate noise and dust data with medical findings. Based on that study, the group recommended that the industrial hygiene program be expanded to cover all quarries and that medical surveillance be implemented on a periodic basis.

12

AGGREGATES MANAGER December 2015

Industry involvement - Chairman, American Chemistry Council’s Crystalline Silica Panel: 2013-Present - Member, Mine Safety and Health Research Advisory Committee: 2002-2006, 2011-2014 - Chairman, NSSGA’s Technical Advisory Committee: 2000-Present - Chairman, NSSGA Safety and Health Committee: 1997-1999 - Chairman, NSA’s OSHA Asbestos Task Group: 1986-1992 - Chairman, NSA/NSSGA’s Occupational Health Subcommittee: 1986-Present - Director, Board of the Industrial Health Council: 1986-Present

Awards - AggMan of the Year: 2015 - NHCA/NIOSH Safe in Sound for Excellence in Hearing Conservation: 2013 - Barry K. Wendt Memorial Commitment Award: 2011 - NSA Safety and Health Professional of the Year: 1993

Joint projects with regulators - MSHA-Noise insulation retrofitting of mobile equipment research of flame resistant material - NIOSH-Whole building ventilation projects, industrial sand and limestone operations - NIOSH-Drill cab dust control ventilation - NIOSH-Ergonomics in mining - NIOSH-Measuring hearing conservation effectiveness - NIOSH/University of Minnesota-Real-time analyzer of diesel particulate matter in underground limestone mine

Benchmarking occupational medical surveillance and industrial hygiene -

3M Cemex Fluor Hanson Lafarge Luck Stone

-

Mathy Construction Martin Marietta Unimin Corp.

U.S. Silica Wake Stone

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AGGMAN OF THE YEAR 2015

helps Vulcan establish the correct priorities for monitoring.

“As the very first industrial hygienist in the aggregates industry, he successfully convinced management at Vulcan and other aggregates companies to be proactive in protecting employees from hearing loss, silica exposure, and other airborne contaminants,” says his long-time coworker Dick Seago. “Kelly not only designed and implemented effective programs to control harmful exposures and protect employees, he willingly shared his programs with other safety and health professionals in the industry. Realizing that this was not enough, he helped to design and implement training programs on methods for conducting industrial hygiene sampling and for implementing controls.”

One example of this is Vulcan’s monitoring program, which became the model for the NSIn 2011, Kelly Bailey was awarded the Barry K. Wendt Memorial Commitment Award. Former Vulcan CEO Don James presented the award to him.

SGA/MSHA Noise and Dust workshop; the workshop has been well attended by members of the aggregates industry. Bailey worked with NSSGA’s

Once the study was completed, Bailey returned to the Chemicals Division only to be asked to come back and implement the recommendations on a full-time basis. From that

Kevin Burns, who later headed up the former MSHA Small Mines Office, to develop the workshop to help other operators.

“The other thing I’m very proud of is our occupational medi-

point on, he continued to develop a series of programs cen-

cal screening for our workers,” Bailey adds. “It was started in

tered on worker health in mining and related construction

the mid 1980s, and much good has come from it. Many who

aggregate businesses.

work in the aggregates industry do not normally seek out

“Kelly tirelessly and passionately devoted his entire career

medical training unless there is something noticeably wrong.

to ensure that employees at Vulcan Materials and across the

The medical screening program allowed our employees to

entire aggregates industry have the benefit of a safe and

confirm that their health is not being affected by their jobs, to

healthy workplace,” notes Doug Palmore, P.E., senior vice

get a check on other basic health parameters, and we have

president, customer and technical services, for Luck Compa-

saved some lives through early detection of abnormalities that

nies. “I have personally benefitted from Kelly’s wisdom and

were not job-related.”

caring through the work he has done with me to advance

“I’ve known Kelly over 25 years and affectionately regard

Luck Stone’s occupational health program and his support of

him as a visionary, courageous leader, and champion in in-

the industry through NSSGA.”

dustrial hygiene/occupational health for the mining industry,”

Bailey helped develop Vulcan’s certified sampling course,

says Cynthia Kirby, Vulcan’s director of safety, health, and

which teaches new safety and health reps who come to the

environment. “Kelly promotes the basic industrial hygiene te-

company how to properly sample for noise, dust, welding

nets of: anticipation, substitution, recognition, evaluation, and

fumes, solvents, and diesel particulate. This allowed Vulcan

control of potentially harmful health hazards such as noise,

to acquire quality data. “That’s very important,” Bailey says.

silica, welding fume, solvent vapors, ergonomic stresses, and/

Over time, data collection evolved into a comprehensive sta-

or other chemical/physical substances. He is a tireless cham-

tistical evaluation of all the exposure data, which, in turn,

pion for miner health and safety.”

14

AGGREGATES MANAGER December 2015

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AGGMAN OF THE YEAR 2015

Bailey has been an advocate for the use of sound science during the development of health and safety programs, as well as the promulgation of regulations.

Influencing industry and regulators

tion (now NSSGA) and other mining and chemical manufactur-

While Bailey has had a profound effect on worker health and

ing associations, to name a few,” Drysdale adds. “All these

safety at Vulcan, his impact is much more widespread. That

efforts and accomplishments have improved the working

may be, in part, due to his ability to influence those around him.

conditions for thousands of men and women, raised the bar

“More than 30 years ago, right out of grad school, I inter-

within our industry, and frequently helped the bottom line of

viewed with Kelly for a job at Vulcan Materials. One thing

many of its members.”

he said cut through all the academic clutter still fresh in my

One of Bailey’s early forays into dealing with regulators

mind, and it strongly influenced my decision to work there:

was in 1986 when the Occupational Safety and Health Ad-

‘You shouldn’t have to trade your health for a paycheck,’” says

ministration passed a final asbestos standard that regulated

Dale Drysdale, CIH, NSSGA’s vice president of occupational

cleavage fragments of actinolite, tremolite, and anthrophylite

and environmental health. “Every decision Kelly has made

(ATA) as asbestos. Bailey says that Vulcan’s geologist at the

about occupational health was based on that simple, but

time, Pete Wiese, came into his office very upset about the

powerful ethos; and, in fact, it became my own.

standard and told him that these were common minerals

“Throughout the years, Kelly has been an occupational

throughout the United States; if something didn’t change, ag-

health leader in the aggregates industry. His reasoned pas-

gregates producers could be thought to be in the asbestos

sion influenced not only Vulcan’s management, which sup-

business.

ported and often celebrated his efforts, but frequently swayed

Bailey worked with Vulcan, the National Stone Association,

other decision makers as well. Kelly has willingly shared his

the American Mining Congress, and the U.S. Bureau of Mines,

time and expertise with other companies and even govern-

among others, to begin an educational process about the min-

ment organizations such as NIOSH and MSHA; and he has

eralogical definitions. “That began a six-year educational pro-

provided knowledge, guidance, and leadership to several

cess of OSHA and the unions. It took nearly 80 percent of my

trade associations — including the old National Stone Associa-

time for those six years, but it was a very important thing not

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AGGREGATES MANAGER December 2015

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to happen; the science was not there. They had done it by mistake,” Bailey says. “By May of 1990, we had a weeklong public hearing. The National Stone Association had a whole half a day that week to present its case, and, of course, we’d been actively engaged with them for the whole six years.

The result was, for the first time, a final rule of OSHA was reversed. They took out the cleavage fragments once we’d convinced them they did not present the same type of hazard that asbestos does.

“It was a pretty substantial victory, and sound science played a very, very significant role in it,” he adds. “You have to have sound science to be at the table, but, unfortunately, it doesn’t guarantee you are going to win all the time. Without it, you really don’t have a chance.”

Bailey also worked with Dick Seago on the Part 46 training rule. “Dick correctly saw that (removing the rider on Part 48) wasn’t going to work very well for the industry,” Bailey recalls. “He convinced MSHA and the industry that it would Bailey has shared his expertise with the industry, including chairing the NSSGA’s Safety and Health Committee, Technical Advisory Committee, and Occupational Health Subcommittee.

be best to have our own rule rather than trying to fit into a coal training rule.”

More recently, Bailey finished testimony to OSHA on its

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AGGREGATES MANAGER December 2015

AGGMAN OF THE YEAR 2015

proposed silica standard. “It was a very comprehensive set of

regulators, academia, and the industry,” Palmore says. “Kelly’s

testimony, documents, and submittals — probably one of the

contributions and positive impact are impossible to measure,

largest rulemaking records in OSHA history,” Bailey says. As

and will be equally impossible to replace as he moves closer

chairman of the American Chemistry Council’s Crystalline Silica

to retirement. I am forever grateful for Kelly’s personal contri-

Panel, he worked with the group to coordinate the testimony.

butions to my understanding of these issues and his genuine

“We’ll have to see how that works out,” he says. “I expect

care for the wellbeing of others.”

OSHA to send that rule to the Office of Management and Bud-

“Armed with wisdom, knowledge, persistence, and determi-

get (OMB) before the end of the year. I don’t know how long it

nation, Kelly Bailey nearly singlehandedly has stood up to sci-

will take OMB to release it, but I suspect the standard will be

entists, lawyers, and regulators alike and taken the air out of

released before the current administration leaves office.”

their attempts to impose unnecessary government regulations

The key to influencing many of these issues is to ensure

on the mining industry,” adds James Sharpe, CIH, an industry

the use of sound science. “First of all, you have to know the

health and safety expert and former vice president of safety

science to be credible,” he says. “It’s helpful to partner with

and health services for the NSSGA. “He is truly one of a kind.”

the government when their activity is based on sound science and not to partner when it’s not.” It’s also helpful if regulators

Looking forward

recognize your business for doing the right thing before it’s

Continuing to have a voice for sound science will be important

required; this also impacts your credibility. “The other point is

because some issues, such as properly defining and measuring

to be persistent,” Bailey says. “They have to know you’re not

asbestos, will continue to be a challenge. “When I look back

going to go away until it’s right.”

at my career, from 1979 to now, this issue has arisen three

CIM_CIM 1/2 HORIZONTAL7 x 4.875 1/20/15 8:37 “Kelly’s leadership and influence have directly ledAM to Page im- 1

proved science and a better understanding of these issues by

times,” Bailey says. “We’ve won many, many battles, but not the war.”

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AGGREGATES MANAGER December 2015

19

4/20/15 3:34 PM

Part of the challenge is due to minerals definitions. “We’ve

ing with,” he adds. “Be engaged with the folks who may have

engaged in a lot of research to help clarify that issue. We’re

already blazed that trail.” He also notes that health and safety

working with NIOSH on workshops to get terms properly de-

professionals should be taking note of the aging workforce

fined — how an elongated particle should be analytically char-

and planning for how to address the issues that will accom-

acterized before you publish something,” he says. “When you

pany an older crew working in an outdoor environment.

read these studies that have very ambiguous characterizations, you don’t know what they are talking about.

“There are still research gaps that need to be filled. We’re working on that as an association, and others are too,” he adds.

Finally, the industry, as a whole, needs more industrial hygienists. “I think the area of health is not going to get diminished. It’s going to be more and more of a factor to take into consideration,” he says.

Environmental issues will also continue to impact the ag-

For example, the trend toward total worker health carries

gregates industry. “You need to be engaged and get involved,”

a lot of responsibilities. Implementing smoking cessation pro-

Bailey says. “Environmentalism based on sound science is a

grams and weight management programs are two ways that

good thing. I like clean air and clean water. Environmentalism

companies can not only help their bottom line, but also im-

based on bad science is a recipe for disaster. It’s led to signifi-

prove the lives of their employees.

cant waste and damage to businesses in the United States.”

In terms of safety, “it all boils down to your employees look-

“I’ve always had the view that if you do the right things at the right time — which is before a regulation tells you you

ing out for each other and giving them the right tools so they

have to do it — you have a good story to tell your employees.

can do their job safely,” Bailey says, noting that the NSSGA is

You are really looking out for them, not because you have to,

a great resource for small producers. “The NSSGA’s Safety and

but because it’s the right thing to do,” he says. “If you wait

Health Committee provides the opportunity to network with

until the government tells you to do it, you really can’t say

others who may have already solved the problem you’re deal-

that to your employees.”

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Untitled-3 1

10/19/15 9:17 AM

AGGMAN OF THE YEAR 2015

Health issues, however, provide a greater challenge for

life with the same intensity of passion he holds for his profes-

employee education compared to safety ones. “These kinds

sional endeavors,” says his wife, Teresa Bailey. “Kelly is my

of illnesses really affect the quality of life. You have to teach

best friend, and our relationship is an equal partnership inter-

employees to respect the hazards. It’s easy to respect the saw

laced with strength of commitment and love. We have fun to-

blade, but do you get that same respect with a welding fume

gether whether we are alone or with our large family of three

or dust exposure without a respirator?” Bailey says. “It takes

daughters, one son, and eight grandchildren. Kelly is a great

more effort to educate workers on chronic health hazards

role model who provides security, love, and guidance to all.”

than acute safety hazards, but it’s the job of responsible com-

For the last few summers, Bailey has had his grandkids

panies to know the hazards employees face and resolve them

spend two to three weeks with him and his wife throughout

before they impact worker health.”

the summer. “That’s a lot of fun,” he says. “When I retire, I

These will be the challenges of current and future industrial

want to be able to pick what I work on. I don’t think retire-

hygienists. Bailey plans to retire in May 2016, but says he

ment ought to be a full-time job. The other part of life needs

will likely do some consulting in his areas of expertise: teach-

to get some attention.”

ing industrial hygiene sampling, data analysis and applica-

“Kelly has dedicated his career to advancing the health and

tion, and setting up occupational health programs. He’ll also

safety practices for the benefit of our most valuable resource:

likely continue to work on the asbestos definition issue, but

our workers,” says Michael W. Johnson, president and CEO of

wants to spend time in other areas as well.

NSSGA. “He has made a profound and positive contribution to

“I look forward to relearning my guitar and teaching myself

the aggregates industry throughout his decades in our indus-

piano,” he says. “I like fly fishing, and I’d like to travel with

try. As he transitions to retirement, those who follow behind

my wife.”

him will have some huge steel-toed boots to fill as his en-

“Kelly is a wonderful husband and approaches his personal

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Tennessee Pride Mom and pop company builds its business with a focus on its fleet and taking pride in its work.

I

t’s all in the family when it comes to Brad-

own until his two sons, Kirk and Adam, graduated

ley Concrete and sister company Lambcon

from college and were ready to become part of the

Ready-Mix. The Lambert family has been

family business.

in the construction materials business for

“I started with three trucks, but always had a

more than 50 years, with its roots in the aggre-

vision of hauling concrete from Chattanooga to

gates industry.

Knoxville,” says Steve Lambert, president. “It took

The concrete businesses are a more recent venture. In 1978, Steve Lambert was running a concrete plant in Dayton, Tenn. He so enjoyed

me 36 years to do that, and I couldn’t have done it without my two sons.”

Bradley Concrete and Lambcon Ready-Mix

making concrete that he started Bradley Concrete

epitomize the concept of a family business. “Our

in Cleveland, Tenn. He ran the company on his

entire family has always been in the rock busi-

AGGREGATES MANAGER December 2015

23

Lambcon Ready-Mix has six plants, with approximately 25 employees at each plant.

ness, starting with my great grandfather, who was one of the

The search for the best wheel loader required numerous

original Lambert Brothers,” says Kirk Lambert. “They were one

product demonstrations. “Companies brought demos to our

of, if not the largest, quarry outfits in the country when sold to

plant, and I was flown to proving grounds to try out other

Vulcan Materials in 1958. That is when my grandfather, George

machines from other manufactures,” Kirk says. “It became ob-

Lambert, made the bold decision to crush on his own.”

vious that Volvo machines were definitely the best choice in

Today, Lambcon Ready-Mix boasts six plants, with about 25 employees at each plant, and more than 100 trucks. With loca-

every way.”

That first Volvo wheel loader purchased in 1999 was a used

tions in Chattanooga, Knoxville, Athens, Cleveland, Lenoir City,

L120D with 3,000 hours on it. “It had a rusted bucket, but we

and Ooltewah, the Lambert family now serves customers large

didn’t have a budget for a new wheel loader. I loved the trac-

and small. “For us, no job is too small or too big,” Kirk says.

tor, so our Volvo representative, Dave Parker, added a new

“We service everyone from small residential jobs all the way up

bucket for us with new pins,” Kirk says. “It runs to this day —

to huge manufacturing plants and even bridges.”

now with over 20,000 hours on it.

“This is the one loader I would choose to run as my pref-

Building the mobile fleet

erence over all others. By itself, it just loaded all the materi-

In 1997, the Lamberts decided to concentrate efforts on grow-

als for a 2,000,000-square-foot Amazon distribution center

ing the ready-mix business, but it wasn’t until 1999 that

and a 400,000-cubic-yard polysilicon chemical plant, supply-

things really stared to take off. “I dove right into this wheel

ing all the concrete from the ground up,” he says.

loader market and tried all of them,” Kirk says. “The wheel loader is the key to the whole deal.”

24

AGGREGATES MANAGER December 2015

The Lamberts now run seven Volvo wheel loaders from an L90E up to an L120G with 3.5- to 5-yard buckets, and contin-

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ue to operate their original L120D every day from 6 a.m. until 7

prevent bouncing at higher speeds so an operator can work

to 8 p.m. with an average volume of 1,000 to 1,500 tons a day.

quickly without feeling like he’s hurting the machine.”

“These are perfect machines for our applications,” Kirk notes.

Getting the job done right

In addition to their long service life, the wheel loaders are fuel efficient and ergonomically designed for maximum opera-

“A ready-mix concrete plant is a simple process,” Kirk says.

tor comfort and safety. Compared to similar sized machines, the

“Making concrete is easy, but it’s complicated to get right.”

loader saves an estimated 50 gallons a week in fuel. “Add that up over a year and that’s a lot of money,” Kirk says.

“And there’s very little need for maintenance. We’ve never had a problem greater than a belt or general maintenance.”

Another key factor is visibility from the cab. “Loaders are big machines and can be dangerous,” he says. “Having a full range of vision all the way around is important; side glass that goes all the way to the floor is great. Safety-wise, the cameras and monitors are indispensable, but having overall visibility at all pivot points, that’s huge.”

Ease of operation is another top consideration for their fleet. “The controls are where they should be,” Kirk says.

“The levers are where they should be.

Comfort is critical. Operators are in the cab 12 hours a day, so it needs to be

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he explains. “The computers calculate the amount and load the trucks through automation.”

Lambcon plants are dry-batch plants. In this case, the truck drum actually does the mixing on its way to the job location.

The Lamberts always smile when they talk about the pride they take in remaining a family business. “When you call Lambcon, you talk to a person,” Kirk explains. “There aren’t too many mom and pop operations like ours anymore.”

The Lambert family understands that a local, personal touch is important to customers. This philosophy finds its way all the way down to taking pride in how clean their trucks and machines look to outsiders. “We keep our equipment clean for two reasons,” Kirk says. “A clean machine will reveal possible Family businesses Bradley Concrete and Lambcon Ready-Mix purchased their first Volvo loader, a used L120D, in 1999. Still in operation, it loads an average volume of 1,000 to 1,500 tons per day.

problems more quickly if one arises. But to me, when a loader or a truck looks good, it makes a first impression that tells people Lambcon is a professional operation with its act together.

When our trucks drive by, you know it.”

Chemically, concrete must be durable. Lambcon uses natural sand and crushed limestone sand and customizes each mix

What’s on the horizon for the Lamberts? “We don’t want to be the biggest. We just want to be the best,” Kirk says. AM

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PULL-OUT GUIDE

By Kerry Clines, Contributing Editor

OPERATIONS ILLUSTRATED C n ey i S m ooth o v

Conveyors are cheaper to operate than mobile equipment.

Lengths can reach several miles.

Maintenance is more predictable.

They convey a steady stream of material.

ng

OPERAT 1

Overland conveyors

Benefits of Overland Conveyors

C

onveyors cover a lot of ground…no pun intended. There are many different types of conveyors that perform different tasks in a quarry, but they all move material from one place to another. Conveyors can stack material; bring it up out of a pit or underground operation; cross over or under a roadway, railway, or river; or travel the length of the pit floor. Of all the different types, overland conveyor can have the biggest impact on an aggregate operation.

“Typically, overland conveying is the alternative to haul truck operation,” says Alan Schmidgall, inside sales manager for Superior Industries. “Basically, an aggregate operation has a mine face and a processing plant, but the face is always moving as the rock is blasted and picked up. As the crushing gets farther away from the plant, the material has to be transported from the blast site to the processing plant.”

Some operations use haul trucks or loaders to transport material from one place to another, but many use overland conveyors. The overland conveyor is capable of moving material much quicker, easier, and more efficiently than mobile equipment, and greatly reduces the amount of time, money, and manpower required.

“Overland conveyors move material for much less money than loaders do,” says Jay Mills, site superintendent at Staker Parson’s Reynolds AGGREGATES MANAGER

Pit #2 in West Valley City, Utah.

“They’re cheaper to run, and move material faster and more efficiently.

Using a loader to move material cost us about 75 to 80 cents a ton. Once we put in the overland conveyor, it cut the cost down to about 12 to 13 cents a ton. That’s a huge savings.”

Robert Hostettler, plant manager at CalPortland’s Santosh Facility in Scappoose, Ore., says overland conveyors allow operations to keep closely connected with the mining portion of the operation as it moves further away from the processing plant. “Extending the pit line makes it possible to maintain a minimal haul distance between the material extraction point and the feed hopper,” he says. “The distance can be decreased by adding more overland conveyors, thus minimizing the haul.”

In addition to cost savings, overland conveyors don’t require as much maintenance and have a much smaller impact on the environment when compared to mobile equipment. There are fewer items that can break or need repair on a conveyor, since they are most commonly comprised of motor(s), gearbox(es), one head pulley, one tail pulley, a take-up, idlers, bearings, and a belt.

Plus, the conveyor is powered by an electric motor or motors, which means fewer emissions, little fuel consumption, and less noise. This is good for the environment and helps maintain a good relationship with neighbors as well, making it a winwin situation for everyone.

Overland conveyors provide an economical and efficient way to move material from one place to another quickly and smoothly, making it one of the best investments an aggregate operation can make. In the traditional sense, the overland conveyor is much more economical than haul trucks. It offers a more stable, lower cost-per-ton option to carry material the same distance as a haul truck. It also requires less maintenance because there are fewer parts to break or wear out.

4

Crosses over obstacles

Sometimes material must be moved across a roadway or railroad within a quarry. Rather than risk the safety of equipment and operators travelling back and forth, an overland conveyor provides the perfect solution.

This overland conveyor goes up on one side of a highway, spans it, and goes back down on the other side.

Where it crosses over the roadway, the conveyor is contained so that any material spilled during transport is captured to prevent it from falling on vehicles below.

TIONS ILLUSTRATED Smooth Conveying 2

Spans long distances

3

Minimizes the haul

When it comes to the length of an overland conveyor, the sky is the limit. Most overland conveyors run 250 to 1,500 feet, but some can be several miles long. Typically, an overland conveyor is custom built, requiring topographical information and a design suited to the terrain, which takes time and can be costly. This Zipline conveyor, developed by Superior Industries, was designed to be a lower cost, off-the-shelf, modular overland conveyor that is quick and easy to install.

Overland conveyors allow operations to stay connected with the mining portion of the operation as it moves further away from the processing plant. Whether it’s a dredging operation following a waterway or a rock face that moves as the rock is blasted and picked up, the material extraction point gets farther away from the processing plant, requiring the material to be transported between the two. An overland conveyor allows an operation to maintain a minimal haul distance by simply extending the line.

5

6

Carries under obstacles

OUR EXPERTS

Environmentally friendly

Alan Schmidgall began working at Superior Industries after graduating from the North Dakota State College of Science in 2005. He started out in the engineering department, moved to project management, and now manages the manufacturer’s team of equipment inside sales personnel.

Robert Hostettler is the plant manager at CalPortland’s Santosh Facility in Scappoose, Ore. He began his career with Triangle Rock Products in Oroville, Calif., after graduating from California State University, Chico, in 2011 with a bachelor of science in Concrete Industry Management.

Jay Mills is the site superintendent at Staker Parson’s Reynolds Pit #2 in West Valley City, Utah.

Overland conveyors can be the solution for some obstacles within a quarry that present unique challenges. When a river runs through the middle of an operation, separating the pit from the processing plant, going over the river might not be possible, especially if the river is used for shipping. This operator decided to dig a tunnel under the river. Haul trucks were used to transport the material through the tunnel for a short time until an overland conveyor could be installed.

When it comes to being “green,” overland conveyors have a much smaller operational foot print than mobile equipment. They are powered by electric motors as opposed to diesel engines, so there are far fewer harmful chemicals released into the air, less fuel consumption, and lower noise levels. Many conveyor components can be recycled or reused in other parts of the plant when they are removed from the pit line.

This operation uses a covered and enclosed overland conveyor to prevent spillage when loading barges.

December 2015

Voices of Experience Alan Schmidgall

O

verland conveyors provide an economical and efficient way to move material from one place to another, says Alan Schmidgall, sales manager for Superior Industries. “The overland conveyor, in the traditional sense, is much more economical than haul trucks,” he explains. “It offers a more stable, lower cost-per-ton option to carry material the same distance as a haul truck, and one operator can run the entire system.”

Schmidgall says maintenance offers another plus for overland conveyors.

Haul trucks are expensive, requiring the replacement of wear parts and tires, as well as general maintenance. Maintenance costs for an overland conveyor, however, are much lower and much more predictable.

When it comes to the length of an overland conveyor, Schmidgall says the sky is the limit. Most are 250 to 1,500 feet long, but some can be several miles long. It depends on the application.

Sometimes material must be moved across a highway. “We’ve done a few of those installations,” Schmidgall explains. “The conveyor goes up, spans the highway, and goes back down on the other side. We use a covered or contained conveyor system, so any spillage is captured.”

Most overland conveyors are custom built, requiring topographical information and a design suited to the individual application. Schmidgall says the development costs for those types of conveyors aren’t prohibitive, but the design takes time and so does the installation. So, Superior developed the Zipline conveyor, a more standard off-the-shelf design that installs easily and has the flexibility to adapt to the needs of a site.

“The focus with the Zipline conveyor was to make a lower cost, pre-designed modular overland conveyor that was quick and easy to install,” Schmidgall says. “However, if you’re going to be at the same site doing the same thing for 20 years, the heavier traditional overland conveyor designed for the specific application is probably still the best option.”

AGGREGATES MANAGER

Alan Schmidgall

“W

e have roughly 2 miles of overland conveyors running from our material extraction point to our processing plant,” says Robert Hostettler, plant manager at CalPortland’s Santosh Facility in Scappoose, Ore. “We run 48-inch belt on all of the conveyors in our pit line, which can handle between 1,000 and 1,200 tons of material per hour. There are four main benefits for using overland conveyors — environmental impact, cost savings, manpower savings, and efficiency/ throughput.”

When it comes to being “green,” overland conveyors are powered by electric motors as opposed to diesel-powered trucks. “There’s a smaller operational foot print with overland conveyors,” Hostettler says. “While transporting material from point A to point B, the electric motors release far less harmful chemicals into the air than do diesel engines. Plus, many of the conveyor components — idlers, pulleys, belting, motors, and gear boxes — are able to be recycled or reused in other parts of the plant when they are removed from the pit line.”

Hostettler says cost savings are realized in several ways. Electric power is more cost efficient and more stable than diesel, and is less affected by market trends. Plus, maintenance on overland conveyors is less labor intensive and less expensive than maintaining mobile equipment wear components.

“Many conveyors are automated and interlocked so that one operator can run the entire pit line safely, regardless of length, with just the push of a button in the switch house,” Hostettler says. “That eliminates the need for multiple operators on site to run the pit line. So, you get a labor cost savings there.”

If you compare truckz to using overland conveyors with capacities in excess of 1,000 tons per hour, Hostettler says, “It would require multiple trucks, operators, etc. to achieve a similar throughput,” Hostettler explains. “Overland conveyors are much more efficient over all, and their capacities are greater.”

Jay Mills

A

ccording to Jay Mills, site superintendent at Staker Parson’s Reynolds Pit #2 in West Valley City, Utah, overland conveyors are cheaper to run than mobile equipment; are better than regular conveyors because they only have one gear box, one tail pulley, and one head pulley; and are way more efficient to operate.

“That’s the reason we put them in at this particular location,” he says. “By using two overland conveyors, we were able to get rid of one of our loaders.

Overland conveyors are amazing, and if you put a stacker on the end of them, it’s paradise. It’s a huge savings.”

The long overland conveyor belts are easier to train and keep centered on the conveyor than shorter belts, Mills says.

The only drawback he sees is that, if the overland belt gets ripped, it costs a lot of money to replace it.

“I am way sold on overland conveyors,” Mills says. “Anywhere you need a long conveyor, that’s definitely the way to go. There’s no negative. We recently installed a Zipline conveyor at this plant.

We’ve used other overland conveyors before, but the Zipline can be installed in about half the time it takes to install traditional ones. It’s very fast. If it holds up, I’ll suggest it for all of our similar operations, because it is so fast to put in.”

Mills says the only difference between a traditional overland conveyor and a Zipline is that the traditional one takes longer to set up. The easy assembly of the Zipline is a plus, but he doesn’t think the Zipline will be any different than the traditional ones in the long run.

One thing that can help an operator determine which overland conveyor to use is the length needed. The maximum length of a Zipline conveyor is 500 feet.

“That’s perfect here, because I’ll never be far enough away from my material that I’ll need anything longer,” Mills says. “If you can get by with 500 feet, the Zipline is the way to go, but if you need it to be longer, it would be worth the extra week it takes to install the traditional overland conveyor.”

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CONSTRUCTION EQUIPMENT

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PARTS & SERVICE

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M AT E R I A L H A N D L I N G

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CRANES

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R E N TA L S

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Top

Rollouts of 2015

It was a big year for big iron, with many equipment introductions focusing on fuel efficiency, productivity, and safety.

by Therese Dunphy, Editor-in-Chief, and Bobby Atkinson, Online Managing Editor

HOW WE MADE OUR CHOICES

When we ask readers how we can best help them keep track of changes in the products and services they use to produce aggregates, almost everyone wants an annual short list of the really important stuff.

No wonder. The sheer volume of introductions is overwhelming. Aggregates Manager covers numerous products each year in its RollOuts departments and Supply Lines features and offers even more product coverage through its website and newsletters.

So each year, our staff reviews all the product introductions we’ve covered for the past year to pick out 25 that we believe are worth further review. Our priorities are new concept products, which are rare; new series/new generation products in categories that relate to the aggregates industry; and other rollouts which serve our readers’ interests by increasing competition in a product category. We also consider reader engagement through website and social media traffic.

Inevitably, we omit deserving products, either because we just didn’t understand the significance of the product or because the announcing company didn’t communicate what was special about the product, or both. In either case, we apologize in advance for these omissions.

ALLIED CONSTRUCTION PRODUCTS, LLC

PORTABLE BOOM SYSTEM

Allied Construction Products, LLC adds a PowerPortable boom system to its Pedestal Breaker System product line. Designed for aggregates and recycling operations, it can be used with stationary or wheel- and trackmounted mobile crushers. Built around Allied’s Rammer, AR Series, and Hy-Ram hydraulic hammers, the 350- to 1,400-class hammers are mounted on a special low-profile boom that adds minimal height and weight to the crusher, but offers a reach of 10 to 15 feet to ensure reach to both the crusher and the feeder. The portable boom system is powered by 20- to 30-horsepower units. It can be connected directly to the crusher’s hydraulic circuit. Functions are controlled through a system of valves. Other control options include an electro-hydraulic remote control with a two-joystick hydraulic control and a wireless remote control option.

Allied Construction Products | www.alliedcp.com

ATLAS COPCO

REMOTE BLASTHOLE DRILLING

Atlas Copco’s BenchRemote remote operator station allows drillers to operate more than 100 yards from the drill, which can be more than 30 yards below them, as long as they maintain line-of-sight radio communications. The increased distance from highwalls and machines on steep or rough terrain can improve worker safety.

The device installs on a vehicle, trailer, or container. Its controls and displays mirror those of the working rig, giving the operator the same capabilities as working from the rig itself. A closed WiFi network communicates operator inputs and machine feedback independent of the local network infrastructure. If the network is lost for any reason, the rig automatically shuts down as an additional safety precaution.

Atlas Copco Mining and Rock Excavation | www.atlascopco.us

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AGGREGATES MANAGER December 2015

TOP ROLLOUTS BALDOR ELECTRIC

RUGGED CRUSHER-DUTY MOTOR

Baldor Electric says its new line of crusher-duty motors feature improved reliability, performance, and energy efficiency to help lower the total cost of ownership.

Baldor-Reliance crusher duty motors are engineered for the demanding high-torque applications and harsh environments of the aggregate, cement, and mining industries. The crusher-duty motor is available in frame sizes 180T to 449T and power range of 5 to 350 horsepower. The rugged cast-iron design minimizes vibration and bearing temperature. With higher breakdown and locked rotor torque performance, the manufacturer says Baldor-Reliance crusher-duty motors meet the demands of the toughest crushing applications.

Baldor Electric | www.baldor.com

CASE CONSTRUCTION EQUIPMENT

FUEL-EFFICIENT EXCAVATORS

Case Construction Equipment’s CX350D crawler excavator provides operational gains over previous models and meets the EPA’s Tier 4 Final emissions standards. Part of a new series of excavators, the line boasts cycle times up to 12 percent faster, improved responsiveness and multifunctional control, up to 14 percent greater fuel efficiency, and increased breakout forces of as much as 6 percent. The arm and boom of the new excavators are stronger and more durable than previous models to support the new power. The 82,483-pound unit features 268 horsepower and bucket digging forces of up to 56,157 pounds. The CX350D also comes with the Case Intelligent Hydraulic System that’s made up of four systems: Boom Economy Control, Auto Economy Control, Swing Relief Control, and Spool Stroke Control. Case Construction | www.CaseCE.com

CATERPILLAR

NEW ARTIC BOOSTS CAPACITY

Cat’s 745C articulated truck includes an engine that meets Tier 4 Final emission standards, as well as new transmissions with expanded electronic control, automatic traction control, automatic retarder control, hill assist and waiting brake systems, and an optional payload weighing system. The upgrades are aimed at delivering lower cost per ton by reducing cycle times, saving fuel, and easing operator workload. The rated capacity for the new model is 45.2 tons. Its 1.7-ton capacity increase, compared to the 740B, combines with its faster cycle times for significant production gains.

Caterpillar | www.cat.com

DEISTER MACHINE CO., INC.

ELECTROMECHANICAL VIBRATING FEEDER

Deister Machine Co., Inc.’s Two-Mass Electromechanical Vibrating Feeder is the newest addition to its lineup of screening, scalping, and feeding equipment. The feeder is designed to allow greater control over high-capacity feed rates and productivity, while lowering costs per ton in aggregate operations.

Units in the Deister EMF Series incorporate a high-profile infeed lip and a heavy-duty formed deck with replaceable liners. A simplified drive is designed with an easy-access exciter frame, which houses the single vibrator motor. Deister says the design results in higher bearing life and eliminates the need to replace belts.

Deister Machine Co., Inc. | www.deistermachine.com

AGGREGATES MANAGER December 2015

35

TOP ROLLOUTS DYNO NOBEL

IMPROVED BLASTING SYSTEM

Dyno Nobel and its joint venture partner, DetNet, offer the new DigiShot 300 RF system, which is designed to improve safety of blasting operations.

The system is designed for single-box firing with the capability of firing up to 450 detonators at a distance of 3,281 feet. It will also support box synchronization of two boxes when firing in hardwire mode. The software allows the machines to be configured as either a bench box or base station, while smart key technology improves safety and security.

Dyno Nobel | www.dynonobel.com

JOHN DEERE

MORE POWERFUL DOZING

John Deere’s crawler dozer, the 850K, not only meets Tier 4 Final emissions standards, but also includes features such as EcoMode and an updated ElectroHydraulic control system. The new control system has features such as blade shake for power-angle-tilt configurations, improved blade response, and rear auxiliary configurable settings to enhance operator productivity. The unit features a PowerTech 6.8-liter Tier 4 final diesel engine with 205 horsepower. The 850K is the first John Deere unit to feature EcoMode, which optimizes fuel economy while maintaining ground speed by automatically adjusting engine speed and transmission settings based on load. The manufacturer estimates the feature can save customers up to 20 percent in fuel costs. John Deere | www.johndeere.com

KCMA CORP.

LOADERS BOAST BUCKET-HEAPING ABILITY

KCMA Corp.’s 95Z7 XTreme wheel loader reflects recent demand for the short boom, load and carry, or two-pass configuration loaders. The machine was tested in various applications and environments. KCMA says the results exceeded expectations for fuel economy and breakout force, but also notes that bucket heaping ability stood out. The 9.0-cubic-yard 95Z7XT bucket weighed in at more than 15 tons with sand and 13 tons with gravel. That unit is also available with a 9.8-cubic-yard bucket. To accommodate the weight demands, the boom arms are shorter, thicker, and stronger. The bucket hydraulic cylinder bore is larger. The chassis was reinforced to handle additional torque and load, while the counterweight was also increased.

KCMA Corp. | www.kawaskiloaders.com

KOBELCO CONSTRUCTION MACHINERY

FUEL-EFFICIENT EXCAVATOR

Kobelco Construction Machinery USA’s Tier 4 Final SK350LC-9E excavator is said to offer better fuel economy, greater efficiency, and reduced service intervals. The 82,200-pound excavator is powered by a 270-horsepower HINO engine. The model incorporates both Selective Catalytic Reduction (SCR) and self-cleaning Diesel Particulate Filter (DPF) systems to keep operational costs low. The dual system minimizes Diesel Exhaust Fluid (DEF) consumption and offers up to a 10-percent reduction in fuel consumption compared to a Tier 3 machine. The hydraulic system also was the focus of major improvements, with a focus on reducing parasitic losses while maintaining peak productivity. The excavator has a digging force of 50,600 pounds, a digging depth of 24 feet, 10 inches, and a suggested 0.875- to 2.75-cubic-yard bucket range.

Kobelco Construction Machinery USA | www.kobelco-usa.com

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AGGREGATES MANAGER December 2015

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KOMATSU AMERICA CORP.

LOADER HANDLES HILLS IN HIGH SPEEDS Komatsu America Corp. rolls out a new wheel loader with a Tier 4 Final certified engine. The WA380-8 wheel loader has a 6.69-liter, 191-horsepower Komatsu SAA6D107E-3 engine that is turbo charged and after cooled. The equipment also comes standard with the SmartLoader Logic software that combines with the lockup torque converter to give the wheel loader better acceleration and hill climbing, and a higher top speed. The WA380-8 also has the Komatsu Diesel Particulate Filter to extend the engine’s life and the Select Catalyst Reduction assembly to cut back on NOx emissions.

Komatsu America Corp. | www.komatsuamerica.com

KPI-JCI AND ASTEC MOBILE SCREENS

NEW JAW CRUSHER FOR SAND AND GRAVEL USE

KPI-JCI and Astec Mobile Screens’ 2056 Vanguard Jaw Crusher, a 20-by56 jaw crusher, works in sand and gravel applications as well as recycled concrete and other mining uses. The crusher has a new single cylinder auto-tension system for less maintenance, better reliability, and less wear on the parts. It also has a new wear seat with easy access and a new corrugated stationary wedge to increase the crusher gap and maintain a steep nip angle. The shaft and bearing assembly are also more serviceable for less maintenance. KPI-JCI | www.kpijci.com

LIEBHERR

MARTIN ENGINEERING

EXCAVATOR OPTIMIZES FUEL USAGE

NEW BELT SCRAPER DESIGN

Liebherr’s R 946 is its first crawler excavator to meet Tier 4 Final emission standards. It has an operating weight of approximately 44 tons (U.S.) and a 272-horsepower engine. The six-cylinder Liebherr engine integrates a new Tier 4 Final exhaust gas treatment system, which features a SCR system using urea injection to post-treat exhaust gases. Liebherr says the unit has a robust steel structure to ensure reliability in tough applications. Through a smart system, which uses sensors placed on strategic locations around the excavator, the excavator can optimize the operation of the engine and hydraulic system to maximize fuel usage.

Liebherr | www.liebherr.com

38

AGGREGATES MANAGER December 2015

Martin Engineering’s CleanScrape Cleaner conveyor belt cleaning system is installed diagonally across a conveyor belt’s discharge pulley instead of like traditional cleaners that are mounted at a 90-degree angle. The design helps the cleaner, which also has a matrix of tungsten carbide scrapers, conform to the pulley’s shape. The cleaning system is said to be able to remove up to 95 percent of the potential carryback material and comes in three sizes to be used on conveyor belts of any size.

Martin Engineering | www.martin-eng.com

TOP ROLLOUTS MASABA

SIDE DUMP UNLOADER

The Masaba Side Dump Truck Unloader is the manufacturer’s newest addition to its line of truck unloaders. Said to eliminate dumping of material on the ground and re-handling, the unit features an 8-foot by 40-foot hopper with a 30-cubic-yard capacity. Under the 3/8-inch steel hopper is a 36-inch by 52-foot conveyor driven by heavy-duty drives. The unit can be customized to specific operational needs and can be stationary or skid-mounted.

Masaba | www.masabainc.com

METSO MINERALS

POLYDECK SCREEN CORP.

EFFICIENT SECONDARY CRUSHING

HEAVY-DUTY DEWATERING PANEL

Metso continues to expand its range of high-capacity crushers with the Nordberg GP7, its largest secondary gyratory to date. The 58-ton crusher is said to feature an ideal combination of feed opening, cavity design, and capacity, which ensures crushing performance with even the hardest of feed material. The gyratory features a feed opening of 18 inches, which remains constant throughout the lifetime of the liners. It has seven strokes, from 1 to 2 inches, available as standard. Its power rating is as high as 737 horsepower. A limited number of access points can be accessed safely and easily.

Metso Minerals | www.metso.com

The new 1-foot by 1-foot polyurethane heavy-duty dewatering screen panel from Polydeck can carry the same weight of thick bed depths, but at a much thinner size. The screen panel doesn’t need an additional substructure to get the job done. It has openings as small as .1 mm by 15 mm and multiple PolySnap or pinstyle fastening options, and it has the ability to integrate surface features like dams into panel construction.

Polydeck Screen Corp. | www.polydeckscreen.com

SANDVIK CONSTRUCTION

DOUBLESCREEN TECHNOLOGY OFFERS MORE SCREENING FLEXIBILITY

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

Sandvik Construction | www.sandvik.com

AGGREGATES MANAGER December 2015

39

TOP ROLLOUTS

SUPERIOR INDUSTRIES

BELT SCALE FOR DRY BULK MATERIAL HANDLING

The belt scale from Superior Industries was designed for dry bulk material handling. It has a unique new design that allows operators to avoid cutting or torching a conveyor frame during installation. The scale can be installed without even interfering with the conveyor frame. The flush mount belt scales were designed with a sturdier weighbridge than most to prevent wobbling or tipping during installation.

The integrator has an onboard Ethernet port, two RS-232 serial outputs, and a battery backup feature. The scale fits belt widths between 18 inches and 72 inches and is made for dry bulk applications of up to 3,000 tons per hour.

Superior Industries | www.superior-ind.com

TEREX CEDARAPIDS

VARIABLE SLOPE CAPABILITY ALLOWS FOR LARGER DECK LOADS The new Terex Cedarapids CRS620S portable screen plant combines the El-Jay high G-force oval stroke motion with adjustable slope operation. This patent-pending technology increases capacity and handles applications not possible with traditional horizontal screens. Hydraulics quickly change the screen slope in 2.5-degree increments up to a maximum of 7.5 degrees to best fit the application. Variable slope capability allows the screen to handle larger deck loads and bigger screen openings for increased production. The patented low-maintenance flex shaft screen drive eliminates belt whip, belt slippage, and the need for spring loaded belt tensioners. Roll-away blending chutes and extended walkways allow easy access to screen cloth.

Terex Minerals Processing Systems | www.terexmps.com

TEREX FINLAY

ROBUST PORTABLE JAW CRUSHER

Terex Finlay’s Finlay J-1170AS mobile jaw crusher is built around the Terex 44-inch by 28-inch jaw crusher. The jaw chamber is available with optional hydraulic release with an automatic overload protection system to prevent damage by uncrushable items in the feed material.

An onboard after screen delivers a single-sized product, removing the need for a second machine. It can also be removed quickly to allow the operator to use a standard unit. An automatic variable speed VGF ensures continuous choke feeding of the crushing chamber, while the hydraulic-assisted closed-side setting adjustment is said to minimize downtime and allow for quick adjustments.

Terex Finlay | www.terexfinlay.com

40

AGGREGATES MANAGER December 2015

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TOP ROLLOUTS

VERMEER

DRILL FEATURES DIGITAL DISPLAY TEREX MPS

LARGE CONE MODULE

Terex Minerals Processing Systems’ MC450X cone module is designed to increase the tonnage, application capabilities, and crushing efficiency. Terex says the unit is its largest cone crusher module yet. The MC450X comes with a Cedarapids MVP 450X cone crusher. New features include high-speed clearing of jammed materials, faster crusher separation capabilities, and userfriendly computer controls. It also comes complete with a heavy-duty I-beam frame, a galvanized steel structure of walkways, stairs, and guard rails.

Terex MPS | www.terexmps.com

Vermeer upgrades its D100x140 Navigator horizontal directional drill with a Tier 4 Final engine and additional features. The D100x140 S3 features a 275-horsepower Cat diesel engine that provides 100,000 pounds of thrust/pullback and 14,000 foot-pounds of rotational torque, plus increased rotational speed of 203 rpm. It is also available with the InSite asset management system, which delivers data across multiple platforms. In addition, the DigiTrak Aurora touch-screen interface provides real-time location information and enhances the operator’s ability to monitor drill performance. It has two Firestrick drill rod options: 15 feet or 20 feet. Stackable rod boxes with a single-pin design and patent-pending auto-lock allow an additional rod to be loaded from an upper rod box.

Vermeer | www.vermeer.com

WEIR MINERALS

VERTICAL TURBINE SLURRY PUMP

VOLVO CONSTRUCTION EQUIPMENT

TIER 4 FINAL WHEEL LOADERS

Volvo’s L90H wheel loader comes standard with a new efficient Tier 4 Final engine. Combined with the new Torque Parallell linkage, the machine is said to have improved fuel efficiency without any drop in performance. The wheel loader is also equipped with a counter shaft transmission that can withstand high stress levels. Volvo’s TP linkage geometry, along with its bucket design, is said to provide excellent bucket roll-back angles that increase material retention in the bucket and keep the load closer to the front axle for increased stability. The loader has the Human Machine Interface system inside that keeps the operator up-to-date on machine information. Volvo’s online telematics monitory system, CareTrack, lets the fleet manager get a real-time look at important machine information.

Volvo | www.VolvoGroup.com

Weir Minerals Floway Pumps’ Floway VTSP — vertical turbine slurry pump — addresses demand for a longer-lasting, abrasives solids handling vertical turbine pump.

Following several years of design, research, and testing, Weir says the unit has been demonstrated to last four times longer in solids handling services when compared and tested with the Floway vertical turbine pump bearing assembly.

The patented bearing design allows for continuous operation in services with a maximum solid content of 10 percent by weight and excursions of 20 percent by weight during temporary upset conditions.

Weir Minerals Division | www.weirminerals.com

AGGREGATES MANAGER December 2015

43

Caring for You

Cone Crusher Understand how training, maintenance, and the right operation tips can maximize their performance.

by Giles Lambertson

44

AGGREGATES MANAGER December 2015

EQUIPMENT MANAGEMENT

A

cone crusher punishes itself during

unit. A well-maintained and properly operated

every minute of operation. It squeez-

cone crusher can process material for 20 to 25

es a dense mass between heavy

years without major overhaul or junking. How-

castings until the mass disintegrates.

ever, this expected life span shrinks when op-

It abrades and minces aggregate until the material

erator inspections are cursory, or bad operating

yields to the applied forces. It rumbles and vibrates

procedures are regularly practiced. All the best

and bangs as its core shaft spins eccentrically to

practices in the world are of no effect if an op-

capture and reduce chunks of aggregate. All of this

erator — or owner — willfully ignores them.

finely engineered chaos demands that an operator be alert to what is happening to his machine.

Maintenance tips

Otherwise, imminent component failure can be

At the heart of training are common sense main-

overlooked amid the crusher’s normal chaotic op-

tenance procedures that rely on the eyes and

eration, and the machine’s performance will suffer.

ears of an operator.

Training

• The walk around – To start a day, an operator

Some manufacturers conduct classes to train new

should circle a cone crusher to visually confirm

cone crusher operators. The volume of partici-

the soundness of the unit. Evidence of an oil

pants in such classes is increasing every year

leak or excessive puddling of lubricant is a red

across the industry, suggesting that owners of

flag. Lubricating and hydraulic oil levels should

crusher operations increasingly recognize the

rest at the Full line — and accessing the oil res-

need to protect their investment. These training

ervoir should be accomplished without knock-

classes introduce proper operating techniques —

ing contaminant into it. The oil strainer should

and improper ones to be avoided — as well as

be clear, conveyor and drive belts aligned and

daily, weekly, and monthly maintenance recom-

taut, bolts tight. Visual and tactile inspection of

mendations. The goal is to maximize the perfor-

the drive shaft housing can ensure there are no

mance of a crusher.

issues there. Material spillage underneath the

Such training also can extend the life of a

machine may need to be addressed, particularly if the material is situated so that residue could find its way into a component and contaminate lubrication. A daily morning walk-around survey establishes a baseline for operating a crusher at an optimum level.

• The peer-in – Overlooking into the crushing chamber from a safe point is a simple way to ensure that no foreign material has ended up there. Such material will either pass through the chamber or contaminate product or, in the case of metal, jam up the crusher and cause

Each year, more and more companies send their operators for training to ensure the best performance from their assets.

damage. A quick check will avoid both eventualities. A few minutes spent examining the chamber liners, while the crusher is stopped

AGGREGATES MANAGER December 2015

45

when abrasive material is being processed. Pinion shaft lubrication and drive shaft play should be checked each week. The integrity of seals will be evident at the end of a week’s operation, and unaligned conveyor and drive belts will show unevenness.

• Annual inspections – A once-a-year top-to-bottom inspection — better yet, once-every-2,000 hours — is a best maintenance practice. However, it is rarely done. Relatively few cone crusher owners take the time to order a thorough, invasive examination of a crusher unit. Yet opportunities to do so are common. Changing out a liner, or performing an emergency repair, can require a crane. With A homogenized, non-segregated feed will help keep the cone balanced while in operation and minimize wear.

the heavy lifting equipment already present and the site’s operation already disrupted, what better time to further dismantle a unit and look for niggling issues — the thin

and locked, can ensure that no cracks have developed,

sleeve, the worn bushing, the compromised seal, or disin-

dangerously exposing the casting beneath the wear plates

tegrating hose? Catching a failing component before it fails

to damaging forces.

and causes ancillary damage is pure preventive maintenance, generally cost effective, and ensures that a crusher

• The warm-up – After starting the crusher’s power plant, the operator should determine that gauges are register-

is operating at full capacity.

ing according to the manufacturer’s recommendations and

Operating tips

that settings are correct for the material to be processed.

Cone crushers are built to withstand pressures and the grind

Oil and hydraulic pressures should hover within acceptable

of abrasive materials, hour after hour, without flying apart

limits. Idling the crusher during warm-up is acceptable,

or otherwise self-destructing, but a savvy operator will heed

but not for an extended period. Once the crusher is run-

a handful of guidelines to extend the life of crusher compo-

ning at crushing speed and material is introduced, another

nents and produce more uniform aggregate products.

check of gauges and computer readouts will ensure that all components are meshing as engineered and that production can proceed.

• Homogenized feed – What is dumped in the cone crusher’s hopper will, of course, determine what drops out below.

Yet regardless of the type of material being crushed, it ide-

• End-of-day check – Some inspections are best made af-

ally is homogenized, that is, mixed together so that finer

ter the crusher is shut down. An oil leak developed during

and coarser elements uniformly congregate in the crushing

the course of the day may still drip warm oil at that point.

chamber. If the conveyor process allows material to segre-

Tramp material from failed components may be freshly

gate, an operator can end up with coarse material on one

in evidence. Spilled material may require removal. Some

side of the chamber and finer material on the other. The

checks made at work day’s end will not have to be dupli-

resulting uneven load creates imbalance, uneven crushing,

cated the following morning.

and undue strain on the crushing mechanisms. The fruits of a non-homogenized feed of material can be seen and heard

• Weekly inspections – These build on daily observations.

An oil filter and tank may pass muster each day, but a

and, ultimately, felt in the pocketbook as chamber liners and balance are sacrificed, resulting in poor product quality.

more complete examination at week’s end might show cor-

46

rosive failure in a line. Liners shown to be intact each day

• Full crushing chamber – Fitfully feeding a cone crush-

should be examined weekly for uneven wear, particularly

er’s chamber because of loading or conveyor issues also

AGGREGATES MANAGER December 2015

EQUIPMENT MANAGEMENT

can create uneven wear on liners. Not only are crush-

crushers are neither a mystery nor a rarity. They can be found

ing forces magnified by the weight of material constantly

at aggregates operations where rock is scattered on catwalks

pressing down from above, the machine itself is given full

and oil tanks are covered with several days’ debris. Such

traction to do its work. A full, then partly full, then full

signs of neglect are not the hallmarks of a high-performing

crushing chamber sometimes is compared to a car travel-

crusher operation nor of a well-maintained and operated cone

ing down the highway without cruise control. Accelerating

crusher. The cost of such neglect, ultimately, is high. AM

to 65 and dropping back to 55 and accelerating again and so on not only wastes the car’s fuel, it can eventually foul the integrity of the fuel injection system. When it comes to cone-crushing material, a full chamber is the best practice.

• Correct application – Cone crushers are versatile machines, but using them as they are set up to function is the best idea. A 4:1 reduction ratio is a standard crusher application. Opting to use it for a 6:1 or 8:1 reduction of material could fall outside the parameters of its intended function, with punitive impact on the machine. Cone crushers can be utilized in various stations of a sequential crushing process, but some applications are more effective than

Giles Lambertson is a freelance writer (and former carpenter) who has been writing about the construction industry for nearly two decades.

Article courtesy of Sandvik Construction.

others. The owner-operator of a cone crusher should distinguish among tasks for best performance.

• Dry material – Dust rising from a crushing operation can be dampened by water sprays, but actual crushing performance will suffer. Generally speaking, material that is wet when it falls into the hopper causes problems.

The water molecules mud together with dust molecules, and finer material becomes pasty. The result is material that doesn’t fall out of the crushing chamber and creates unwanted pressures in the chamber, unnecessary wear of liners, and less-than-optimum performance.

Poorly maintained and operated cone

AGGREGATES MANAGER December 2015

47

FirstLOOK

by Marcia Gruver Doyle, Editorial Director

Standard power-split transmission is expected to improve fuel efficiency by up to 30 percent compared to conventional drive loaders.

LIEBHERRʼS XPOWER Wheel Loaders

Liebherr focused on fuel efficiency and ease of maintenance when designing its XPower loaders, which will debut in the United States in mid 2016.

A

s part of a press event

tional drive loaders. The loaders will

at hand. The hydrostatic transmission,

in England, Liebherr in-

debut at the bauma trade show in Ger-

for example, excels at short loading

troduced its new XPower

many next April, and will appear in the

cycles going into a pile, while the me-

large wheel loader lineup.

United States by mid 2016.

chanical transmission shines in long

Calling it a “significant milestone,”

48

The power-split drivetrain on the

distances and driving uphill.

Liebherr says it will use a power-split

L 550 through L 586 models combines

transmission as standard throughout its

a hydrostatic drive and a mechani-

mission is the future because it has the

entire new XPower large wheel loader

cal drive, and uses a continuously

advantages of both types,” says Martin

lineup, a decision it says will help give

variable transmission gearbox to au-

Gschwend, sales director, Liebherr-

the machines up to a 30-percent fuel

tomatically adjust between the two

Werk Bischofshofen. Another plus of

efficiency boost compared to conven-

drives, matching the drive to the job

this transmission: there is less internal

AGGREGATES MANAGER December 2015

“We believe the power-split trans-

K

stress, which increases component life.

Leibherr emphasizes the power-split is standard, without additional cost. In

Quick Specs Model

Horsepower

Bucket Capacity (cu. yds.)

Operating weight (lbs.)

L 550 L 556 L 566 L 576 L 580 L 586

191 224 272 292 313 354

3.82 4.30 5.02 5.62 6.21 7.17

39,021 40,565 52,690 56,658 60,957 71,870

fact, Gschwend says the XPower loaders will only have a 1 percent inflation-related price increase when Liebherr starts production.

In addition, each XPower model will now use the axle previously used in the next-size-up machine (i.e, the new L 556 XPower will feature the former L 566 axles). “We’re committed to increasing the lifespan of the loaders,” Gschwend says, “and customers expect

manual locks, most of the time when

back hood opens backwards for access to

more service.”

you need it, it’s usually too late, so we

the engine compartment. In the open po-

adjust it automatically,” says Mark Wal-

sition, the hood also has a small service

than 65,000 hours on prototype XPower

cher, product manager for wheel loaders,

platform in front, allowing maintenance

loaders, testing them at various customer

Liebherr-Werk Bischofshofen.

personnel to stand comfortably while

To date, Liebherr says it has put more

sites, including quarries, sawmills, and

Liebherr offers both a Z-bar and an

working within the engine compartment.

recycling companies. “There has not

industrial linkage on its L 550, L 556, L

“On the way into the cabin, you can

been a single main component failure,”

566, and L 580 models. The Z-bar linkage

check several service points,” Walcher

Gschwend says, and the power-split

now offers up to 20 percent more break-

says. Underneath the left-side cabin

transmission and larger axles “have

out force than previous models. Buckets

stairs, there is access to several service

proved to be particularly durable.”

have been reinforced, with the bucket

points, including the transmission oil and

The company is using its Liebherr

floor strengthened, and bucket volumes

greasing system. The cabin door can be

Power Efficiency drive system, intro-

have increased by .26 to .65 cubic yards

locked in the open position, and the door

duced on its previous loader lineup, to

from previous models. “Either linkage

lock also serves as an access step for

manage the Tier 4 Final Liebherr engine,

is available at no additional cost so the

cleaning the front window on the outside.

transmission, and hydraulics. The en-

customer can choose what’s best for his

gines, mounted on the back of the load-

operation,” Walcher says.

ers and thus eliminating the need for a

The redesigned tapered hood offers

XPower cabs became larger, increasing by roughly 4 inches in both width and length, and the air conditioner’s cool-

counterweight, use SCR emissions re-

increased visibility. “Most operators like to

ing capacity increased by 10 percent.

duction technology and operate at 1,100

drive through the mirrors and not through

The steering column can be adjusted to

to 1,800 rpms. The L 550 and L 556 use

the display,” Walcher says, “so we took

three different positions, and a hydraulic

a 4-cylinder, and the L 566 to the L586

care with the view to the rear bumper.”

control lever is integrated into the opera-

use a 6-cylinder engine.

Four working lights are now integrated

tor’s seat. Noting that different operators

Because the XPower drivetrain inde-

in the rear hood, illuminating the back

prefer different positions for the in-cab

pendently supports braking, the operat-

of the machine. As with most large ma-

display, Liebherr made the touch-screen

ing brakes have only a support func-

chines, a rear view camera is standard.

display adjustable. Larger window areas

tion, reducing brake wear. Tire wear is

Continuing a feature found in previous

extend further than in previous models,

reduced by up 25 percent, due to the

machines, the cooling package is located

continuous force control in combination

right behind the cab, where air is clean-

with automatic 45-percent self-locking

est. This section of the back end is ac-

Liebherr’s telematics system. Data from

differentials, providing tractive force

cessed by a hood that lifts up for air filter

the system can be accessed for one

whenever needed. “With 100-percent

cleaning and maintenance. The remaining

year free of charge. AM

improving visibility.

The loaders are equipped with LiDAT,

AGGREGATES MANAGER December 2015

49

Supply

SUPPLY LINES

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

BETTER BREAKERS

With features that allow for recycled recoil energy, shock absorption, and elimination of blank firing, today’s breakers are better than ever.

Tie-rod free breakers simplify maintenance Experience power and reliability in a small breaker with Allied Construction Products’ Rammer Small Range Breakers, the 555, 777, and 999. Designed without tie rods, the breakers incorporate Allied’s Constant Blow Energy plus operating system. A field-replaceable integrated one-piece tool bushing design includes the thrust ring, upper bushing, lower bushing, and dust seal, which require fewer parts. A boxtype housing has high-tech dampening material that reduces noise and vibration and protects the power cell. Installation is simplified through the use of a swiveltype hose connecting block.

Allied Construction Products www.AlliedCP.com

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

Bobcat | www.bobcat.com

50

AGGREGATES MANAGER December 2015

Efficient, powerful breaking Atlas Copco’s 4.5-ton HB4100 hydraulic breaker fits 40- to 70-ton carriers and gives operators a hard-hitting and efficient tool for a wide range of applications, including secondary breaking. The breaker’s EnergyRecovery system automatically uses the piston’s recoil energy to power the next blow, which minimizes vibrations and the hydraulic power demand from the carrier. The unit also features Atlas Copco’s AutoControl system, which automatically adjusts how hard the breaker hits based on the density of the material being broken. This means the breaker doesn’t need to constantly run at full force, which minimizes operating costs.

Atlas Copco | www.atlascopco.us

Hydraulic rig-mounted breakers Chicago Pneumatic offers a full line of hydraulic rig-mounted breakers for different applications.

Its lineup includes medium and heavy hydraulic breakers used by the aggregates industry. The RX line is said to be reliable with the power and toughness needed to get the job done and is built to last. The medium range features three models and is used for rock excavation and quarrying. The heavy range offers five models to be used in rock excavation and mining applications.

Chicago Pneumatic www.cp.com

Strike power increases productivity Doosan hydraulic breakers are available in impact energy classes from 2,720 to 10,880 joules and are designed for use with its crawler excavators (DX140LC-5 through the DX350LC-5) and DX140W-5 wheel loader. The breakers feature an energy recovery system that increases strike power for maximum productivity. The nitrogen-powered units are equipped with an upper/lower suspension system that isolates the power unit from the housing. Additional features include a patented main valve design that reduces hydraulic pressure, a suspension system that extends boom life by absorbing vibration, and accessories such as a bracket cap, hoses, automatic greaser, and toolbox.

Doosan | www.DoosanEquipment.com

Unit features severe-duty casing Indeco North America’s HP 13001-ABF hydraulic breaker is particularly suited to aggregates applications. Featuring a severe-duty casing, it is designed to fit excavators weighing from 86,000 to 176,000 pounds. Features include a special low-alloy steel construction for longer working life, the manufacturer’s unique ABF (anti-blank fire) technology to eliminate damaging blank or dry firing, an intelligent hydraulic system that varies hammer blow and frequency according to material hardness, a dual shock absorber system that reduces vibration, a field-replaceable lower insert bushing, and a power greasing system to reduce wear. The unit weighs 11,150 pounds and delivers 270 to 540 blows per minute.

Indeco North America hwww.indeco-breakers.com

Minimum power, optimal productivity

Variable-speed technology

JCB hydraulic breakers are designed to break a wide range of materials using minimal power for optimal productivity. All combine hydraulic force and recovered energy in the hydraulic system through the use of a highly efficient internal control valve. Energy not absorbed by the rock is reused during the following blow, placing less demand on the carrier. Reused energy requires no additional hydraulic flow from the pump, improving efficiency while saving fuel. All breakers are available with either a moil or chisel tool as standard equipment. The heavy-duty housing is constructed from high wear-resistant steel for reliability across a wide range of applications.

JCB | www.jcbna.com

Montabert’s V32 heavy-range hydraulic breakers feature automatic variable-speed technology that senses changes in material hardness and adjusts impact energy and striking rate, maximizing productivity while reducing harmful energy transferred back to the carrier. The variable-speed system is designed for quarrying and excavating applications. Designed for use on excavators weighing between 39,700 and 66,150 pounds, the 3,408-pound hydraulic breaker delivers between 400 and 1,050 blows per minute. Standard features include a progressive start system that prevents slipping by creating a niche in the material before full power is applied. A blank-fire protection system reduces metal-on-metal contact, and an energy recovery system recycles recoil energy to increase strike power.

Montabert | www.montabert.com

Economical breaking of oversize Surestrike says its hammers are the most productive and economical solution for oversize rock breaking. Models range from 10,000 foot pounds to 150,000 foot pounds which easily break materials such as limestone, basalt, granite, trap rock, iron ore, slag, etc. The high, single-blow impact energy, coupled with low maintenance and low wear part costs, make the hammers a productive and profitable attachment for all quarry owners and operators.

Surestrike | www.surestrike.biz

AGGREGATES MANAGER December 2015

51

Cubee the AggMan helping educate children about the importance of aggregate since 1998 “The Story of Cubee the Aggregate” helps teach children at the youngest ages about the important role aggregate plays in their daily lives. Geared for students in grades K-3, Cubee and his aggregate friends will take children on a magical journey from Cubee’s birthplace in the neighborhood quarry to his new home in the schools, roads and other structures that enrich our communities and our lives.

The “You’re on Rock” Workbook presents basic earth science information while emphasizing the vital role of the industry in our world. An aggregate activity book for junior geologists, mining engineers and earth scientists. Geared for students in grades 4-6.

Cubee the AggMan T-Shirts are available.

To learn more about these great tools for community outreach, adopt-a-school programs, and receive sample copies of the coloring/workbooks,

Call 800-430-4540 e-mail: cubee@aggman.com

or visit www.AggMan.com

Scouts were asked not only to identify the various minerals, but also to describe their characteristics.

Boy Scouts and

Merit Badges Following the introduction of the Boy Scouts’ new Mining in Society merit badge, Cemex offered a oneday camp to help Scouts learn about mining and earn the badge.

T

he launch of the Boy Scouts

personal protective equipment is required in

Mining in Society merit badge in

mining operations, conducted demonstrations,

February 2014 spurred discus-

and even tasked the Scouts with filling out a

sion among Cemex officials about

near-miss card by the end of the day.

hosting a summer camp that would enable scouts to earn the badge. Earlier this year, we made it happen.

On Aug. 4, 2015, 25 Boy Scouts from three packs in Lake and Polk Counties filled the Engstrom Classroom of our 474 Sand Mine.

Scouts, along with their leaders and parents, arrived in the morning for a 7-hour event, and, by the end of the day, had earned their

by Jenna Emerson

Mining in Society and Geology merit badges.

Like our regular operation meetings, the camp began with a presentation on safety.

Safety Manager David Thompson told the Scouts about what was expected of them with regards to safety. He explained what

Mineral identification was a fun activity for many of the Scouts.

AGGREGATES MANAGER December 2015

53

Need to navigate your way around the industry?

Get the the most current information with the Atlas on CD While the printed version of the Aggregates Manager 2015 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more.

The Atlas on CD contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2015 Aggregates Industry Atlas in pdf format.

Order additional copies of the Aggregates Manager 2015 Aggregates Industry Atlas on CD or the printed version of the Atlas today!

Atlas

Printed Version

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

$50 per copy $45 per copy $35 per copy $20 per copy

CD-ROM $250

Plus shipping and handling.

Shipping: $4.50 per Atlas $.70 per CD $8.00 Handling Fee

DATA FILE $200 (online download only)

To order, visit AggManAtlas.com or call 1-800-430-4540

COMMUNITY RELATIONS

After the safety presentation, Scouts

was a great teaching exercise that the

and their parents were loaded onto

Scouts really seemed to enjoy.

a bus for a mine tour. Plant Manager

At the end of the day, I made a pre-

Don Bogart led the tour. He explained

sentation about community relations.

the sand mining process and gave a

Although this is not part of the badge

behind-the-scenes tour of the plant

requirements, I wanted the Scouts to

and dredge.

understand Cemex’s role in the com-

Next, Ecologist Annie Doyle, of

munities where we operate and our

Flatwoods Consulting, led an ecolo-

commitment to education.

gy hunt, which required the Scouts

We look forward to replicating this

to identify 10 native plants and 10

camp all over Florida and the United

native animals. Cemex Environmental

States. AM

Manager James Mott then led great

Jenna Emerson is the legislative and public affairs manager for Cemex in Florida and the Carolinas.

discussions on environmental controls and permitting. He also had students conduct fieldwork as he had them read water levels in the site’s ponds.

Cemex Geologist Dr. Aleta Mitch-

As part of their training, Boy Scouts learned about the importance of safety and wearing the appropriate personal protective equipment.

ell-Tapping was up next. She assem-

through a minerals exercise where

bled an excellent presentation on Flor-

they were asked to identify various

ida geology and minerals. Scouts went

minerals and their characteristics. It

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

IDLERS | PULLEYS | IMPACT BEDS | ACCESSORIES

IMPROVE YOUR

CONVEYING PERFORMANCE

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

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

• Resource evaluation • Expert testimony

• Technical writing and review • Lecturer

Contact me at:

Bill-Langer@researchgeologist.com www.researchgeologist.com BillLanger_AGRM0115.indd 1

12/16/14 1:21 PM

Built for Maximum Impact CEMA D Impacts designed with reinforced end plates and angle iron to take maximum load & impact Luff Industries Ltd. tf: 1.888.349.LUFF (5833) e: info@luffindustries.com w: www.luffindustries.com

AGGREGATES MANAGER December 2015

55

Rock Review Commission determines that ALJ erred in invalidating Brody POV notice prior to hearing.

by Patrick W. Dennison

A Roadmap for

POV LITIGATION?

T

Patrick Wayne Dennison is an attorney in Jackson Kelly PLLC’s Pittsburgh, Pa., office, practicing in the Occupational Safety and Health Practice Group and the Coal and Oil and Gas Industry Groups. He can be reached at 412-4348815 or pwdennison@ jacksonkelly.com.

56

he Review Commission vacated ALJ Moran’s decision in Brody Mining, LLC, sending the case back for further proceedings after concluding that ALJ Moran erred in invalidating the POV notice issued to Brody. Brody Mining, LLC, Docket Nos. WEVA 2014-82-R, et al. (Sept. 29, 2015).

The majority’s decision, led by Commissioners Young, Cohen, and Nakamura (majority), first upheld jurisdiction based on a January 2014 order that consolidated all contests of the § 104(e) withdrawal orders. The majority rejected the Secretary’s argument that the interlocutory appeal of the facial validity of the rule pending before the D.C. Circuit deprived the ALJ of jurisdiction. Chairman Jordan and Commissioner Althen concurred with the majority’s decision on jurisdiction.

After determining that the ALJ had jurisdiction, the majority then concluded that the ALJ erred by dismissing the pattern notice prior to the hearing. In so concluding, the majority relied on the criteria the Mine Safety and Health Administration (MSHA) reviews to identify mines for POV and stated: a “pattern of violations” . . . is established by an inspection history of recurrent S&S violations of a nature and relationship to each other such that the violations demonstrate a mine operator’s disregard for the health or safety of miners. No particular number of S&S violations is required in or-

AGGREGATES MANAGER December 2015

der to constitute a pattern of violations, and a finding of a pattern of violations does not presuppose any element of intent or state of mind of the operator.

The majority agreed with the Secretary that a “pattern” does not require a particular number of citations and concluded that the ALJ erred by requiring a precise number. The majority also found the ALJ’s dismissal of the charge prior to hearing to be an “overly harsh remedy.” In a small victory for mine operators, the majority agreed with the ALJ that “the Secretary is ordinarily required to disclose his theory of how the groupings in a POV notice constitute one or more patterns of violations” and “Brody was entitled to the Secretary’s theory of how the groupings amounted to patterns prior to the hearing on the pattern so as to be able to defend against the pattern charges.”

The majority provided a “roadmap” for litigating future POV cases: the Secretary may call witnesses, “such as inspectors or district managers, who will testify about how the S&S violations constitute a POV” and, through prehearing orders and discovery, the operator may become familiar with the Secretary’s theory of the pattern. The majority cautioned, however, that no discovery or inquiry regarding “MSHA’s prosecutorial discretion in issuing a POV notice” was appropriate.

Because the majority found that the ALJ’s dismissal prevented the Secretary from presenting evidence for (and Brody from defend-

ROCKLAW

demonstrated a denial of due process warranting dismissal. ing against) a pattern charge, the case was remanded with Althen questioned the initial POV determination by MSHA, directions to apply the Commission’s stated definition of given the Secretary could not explain the relationship among POV to determine whether the Secretary has proven one or the alleged violations that led to that determination until after more patterns of violations with respect to the 29 citations a hearing. Because of the “outcome determinative element” and orders affirmed as S&S. of the POV charge, the Secretary must provide “in advance” a In a separate concurrence, Chairman Jordan agreed that sufficient theory of such relationships to allow the operator to the ALJ had jurisdiction and the decision should be vacated prepare to rebut the charge. Commissioner Althen envisions and remanded. However, she rejected any consideration of balancing information covered by the deliberative process procedural/due process error that resulted from the Secreprivilege with sufficient discovery, noting that such information tary’s refusal to provide the theory of POV, stating that the would not be of the type to come from individual inspectors.

POV notice “informed” Brody of the specific conduct upon It is unclear what the ALJ will do on remand with the which the Secretary would rely to support the POV. She likCommission’s directions. Further, Brody’s challenge to the ened the POV notice to other types of enforcement actions facial validity of the rule is still pending before the U.S. (S&S, unwarrantable failure) which, she contended, the ComCourt for Appeals for the D.C. Circuit. As my colleague, Brad mission has never concluded that due process required the Oakley, said in his November 2014 article “Challenges ConSecretary to provide his underlying theory for the validity of tinue on POV Rule,” operators should continue to monitor issuance. She also found that Brody failed to prove prejudice compliance performance, implement specific compliance concerning what it would have done differently at hearing. goals, and collect as much evidence as possible to chalCommissioner Althen (concurring in part and dissenting in lenge improperly issue citations/orders should MSHA issue a part) dissented and found that the majority’s decision regardPOV notice. AM ing the identification of a specific number of S&S violations to be a “makeweight to justify reversal.”

Althen found that the ALJ directed the Secretary to provide an explanation of the theory by which the 54 alleged violations set forth in the POV notice constituted a pattern of violations, not that the Secretary had a duty to provide a specific number of violations necessary to prevail, as the majority found. Althen concluded the majority’s decision erroneously “plucks one word” from the Judge’s lengthy disEvery Beka-Max EP1 automatic lubrication system is built to keep missal order to “conjure a reason for your machine performing smoothly in all seasons and altitudes. reversal,” but the Secretary failed to • Cast aluminum base withstands impacts and hot/cold provide any of the necessary informatemperature swings without leaks tion covered by the ALJ’s order.

• No springs! Eccentric drive gear ensures reliable service Althen recognized that the majorin all climates and conditions ity’s decision requires the Secretary • Engineered to pump grease to provide “exactly the kind of infordown to -13°F/-25°C mation required by the judge in this case” and basically “reverses the judge for applying a standard with which they agree and which they themselves now impose upon the Secre1 . 888. 862. 7461 tary.” Althen found that the failure to www.beka-lube.com provide an ascertainable basis for the B E K A - L U B R I C AT I O N S P E C I A L I S T S S I N C E 1 9 2 7 POV determination, standing alone,

Here are the

COLD HARD FACTS about automatic lubrication!

026-073 Agg Manager 4.5x4.5 4C.indd 1

57

2015-10-06 12:14 PM

AGGREGATES MANAGER December 2015

Advertising COMPANY

WEB

PAGE #

Baldor Electric Co.

www.baldor.com

Beka-Max of America, Inc.

www.beka-lube.com

7 & 28 57 55

Bill Langer - Research Geologist

www.researchgeologist.com

Breaker Technology, Inc.

www.rockbreaker.com

27

C.L. Dews & Sons Foundry

www.dewsfoundry.com

59

Clearspan Fabric Structures

www.clearspan.com/adam

59

CWW Conveyor Systems, LLC

www.cwwconveyors.com

25 IBC

Elrus Aggregate System

www.elrus.com

Flexco

www.flexco.com

9

FMI Corp.

www.fminet.com

4

Kespry, Inc.

www.kespry.com/aggregates

15

KPI-JCI and Astec Mobile Screens

www.kpijci.com

2

Kruse Integration

www.kruseintegration.com

59

Linear Rubber Products

www.belting4conveyors.com

59

Luff Industries, Ltd

www.luffindustries.com

55

Martin Sprocket & Gear, Inc.

www.martinsprocket.com

22

Midwestern Industries

www.midwesternind.com

47

Motion Industries, Inc.

www.motionindustries.com

IFC

NSSGA Membership

www.nssga.org

26

Polydeck Screen Corp.

www.polydeckscreen.com

18

Pugmill Systems, Inc.

www.pugmillsystems.com

59

Rock Systems, Inc.

www.rocksystems.com

59

Rulmeca Group

www.rulmeca.ca

19

Scott Equipment

www.scottcompanies.com

33

SDLG North America

www.sdlgna.com

21 58

Stedman Machine Co.

www.stedman-machine.com/impact

Superior Industries

www.superior-ind.com

17

Terex Minerals Processing Systems

www.terexmps.com

BC

Topcon Positioning Systems

www.topconpositioning.com

20

Volvo Construction Equipment

www.volvoce.com/smartcare

13

World of Asphalt 2016

www.worldofasphalt.com

41

World of Concrete 2016

www.worldofconcrete.com

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

58

AGGREGATES MANAGER December 2015

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59

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

In Stone Straight from the

SOURCE An interview with Toobig Uglyrock.

D

uring this past year, I have quoted many people in my articles about Barre Granite. I unintentionally ignored the rocks, so I interviewed one.

Here it is.

Langer: I am talking with a member of the Barre Granite pluton. You said I should call you Toobig Uglyrock. So, Mr. Uglyrock, tell the readers a little bit about yourself.

Uglyrock: Back in 1793, when the privilege to name Barre, Vt., was decided by a fist fight (January Carved in Stone), some of my relatives that were exposed on the flanks of a nearby hill had already been broken away from the ledges and turned into millstones. Other kinfolk were used as lintels, thresholds, hearthstones, steps, and in fences and walls (February and March Carved in Stone).

Oswego Harbor breakwaters, 1925.

Langer: I understand another use of Barre Granite was as paving blocks.

Uglyrock: Oh, yes. When people quarry rock some of it breaks into pieces that are too small for gravestones. They just toss ‘em over the bank into a huge pile like the one I was in. They call it a chat pile. So happens that some of the waste rocks are perfect sizes to be worked into paving blocks (June Carved in Stone), but I was too big to be used as a paving block.

Langer: Weren’t some of your most famous relatives selected for use because of their beauty?

Uglyrock: Yes. Back in the 1830s, some of my siblings were used in the Vermont Statehouse (May Carved in Stone). They were very pretty. I was ugly, and when they dug me up, they pushed me over the bank into the chat pile.

Langer: Oh, dear. (Sigh.) Aren’t most of your relatives used as gravestones?

Uglyrock: Well yes, I have thousands and thousands of beautiful cousins that are gravestones, monuments, and mausoleums. They have been shipped all over the country (July Carved in Stone).

Langer: So, Toobig, is it difficult to quarry your granite family?

Uglyrock: You bet. I was quarried back before electricity and steam power. I was drilled by hand with hammers and drills, and split with feathers and wedges. But we rocks also have inherent weaknesses that experienced quarrymen exploited, making their job easier (April Carved in Stone).

Langer: It must have taken many people to quarry so many of your relatives.

Uglyrock: Many Americans as well as Scottish, Italian, and other immigrants worked in Barre’s quarries and sheds (August and September Carved in Stone). During the early 1900s, the mechanical working of stone created dust, and inhaling granite stone dust caused the horrific disease known as silicosis. Many workers exposed to the dust, laborers, and owners, died well before their time, leaving their widows to fend for their families (October and November Carved in Stone). Barre was among the first of the mineral industries to address the issue by installing dust-removing equipment.

Langer: Toobig, I see you have been loaded on a railcar. Do you know where you are going?

Uglyrock: Well, these days a lot of my relatives in this chat pile have been run through a crusher and are used as road base and asphalt aggregate. Me? I’m too big. I think I am going to a landfill; a place they take stuff nobody wants.

Langer: Wrong! You are headed to the Port of Oswego on Lake Ontario in New York State. You are going to be used as jetty rock to help provide a safe haven for boaters.

Uglyrock: Really? Hey boaters. You can call me Barre Breakwater!

Author’s note: Thanks to Harry Hart, from North East Materials Group, LLC, for pointing out the use of Barre Granite as jetty stone and aggregate.

60

AGGREGATES MANAGER December 2015

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