Aggregates Manager December 2018

Automated drills PG13 | Modifications just got harder PG36 | Frack sand boom PG40

Your guide to profitable

December 2018 | www.AggMan.com

AggMan of the

Year

2018 18

Check out the Top RollOuts of 2018

28

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Manufacturers’ increased focus on sand plants was reflected in the number of such plants listed among this year’s Top Rollouts.

PAGE 18

On Our Cover: Karen Hubacz-Kiley is the AggMan of the Year for 2018.

Cover photos courtesy of Karen Hubacz-Kiley and Patrick Dunne.

In addition to maintaining the radial stacker itself, the travel path must be kept smooth and level.

PAGE 28

TABLE OF CONTENTS DECEMBER 2018 |

VOLUME 23, NUMBER 12

FEATURE ARTICLES

6

AggMan of the Year: Karen Hubacz-Kiley Whether driving a dump truck or testifying before Congress, Karen Hubacz-Kiley is a small producer with a big industry presence.

COLUMNS & DEPARTMENTS 3 Editorial Share your photos or videos with Aggregates Manager and get your 15 minutes of fame.

18 Top 25 RollOuts

4 Data Mining The latest financial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook.

28 How Does Your Maintenance Stack Up?

36 Rock Law Changes to the petition for modification process may result in increased work and operational costs for operators.

Sand plants, technology upgrades, and wheel loaders are prominent among this year’s new equipment.

When it comes to radial stackers, lubrication and belts offer opportunities for ensuring efficient operation.

38 Advertiser Index See who’s who and where to find their products.

OPERATIONS ILLUSTRATED

13

Autonomous Drilling.

Autonomous drills offer increased accuracy, but quarries aren’t turning over the keys to robots just yet.

39 Classified Ads Aggregates industry classifieds.

40 Carved in Stone Fueled by fracking, production of silica sand has nearly quadrupled since 2000.

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December 2018

EDITORIAL

Vol. 23, No. 12

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

aggman.com /AggregatesManager /AggManEditor

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

Get Your

15 Minutes of Fame

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

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

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

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

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

Aggregates Manager TM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2018. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them.

Publisher reserves the right to refuse non-qualified subscriptions.

Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

N

early everyone enjoys a brush with fame. In the Elizabethan era, there was an expression, “nine days’ wonder” to describe someone or something that created short-lived fame. In the ’60s, Andy Warhol said, “In the future, everyone will be world-famous for 15 minutes.” This quote sparked the concept of 15 minutes of fame. Today, fame may be even more fleeting. For example, a company, 15 Seconds of Fame, exists solely for the purpose of sharing videos from live events (imagine the jumbotron from your favorite sporting event) with those who were featured in them.

Over the years, the people and plants featured in Aggregates Manager often enjoy similar high profiles in the weeks and months that follow. Our staff regularly receives requests for extra copies of issues from individuals and companies alike. As we visit operations, it’s not uncommon to see articles framed and on display in offices and lobbies. It’s a lasting way to capture that moment of celebrity.

Social media often draws a similar response. Facebook posts can enjoy enormous numbers of likes, or tweets can go viral. It’s the social media equivalent of fame. Over the last few years, we’ve seen more and more aggregate producers who share pictures of their sites — often with entertaining and engaging stories about their field.

We’d like to help aggregates operations and personnel raise their visibility within the industry by sharing pictures and videos of sites on our various channels: in the magazine, website, and social media channels. Many operators take interesting and, sometimes, downright breathtaking pictures of their sites. We want to share those with a broad audience.

How can your pictures and videos be shared with our readers? It’s simple. Go to our website (www.aggman.com) and click on the Contests tab. There, you can find a link where you can upload your photos and videos and submit a few basic pieces of information so we can verify your submission. Simply fill out the form and upload your favorite picture or video. (Due to file size, videos should be no longer than three minutes.)

And, if you happen to be an amateur photographer, you may even see your photo on the cover of Aggregates Manager. Because these vertical photos are typically 10 to 12 MB, most cell phone pictures won’t be high enough resolution for a cover.

So, the next time you walk out into your operation, look at it with a fresh set of eyes and snap a picture or take a photo. Just be sure you do it from a safe location and do not obstruct operations. We look forward to seeing operations through your eyes. AM

AGGREGATES MANAGER / December 2018

3

mining

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

Diesel Fuel

Prices 11/5/18

United States $3.338 One Week -0.017  One Year +0.456

New England $3.362 One Week -0.003  One Year +0.550 

Central Atlantic $3.498 One Week -0.025  One Year +0.523 

Lower Atlantic $3.205 One Week -0.012  One Year +0.441 

Midwest $3.286 One Week -0.024  One Year +0.425 

Gulf Coast $3.106 One Week -0.011  One Year +0.438 

Rocky Mountain $3.398 One Week -0.007  One Year +0.433 

West Coast $3.833 One Week -0.015  One Year +0.501 

West Coast less California $3.564 One Week -0.026  One Year +0.463 

California $4.068 One Week -0.006  One Year +0.527  Source: U.S. Energy Information Administration (dollars per gallon, prices include all taxes).

$4.79

52-Week High $8.51

CRG

$30.64 

$27.07

$37.42

EXP

$77.47 

$64.95

$122.49

Granite Construction Inc.

GVA

$55.69 

$39.51

$68.58

HEI

$68.61 

$62.44

$109.41

$9.31 

$8.10

$12.59

HCMLY

Martin Marietta Materials, Inc.

MLM

$189.76 

$150.75

$241.33

MDU Resources Group, Inc.

MDU

$26.29 

$24.29

$29.62

Summit Materials

SUM

$14.65 

$11.67

$34.06

United States Lime & Minerals, Inc.

USLM

$75.05 

$70.56

$88.00

U.S. Concrete

USCR

$39.69 

$27.68

$86.35

Vulcan Materials Co.

VMC

$109.20 

$82.52

$141.20

Source: Wall Street Journal Market Watch. Currency conversion calculated on date of close 11/7/18.

COMPANY SPOTLIGHT

East Coast $3.360 One Week -0.017  One Year +0.481 

$5.64 

52-Week Low

Eagle Materials Inc.

LafargeHolcim Ltd. ADR

U.S.

CX

Current Value

CRH plc

HeidelbergCement AG

On-Highway

Ticker

F

or the third quarter, ended Sept. 29, Summit Materials, Inc. (SUM) reports net income of $71.3 million or $0.64 per basic share, compared to net income of $81.3 million or $0.74 per basic share in the comparable prior year period. Summit’s net revenue increased 11.6 percent in the first nine months of 2018 as compared to the same period in 2017, primarily due to acquisitions.

“We experienced significant inclement weather in the third quarter, as well as continued inflationary cost pressures in our businesses beyond our expectations,” said Tom Hill, CEO of Summit Materials, in a press release.

Summit Materials, Inc. (SUM) “While we achieved organic volume and price increases in our aggregates and products during the third quarter, our net income declined and our Adjusted EBITDA remained flat in the third quarter of 2018 as compared to the third quarter of 2017, reflecting lower contributions from our cement segment and Houston operations together with inflation in our variable costs. We had expected normal weather going into the third quarter; instead, weather patterns continued to have a significant negative impact on most of our operating geographies.”

In Summit’s aggregates segment, net revenues increased by 21.0 percent to $109.6 million in the third quarter, compared to the prior year period. Organic aggregates sales volumes increased 3.9 percent in the third quarter, compared to the prior-year period. Organic growth in the aggregates sales volumes was due to higher volumes in the West Region, which more than offset a decline in organic sales volumes in the East Region. Organic average selling prices on aggregates increased 1.5 percent in the third quarter 2018 due to improvements in price within both the West and East segments during the period.

Through the first nine months of 2018, Summit has completed 13 acquisitions with a total investment of $300 million. Since its last quarterly update, it completed two bolt-on acquisitions valued at $72 million. These include the acquisition of Idaho-based Walker Sand & Gravel and Georgia-based Aggregate Reserves. Walker Sand & Gravel expands the company’s market position and reserve base in Idaho. Aggregates Reserves includes property in the greater Atlanta area containing more than 100 million tons of permitted reserves and an active quarry, which is leased to a third party through mid 2021. The company will receive royalty payments until the end of the lease, at which time it will take over quarry operations.

Source: Market Watch

Data

STOCK REPORT

AGGREGATES INDUSTRY OUTLOOK Aggregates Industry Outlook The November Aggregates Industry Index registered its largest decline since November 2017, falling 4.37 percent from October to 130.68.

The decrease can be attributed to significant declines in the outlook for monthly sales (-8.47 percent) and quarterly sales (13.59 percent).

Most of this month’s responses were registered prior to the Nov. 6 election, but following a steep decline in the stock market in late October.

150 145 140

138.44

136.65

134.94

134.72

133.44

132.22

135

130.86

130.68

138.89

130

135.83 132.73

125

129.35

120 115 110 105 100 Dec. 2017

Jan. 2018

Feb. 2018

March 2018

April 2018

May 2018

June 2018

July 2018

Aug. 2018

Sept.

2018

Oct. 2018

Nov. 2018

Orders are up over the previous year, but labor shortages, as well as trucks, may begin to cause problems soon. We ran short on trucks all summer and fall. It is going to be very important that able-bodied persons re-enter the workforce in the coming year. I think that a focus on vocational training would go a long way toward curing many of our nation’s and industry’s woes.

We have allowed ourselves to be convinced that our children are too good to do this type of work. It’s like the old adage, ‘I would never join a club that would have me for a member.’ We talk about jobs, but go try and hire somebody. Vocational programs that produce a well-rounded worker, suitable for industry, should be front and center in our nation’s schools.

— Jon Thompson, President, Letart Corp.

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

MOBILE EQUIPMENT FINANCED Type of Equipment

TOP STATES

07/01/201809/30/2018

Wheel loader (250-1,000 horsepower)

178

Excavator (160-520 horsepower)

94

Wheel Loader

Washington

5

Wisconsin

Minnesota

5

Wheel loaders Cat 980M

Top Cat 982M units financed Komatsu WA500-8

Number financed 19

California

9

14 12

Case 1121G

12

Deere 824K

9

5

8

Missouri

5

Colorado

Michigan

5

5

9

Ohio Pennsylvania

Texas

16

Excavators Excavators

Number financed

Cat 336FL

12

Top Cat 330FL units Volvo EC480E-L financed

8

4

California

Pennsylvania

5

5

6

Case CX350D

5

Cat 325F LCR

5

Texas

8

5 North Carolina Alabama

AGGMAN OF THE YEAR

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

AggMan of the

Year

2018 Karen Hubacz-Kiley

Whether driving a dump truck or testifying before Congress, Karen Hubacz-Kiley is a small producer with a big industry presence.

6

AGGREGATES MANAGER / December 2018

K

aren Hubacz-Kiley is a woman deeply rooted in family. Whether it’s the family she grew up in; the one she created with her husband, Dale; her business, Bond Construction Corp.; or relationships she has with industry friends and within organizations, a sense of family exists in each. A natural leader, her peers describe her as a straight shooter, loyal, wise, outspoken, courageous, and — from those who know her well — wicked awesome.

Finding these same qualities in her, the Aggregates Manager staff is pleased to recognize Karen Hubacz-Kiley as the AggMan of the Year for 2018.

Growing up in the business There was little doubt, even from an early age, that she would follow her father and uncle into the family business. “I was a daddy’s girl, so I was always with my dad,” Hubacz-Kiley says. “So, this company was my sandbox as a kid.” From the time she was young, she knew Bond Construction was where she wanted to be.

Her father, Ed Hubacz, recalls that at around the age of 14 or 15, she put on her hard hat and gloves and pulled roots before they made their way into the crusher. As she grew older, she took on increasing levels of responsibility. “She was always by my side and grasped everything very well,” he says. “She started from the bottom and worked her way up. If somebody asks her about this or that, she can answer the question because she worked her way into her position.”

After a couple years, Hubacz-Kiley told her father she wanted to get her commercial driver’s license (CDL). He protested, saying that being on the road was not the right place for her, but his protest fell on deaf ears. “When you tell Karen she can’t do something, the next thing you know, she is doing it,” he says. She spent a couple years driving trucks before learning how to bid jobs, run dispatch, and apply for permits, among other skills.

“She had a few struggles at first because it’s a male-dominated industry. She had to work harder,” notes her husband, Dale Kiley, an associate attorney at Bourgeois White, LLP. “She did that by getting involved in every aspect of the business. There was nothing beneath her. In doing that, she gained the respect of all of her employees.”

As her father approached retirement and began to cut back at the office, her responsibilities continued to grow, and her position evolved from manager to director to chief operating officer in a natural progression.

Hubacz-Kiley is currently one of several family members working in the business: her cousin, Nancy HubaczMason, is CFO; another cousin, Jodi Ann Hubacz, heads marketing and oversees dispatch; and her daughter, Sadie Kiley, is the weighmaster.

Growing influence Just over a decade ago, Hubacz-Kiley attended her first National Stone, Sand & Gravel Association (NSSGA) meeting in Las Vegas during ConExpo-Con/ Agg. Shortly after, she went to her first Young Leaders Council meeting.

“It was a lot for my father and uncle to swallow,” she says. “If it wasn’t for Hank Lane (from John S. Lane & Son, Inc.) telling my father, ‘Eddy, let Karen do this. It’s good for her,’ I don’t think it would have happened.’”

She was given the nod to get involved, with the caveat that Hank’s son, Jon, and salesman, Joe Salvon, would keep an eye on her. “Karen didn’t need a whole lot of looking after,” laughs Lane, vice president, John S. Lane & Son, Inc. “I don’t think there’s ever been a challenge Karen has shied away from.” Salvon, who had served as chairman of the Young Leaders Council, continued to encourage her involvement in that group and NSSGA as a whole.

It was also through Young Leaders that she met her best friend, Jennifer Hise, vice president of CEMCO, Inc.

Hise recalls that the two met while waiting for an airport shuttle to their hotel. “Through that long weekend, we truly clicked,” she says. “Both of us are third generation members of a family business and are taking over the companies. We can relate with one another, regardless of the miles between us or the difference in time zones. It creates a real sense of security to have someone who can serve as a sounding board.”

With a growing network of industry friends and contacts, HubaczKiley quickly became a recognizable figure at the meetings. “First of all, you don’t blend in. There are not a whole lot of women who are producer members,” she says. “Second, I’m not a wallflower. I just felt I was with my people for the first time, so it was very empowering to be with all these other people in the industry.”

Former NSSGA Chairman and CEO Joy Wilson quickly recognized her leadership potential and, within a few years, Hubacz-Kiley found herself first serving on the Board of Directors, then joining the Nominating Committee.

“I became exceptionally active in a Small Producers meeting. John Albright was the chair,” she recalls. “At the very first meeting, John introduced himself and said there was a seat right next to him. By the end of the meeting, I had somehow become co-chair.”

Hubacz-Kiley says that small producers are accustomed to being self-sufficient and doing everything for themselves, so while they may want assistance, it’s not always in their nature to ask for it. She often steps into that void and brings their issues forward.

“I get a lot of phone calls from other small producers if they have concerns.

They certainly can come through me, because they know that I’m not afraid to speak up,” she says. “NSSGA is not just about the big guys; it’s about everybody. I have the same one vote as Ward Nye or Tom Hill has. I’m treated as an equal to them. We all have different issues, but we have a lot of AGGREGATES MANAGER / December 2018

7

AGGMAN OF THE YEAR the same issues, and I think we’re all here to speak with one voice on many different levels.”

Hubacz-Kiley currently serves as NSSGA’s Membership Committee chair and is its liaison on the Executive Committee.

Fighting for better rulemaking

After putting her CDL to good use for a couple of years, Hubacz-Kiley continues to personally evaluate the skills of potential new drivers.

Hubacz-Kiley has also given a voice to small producers through Congressional testimony. Last December, she shared how the 2015 Waters of the U.S. Rule, better known as WOTUS, would impact small operators. It’s an issue that deeply affected her company.

“I went through a giant turmoil being sued by an action group, and I would never want somebody to have to go through what I did,” she says. “I feel that I owe it to everybody else in our industry to be sure that these

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AGGREGATES MANAGER / December 2018

regulations are science-based.”

Her experience began when a New England-based group called Clean Water Action served notifications to multiple quarries and sand and gravel operations, complaining that they did not have the appropriate storm water permits. “We do not have a storm water permit, because we do not discharge into the waters of the U.S.,” Hubacz-Kiley explains.

“Their claim against us was that we were (discharging into waters of the U.S.), so they filed against us in a federal court.” Through the lawsuit, she was required to let the group onto her site and escort them around to inspect it. Despite the lack of discharge, the group continued to press its claims.

“I fought it to the best of my ability,” she says, noting that the prolonged battle included significant financial ramifications.

“Eventually, I had no other choice

but to fall on the sword.” The company paid a settlement to the action group and made a charitable donation that Hubacz-Kiley insisted stay in the town of Spencer where Bond Construction is based. Under the court decree, the company was supposed to be monitored for two years, but after receiving the settlement, the action group never again stepped foot on the property.

Testifying before Congress, she emphasized the need for clarity in definitions. “The rule must be replaced so there is a clear, black and white distinction on where we can and can’t quarry rock,” she said. “I don’t want to have to hire a team of lawyers and environmental consultants every time I want to expand our operation to fulfill a need. If they get it wrong, then Bond Construction could face fines as high as $50,000 per day.”

She also submitted comments on the Mine Safety and Health Administration’s (MSHA) Rule on Workplace Exams. “We strongly oppose the rule, because it will bureaucratize the process of managing for safety and increase our costs with no benefit to the safety of our workers,” Hubacz-Kiley wrote.

Hubacz-Kiley hosted a roundtable with NSSGA employees to discuss the concerns of small producers and how the association could be of assistance.

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AGGREGATES MANAGER / December 2018

9

AGGMAN OF THE YEAR of burdensome regulations on small, family-run businesses like hers.”

Educating public officials

Hubacz-Kiley hosted Rep. Jim McGovern and other elected officials this summer. Her daughter, Sadie, is pictured to Hubacz-Kiley’s left.

Her willingness to speak up on behalf of the industry has garnered the respect of those around her. Kiley notes that, as the leader of a small family operation, his wife tackles issues that larger companies may have entire departments to handle.

“She’s very focused on the industry and her business,” he says. “That’s what drives her.”

“Karen…has been a tireless advocate

for aggregates operations for many years. Anyone that has met Karen knows that she has a unique passion for who we are and what we do — a love for the industry that only comes from growing up in it,” adds Michael Johnson, president and CEO of NSSGA. “That passion has been appreciated as she has chaired our Membership Committee and educated lawmakers on the impact

In addition to Congressional testimony and the submittal of comments, HubaczKiley is cultivating relationships with her lawmakers and making sure they understand the role operations play within their communities and how they may be affected by relevant legislation.

In August, she hosted Rep. Jim McGovern, Massachusetts State Sen. Anne Gobi, and Massachusetts State Rep. Donald Berthiaume, Jr., as well as the Town Administrator Thomas Gregory and Board of Selectmen members Ralph Hicks and Wendy Bertiaume at her site.

Jim Reger, executive director of the Massachusetts Aggregate and Asphalt Pavement Association, attended the open house, as did other local aggregate producers, including Seth Hankowski of All States Materials Group and Jonathan Androlewicz and Jenna Androlewicz of Rampco Construction Co. Inc. Together,

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AGGREGATES MANAGER / December 2018

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Testifying before Congress about the impact of WOTUS, HubaczKiley gave a voice to the concerns of small producers struggling with the rule’s lack of clarity.

they were able to share their industry perspective and concerns with their elected officials. “There was quite a crowd,” she says.

“It went exceptionally well.”

Inviting legislators was a natural follow up for HubaczKiley, who often hosts groups to tour the site. “We should be proud of our companies,” she says. “My doors are always open to anybody.”

Typically, Hubacz-Kiley targets her efforts toward high school students rather than elementary aged ones. In particular, she likes to host students interested in environmental sciences. “These are the kids who could be working for the EPA, DEP, or local conservation commissions,” she says. “It’s a great thing to educate them so they know what we’re doing and how we’re doing it.”

Keeping it real While Hubacz-Kiley is clearly a rising industry leader, she still spends most of her days like many other small producers: getting to work early, conducting pre-shift inspections, meeting with plant personnel, answering emails, and putting out fires.

She can also still be found putting her CDL to use by delivering a load of aggregate. “If I’m in the truck, it’s for a very good customer,” she says. “For me to drive up shows this customer that they matter, and it shows my employees that I have no issue jumping in and getting the job done.”

“One of the things that I truly love about Karen is that passion and the humility. She’s willing to get out, drive a truck, get dirty, and be in the middle of everything. I think that type of leadership really touches so many people. She’s always had that ability to be out there,” says Joel Galassini, regional president – Texas, CEMEX. “Now, she’s not only comfortable out in the field, but also sitting around an executive table with the titans of the industry. She didn’t have to change who she is to fit in. Karen can drive the truck with her pearls on. I think that’s courageous and fantastic.” AM

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OPERATIONS ILLUSTRATED

By Nathan Medcalf, Contributing Editor

Autonomous Drilling Boosts Accuracy

Autonomy is the direction of new drills.

Use of autonomous drills leads to greater profitability.

Autonomous drills can handle 95 percent of drilling jobs without an operator.

OUR EXPERTS

Operate drills remotely with latest autonomous drills.

Hans Schill is application center manager at Epiroc. Schill is passionate about providing flexible automation technology solutions to help U.S. customers improve productivity. He graduated from Orebro University in Sweden with a degree in electrical engineering and has several years of experience in automation development and managing development teams.

Wes Vietmeier is business line manager, underground equipment, Sandvik Mining and Rock Technology.

He holds bachelor’s degrees in chemical engineering from the University of Pittsburgh and in physical education from Marietta College. Vietmeier has worked 25 years in the industry and is currently responsible for product support and development of underground equipment in the United States. He lives in Pittsburgh, Pa.

Bryan Scott is the supervisor of Aggregate Industries’ Morrison Quarry, part of LafargeHolcim. He began his career as a laboratory technician in 2010 and joined Holcim in 2011. He worked his way up to serving as a quarry supervisor in Ada, Okla., before moving to Morrison Quarry in Colorado. Scott holds a bachelor’s degree in chemistry from East Central University.

AGGREGATES MANAGER / December 2018

13

Quarries Aren’t Turning Over the Keys to Robots Just Yet

W

hen heavy equipment manufacturers roll out new technologies, end-users are given an option to change how they have been doing things by purchasing and employing the new technologies or sticking to traditional methods.

Sometimes changes are small and don’t require much retooling or restructuring from the end-user, such as a new drill bit that increases productivity and lasts longer. Other changes, such as the opportunities provided by automation, can radically change drilling operations.

Many innovations in drilling have either increased drilling productivity, hole accuracy, or personnel safety, and automation promises all of these benefits. Automation has demonstrated that it is configurable, improves consistency of hole construction by removing operator imprecision, and provides data that can be analyzed to drive performance improvements; it also has the potential to increase jobsite safety by removing the operator from a hazardous environment and away from heavy equipment in motion.

Epiroc first introduced autonomous features on drills when they introduced configurable safety software. “This smart software functionality enables a customer to customize safety features such as rod-in-hole lockout, operator-in-seat deallocation, tramming isolation, and an engine idle-down timer,” says Hans Schill, application center manager, Epiroc. And the number of autonomous features on Eprioc drills has increased almost annually.

Automation can be unnerving. It means that humans are

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no longer every link in a decision-making chain, but comprise only part of the chain, and the other links are robots.

“A lot of drilling companies don’t use automation to its full potential,” says Wes Veitmeier, business line manager underground equipment, Sandvik Mining and Rock Technology.

Many drilling operations that use autonomous drills remain nearly unchanged. Since the machine can drill autonomously, the operator can take care of other job duties, such as planning the next drill pattern, checking machine readings, and observing production data while the drill is drilling. The ability to do these tasks simultaneously instead of alternatively has led to greater productivity.

“Automation has allowed us to get more work done in the same amount of time by freeing up our driller to work on other items on the pattern while the drill is on autopilot,” says Bryan Scott, Morrison Quarry supervisor, Aggregate Industries, part of LafargeHolcim.

“Another popular use of automation is during shift changes,” Veitmeier says. Near the end of a shift, an operator can set the drilling pattern, which the drill will carry out without operator intervention. When the new operator arrives, they check what the drill is programmed to do, and then intervene when needed.

“To support a safe work environment, proximity detection is becoming a popular feature on drills,” Veitmeier says.

“When someone walks up to the machine, it automatically shuts off.”

More accurate hole placement

Autonomous drills have been proven to place holes more accurately than humans. Accurate drilling leads to more proficient blasts, which leads to more even material blow out, which leads to less handling of unwanted-sized material, less crushing, and less crusher maintenance.

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Drivers needed

Remote tramming is a feature that is not yet available on most drills. Right now, in order to tram, a person has to be inside the drill.

There is a lot to consider when tramming remotely. Adequate sensors and cameras are needed, and the area must be mapped out.

Manufacturers also recommend that no people be in the presence of remotely trammed drills.

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Keep a safe distance

Advances in automation, as well as sensors and cameras, allow for remote operation of drills, which can be located in remote and hazardous conditions. This is called teleremote operation. The remote control station is often designed exactly as the cab of the drill and can be standalone (for inside an office) or installed on an open or closed trailer.

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Below ground drilling

Autonomous drills can be found above and below the ground. Many features are the same, except the below ground drills can’t rely on GPS — they often use a local network for connectivity. There is also a higher use of remote operation with underground drills, since underground drill operators face more safety risks than above ground drill operators.

AGGREGATES MANAGER / December 2018

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Voices of Experience Bryan Scott

Hans Schill

Wes Vietmeier

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ggregate Industries’ Morrison Quarry employs one semi-autonomous drill. “This drill has auto drill and retract features which, once programmed, allow the operator to set the machine to automatically drill, add/remove steel from the carousel, and retract from the hole once it is completed,” says Bryan Scott, Morrison Quarry supervisor, Aggregate Industries, part of LafargeHolcim, noting that automatic rod handling reduces wear on componentry and reduces stress on the machine.

“These features have allowed us to increase efficiency by allowing the driller to perform other functions in parallel, such as laying out the next drill pattern,” Scott says. Automation enables the operator to do other work while the drill is on autopilot, thereby allowing the operator to accomplish more work, which is the greatest change brought about by employing the semi-autonomous drill.

Besides drilling, the machine has several other autonomous features, including self-diagnostic capabilities that help track down problems quickly and effectively to minimize downtime. It can also be set up to be operated remotely, which allows one operator to operate up to three drills simultaneously.

“The drill also allows us to achieve more accurate and consistent drill patterns,” Scott says. The extra precision in drilling gives optimal blast results and increases safety. In combination with the drill’s hole navigation system, remote operation removes the need for operators and surveyors to work in hazardous areas.

In the near future, the quarry plans to employ more GPS on its autonomous drills. “We are currently looking into getting the GPS features of the drill fully functional, which would allow us to design the drill pattern in the office and upload the coordinates to the drill, thereby allowing the operator to move from hole to hole without laying out the pattern with tape and paint.”

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o drills are fully autonomous; they still rely on an operator at some point.

Epiroc (formerly Atlas Copco) began installing autonomous features in 2010 when it equipped SmartROC D65 drills with safety software. “This smart software functionality enables a customer to customize safety features such as rod-in-hole lockout, operator-in-seat deallocation, tramming isolation, and an engine idledown timer,” says Hans Schill, application center manager, Epiroc.

Then, Rig Remote Access was introduced. “This optional equipment connects drill rigs to a mine or quarry office network for transfer of drill plans and data to and from the drill,” Schill says.

Next came the BenchREMOTE mobile control station and Surface Manager.

BenchREMOTE is a teleremote control station that can be used up to nearly 330 feet from the drilling area and nearly 100 feet above the rig’s position. The controls are identical to those on the rig.

Using the remote station, the operator can perform the same drilling functions that can be done in the cab, as well as run up to three drills at the same time.

Surface Manager office software manages drill plans, allows for the creation of geo-fences and conversion of production data into reports.

“The Epiroc Hole Navigation System (HNS) works with GPS satellite coordinates to guide the drill to the exact spot for drilling each hole,” Schill says. “It ensures that all holes are drilled to the correct depth and at the correct angle according to the drill plan, improving precision and reducing non-drilling time.

HNS removes the need to both manually mark and survey hole positions, improving efficiency and safety on the bench.

The latest automation innovation in Epiroc drill rigs is the introduction of rig access control, a security improvement that requires a special USB stick to gain access to important drill parameters and settings.

utonomous drilling is receiving cautious acceptance from drillers. “A lot of people are still experimenting with autonomous drilling,” says Wes Veitmeier, business line manager underground equipment, Sandvik Mining and Rock Technology. “It just started getting acceptance this year.

A lot of people are using it between shift changes, so they’re getting in a little more drilling each day.”

At the present stage, autonomous drills can drill 90 to 95 percent of what is needed without operator intervention, but operators are still needed for the remaining work. “You can’t drill lifter holes autonomously because tubing is inserted after drilling, and that function needs to be done manually,” Veitmeier explains.

“Burn cut is the other application that can’t be completed autonomously. In a larger hole, a reamer is inserted into the center of the drill, and someone needs to be there to change the bit,” he adds However, automatic bit changing is a feature that will be available in the notso-distant future, he says. “Soon, you can program the drill to change the bit either after a predetermined number of holes or after the drill reaches a certain pressure.”

According to Veitmeier, consistency in drilling and operation; a much higher accuracy of the holes, which results in better blasts and less over break; and pulling more of the round are the benefits to autonomous drilling.

“Say you drill an 18-feet hole, blast it, and pull out only 16 or 17 feet of it,” Veitmeier says. “When you drill holes more accurately, you get exactly what the blast pattern is designed to do, so you get more tons per blast.”

Autonomous drills have the potential to allow one operator to operate two to three machines. “Depending on the nature of the operation, an operator can set up a drill to start drilling, go to the next drill, set it to drill, and so on,” Veitmeier says.

Bauma go here

Top25RollOuts of 2018

by Therese Dunphy, Editor-in-Chief

Sand plants, technology upgrades and wheel loaders are prominent among this year’s new equipment.

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 RollOuts and offers even more product coverage through the newsletters and online products.

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.

Drilling and Blasting DYNO NOBEL

INITIATION SYSTEM REDUCES BLAST DELAYS

Dyno Nobel describes its DigiShot Plus 4G electronic initiation system as the most sophisticated addition to its electronic line. Developed with joint venture partner DetNet, the system is designed to help reduce overall costs and increase productivity by reducing blasting delays and introducing programming speeds seven times faster than existing systems. The system has two robust downline wires with two deployment methods designed to improve safety by reducing time spent on the bench.

The wire and detonator are packaged as coils or with spools. There are three types of wire: standard, deep hole, and XTM (extreme conditions). It contains the new 4G chip and is fully programmable with 15 times more memory for storing and tracking unique identification numbers, GPS coordinates, and time and date of blasting.

Dyno Nobel | www.dynonobel.com

SANDVIK

290-DEGREE REACH MINIMIZES REPOSITIONING

The Ranger DXi series top hammer drills, from Sandvik Mining and Rock Technology, offer 592 square feet of drilling coverage and a powerful rockdrill. The rigs feature a revolving superstructure with a 290-degree reach. This saves time and minimizes the need to reposition the rig. Its counterweight structure ensures stability by maintaining weight opposite the boom. A low center of gravity and high tramming power make the rigs extremely mobile. Operator ergonomics and low cab noise are among the focus area of the new cab, which also offers room for a trainer behind the operator seat.

Sandvik | www.rocktechnology.sandvik.com

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Processing DSC DREDGE

NEW DREDGE DESIGN CONCEPT

DSC Dredge’s Sharkuda design includes two provisional patents: walking carriages and a wide-format swinging ladder. The concept allows for continuous, uninterrupted production representing time savings, cost savings, and safety advantages, the company says, because the dredge moves without cables. The unit is powered by either a 500to 1,200-horsepower Cat diesel engine or AC electric power and can dredge to depths of 43 feet. It features a hull-mounted, heavy-duty dredge pump and a PLC operating system.

DSC Dredge | www.dscdredge.com

EAGLE IRON WORKS

ECONOMICAL LINE OF SCREW WASHERS

Eagle Iron Works’ Condor screw washers feature the standard Eagle Iron Works outboard bearings, rising current classifier, and adjustable weirs, but are built with a Class 1 Dodge reducer. It offers standard value line urethane flight shoes, with an option to upgrade to premium Eagle Armor shoes. Washer tubs are constructed with the same U.S. steel construction, capacities, and mounting points as the Classic Screw Washers. The Condor is available in single- and dual-shaft models of fine material washers in 36-inch, 44-inch, and 54-inch sizes, as well as single- and dualshaft models of coarse material washers in 30-inch, 36-inch, and 44-inch sizes.

Eagle Iron Works | www.eiwllc.com

HAVER & BOECKER

UNLOAD

VIBRATING SCREEN CAN BE INCLINED OR DECLINED

Haver & Boecker offers the Tyler L-Class vibrating screen for classifying wet or dry material, as well as dewatering. The 6-foot-wide units can be customized in two lengths, 16 and 20 feet. Primarily mounted horizontally, the L-Class can also be inclined or declined by up to 3 degrees. When positioned at a negative incline of about 3 degrees, the vibrating screen’s G-force moves wet material uphill on the screen. Gravity and natural operation of the equipment help screen out water before material reaches the discharge end. The unit handles up to 400 tons per hour and features a 45-degree mounted double-shaft overhead drive system with direct-mounted motors. Multiple speed and stroke options are available by changing the pulleys and plate weights.

Haver & Boecker | www.havercanada.com

www.kpijci.com

AGGREGATES MANAGER / December 2018

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ROLLOUTS

KLEEMANN

KOLBERG-PIONEER, INC.

SCREENING PLANT OFFERS EASE OF MOBILITY

DROP-IN CARBIDES REDUCE MAINTENANCE TIME

Kleemann’s track-mounted triple-deck classifying screen, the MS 703i EVO, has a screening area of 102 square feet and features convenient transport dimensions and short setup times. With an hourly output of up to 551 tons, the hopper can be fed by a wheel loader, as well as an upstream crushing plant. Material on the wide conveyor is conveyed to a screen box. The screening angle on the box can be adapted to the application. An impact plate at the conveyor discharge is said to evenly distribute material on the screen surface. The plant is operated by a mobile control panel that can be installed at three different points for optimum visibility.

Kleemann | www.wirtgen.com

Drop-in carbides are available for all models of vertical shaft impactors (VSI) from Kolberg-Pioneer, Inc. (KPI). The manufacturer says the drop-in carbide wear parts will significantly decrease downtime required for service and maintenance. The new carbides are estimated to reduce replacement time to approximately 20 percent of what it is with other solutions. They can also be retrofitted into existing VSI crushers from KPI. Kolberg-Pioneer, Inc. | www.kpijci.com

MCCLOSKEY WASHING SYSTEMS

COMPACT SAND PLANT OFFERS PORTABLE OPTION

McCloskey Washing Systems’ Compact Sand Plant (CSP) 200 has a 14- by 6- foot dewatering screen, a self-regulating cyclone tank with built-in float system, and anti-turbulence sections. The manufacturer says it enables superior separation efficiency, yields drip-free final washed sand product, and produces up to two in-spec sands — to the operator’s desired grade — at up to 200 total tons per hour. The plant is also said to offer quick assembly times and low operational and maintenance costs.

McCloskey Washing Systems | www.mccloskeywashing.com

SANDVIK

UPDATED SCREENER OFFERS HIGHER PRODUCTION RATES

Sandvik updates its popular QE341 with the QE342. Designed for higher production rates, the crusher-style chassis accommodates more powerful and efficient engine power packs. Its wear-resistant rigid hopper is compatible for two- or three-way split configurations. The screen-box jack-up facility creates easier access to the bottom deck for maintenance and screen media changes. The unit’s electrical control system incorporates several features to improve both the operational effectiveness and machine safety, including one global plant button to commence sequential automatic start-up and automatic shut-down of the plant while in operating mode. The 1,800-rpm engine operating speed translates to lower fuel consumption and reduced noise.

Sandvik | www.rocktechnology.sandvik.com

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SANDVIK

CRUSHER AUTOMATION AND TELEMATICS

Sandvik launched a new automation and control telematics system, My Fleet. Developed initially for its Q range of premium crushers, the digital solution adds a monitoring, control, and data tool that provides hard data, thereby eliminating guesswork.

The cloud-based system is available in two packages with tiered capabilities. The free package offers machine location and utilization data, while the premium package includes an array of parameters for more in-depth analysis and monitoring of the equipment. Both tiers are accessible online, 24/7, 365 days a year via a customizable user interface within the Sandvik portal. The system debuts in the Q range crushers and will then be made available to mobile screens and scalpers, as well as Sandvik’s Heavy Duty range.

Sandvik | www.construction.sandvik.com

Mobile Equipment

STOCKPILE

TEREX WASHING SYSTEMS

WASH RECYCLING PLANT ON A SINGLE CHASSIS

Terex Washing Systems’ AggWash 300 offers screening, scrubbing, sizing, and sand recovery on one modular chassis. Designed to address higher production requirements for recycling and aggregate applications, the plant is readily portable. It incorporates two 16- by 5-foot triple-deck Terex Cedarapids LJ-TS Series horizontal screens with a triple-shaft vibrator mechanism that provides high G force along with an efficient oval motion. A high capacity logwasher has twin-shaft angle adjustment to scrub gravel fraction and float out contaminants. A 6- by 4-foot trash screen is designed for dewatering of lightweight contaminants from the logwasher, and the plant has an integrated sand plant incorporating rubber lined pumps and hydrocyclones. The plant is also said to offer class leading walkaround access for ease of maintenance.

Terex Washing Systems | www.terex.com

www.kpijci.com

AGGREGATES MANAGER / December 2018

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ROLLOUTS CATERPILLAR

DOZER INCREASES PRODUCTIVITY, FUEL EFFICIENCY

Caterpillar’s D8T dozer moves up to 18 percent more material than its predecessor, while using the same amount of fuel. Much of the fuel efficiency increase is due to its fully automatic, four-speed transmission. The powertrain continuously optimizes the dozer for maximum power and efficiency based on the load. Operators do not need to upshift or downshift, allowing for operators of varying skill levels to efficiently use the machine.

The Semi-Universal blade has also been upsized, with a capacity of 13.4 cubic yards, making it the largest SU blade in the size class. Optional performance cutting edges increase blade payload by up to 25 percent compared to standard cutting blades. The dozer is powered by a Cat C15 Acert engine, with a class-leading 354 net horsepower.

Drawbar power is increased by up to 13 percent. A range of technology options, from simple grade indicators to full factory-integrated GPS, is available.

Caterpillar | www.cat.com

CATERPILLAR

NEW EXCAVATORS BOOST TECHNOLOGY, FUEL SAVINGS

Caterpillar’s Next Generation 320 excavator is said to offer 20 to 25 percent fuel savings over its predecessor. A Smart mode operation automatically matches engine and hydraulic power to digging conditions to optimize fuel consumption and performance. Maintenance costs are also cut, by up to 15 percent over the previous model, by extended and more synchronized maintenance intervals on the new machines. The excavator is equipped with the Next Generation Cat Excavator cab which offers standard features, including keyless push-button start, an 8-inch touchscreen monitor with jog dial keys, and sound-suppressed rollover protective structures. The 320 includes what Cat describes as the industry’s highest level of standard factory-equipped technology. It has Cat Connect Technology, which is said to increase operating efficiency by up to 45 percent over traditional grading operations. Cat Grade 2D is also standard and offers guidance for depth, slope, and horizontal distance to grade. Standard Grade Assist automates boom, stick, and bucket movements. Cat Payload offers precise load targets for increased efficiency, while Cat Link hardware and software connects sites to the office.

Caterpillar | www.cat.com

DOOSAN INFRACORE NORTH AMERICA, LLC

INCREASED UPTIME PROTECTION

The Doosan DL280-5 wheel loader is said to provide operators with enhanced performance and comfort, as well as increased uptime protection. The 3.7-cubic-yard loader has a dump height of 9 feet, 2 inches. A wide fin radiator provides more effective cooling with larger fin spacing, which reduces clogging.

Powered by a 172-horsepower diesel engine, the wheel loader is designed with heavy-duty axles to deliver additional machine performance in harsh applications. A benefit of the heavy-duty axles is that owners can use solid tires for enhanced uptime protection. Another new feature is an upgraded forwardneutral-reverse joystick which is easier to activate and more ergonomic, thereby improving operator comfort.

Doosan Infracore North America, LLC | www.doosaninfracore.com

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HYUNDAI CONSTRUCTION EQUIPMENT

IMPROVED BUCKET DESIGN

Hyundai’s HL960 HD wheel loader has an operating weight of 42,549 pounds.

Powered by a Stage 4 Cummins QSB6.7 electronically controlled diesel engine, it has 222 net horsepower. The loader was designed with a heavy-duty axle with enhanced load capacity for durability. The maximum load capacity is 97,003 pounds at the front and 77,162 pounds at the rear. The loader has an auto shutdown feature when it enters the idling state. The standard five-speed transmission with Lock-up Clutch also helps improve fuel efficiency. Joystick controls for boom, bucket, and third hydraulic line are standard. An improved bucket design features a wider opening, curved side plates, and an enhanced spill guard to maximize its 4.3-cubic-yard bucket capacity. The ROPS/ FOPS cab is 10 percent larger than before and has a fully adjustable seat. The new cabin is fully sound-proofed and air conditioned. A 7-inch-wide screen monitor is larger than in previous models.

Hyundai Construction Equipment | www.hceamericas.com

JOHN DEERE

DOZER GETS GRADE CONTROL UPGRADE

John Deere’s 950K Power-Angle-Tilt crawler dozer includes John Deere SmartGrade to improve quality of work and mine site accuracy via complete integration of the Topcon 3D-MC2 Grade-Control System. The system is fully incorporated into the machine cabin, structures, and software. By integrating it into the machine, external cables to the masts are eliminated, thus reducing breakage and lowering vulnerability to theft and damage. Auto SmartGrade allows the operator to adjust the system when moving the machine from one soil type to another. It also automatically lifts the blade over heavy loads before track slippage occurs, then returns the blade to grade. The manufacturer estimates the SmartGrade dozer is nearly 7 percent more accurate across the entire speed range of the dozer when compared to conventional masted systems.

John Deere | www.johndeere.com

AUTOMATE

JOHN DEERE

MASTLESS GRADE-CONTROL MOTOR GRADER

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

John Deere | www.johndeere.com

www.kpijci.com

AGGREGATES MANAGER / December 2018

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ROLLOUTS

KOMATSU AMERICA CORP.

MORE FUEL-EFFICIENT, PRODUCTIVE LOADER

Komatsu America Corp.’s WA480-8 wheel loader is equipped with a 299-horsepower, Tier 4 Final, SAA6D125E-7 engine and uses up to 20 percent less fuel than its predecessor. Operator friendly design features include an optional advanced joystick steering system, eliminating the steering wheel, which may cause operator fatigue.

The “generous curves” bucket design fills and retains material, making the machine nearly 8 percent more productive than the previous model. An auto dig system controls bucket tilt and lifting by sensing pressure applied to the work equipment, while a swing-out rear door and standard auto-reversing fan allow easy access to the radiator for ease of cleaning. The loader is designed for three-pass loading of onhighway trucks and hoppers.

Komatsu America Corp. | www.komatsuamerica.com

KOMATSU AMERICA CORP.

CAMERA SYSTEM IMPROVES VISIBILITY

Komatsu America Corp.’s PC238USLC-11 hydraulic excavator is equipped with a Tier 4 Final engine and a new viscous fan clutch. Engine parasitic loads are now lower, resulting in productivity gains of up to 4 percent over the previous model.

The excavator is available with Komatsu’s new KomVision system, a bird’s-eyeview camera system that combines input from three cameras into a surround-view image of the machine and its surroundings to provide better situational awareness for the operator. The unit is powered by an SAA6D107E-3 167-net horsepower engine. Maintenance accessibility has been improved through new monitor panels and machine design. A new operator ID system provides telematics data to track operators, applications, and machine operations for up to 100 individual ID codes.

Komatsu America Corp. | www.komatsuamerica.com

VOLVO CONSTRUCTION EQUIPMENT

UPDATED TECHNOLOGY IMPROVES FUEL EFFICIENCY

Volvo Construction Equipment’s H-Series wheel loaders incorporate the latest technology, including the next-generation OptiShift and load-sensing hydraulics and transmission. The updates result in faster cycle times and improved fuel efficiency.

The new OptiShift technology allows operators to customize the lock-up engagement of their machines and integrates the patented Reverse-By-Braking function and the new torque converter with lockup. The new transmission works with the engine and axles to improve stability and efficiency, while the new converter delivers increased torque output for better performance at low speeds. Steps between gears have been reduced for faster acceleration and smooth operation. The H-Series 2.0 update, combined with the engine, attachment organization, and dry P-brake, results in up to 20-percent greater fuel efficiency. It is available on the L150H, L180H, L220H, and L260H. Volvo Construction Equipment | www.volvoce.com

Miscellaneous BRIDGESTONE AMERICAS, INC.

OFF-THE-ROAD TIRE MONITORING

Bridgestone Americas, Inc. rolls out PressureStat, a tire pressure monitoring system for off-the-road tires in quarry, construction, and other applications.

The easy-to-use system provides instant access to tire pressure and temperature data on a real-time basis. It includes valve stem sensors, onboard alerts, Bluetooth connectivity to mobile devices, instant inspection reports on an entire fleet available on desktop or mobile device, and streamlined forecasting and analysis — when combined with TreadStat software.

Bridgestone Americas, Inc. | www.bridgestoneamericas.com

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AGGREGATES MANAGER / December 2018

THE RIGHT EQUIPMENT FOR YOUR OPERATION.

From Unloading to Stockpiling Your ability to control your product, its quality and mixes is essential to your operation. We design and manufacture equipment, like our SuperStacker® telescoping stackers, to help you do just that. We offer advanced automation to do everything from unloading material to desegregating stockpiles. Let our experts partner with you to find your ideal solution.

Learn more at kpijci.com/material-handling

KOLBERG-PIONEER, INC.

an Astec Industries Company

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

ROLLOUTS CARDINAL SCALE MFG. CO.

DIGITAL TRUCK SCALES FEATURE ROBUST DESIGN

Cardinal Scale’s Armor series digital truck scales are designed with 135-ton capacity, no moving parts below the scale deck, SmartCell stainless-steel waterproof digital load cells, and IoT-enabled iSite remote monitoring software. The debris-inhibiting load cell stand design limits obstructions to the scale’s performance with the digital load cells mounted high within the stand near the scale deck. Fabricated from 1-inch-thick steel to minimize rust and corrosion damage, the load cell stands feature a baked-on tan powder-coat paint finish. The NTEP legal-for-trade scales offer quick installation with load cell stands pre-installed. Each weighbridge features interconnecting load blocks and receivers for no-bolt installation.

Cardinal Scale Mfg. Co. | www.cardinalscale.com

EPIROC

SYSTEM AUTOMATICALLY ADAPTS BREAKER’S BEHAVIOR

Epiroc is outfitting many of its rig-mounted heavy hydraulic breakers with the patented Intelligent Protection System (IPS), which combines with its AutoControl and StartSelect functions for a fully automated system. AutoControl optimizes breaker performance by automatically adjusting the piston stroke length. StartSelect offers manual switching between two modes: AutoStart (which enables easy positioning at the beginning of the breaking cycle) and AutoStop (which automatically stops the breaker to avoid blank firing at the end of a breaking cycle). These functions are combined in the IPS, which ensures the hydraulic breaker always starts in the AutoStart mode. When the contact pressure between chisel and material increases and AutoControl switches from a short piston stroke to a long piston stroke, IPS switches automatically to the AutoStop mode. When the chisel breaks through the material, the breaker automatically shuts off.

Epiroc | www.epiroc.com

FLEXCO

HEAVY-DUTY BELT TRAINER PROTECTS BELTS

Flexco’s PTEX HD Belt Trainer is a high-performance tracking idler capable of handling wider belts and tougher conditions. Featuring pivot-and-tilt technology, it can be used in applications that require tracking to prevent damage to the belt or conveyor structure, including single-direction and reversing belts. The pivot-and-tilt feature keeps the belt away from the structure, while retaining material on the belt without the use of sensor or edge rollers. The tapered ends on the roller drive the mechanism, allowing the two forces to move the belt back to center.

The belt trainer is available for belt widths of 42 to 84 inches and can be used on vulcanized or mechanically fastened belts on most applications up to 2,400 PIW maximum tension.

Flexco | www.flexco.com

MPS, INC.

KEEPS MINERS COOL

MPS, Inc. rolls out the Kalis Dry Cooling Helmet Pad from Centurion Safety Products, Inc. The helmet pad cools for three days without recharging and installs easily into most hardhats with suspensions. By adding 1.5 ounces of water, the pad’s proprietary fabric promotes evaporation and cools more than 20 degrees below ambient temperatures. It remains dry during use and does not require refrigeration, freezing, or submersion to activate. The helmet pad should recharge more than 700 times before degradation, giving it an estimated life span of up to five years.

MPS, Inc. | www.go-mpsinc.com

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WHY JOIN NSSGA AS A SMALL PRODUCER?

When I recently needed guidance on a regulatory issue that I was never faced with before, I turned to my friends at the NSSGA …

And it was a very wise decision.

KAREN HUBACZ-KILEY BOND CONSTRUCTION CORP.

Burdensome federal regulations and legislation can be costly.

While most large producers have teams to deal with these regulations and laws, small producers often do not. NSSGA is here to help you deal with many issues the federal government throws at you. We offer: • Experts in environment, health and safety that are full time and just a phone call away.

• Access to other small and large producer members nationwide who understand your issues and concerns and are willing to help.

• Involvement in our Small Producer Subcommittee and Membership Committee.

• Timely webinars that emphasize the latest to train staff right at home or at work.

We understand that time is money and you cannot always leave your operation to attend meetings. We host quarterly committee calls in addition to in-person meetings, so you don’t miss a thing.

YOU ARE NOT ALONE. WE ARE IN THIS TOGETHER.

JOIN NSSGA TODAY!

FOR MORE INFORMATION, CALL 703-525-8788

EQUIPMENT MANAGEMENT

How Does Your

Maintenance Stack Up? When it comes to radial stackers, lubrication and belts offer opportunities for ensuring efficient operation.

T

he radial stacker is a crucial aspect of any quarry operation. However, when it comes to maintenance, this machine is often overlooked. As with any other piece of equipment, the radial stacker should be properly maintained, and those working with the stacker should be adequately trained on both operation and regular maintenance. It is critical to maintain all equipment; if one machine shuts down, the whole operation can come to a halt.

Lubrication Regularly lubricating the stacker is an important part of maintenance. The head and tail pulleys, and additional grease points, need to be kept on a consistent maintenance schedule.

Depending on the design of the stacker, operators may also have to lubricate live shaft returns, snubber idlers, or a combination of the two. If the stacker extends, guide and support rollers will also have to be kept maintained. Operators and maintenance crews should be trained and familiar with these crucial grease points and should follow the manufacturer’s lubrication recommendations for grease type and intervals.

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AGGREGATES MANAGER / December 2018

Belt tensioning and training Belt tensioning and training are also regular maintenance practices. New belts, as well as stretched-out belts, require tensioning.

When tensioning a belt, operators should only tighten it enough to prevent slipping on the head and drive pulleys, further tensioning can shorten the life of the conveyor belt and bearings. If a belt is over-tensioned, it will become very difficult to keep trained. Tension should be checked regularly, especially on newer belts.

Training a belt to track correctly is imperative for efficiency. When training a belt, operators should be sure to use the idlers, rather than the stacker’s take-up. Using the take-up to train the belt can result in tension changes.

When training a loaded belt, operators

As the radial stacker moves up and down and side to side, adjust the transfer point to land in the center of the belt and on the center of the anchor pivot.

AGGREGATES MANAGER / December 2018

29

EQUIPMENT MANAGEMENT in keeping the stacker clear of excess material, especially in wet applications.

However, the belt cleaner needs to be properly installed. If the cleaner is too loose, it will have no effect, and if it is too tight, it can affect the horsepower requirements, as well as the tracking.

Training and recordkeeping

When training an empty belt, adjust the return idlers in the direction the belt should be steered. When training a loaded belt, adjust using the troughing idlers.

In addition to the radial stacker itself, maintain a smooth, level path for it to travel and ensure appropriate tire pressure. This will prevent additional stress from being placed on the stacker.

should make adjustments using the troughing idlers, rather than return idlers, as a loaded belt will react much differently than an empty one. Operators should adjust the incoming feed material, or transfer point, to land in the center line of the belt and on the center of the anchor pivot. As the radial stacker moves up and down and side to side, the adjusted material positioning will ensure the product is hitting the stacker in the same place, regardless of its position.

When training an empty belt, producers should adjust return idlers in the direction they want to steer the belt, just like steering a bicycle using handle bars.

This process takes more time, as it may

30

AGGREGATES MANAGER / December 2018

require several revolutions of the belt to have a noticeable effect. Making too much of an adjustment can cause the belt to migrate too far in one direction.

Once the empty belt is trained, operators will want to test it with material. If a lot of adjustments were made, one should re-examine the transfer point to ensure the material is falling in the center and over the anchor pivot.

In addition to properly tracking the belt, the radial stacker should be cleared of material build-up daily. Excess built-up material can affect the belt tracking, damage parts, and increase horsepower requirements.

A belt cleaner can be added to aid

Being proactive in the maintenance of equipment is critical. Operators should keep an accurate, detailed record of repairs, including completion information and historical data. Such a record allows maintenance crews to troubleshoot and focus on issues in their infancy, rather than suffering a major breakdown in the future. This simple record can also act as a powerful training tool and reminder for ordering regular wear parts.

The final aspect of maintaining a healthy machine is working with those who operate the stacker every day.

Operators can provide valuable information regarding both maintenance and application improvements, which can help save producers time and money, as well as increase profitability and efficiency.

Along with the regular maintenance of the radial stacker itself, its travel path also needs to be monitored. Its radial travel pattern, over time and with changing weather conditions, can become worn down. The worn travel path can make the stacker unstable and cause the machine to use more power to navigate the tattered path. Using more force and power to travel over the path can cause additional stress on the equipment. Maintaining a level, smooth path, as well as appropriate tire pressure, ensures the safety of operators and the longevity of the stacker.

Radial stackers are an imperative part of any operation. Without proactive maintenance, stackers can quickly become inefficient. Following a disciplined maintenance routine can increase the effectiveness and the life of radial stackers, saving producers time and money. AM

Article courtesy of Kolberg-Pioneer, Inc.

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by Patrick W. Dennison

ROCKLAW Modifications = More Time + Money Changes to the petition for modification process may result in increased work and operational costs for operators.

T

Patrick W. Pennison is a member in Jackson Kelly PLLC’s Pittsburgh, Pa., office where he practices in the Construction and Energy industry groups, focusing primarily on litigation, workplace health and safety, and labor and employment.

He can be reached at 412434-8815 or pwdennison@ jacksonkelly.com.

36

he Federal Mine Safety and Health Act of 1977 (The Mine Act) regulates safety and health in the mining industry, primarily through mandatory safety and health standards promulgated under § 101(a) of the Mine Act, 30 U.S.C. § 811(a). Under § 101(c) of the Mine Act, however, a mine operator may petition for, and the Secretary may modify the application of, a mandatory safety standard. Thus, a petition for modification serves as a request to modify the requirements of an existing safety standard specific to a mine site and allows that mine operator to achieve compliance by means different than those required by the standard. But, given recent responses by the Mine Safety and Health Administration (MSHA) after operators filed petitions, the process for modifying compliance with safety standards may be changing to the detriment of mine operators.

Section 101(c), which permits MSHA to modify the application of an existing safety standard, states as follows: Upon petition by the operator or the representative of miner, the Secretary may modify the application of any mandatory safety standard to a coal or other mine if the Secretary determines that an alternative method of achieving the result of such standard exists which will at all times guarantee no less than the same

AGGREGATES MANAGER / December 2018

measure of protection afforded the miners of such mine by such standard or if the application of such standard to such mine will result in a diminution of safety to the miners in such mine. 30 U.S.C. § 811(c).

Historically, the petition for modification process began with: (1) the filing of a petition; (2) an investigation by MSHA; and (3) the issuance of a proposed decision and order by MSHA which denies or grants the petition. See generally 30 C.F.R. § 44.1 et seq. If MSHA denied the petition or granted it with unacceptable conditions, the operator could request a hearing before an administrative law judge (ALJ) of the Department of Labor. 30 C.F.R. § 44.14. (Note: these ALJs are not the same judges who hear citation contests and other issues under the Mine Act.) After a hearing, the ALJ issues an initial decision, which may then be appealed to the Assistant Secretary of Labor of Mine Safety and Health. 30 C.F.R. § 44.33. The Assistant Secretary has 120 days to issue a decision and review the case or the record before the ALJ. 30 C.F.R. § 44.35.

Getting to the stage where MSHA issues a proposed decision and order, however, appears to be getting more difficult, costly, and time consuming for operators. In the past, after a mine operator filed a petition for modification, MSHA would conduct an investigation which typically consisted of mine visits by MSHA personnel to gather relevant

data and information. But recently, after several months of measure of protection requires an evaluation of the safety no action and instead of conducting an investigation, MSHA benefits resulting from the standard and the safety benefits has sent lengthy requests for information to operators, resulting from the alternative method. It does not require which MSHA purports are required to effectively evaluate the operator to adopt the ‘safest’ alternative method, only the application of the mandatory standard in accordance one that meets the legal burden for approval. See UMWA with § 101(c) of the Act. v. MSHA (Cyprus Emerald Resources Corporation), 920 F.2d Many of the petitions already included detailed informa960, 963-4 (D.C. Cir. 1990); see, e.g., Mettiki Coal Corp., No. tion concerning the proposed alternative method of comp1999-MSA-6, n.24 (ALJ Richard J. Stansell-Gamm, April 7, liance, but MSHA’s requests insist that the response must 2000). The standard of review does not require the operainclude a detailed statement of the facts (including details of tor to show that the alternate method provides the same the alternate method proposed) the petitioner would show sort of protection as the standard. See, e.g., Emerald Mines to establish grounds upon which it claimed a modification Company, 83-MSA-17, decision of Ass’t. Secretary O’Neal, at is warranted. Additionally, MSHA’s requests require facts 7-11 (Sept. 22, 1989), aff’d. in part and rem. in part, 920 F.2d that establish and support the alternative method allegation, 960 (D.C. Cir. 1990); UMWA v. MSHA (Quarto Mining Co.), including facts describing the necessity of the modification.

924 F.2d 340 (D.C. Cir. 1991).

Some of the requested information is already available to The precise impact from the changes to the petition MSHA, but many of the requests would require extensive for modification process remains to be seen, but operators and unnecessary testing on the part of the operator. In some should at least anticipate increased time and costs associacases, MSHA’s requests provided operators less than two ted with filing such petitions. If an operator receives a weeks for a response. In that respect, MSHA’s requests for request for information from MSHA after filing a petition for information seem adversarial in nature. modification, it should be diligent in communicating back Furthermore, MSHA’s information requests conflict with to MSHA to avoid the unnecessary dismissal of petitions. the legal review of petitions under 30 C.F.R. § 44.14. Courts Operators should also document communications with have interpreted the language of § 101(c) to provide for a MSHA thoroughly in the event MSHA’s actions warrant two-part standard of review of petitions for modification review. AM which focuses on: (1) whether the conditions of the petition will at all times guarantee no less than the same measure of protection afforded by the mandatory safety standard; and (2) taking into account both the advantages and disadvantages of the alternative method, including effects unrelated to the goals of the original standard, whether the modification will achieve a net gain or at least equivalence in overall ovation • Service • Customizat mine safety. See, e.g., UMWA v. ent • Quality • Inn i on m t i m m o C MSHA (Utah Power & Light), 823 F.2d 608, 610 (D.C. Cir. 1987); see, • Customizable to your exact aggregates dredge@dscdredge.com 156 Airport Rd application and production requirements. e.g., UMWA v. MSHA (Jim Walter Reserve, LA 70084 • Outstanding service after the sale with Resources), 931 F.2d 908, 911 (D.C. +1-985-479-1355 www.dscdredge.com 24/7 technical support.

Cir. 1991); UMWA v. MSHA (Southern Ohio Coal Co.), 928 F.2d 1200 (D.C. Contact DSC Dredge to help you Follow us on: Cir. 1991). Whether a proposed make THE RIGHT CHOICE. modification provides the same AGGREGATES MANAGER / December 2018 CSC Dredge_AGRM1018pg15.indd 1

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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

Such Quantities of Sand Fueled by fracking, production of silica sand has nearly quadrupled since 2000.

A

bout 15 years ago (July 2003), I wrote an article with the same title as this.

That article addressed common sand used for construction. This article addresses a special type of sand referred to as silica sand or industrial sand, which is sand composed mostly of quartz (silica). Silica sand is used for a variety of industrial processes such as abrasives, engine traction, fillers, filtration, foundry sand, glass manufacturing, golf courses, metallurgy, roofing granules, and so forth.

Through the Looking Glass Construction sand is viewed by many folks as an infinite resource that is readily Lewis Carroll - 1871 available. Actually, sand suitable for construction really isn’t as readily available as many people think because it must meet specifications for the intended use.

Silica sand also has to meet specifications, and they are much more rigorous than specifications for construction sand. In almost every case, deposits suitable for use as construction sand cannot economically be processed into silica sand.

This is because many young geologic deposits used for construction sand, such as modern river alluvium or terrace deposits, consists of a variety of minerals including quartz, feldspar, and other rock particles. It commonly is too expensive to separate the other minerals to make pure silica sand.

Silica sand commonly comes from old geologic deposits that, over geologic time, have been subjected to repeated erosional cycles that break down and remove the softer particles, leaving only pure quartz grains. One of the most effective geologic agents for removing impurities is the wind, and older aeolian (wind-blown) deposits are some of the best, most frequently utilized sources of silica sand.

The industrial sand deposits mined in the United States vary greatly in chemistry, location, and physical characteristics. In general terms, the highest quality industrial sand deposits are located in the Midwest. Nevertheless, there are high quality silica sand deposits throughout much of the United States.

This is fortunate because, recently, there has been a huge escalation in demand for silica sand. Unless you have been hiding under a rock, you probably know this increased demand is for sand used in a process called hydraulic fracturing (fracking) to develop natural gas from shale.

The process involves injecting a mixture of water, silica sand (commonly known as proppant or frac sand), and chemicals into rock formations at high pressure to fracture the rock and prop open the newly formed fractures. This increases the flow rate of natural gas or oil to the well.

Frac sand has some of the most rigorous specifications of industrial sand applications. In this specialized application, strong, smooth, round silica sand grains of specific sizes are used to maximize permeability. The structural integrity of silica sand provides the required crush resistance of the high pressures present in wells. The nearly spherical shape of the grains contributes to its strength, as well as the permeability of the fractures held open by the proppant.

You might wonder how much demand really has increased. Back at the turn of the century, silica sand production was about 30 million tons per year and was evenly divided between glassmaking, foundry sand, and all other uses. Frac sand production was trivial. Today, annual production is about 110 million tons; nearly four times as great as it was at the start of the century, and nearly two-thirds of the production is for frac sand.

Such quantities of sand indeed. AM The Walrus and the Carpenter Were walking close at hand: They wept like anything to see Such quantities of sand.

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AGGREGATES MANAGER / December 2018

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