Aggregates Manager September 2015

September 2015

www.AggMan.com

21

Learn the economic and equipment considerations of underground operations

32

Vulcan pilots NIOSH noise and dust technology

38

MSHA uses policy to revise workplace examinations

Baldor’s Crusher Duty motor line features improved reliability, performance, and energy efficiency to lower the operators total cost of ownership. With higher break down and locked rotor torque performance, Baldor•Reliance Crusher Duty motors meet the demands of the toughest crushing applications worldwide.

And, you can find Baldor•Reliance Crusher Duty motors at your local Motion Industries location. Our local sales and service specialists are experts in application and technical support, providing the parts and the know-how you need to stay up and running.

Scan this code with your smartphone for more information http://esp.to/wW067D

The brands you count on from the people you trust…that’s Baldor and Motion Industries.

Call. 800-526-9328 Click. www.MotionIndustries.com Visit. Over 550 Locations

©2015 Motion Industries, Inc.

On Our Cover: Rogers Group’s Pottsville Quarry earns recognition for its environmental and community relation efforts, all while putting safety first.

Cover photo by Kerry Clines.

32

10

Miners at Vulcan Material’s Havre De Grace quarry test NIOSH equipment that monitors both noise and dust exposures.

Martin Engineering’s new CleanScrape conveyor belt cleaning system is installed diagonally across a belt’s discharge pulley.

CONTENTS SEPTEMBER 2015 VOLUME 20, NUMBER 9

COLUMNS & DEPARTMENTS

FEATURE ARTICLES

14

27 32

Reaching for the Stars The stars may seem unattainable, but Pottsville Quarry was awarded Two Stars of Excellence by the National Stone, Sand and Gravel Association during its annual convention in March.

A Sensible Approach to Scales

By incorporating the five key elements of a good maintenance program, upkeep can more than pay for itself.

Assessing Noise and Dust Exposure NIOSH and Vulcan Materials Co. team up to test how well Helmut-CAM technology measures miner exposure levels.

OPERATIONS ILLUSTRATED Underground operations.

21

The options for underground processing are limited only by imagination and financial constraints.

3

EDITORIAL Tracking the industry’s pulse.

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

MINING The latest financial analysis of issues impacting in the industry and 6 DATA Aggregates Manager’s exclusive aggregates industry outlook.

Volvo’s EC160 excavator, and other new equipment for the aggregate 9 ROLLOUTS market.

LAW The Mine Safety and Health Administration uses policy rather than 38 ROCK rulemaking to substantively revise workplace exam standards.

ADS Aggregate industry classifieds.

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

43 ADVERTISER IN STONE The life of a granite miner in the 19th century consisted of 44 CARVED physically intense work, carb-laden meals, and impromptu entertainment.

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

September 2015

Vol. 20, No. 9

aggman.com /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

Keeping a Finger on the Pulse of the

AGGREGATES INDUSTRY

F

or more than a decade, Aggregates Manager has surveyed aggregates producers to determine current market conditions, forecast future conditions, and assess current challenges to the market. These annual forecasts, published in our January issue, help operators benchmark

their conditions against those of their peers and better plan for their businesses.

Based solely on operator feedback, these forecasts have accurately predicted the 3200 Rice Mine Rd NE Tuscaloosa, AL 35406 800-633-5953 randallreilly.com

highs and the lows of the market. It’s a valuable piece of market intelligence that

Corporate

companion piece — the Aggregates Industry Outlook. Like the annual forecast,

Chairman: Mike Reilly

the results of this index are based on those who know the market the best —

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

has just one flaw — it is available only on an annual basis.

In this issue, you’ll find the solution to that flaw, the print debut of a monthly

operators. Earlier this year, we invited a select group of industry leaders to join

Chief Financial Officer: Russell McEwen

the panel and help launch this index. We are extremely grateful for the time and

Senior Vice President, Sales: Scott Miller

insights they have already shared as we developed this index and will continue

Senior Vice President, Editorial and Research: Linda Longton 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.

to provide through future surveys.

Just before each issue goes to print, we ask panel members their opinion of current and future business condition and production demand. Their responses are given a numeric value, which represents the panel’s opinion of the overall health of the aggregates industry. A score of 100 is neutral, with any number above being positive and any number below being negative. As you’ll find on page 7, this month’s score is a healthy 130, well above neutral.

Now that the index is established, I invite any interested operator to join this panel. Just send an email to tdunphy@randallreilly.com, and I’ll send you a link to join. Each month, I’ll send out a quick six-question survey that takes just a

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.

minute or two to complete.

Membership on this panel has its advantages. Panelists get the results as soon as they are compiled, typically two to three weeks before the issue has printed and mailed. Members who submit their mailing addresses and photos also receive a free copy of our 2015 Atlas CD, valued at $250. And, most importantly, all operators can keep their finger on the pulse of the industry by viewing the monthly results and comparing them to their own business conditions.

AGGREGATES MANAGER September 2015

3

State & Province

NEWS

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

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

Massachusetts

Former quarries that now serve as swimming holes were put to an additional use over the summer. The Boston Globe reports that the Dusan Tynek Dance Theatre, a New York-based company, performed a site-specific routine at Little Parker Quarry in Rockport. The performance, presented by the Windhover Performing Arts Center, used the architecture of the quarry — including ledges, cliffs, terraces, and water — as part of the dance.

Connecticut

Massachusetts

Iowa

North Carolina

A zoning application in Waterbury faces opposition from neighbors, according to Republican American. The request comes from Michael Hychko, who applied for a special permit for commercial earth excavation and hazardous industrial operations, as well as several variances. If approved, he will be able to excavate up to 37.4 acres at a time. Neighbors are opposed to reopening the nearly century-old quarry, saying that it will lower their property values and diminish their quality of life.

A total of 29 Boy Scouts from nine different troops participated in an Eagle Scout and merit badge clinic in Dewitt, the Iowa Limestone Producers Association reports. They visited Wendling Quarries’ Shaffton Quarry and Olson’s Sand Pit to work on the Mining in Society merit badge. While touring the operations, they saw a blast. In addition, a representative from the Mine Safety and Health Administration talked to them about the importance of staying out of both active and abandoned operations. Finally, the Scouts compared their principles of Leave No Trace, which focuses on minimizing environmental impacts, to the industry’s reclamation efforts.

Selectmen in Milford are considering filling in Shadowbrook Quarry following the death of a teenager who jumped into Fletcher Quarry last year. According to The Milford Patch, the group discussed efforts in neighboring communities to fill in unused quarries. One selectman asked that the town planner or engineer provide information on the feasibility of such an effort.

To date, the board has had the police department post “no trespassing” signs on the property, which is owned by the town.

A state Senate budget bill would eliminate a Department of Labor division that provides training for workers at mines and quarries. The News Observer reports that the proposal, which would eliminate five safety and health positions within the Mine & Quarry Inspection Division, drew criticism from a House committee. Jay Stem, director of the North Carolina Aggregates Association, told the newspaper that many businesses that benefit from the training are small operations that can’t afford to lose the state’s help. “A lot of the quarries are small, family-owned quarries,” he said. “They don’t have the resources to get the training at market prices.” He credited training provided by the agency as one reason why the state’s fatality rate has remained low.

Kentucky

A decision from the courts puts Charles Deweese Construction’s plans for a Simpson County quarry back on track. County officials issued a conditionaluse permit to the company in 2012, only to revoke it two years later. According to the Bowling Green Daily News, the board of zoning adjustments then rejected a subsequent application, which was appealed to Special Judge Tyler Gill, who overturned its decision and reinstated the permit. In his opinion, Gill wrote that the board’s vote to revoke was “not based on substantial evidence, violated principles of due process, and was legally arbitrary.”

4

AGGREGATES MANAGER September 2015

Oklahoma

The Dolese Bros. quarry in Hartshorne just got a $14 million upgrade, according to the McAlester News Capital. Mark Helms, Dolese Bros. president and chief executive officer, told the newspaper the plant produces approximately 1 million tons per year, with about 25 employees. “Our plant that we had was very old — probably 30-plus years old,” Helm said. “It couldn’t meet the current production requirement. We had to upgrade for capacity, and we had to upgrade for safety.”

Pennsylvania

A 20-year-old male, Demond Alexander Link, was presumed drowned after his body was found in the Birdsboro Climbing Quarry. 69News reports that crews rushed to the area after receiving reports that someone had gone missing underwater at the site. The search lasted until late into the evening and resumed the following morning, when his body was recovered.

Tennessee

Construction has begun on a new 76-acre multipurpose entertainment venue in Thompson’s Station. According to the Tennessean, Graystone Quarry Events broke ground on the venue, which is planned for weddings, corporate meetings, or concerts. The site will feature a 15,000-square-foot event space in two buildings. A Tennessee barn, resembling a mountain lodge, will be built, as well as a boutique amphitheater, which will be located at the bottom of a reclaimed limestone quarry.

Pennsylvania

Neighbors of the proposed Gibraltar Rock quarry in New Hanover are concerned about chemical groundwater pollution adjacent to the operator’s site. According to The Mercury, pollutants were found on the nearby site last summer. Neighbor William Snook says he is worried that, although the main body of underground pollutants is currently contained behind a wall of underground diabase, it could be released when Gibraltar begins blasting and fractures the rock. The Pennsylvania Department of Environmental Protection wrote that both surface water and groundwater collected during operations “shall be tested for VOCs.” In June, the township supervisors voted 3-2 to grant preliminary site plan approval for the first portions of the project, which had been tied up in court and zoning proceedings for nearly a decade.

South Carolina

A neighborhood group, the Ridge Protection Coalition, is fighting plans for a 500-acre quarry in Lexington County. To date, it has addressed the Lexington County Council twice, but group leader Lisa Lewis said the group isn’t being given an adequate voice during council meetings. Council Chairman Johnny Jeffcoat said the body hasn’t ignored the group, but that it is “limited in what it can do to stop a business that is following extensive regulations, most of them controlled by the Department of Health and Environmental Control. He added that Vulcan Materials Co. Vice President of Operations Roger Dunlap told him the restrictions now imposed on the site are among the most stringent the company has ever had to deal with. The Free Times reports that three lawmakers from the county are seeking statewide legislation that would provide larger buffer zones around quarries.

AGGREGATES MANAGER September 2015

5

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

$7.95 q $30.43 p $83.63 p $34.16 q $77.72 q $13.43 new $175.03 p $18.66 q $26.39 p $54.02 q $56.45 p $97.77 p

52-Week High

52-Week Low

$12.92 $31.33 $105.69 $39.09 $78.45 $16.37 $175.53 $31.73 $29.00 $76.98 $57.57 $99.04

$7.69 $16.89 $68.54 $30.44 $77.37 $12.70 $103.09 $16.63 $19.65 $52.25 $21.48 $54.10

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 8/16/2015.

U.S. On-Highway Diesel Fuel Prices 8/10/2015

One Week

United States

$2.617

-0.051 q

-1.226 q

East Coast

$2.713

-0.056 q

-1.174 q

New England

$2.847

-0.048 q

-1.135 q

Central Atlantic

$2.832

-0.053 q

-1.142 q

Lower Atlantic

$2.595

-0.059 q

-1.205 q

Midwest

$2.515

-0.046 q

-1.272 q

Gulf Coast

$2.487

-0.049 q

-1.263 q

Rocky Mountain

$2.640

-0.045 q

-1.236 q

West Coast

$2.846

-0.060 q

-1.170 q

West Coast less California

$2.706

-0.055 q

-1.229 q

California

$2.960

-0.064 q

-1.124 q

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

6

AGGREGATES MANAGER September 2015

One Year

150 120

Raw score: 129.05

Raw score: 130.00

July

August

90 60 30 0

The Aggregates Industry Outlook score rose slightly in August, up 0.73 percent from July’s rating of 129.05. Lower energy costs were a primary driver for positive responses from some producers. Concerns about long-term transportation funding, however, continue to cast an element of uncertainty for many.

Comments: The lack of a long term, properly funded transportation bill has created uncertainty in our state and local highway programs. They are unable to commit to their intended plans without federal funds in place.

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

Here in Colorado, we experienced an unusually wet spring breaking all time record rainfall amounts in May, which softened numbers in Q2, but have rebounded nicely, and the rest of the year looks to be at or above projections.

— Grant Smith, Production Manager, Transit Mix Concrete Co.

The economy is improving at a slow pace, with expectations that it will continue. Declining energy costs are helping in various sectors. The possibility of rising interest rates at the Fed may moderate this growth, but not stop it.

— Rick Gerroll, Sales Executive, County Materials Corp.

While fuel/oil pricing is low, I see the aggregate market staying positive. However, a drastic increase in fuel/oil pricing could stop it in its tracks.

— Karen Hubacz-Kiley, Chief Operating Officer, Bond Construction Corp.

Weather has impacted year-to-date volume, creating a pent up demand for the remaining period and next spring.

— Damian Murphy, Executive Vice President and Central Regional President, Summit Materials

AGGREGATES MANAGER September 2015

7

FOR INDUSTRIAL MINERALS THIS IS THE SHAPE OF THINGS TO COME Shape matters more and more in future-focused applications such as industrial minerals.

Sandvik VSI crushers give you control over fractions down to micron level and virtually eliminate metal contamination. That means you can match the most demanding quality specifications and increase product value by up to tenfold. Our VSI crushers set the standard for energy efficiency and uptime, while our unique bi-flow feed system boosts capacity by up to 20% with no loss of crushing performance. It all adds up to maximum value at minimum cost per tonne.

Discover what Sandvik precision could mean for you bottom line.

Please contact us for details of your nearest dealer: 1-800-826-7625 info.cns@sandvik.com construction.sandvik.com/vsi

by Bobby Atkinson, Online Managing Editor: BobbyAtkinson@randallreilly.com

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

More fuel-efficient excavator The new E-Series crawler excavator from Volvo, the EC160, features the company’s Tier 4 Final D4 engine. The engine upgrade gives an 8-percent increase in fuel efficiency while also boosting the tractive force and engine power by 5 percent. The excavator also has an optimized hydraulic system to work with the electronic control system. It features ergonomic machine interfaces that include joysticks, keypad, and a large LCD monitor. Operators can also use the integrated work system to choose the right mode for fuel efficiency and engine performance.

Volvo Construction Equipment | www.VolvoCE.com

Optional undercarriage system for dozers Komatsu America Corp. added its popular Parallel Link Undercarriage System as a new option on the D155AX-8 dozer. The rotating bushing undercarriage option comes in three different shoe widths, and the company says it doubles the life of a normal undercarriage.

The PLUS system is said to lower repair and maintenance costs by up to 40 percent. The system uses oil lubricated, rotating bushings that move freely. PLUS undercarriage components also are designed for equal wear life.

Komatsu America Corp. | www.komatsuamerica.com

New belt scraper design Martin Engineering’s new 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 can 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

AGGREGATES MANAGER September 2015

9

ROLLOUTS

Telematics subscription extended John Deere extended the base subscription of its JDLink Ultimate telematics service from three to five years. The telematics service allows owners and fleet managers to remotely monitor equipment using any device with an Internet connection. The service provides alerts and allows customers to view machine location, utilization, performance, and maintenance data to manage where and how equipment is used.

John Deere | www.JohnDeere.com

New Tier 4 wheel loader 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

Secondary belt cleaner Flexco’s new FMS Medium Duty Secondary Cleaner is made of heavyduty steel and corrosion-resistant powder coating. It can be used on mining conveyors with speeds up to 1,000 feet per minute. The cleaner, with 6-inch-wide metal blades, can be used on belts from 18 to 72 inches wide. The cleaner can also come with impact-resistant C-Tip tungsten carbide blades.

Flexco | www.flexco.com

Digital weighing instrument Fairbanks Scales’ new digital instrument for inbound/outbound weighing applications, the FB6011, has an Intalogix digital load cell communications technology and is packaged with a NEMA 12 desktop enclosure. The unit has three modes of operation, built-in traffic controls, multiple communication ports, and transaction export functions. The instrument sends all data through a connection to a personal computer and can export the information directly to a USB flash drive.

Fairbanks Scales | www.fairbanks.com

10

AGGREGATES MANAGER September 2015

PRODUCTIVITY WITH MOBILITY Terex® Minerals Processing Systems Portable Plants Deliver We understand your crushing and screening business and have the right equipment for you to get the job done. Choose from our extensive line of portable plants, including jaw, cone, horizontal shaft impact, vertical shaft impact, horizontal screen, inclined screen, washing screen and rip rap plants — as well as the new CRJ3750 jaw plant.

Features of the NEW Terex® Cedarapids CRJ3750 Jaw Plant: Rugged JS3750 jaw crusher with large 37" x 50" (940 x 1270 mm) feed opening handles severe crushing applications 52" x 20' (1321 x 6096 mm) high-stroke vibrating grizzly feeder Optional hydraulic feeder module lift system allows quick and safe removal of the hopper module without a crane “Straight-line” undercrusher conveyor for reliability Optional extended undercrusher conveyor for higher discharge Quad or 3+1 axle options provide portability in most any location

2 Wa -Year rran ty*

CRJ3750 jaw plant shown with optional electrical switchgear panel and hydraulic lift system, extended length undercrusher conveyor with hydraulic fold, truck dump hopper with hydraulic extensions, hydraulic feeder module lift system, and hydraulic leveling/run-on jacks.

Terex® Cedarapids MACS Plants Terex® Cedarapids Cone Plants Terex® Canica VSI Plants

Terex® Cedarapids Screen Plants Terex® Simplicity Rip Rap Plants Terex® Simplicity Wash Plants

Visit www.terexmps.com to find your local distributor and learn how we can work for you.

Terex® Minerals Processing Systems Cedar Rapids, Iowa | Tel +1 (319) 363-3511 | Toll Free +1 (800) 821-5600 Durand, Michigan | Tel +1 (989) 288-3121 | Toll Free +1 (888) 571-8352 | MPSsales@terex.com

Terex, the Terex Crown design, Works For You, Cedarapids, Simplicity, Canica, and MACS are trademarks of Terex Corporation or its subsidiaries. Copyright 2015 Terex Corporation. *Terms and conditions apply; please contact your local distributor.

Longlasting level indicators External wear liner prevents spillage Martin Engineering’s new wear liner breaks from the conventional internal design. The new EVO External Wear Liner is on the outside of the chute box to improve on skirtboard sealing and prevent spillage. To put the liner outside the chute, the manufacturer raised the chute work above the belt. The abrasion-resistant liner and the skirt seal are then mounted outside the box. The external design is said to make for good performance with fewer hours of labor and at a cheaper cost.

Dynatrol says its point level detectors are long-lasting bulk solids level indicators that work at high, intermediate, or low point level detection.

There are no moving parts and no adjusting. The vibrating probe stops build-up and is said to be durable in difficult conditions like bins and tanks. The point bulk solid level detectors can be used with sand, gravel, rock, crushed stone, ore, talc mine, crushed dolomite, and recycled crushed concrete.

Dynatrol | www.dynatrolusa.com

Martin Engineering | www.martin-eng.com

SL-3 STATIONARY LOADER®

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Built How You Need It Boom configuration and control option customized for your location

Flexible Durability Simple design to minimize wear in harsh environments

TOPPER. PICKER. GRABBER. LIGHTNING LOADER® No matter what name you give it, a Petersen Lightning Loader® will make your scale house or transfer station run like a well-oiled machine.

Visit petersenind.com or call 800.930.LOAD (5623) to learn about our full line of original Lightning Loaders®.

12

AGGREGATES Untitled-14 1 MANAGER September 2015

WE BUILD LEGENDS.

5/13/15 9:22 AM

ROLLOUTS

A more powerful portable fan The new Black Jack fan from Big Ass Fans stands at 6.5 feet and is said to use less power than a toaster while delivering a powerful blow. The fan moves air up to 120 feet, but does so quietly. The fan has a 25-foot power cord and is wet rated. The gearless direct-drive motor is what keeps the fan quiet and energy efficient. It also has wheels for indoor and outdoor use.

Big Ass Fans | www.bigassfans.com

Updated communication package Trimble partnered with push-to-talk application Zello to improve its TrimFleet Suite for construction material producers. The new TrimFleet Communicator is a voiceover IP radio replacement that helps to improve communication. The update allows reliable, company-wide communication to the other TrimFleet Mobile and TrimView users. Drivers can talk to channels, make private point-to-point calls, or call dispatch directly. It also gives the drivers quick access to contacts, channels, and emergency broadcasts.

Trimble | www.trimble.com

WITH YOU ALL THE WAY Our mapping solutions make mass data collection projects a walk in the park, with tailored options designed to help you achieve results with confidence.

Let’s explore the possibilities together.

MAPPING SOLUTIONS

topconpositioning.com

Untitled-6 1

13

AGGREGATES MANAGER Setpember 8/5/15 2015 10:15 AM

Reaching for the Stars The stars may seem unattainable, but Pottsville Quarry was awarded Two Stars of Excellence by the National Stone, Sand and Gravel Association during its annual convention in March.

by Kerry Clines, Contributing Editor

14

P

ottsville Quarry is Rogers Group,

was decided that a plant upgrade was needed

Inc.’s largest producing plant in

to keep up with demand and improve produc-

southern middle Tennessee, but it

tion, so the quarry was shut down the winter of

hasn’t always been so. The quarry

2007-2008. By the time the upgrade was com-

was just a glimmer in the eye of company exec-

plete, the economy had gone downhill, and Rog-

utives when the greenfield site was purchased

ers Group began to question the money spent

in the mid-1980s.

on the upgrade, as well as the quarry itself.

“We brought in a portable plant, set it up,

Business has begun to pick back up, howev-

and crushed for a year or two,” says Bryan

er. “Last year was the first year since I took over

Wolaver, plant manager. “Then, the location was

the plant in July 2008 that it has run consis-

shut down for five or more years due to a lack

tently all year long,” Wolaver says. “We’ve had

of business. When the quarry started back up,

enough business to keep it going. We also built

we ran a portable plant and a stationary plant

an asphalt plant on site last fall, and started op-

until 2007.”

erating it in October.”

Business was really good in 2007, mostly due to the construction of State Highway 840

The new plant

that encircles the city of Nashville, located about

When the new plant was constructed, extra

an hour’s drive north of Pottsville. The quarry

care was taken to make it a standout. The

was running 24 hours a day/six days a week. It

plant has two motor control center (MCC) build-

AGGREGATES MANAGER September 2015

PLANT PROFILE

ings — one red and one blue. All of the

ton” type. A second automation system is

trucks. The pugmill is positioned over

processing equipment is labeled accord-

in operation now, but he wants a better

a scale, so the drivers can control how

ing to which MCC building contains the

system that will allow an operator to

much is loaded into their trucks.

controls. Conveyors are named C1, C2,

start up the plant, hit a few buttons, and

C3, etc.; crushers are CR1, CR2, CR3,

then sit back and watch it run. So, plans

ed at the pugmill, but Wolaver says the

etc.; screens are named S1, S2, S3, etc.

have been made to install a third auto-

customers tend to overload their trucks,

The names are printed on each piece of

mation system sometime during the next

and contractors want different amounts of

equipment in red or blue, which is deter-

year or two.

water in their mixes, so it’s better to have

mined by which MCC building contains those controls.

“If you go into an MCC building to lock

“We had a big tour for our board right

Ideally, an employee wouldn’t be need-

someone there. When there are three or

after the new plant opened,” Wolaver

four jobs going at the same time, one job

says, explaining that many of the board

runs out of the pugmill and the other jobs

out a blue C2 and you see everything

members don’t get out to see a quarry.

run off the ground.

in red, you know you’re in the wrong

“We stationed employees around the en-

building,” Wolaver explains, adding that

tire operation to explain what was going

stripping and keeps a shot lined up to

this simple procedure helps to prevent

on in each location.”

ensure that rock is always on the ground

confusion.

The plant has had two automation

This spring, the old pugmill control sys-

The quarry stays six months ahead on

in the pit. “We blast once a week, usu-

tem was replaced with a new automated

ally about 45,000 tons,” Wolaver says,

systems. Wolaver refers to the first auto-

control system that allows truck drivers to

adding that they crush 25,000 to 30,000

mation system as a “real fancy pushbut-

drive up and pull a rope to fill their own

tons a week, depending on demand. “We AGGREGATES MANAGER September 2015

15

Award from the company for doing an SOP on every 30-minute or longer job here, ranging from a screen change or crusher breakdown to airing up a tire on a pickup truck. By breaking it down even more, we make people think more about what they’re doing.”

Once a year, usually in April, the quarry has a Safety Stand Down meeting, which is more intense than the daily meetings and usually includes upper management, such as vice presidents, area managers, and directors.

The intent of the Stand Down is to get people focused on what has caused isThe point where material leaves the primary crusher and is transferred to a conveyor that feeds the screen tower is enclosed to help control dust.

sues in the past.

might have a little bit left over from the

If anything out of the ordinary is going

that are more dangerous to do than

week before, but we don’t want to run

on that day, it is brought to the crew’s

anything else, and the crew knows

out, so we always keep an eye on that.

attention so that they are prepared.

what those are,” Wolaver says. “We

We can make about 11 different prod-

Near-misses and/or fatalgrams sent out

want them to bring those things to the

ucts, 13 if you count surge and shot

by the Mine Safety and Health Admin-

attention of upper management so they

rock, and most of them can be made on

istration are also discussed.

can be addressed and fixed.”

the fly.”

Everything that comes out of the

“There are certain things in the plant

“We consider anything that could

One of the quarry’s biggest safety

have caused injury or serious property

concerns is with the truck drivers pick-

plant is shipped by truck. As many as

damage a near-miss,” Wolaver explains.

ing up loads for customers. If a driver is

300 trucks per day can be loaded and

“Usually, there are two or three that

observed doing something unsafe, it is

sent on their way, depending on the

come out every day, so we discuss

reported to his company. If it is repeated

day of the week and the weather.

them and post them on the bulletin

over and over again, the driver is banned

board. We do whatever it takes to keep

from the facility. “We haven’t had to

everybody on their toes.”

ban anyone from this operation yet, but

Normally, the 11-man crew works one 10- to 11-hour shift each day beginning at 6:30 a.m. Sometimes the

The crew always does a Job Safety

crew stays later, depending on what

Analysis (JSA) before performing a task.

issues might have arisen during the day.

A JSA is a thought process to make an

Two stars

If a major breakdown occurs, the crew

employee think about what steps are

The Pottsville Quarry earned Two Stars

will stay to fix it so it’s ready to go the

necessary, what tools are needed, and

of Excellence from the National Stone,

next morning.

whether or not help is required to per-

Sand and Gravel Association for en-

form a particular task. This ensures that

vironmental efforts and community

Safety first

we’ve come close,” Wolaver adds.

nothing is left out and helps to keep

relations. “This facility has been one of

Safety comes first at Pottsville Quarry,

the crew from becoming complacent

our top performers,” says Van Medlock,

so safety meetings are held at the

and getting too comfortable with what

director of environmental services for

beginning of every shift. At the meet-

they’re doing.

Rogers Group. “It won one of the first

ings, Wolaver asks about any occur-

“Most one-hour jobs already have an

environmental awards. It meets all the

rences that may have happened the

SOP (standard operating procedure),”

new NSPS air regulations and hasn’t

day before that need to be addressed.

Wolaver explains. “We got a President’s

been cited for any violations related to

16

AGGREGATES MANAGER September 2015

PLANT PROFILE

water, air, and mining in the state of Tennessee. Bryan has been here from the beginning, having seen the facility through its infancy. Now, the plant has matured into a top aggregate provider in this area.”

Environmental efforts The quarry is located in a flat, dry area where fugitive emissions can get out of hand quickly on a windy day, so a water truck keeps the roadways wet.

Periodically, a sweeper is used on the paved areas in the plant to pick up the dust and get rid of it, so it doesn’t collect and become a problem. Stockpiles are also kept close to the heads of stacking conveyors to prevent material from freefalling 20 or 30 feet. This helps prevent

The tower that contains the scalping screens is enclosed on three sides to help control dust.

The open side, which allows for easy maintenance and screen-change access, faces in the non-dominant wind direction.

fines from becoming airborne.

“Our screen towers are enclosed, because they are the number one source of particulate matter related to emissions,” Medlock says. “The enclosures protect that structure by keeping the wind off of it and keeping it in a calm state or environment. It also helps with the noise. One side is open on the nondominant wind side, which helps with maintenance access to the screens.”

Wire screen cloth is used in most of the screen tower, but rubber panels are used on the top deck of scalping screens and the bottom deck of finishing screens to help reduce noise. The rubber panels

A second, smaller set of screens contains the finishing screens, which separate the rock into different saleable products.

allow a wetter material to be processed, which also helps cut down on dust.

“Our goal is to exceed regulations,”

call Smoke School, which teaches them about emissions,” Wolaver adds. “It’s

the plant. We do that company-wide.”

The operation ensures that its equip-

Medlock says. “Like with anything,

a half-day training class that teaches

ment runs as clean as possible. Annual

there will be the occasional misstep

them to recognize opacity. The employ-

bulk tank cleaning and a filter bank

or malfunction. The important thing is

ees start in the classroom and then go

on the fuel station help to improve the

how we respond to that. If there’s a

out in the plant to do two 45-minute

quality and cleanliness of the fuel go-

problem here, Bryan shuts the plant

runs with white smoke and dark smoke.

ing into the equipment. Plus, an outside

down until it’s fixed.”

Once they are certified, they can just

company performs yearly checks on

look and see if something’s not right at

emissions.

“We send employees to what we

AGGREGATES MANAGER September 2015

17

In 2009, a wheel wash was built at the scalehouse to ensure that trucks leaving the site don’t track dirt and dust out of the quarry. “It’s a straight shot from the ticket office to the highway, so we put our ticket box at the end of the wheel wash,” Wolaver explains. “That way, when the drivers stop to get their tickets, the wheel wash has plenty of time to run everything back down the trough. When the trucks leave here, their tires are pretty clean.”

Community relations There is no development around the By locating the ticket box at the end of a wheel wash, the operation ensures that truck tires are clean before they leave the site.

quarry yet, but that doesn’t mean that there are no neighbors. “Anywhere you put a quarry, people start buying up

“We’ve got just about everything you

around conveying systems and en-

land around it,” Medlock says, explain-

can imagine on the equipment,” Wolav-

closures, and got a good feel for the

ing that it’s because the shipping costs

er says. “We’ve got idle-limit devices

operation. Those guys issue permits,

for housing and construction material

to keep them from idling too long. We

but they had never seen a processing

are cheaper, and delivery is timely.

have loader training once a year from

plant and weren’t familiar with how

“So, it’s coming. We try to fit into our

Komatsu. We also have a group in our

any of it worked to produce a finished

surroundings as well as possible and

company that is learning how to train

product. They got a good hands-on

maintain a berm with native trees and

our people to operate the equipment

experience here, and we got accolades

vegetation.”

properly. That helps out with efficiency

from their supervisors who commented

and productivity, especially on the pri-

that those who visited our operation

Hill Elementary School in town. For the

mary side of the plant.”

really had their eyes opened that day.

past couple of years, quarry personnel

They usually only look at emission

have provided and delivered lunch to

controlled by a baghouse that contains

factors and the numbers, and have no

the teachers as they were preparing

468 10-foot-long bags. The dust col-

idea what a crusher is or a conveyor or

their classrooms for the new school

lected in the bags is recycled. The

a screen. Now they understand what

year. Coloring books are made available

mixes have been designed so that the

we’re doing.”

to all the local schools as well, in case

Emissions at the asphalt plant are

baghouse dust can be fed right back into them.

In early May, five permit writers from

Water discharged from the plant

The quarry partners with the Chapel

the teachers want to work it into their

goes to settling ponds and eventually

curriculum. Students also make field

to the sump in the pit for additional

trips to the quarry during the year for a

the Division of Air Pollution and Control

settling. Water samples are taken

close-up look.

and two field inspectors visited Potts-

regularly to make sure that any water

ville Quarry. Plant personnel offered

leaving the property is clean and com-

a year, usually in the spring when

tutorials on rock-crushing plants and

plies with the limits established in our

the weather’s nice, and teach them

asphalt plants.

NPDES permit. If the level of TSS ever

about the equipment and the pit,”

“They were here almost four hours…

“We bring the students out once

exceeds the permissible limit, an evalu-

Wolaver says. “We usually try to

learning,” Medlock says. “They stuck

ation is performed and corrective action

schedule a blast during the visit, be-

their heads in the baghouses, walked

is initiated.

cause they all want to see one. We

18

AGGREGATES MANAGER September 2015

PLANT PROFILE

have a video about our operation on YouTube (https://www.youtube.com/

to its customers and supporters.

through that zoning process, if we haven’t

“Longevity is part of any operation’s

been a good neighbor, there will be a lot

watch?v=lhhqd6xW4q4). We show the

objective,” Medlock says. “To get longev-

of upset people who might say they don’t

video prior to school tours to introduce

ity, you can’t have a lot of outcry from

want to give us anything else.”

the students to our operation.”

the neighbors. We have another 70 to

The crew at Pottsville Quarry works

Rogers Group also has free educa-

80 years of reserve, but not everything

hard to make sure that doesn’t hap-

tional materials available on its website,

has been zoned yet. When we go back

pen. AM

www.rogersgroupinc.com. Rockology 101 includes activity sheets, experiment guides, and other documents for use by parents, teachers, and anyone else who is interested in learning more about the industry.

One of the employees’ favorite outreach activities at the quarry is the “Barbecue in the Pit.” Contractors, developers, house builders, and truckers, as well as local and state elected officials, are invited to the quarry for barbecue. This is the quarry’s way of showing its appreciation

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scalping screen • FLSmidth Raptor XL400 standard secondary crusher • Seco 6-x 20-foot finishing screens (2) • Symons 5.5 short-head tertiary crusher • Seco 6- x16-foot wash screen • Kolberg sand screw • Masaba 36-inch x130-foot radial stacker

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Daily Materials Processing Report Daily Materials Processing Report Report Period

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PULL-OUT GUIDE

By Mary Foster, Contributing Editor

OPERATIONS ILLUSTRATED si r o n U n d erg r u d P o ce s ng

Decisions for an underground mine tend to be more challenging than above the surface.

Conveying material to the surface provides economic benefits.

Underground aggregate processing is typically limited to the primary stage.

Take maintenance and service into consideration when designing underground plants.

OPERAT 1

Mine the strata

Underground Processing

A

n underground aggregate mine is a different world than a surface operation, presenting unique challenges that surface mining does not. It can be a costly undertaking, requiring special engineering of tunnels, rooms, and pillars that are dependent on the geology of the site. It is dark, even with extensive lighting installed. And underground mining requires Part 48 training, which is more specialized and time intensive than traditional Part 46 training for surface mines.

Underground mining also requires a different type of worker than a surface operation, and it can be difficult to find and maintain experienced operators and mechanics.

According to Paul Smith, international marketing manager for the Astec Aggregate & Mining Group, despite of its challenges, an underground aggregate mine affords benefits that can’t be duplicated at the surface. For instance, because the mine operates at a uniform temperature and isn’t affected by rain or snow, it is operational year round. Additionally, the equipment always starts up warm. “And possibly the biggest benefit producers are considering today is the fact that, for neighbors, an underground operation is comparatively out of sight and out of mind,” Smith says.

Whether a producer is seeking additional reserves in an existing operation or opening a greenfield site, there are considerations that AGGREGATES MANAGER

must be made about how and where to process the material. Most underground aggregate operations will blast and then truck or convey material to the surface for processing.

Others will conduct primary processing underground, and then move the material to the surface. However, if the geology is appropriate, notes Smith, any process that can be conducted at the surface may also be brought underground — limited only by imagination and money.

Bob Schmidt, executive vice president and chief operating officer of New Enterprise Stone and Lime, agrees. “You can use any of the same equipment underground for the same stages that you would process on the surface,” he says. “It would depend on the thickness of the strata; you would have to have wide tunnels — 40 to 45 feet wide; and you’d also have to take 50 to 60 feet out of the floor for the necessary depth to add equipment. Other than that, ventilation and dust control are the only equipment decisions you would have to make that are any different than you would make at the surface.”

Schmidt offers some caveats with this statement. “You could put the entire plant underground, but access to product inventory becomes problematic. It is not practical for delivery trucks to enter the underground mine. Inventory of fractionated aggregate sizes could be stored underground, conveyed to the surface, and combined on demand to create the finished aggregate products.”

Depending on the thickness of the strata in an underground aggregate mine, a producer can use any equipment underground that he would use for the same stages in processing on the surface — limited only by imagination and money. Processing beyond the primary, however, typically requires wide tunnels of at least 40 to 45 feet, with room height of at least 50 to 60 feet in order to add secondary and even tertiary equipment.

4

Special conditions, special equipment

An underground mine is a difficult environment where equipment and processes that would be used above ground are more complex to replicate beneath the surface. For instance, if the seam of stone is vertically narrow, the mine height will be limited. A specially designed loader can work beneath a low ceiling, directly loading into a stationary or tracked crusher, with sized material dumping to channel conveyors to move it out of the mine.

TIONS ILLUSTRATED Underground Equipment and Economics 2

Production preferences

3

Equipment decisions

Most underground aggregate operations will blast and then truck or convey material to the surface for processing, versus other types of underground mining, where the entire process may be handled underground.

Other producers will conduct primary processing underground, and then move the material to the surface to complete sizing and separation. Fewer operations yet will opt to process material underground beyond the primary.

Producers must make the same decisions underground as they do at the surface for crushing. In abrasive stone, an impactor will provide a large reduction ratio without the wear that a jaw would receive. If the material is not as abrasive, a jaw or cone may be a better choice. Most limestone producers who process underground will opt to install a jaw crusher as the primary.

5

6

Maintenance matters

Maintenance is another consideration that must be made when planning processing stages below the surface. Everything from changing crusher manganese to pulling the pitman for bearing changes to getting a lube truck around the crusher requires space to work on the equipment. The producer must look at the whole maintenance plan, and design the plant to accommodate it.

OUR EXPERTS

Bob Schmidt joined New Enterprise, Pa.-based New Enterprise Stone and Lime as executive vice president and chief operating officer in September 2014. He has enjoyed a career that has spanned more than 30 years as a senior executive in the construction materials industry. With a bachelor’s degree in business, and both bachelor’s and master’s degrees in civil engineering, Schmidt is a certified professional engineer and licensed professional business coach.

Moving material

Fuel for trucks can be costly. If the geological strata permits, there are operational cost benefits to crushing at the primary stage underground, reducing the material to a point where it may be easily conveyed to the surface for additional processing. Depending on the length of beltline required to get the material to the surface, sizing the material to 6- or 4-inch-minus will help prolong belt life.

Paul Smith is the international marketing manager for the Astec Aggregate & Mining Group. Smith has worked in the industry since 1989 for Kolberg-Pioneer and Johnson Crushers. During his 25 years of experience, Smith has contributed to the design, promotion, training, and sale of the company’s products and services. He has also been an editorial contributor in the industry press and is a regular speaker at national, state, and corporate industry events.

September 2015

Voices of Experience Paul Smith

“T

t

here are definite advantages to mining aggregates underground,” notes Paul Smith, international marketing manager for the Astec Aggregate & Mining Group. “You’re reducing both visual and audio emissions, and you can more easily encapsulate dust. Because it is out of sight and hearing for the most part, especially in populated areas, permitting will be easier, which should fuel a bigger trend toward going underground.”

There are many factors that aggregate producers need to take into consideration when planning an underground mine — including the processing plant. Will you haul or convey shot material to the surface for processing? Will you process at the primary stage underground? Will you go out on a limb, so to speak, and also process a secondary stage underground?

“Really, almost anything is possible for underground processing, if you’re willing to plan for it. Your imagination is the limiting factor — and money, of course,” Smith says. “It’s a difficult environment where everything you must replicate that you would have at the surface is more complex and challenging.”

Smith says that most underground aggregate operations in the United States are limestone operations. “Even though limestone producers often like a primary impactor, in underground situations, jaw crushers are typically the primary processing choice because they don’t produce as much dust. Dust and ventilation are among the biggest issues with underground mining.” Smith adds that, if a secondary stage is added underground, a cone crusher is a good choice because it also produces less dust than an impactor.

Screening underground can create issues because of the need for height, according to Smith. A mine with a thinner strata will not have the roof height needed to accommodate screens. “Honestly, most producers will crush down to five, six, eight inches-minus, and then convey to the surface for additional processing. And conveying is usually preferable to trucking because it is more economically feasible,” he notes, adding that, if nothing else, finer processing and finishing will have to take place above ground for stockpiling and loadout purposes.

Maintenance is another consideration that must be made when planning processing stages below the surface. “Everything from changing crusher manganese to pulling the pitman for bearing changes to getting a lube truck around the crusher requires space to work on the equipment,” Smith says. “You have to look at your whole maintenance plan, and design the plant to accommodate it.”

Bob Schmidt

T

t

he economics of processing aggregate material underground may be controlled by geology and material type. If your geological strata permits, there are operational cost benefits to crushing at the primary stage underground, reducing the material to a point where it may be easily conveyed to the surface for additional processing.

“It is easier on your conveyor belts if the material is reduced to less than 6-inch to get the material to the surface,” says Bob Schmidt, executive vice president and chief operating officer of New Enterprise Stone & Lime. He adds, “I once worked with an underground mine near Louisville, Ky., that was 1,000 feet under the surface. We had a mile of conveyors with that mine to move material above ground.”

Schmidt has been involved in opening numerous underground aggregate operations over the years, which have taken a variety of processes underground. And he says that producers can use the same processing equipment underground as they do on the surface. “It just depends on the thickness of the strata that you’re mining,” he notes. By creating wide tunnels and taking enough material out of the floor to create depth, a producer can use a jaw, an impactor, or even a gyratory crusher.

“You have to make the same decisions underground as you do at the surface for crushing,” Schmidt says. “If you have less abrasive stone, an impactor will give you the reduction you need. If your material is abrasive, you could use a jaw combined with a secondary cone.” Schmidt says that most underground limestone producers opt to install at least the primary crusher underground and convey to the surface for subsequent crushing and screening stages.

Operations may also choose to bring a tracked crusher underground for primary processing. Schmidt previously worked with a producer in Kansas City that was mining a 25-foot seam of stone, which limited the mine height to 15 feet. “We used a tracked mounted jaw crusher and special load-haul-dump loaders. The loaders had 12-yard buckets that dumped directly to the crusher, which was mobile. When the loaders couldn’t keep up, we would move the crusher and hang additional channel conveyor from the roof to convey the material out of the mine,” he says.

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EQUIPMENT MANAGEMENT

A Sensible

Approach to Scales By incorporating the five key components of a good maintenance program, maintenance can more than pay for itself.

T

here’s an urban legend out there about the company whose main-

program must have five key components:

tenance crew mistakenly installed

use of a state-licensed service provider; con-

a new crusher with the rotor

ducting calibration using state-certified test

spinning backwards. It still worked! And you

weights with written calibration and test re-

think you have issues?

port for proof of accuracy; a thorough testing

Companies purchase scales because the value of goods entering or exiting a facility is based on their weight. Without assured scale accuracy, a company can lose thousands, if not hundreds of thousands of dollars annually.

by Russ Desilets

To be most effective, a scale maintenance

Depending on the requirements and type of

process; visual inspection services and minor repairs; and thorough reporting.

Calibration is the key component of periodic maintenance

weighing device, annual maintenance costs

After a scale is installed, it is tested by the

for a truck scale may run anywhere from

governing state’s weights and measures

$1,000 to $3,000. If one compares that to the

organization. This test ensures the scale’s

potential cost of weighing errors, most users

commercial accuracy and protects the scale

find that a good scale maintenance program

buyer, scale seller, and scale installation

more than pays for itself. Oftentimes, it also

company. Upon state approval, the scale is

pays for the actual cost of the scale.

certified and open for weighing.

AGGREGATES MANAGER September 2015

27

EQUIPMENT MANAGEMENT

However, it is important to understand that this initial calibration does not come with a guarantee of continued accuracy. Calibration can never be guaranteed, because accuracy is highly dependent on the way a scale is used and maintained. Weather, use, and wear are just a few of the factors that can change the accuracy of a weighing device.

That is why periodic calibration is so essential. Test frequency depends on a variety of factors, including: • Number of weighments per day, • Price of the product being weighed, • Number of days the scale is used annually, and • Acceptable error rate.

What’s the potential loss from a poorly calibrated scale?

Seemingly minimal errors can substantially cut into profits over time. Take the Acme Aggregate Co. example shown in Figure 1, in which 200 pounds may appear miniscule, since a typical truckload of sand or gravel can exceed 80,000 pounds. However, when one does the math, the truth is revealed — an annual revenue variance of about $345,000.

Figure 1. Acme Aggregate Co. Weighing volume

500 trucks per day

Weighing frequency

Five days per week

Five days per week

$26.50 per ton

Scale inaccuracy

-200 pounds

Lost annual revenue

$344,500

Five components of a good scale maintenance program 1. Use a state-licensed service provider. It is important to understand that the state weights and measures organization is the only entity that can issue a scale certification. A

Initial calibration of a scale is not a guarantee of continued accuracy. How a scale is used and maintained affect its accuracy.

commercial scale company cannot certify a scale — but it

attached a lockout tag to the scale, rendering it unusable

does have the authority to recalibrate and reinstate an in-

for commercial trade.) So make sure the commercial scale

accurate scale that has been “tagged-out” by the state, as

company shows you its valid license.

long as the scale company is state-licensed and registered in good standing. (Tagged-out means the scale has failed a

2. Conduct calibration using state-certified test weights.

state weights and measures accuracy test, so the state has

Calibration must be completed using state-certified test

28

AGGREGATES MANAGER September 2015

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weights. An established scale service company typically

3. Make sure testing process is thorough. To test a weighing

has its entire inventory of test weights tested and certified

device properly, one must first determine the length of the

annually, in accordance with state weights and measures

platform and the total number of sections along that length.

standards.

A scale section is determined by the presence of a load

Beware of service companies that test only a portion

point, which is simply the location of a load sensor (also

of their overall weight inventory each year. Preparing the

known as a load cell or strain gauge). Load points are

weights and delivering them to a metrology laboratory for

where weight is transferred from the load to the scale and

testing requires an enormous amount of time and money, so

where scale accuracy is maintained.

it may be tempting for some service companies to skip this

It is of critical importance, and mandated by the test-

important step. All too often, weights may be condemned

ing procedure of the National Institute of Standards and

and un-certifiable. This is why it is important to verify with

Technology’s (NIST) Handbook 44, that the accuracy of load

your service provider that its weights have been certified.

points are maintained, so as weight is applied, it is trans-

Here’s a tip for conducting this test weight verification: All

ferred evenly. If a load point or section fails a strain test,

test weights have a stamp provided by the governing state

then it must be calibrated to conform to requirements by

weights and measures entity. It is also common practice,

making a mechanical or electronic adjustment.

among companies that value quality, to request a copy of

The load point is not calibrated to a certified weight, but

the test weight certification from the scale service provider.

rather calibrated to ensure that all sections weigh exactly

Weight serial numbers will be present on the certifications,

the same or within government specifications outlined in

and the customer can verify these numbers against the serial

Handbook 44 and/or issued by a state-sanctioned weights

numbers on the test weights used by the service company.

and measures organization.

Like 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

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EQUIPMENT MANAGEMENT

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inspection should include a written report documenting test

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NIOSH and Vulcan Materials Co. team up to test how well Helmet-CAM technology measures miner exposure levels.

by Andrew Cecala, Amanda Azman, and Kelly Bailey

S

32

ince the National Institute

and applied to other health contami-

of individuals from his Industrial

for Occupational Safety

nants, including noise exposure. Re-

Hygiene staff, traveled to the Havre

and Health (NIOSH) and

cently, NIOSH partnered with Vulcan

De Grace Operation to learn about the

Unimin Corp. developed

Materials Co. to be the first to test

Helmet-CAM assessment system and

the Helmet-CAM assessment technol-

and evaluate the Helmet-CAM system

to participate in this testing. Nine

ogy, which integrates video and dust

for noise assessment at its Havre De

different Vulcan Material Co. miners

data into an exposure assessment

Grace mining operation near Bal-

wore the Helmet-CAM system for

tool, it has proven to be so effective

timore, Md. Kelly Bailey, Vulcan’s

approximately a 2-hour time period.

for assessing respirable dust expo-

corporate director of Safety, Health,

sure that it is now being expanded

and Environment, along with a team

AGGREGATES MANAGER September 2015

The system included a video camera attached to the worker’s hardhat,

TECHNOLOGY

as well as a dosimeter and a respirable dust monitor for a combined noise and dust assessment to be made simultaneously. The launch of this new health contaminant assessment was extremely positive for Vulcan’s corporate health and safety staff, for the plant’s management team, for the miners who actually wore the Helmet-CAM system, as well as for NIOSH personnel involved in this testing.

NIOSH is currently in the final stages of modifying the related software (EVADE v2.0) to allow the Helmet-CAM technology to be used with other types of health assessments, and this approved version should be ready for public release within

Figure 1. This beta version of EVADE (version 2.0) software shows graphs representing both the miner’s noise exposure (1-second noise measurements plotted as a function of time) and respirable dust exposure. In the upper right of the figure above the graphs, the activity being performed is viewed.

the next few months.

Developing the Helmet-CAM

inexpensive technology to set up and

be tailored and implemented to lower

use. It consists of a lightweight video

exposures.

camera, a direct-reading data-logging

After extensive field testing by NIOSH

The Helmet-CAM assessment technology

aerosol monitor, and a method for hous-

at numerous mine sites in many differ-

system breaks a major roadblock pre-

ing these instruments in a way that

ent states, Helmet-CAM has become a

venting the assessment of how, when,

allows workers to perform their work in

driving impetus for mine operators to

and where workers are being exposed

a safe and unimpeded fashion. A small

implement engineering control technol-

to respirable silica dust. Respirable silica

compact video camera is attached to a

ogies and interventions to lower respi-

dust and the development of silicosis

worker’s hardhat and records the work-

rable dust exposures. Numerous exam-

remains a serious health issue for all

ers’ job tasks and movements while

ples can be cited by major stakeholders

workers around the world. A significant

wearing the system. Simultaneously,

as to the benefits of identifying elevated

challenge in the fight against silicosis

an instantaneous aerosol nephelometer

respirable dust exposures which, in

has remained the inability to deter-

quantifies the worker’s respirable dust

turn, results in the implementation of

mine the magnitude of respirable silica

exposure at specific time intervals —

engineering controls/interventions to

exposures in the workplace. This chal-

typically 2-second intervals. Once the

successfully lower worker’s exposure.

lenge has been reduced significantly

video footage and respirable dust data

Accordingly, this technology has been

by the development of the Helmet-CAM

are downloaded to a computer, the

adopted by many of the member com-

technology, which provides a quick

EVADE (Enhanced Video Analysis of Dust

panies in the Industrial Minerals Asso-

and proven method to identify elevated

Exposure) software merges the data

ciation–North America and the National

levels of worker exposure, and a simple

for simultaneous viewing to provide

Industrial Sand Association. Helmet-CAM

assessment tool to determine the effec-

an assessment of specific aspects that

has also been adopted as a training tool

tiveness of targeted engineering control

impacted the workers’ respirable dust

for a number of major industrial sand

techniques or interventions to lower

exposure. By identifying those culprits

producers. For example, plant manage-

respirable dust exposures.

responsible for elevated respirable dust

ment at one company included the

exposure, a hierarchy of controls can

Helmet-CAM as part of its management

Helmet-CAM is a simple and relatively

AGGREGATES MANAGER September 2015

33

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TECHNOLOGY

EVADE program and understand what they are seeing. This can be a useful training exercise — workers can see their activities and understand exactly how those activities contributed to their overall noise exposure. This level of training and worker involvement is not possible with standard dosimetry and time-motion study.

Simultaneous noise and dust testing Based on the success of Helmet-CAM for the identification and control of respiFigure 2. A dosimeter microphone is attached to miner’s right shoulder harness, while a10mm cyclone to classify respirable dust is attached to the left harness.

rable silica dust, the natural progression is to then expand this technology for assessment of other related health ef-

performance appraisal requirements,

various tasks and documenting those

fects, such as noise exposure, which can

making the use of this technology man-

tasks in accordance with the time. Then,

be done simultaneously (see Figure 1).

datory for assessing workers’ exposures.

the tasks are aligned with the dosimeter

Through a long-standing and positive

The Helmet-CAM assessment technology

measurements based on time, to deter-

working relationship between Vulcan

is being used extensively throughout

mine where the most hazardous noise

Material Co.’s Kelly Bailey and NIOSH,

the United States in the mining indus-

levels were generated. This is time-in-

noise assessment testing was performed

try and at various locations around the

tensive for the observer, and may cause

during the last week of September 2014

world, including Canada, Mexico, South

the worker to alter his or her normal ac-

at one of Vulcan’s mining operations.

America, Europe, Asia, and Australia.

tivities. Thus, the data obtained may not

To perform this testing, a team of

be representative of the worker’s actual

researchers from NIOSH’s Office of Mine

daily activities.

Safety and Health Research (OMSHR)

Assessing noise exposure

With the Helmet-CAM, the need for

facility in Pittsburgh, Pa., traveled to

Assessment of sound levels in various

time-motion study is eliminated. The

Vulcan’s Havre De Grace Facility near

working areas is important to determine

video, when synchronized with the

Baltimore, Md. These researchers met

the tasks that are contributing to the

dosimeter data, allows for determining

with Bailey and a team of his health

noise exposure of individual workers.

the specific tasks that led to the most

and safety staff, along with key plant

There is no visual indicator to workers

noise exposure. The observer can view

management team members, to explain

that they are in an area with hazardous

the individual tasks the worker was

the Helmet-CAM assessment technology

noise levels, so they are often unaware

performing throughout the day, as well

and to lay out a proposed test plan. The

of the potential danger. Importantly,

as locations where he or she was work-

following morning, Helmet-CAM assess-

dosimeter data alone does not indicate

ing while simultaneously viewing the

ment testing was initiated for both noise

the cause of noise exposure — just the

sound levels associated with those tasks

and respirable dust.

times that the exposure was acquired.

and locations. This can remove much of

Therefore, dosimetry measurements

the potential for error in note-taking or

management team requested that three

must be done along with an observer

task observation. An additional benefit

different miners come into the mine’s

completing a time-motion study of the

of using the Helmet-CAM is how easy

conference room to be set up with the

worker. The time-motion study involves

it is for workers to view and review the

Helmet-CAM technology. When the min-

following the worker through his or her

noise exposure information through the

ers arrived and were ready to be fitted

To begin the process, the mine’s

AGGREGATES MANAGER September 2015

35

Figure 3. Various Vulcan miners wear the Helmet-CAM system for simultaneous noise and dust assessment as they perform their regular duties.

with the system, the first component

tor for both noise and respirable dust

90 dB(A) with a threshold of 90 dB(A)

was to attach a small compact video

simultaneously. For noise exposure as-

and a 5-dB exchange rate.

camera to the miner’s hardhat. This

sessment, NIOSH chose to use the Lar-

For respirable dust assessment, the

camera was used to record the worker’s

son Davis Spark noise dosimeter. Noise

Thermo Scientific pDR-1500 instanta-

location and the tasks and functions

dosimeter data can be used to deter-

neous monitor was used. Initially, NIOSH

being performed over the time while

mine sound levels at any point in time

performed a comprehensive laboratory

wearing the system. NIOSH chose to use

or to determine noise exposure over a

study with this light-scattering nephe-

a V.I.O. POV camera, but there are many

specific period of time. The dosimeter

lometer to ensure that the unit provided

different types of commercially available

was set up to continuously record A-

comparable dust data to what would

compact video cameras available (GoPro,

weighted sound levels at 1-second

be obtained with MSHA compliance and

Contour, Fire Cam, Polaroid XS100i, and

intervals. The 1-second samples could

in-house gravimetric dust sampling.

others) that can be used with the Hel-

then be compiled over any time period

The unit was slightly modified so that

met-CAM technology. The V.I.O. system

of interest to evaluate exposure. Prior

a 3-foot section of conductive tubing

employs a video lens that was attached

to the start of the shift, the dosimeter

could be used to connect to the 10-mm

to the miner’s hardhat using a com-

microphone was attached to the mid-

Dorr-Oliver cyclone, which is the typical

mercially available flashlight clip and

point of the worker’s left shoulder. After

pre-classifier device used for respirable

duct tape. A thin cable, approximately

the predetermined work time period

dust sampling in the metal/non-metal

18 inches in length, connects the video

had ended, the dosimeter was removed

mining industry. The pDR-1500 was

lens to the digital video recording por-

from the worker, and the noise data

also set to a 1.7-liter/minute flow rate,

tion of the device. This video device

was downloaded and analyzed to deter-

which is the required flow rate as es-

creates two digital video files with “avi”

mine the amount of noise exposure the

tablished by the American Conference

and “thm” extensions, which are used

worker encountered. Exposure calcula-

of Governmental Industrial Hygienists

by the EVADE software program.

tions derived from the dosimeter data

(ACGIH) for the metal/non-metal indus-

were based on the MSHA permissible

try. For testing, the 10-mm cyclone was

CAM system is the assessment compo-

exposure level (PEL) of an 8-hour time-

placed on the miner’s lapel, within the

nent, which, in this case, was to moni-

weighted average (TWA) sound level of

miner’s breathing zone and similar to

The second component of the Helmet-

36

AGGREGATES MANAGER September 2015

TECHNOLOGY

the method used for a compliance-type

camera lens was also duct-taped in

so that it can assess any type of physi-

dust sample. A 3-foot length of con-

place to ensure that it did not move over

cal, chemical, or biological agent where

ductive tubing was used to connect the

time and lose its alignment as workers

an instantaneous monitoring device is

10-mm cyclone to the main body of the

performed their job tasks. At this point,

used — such as monitoring of diesel

pDR-1500 monitor. The instrument was

the video camera, dosimeter, and dust

particulate matter, chemical, and noise

configured to integrate samples over a

monitors were all started simultaneously.

exposure levels.

2-second period for this testing.

It was critical that all three units were

The last item necessary for the

In a recent cooperative study be-

started at the same time, because there

tween Vulcan Materials Co. and NIOSH,

Helmet-CAM system was a method to

is no current adjustment in the EVADE

the Helmet-CAM technology was shown

house the video camera, as well as the

software to offset the start time.

to successfully be able to simultane-

noise and dust instruments, in a way

The miners were asked to return

ously monitor and provide assessment

that would allow the miner to perform

to work and to wear the Helmet-CAM

for both noise and respirable dust ex-

his or her work in an un-impeded

system for a pre-determined time frame

posures to miners. Further, the EVADE

fashion and with minimal interference.

(Figure 3). The miners were instructed

software that complements the Helmet-

For this testing, the best approach

to perform their routine duties and

CAM technology is currently being ex-

was to provide a lightweight backpack

tasks without any changes or devia-

panded (version 2.0) to allow multiple

with a number of pockets to house the

tions in relation to their wearing of the

video files and contaminant data to be

camera’s logger unit and the noise and

device. For all testing, the video sound

viewed simultaneously.

dust monitor (this approach emerged

function was deactivated because it

as the method preferred by miners in

was not needed.

all of NIOSH’s previous testing). An ad-

After approximately two hours, the

The software for assessing worker’s respirable dust exposure to respirable dust (EVADE version 1.0) for the Helmet-

vantage of using the backpack is that it

miners returned to the mine’s con-

CAM technology is currently available

has two shoulder harnesses, as well as

ference room, and the video camera

at the NIOSH Mining website at www.

two other straps — one at chest level

footage was downloaded to a laptop

cdc.gov/niosh/mining/Works/cover-

and the second at the waist — which

computer. Because numerous workers

sheet1867.html. Within the next few

allows the backpack to be securely

were to be evaluated at the same site,

months EVADE version 2.O will also be

adjusted and tightened to the wearer’s

it was important to differentiate the

available at this website. AM

needs. The other benefit with the two

numerous videos, dosimeter data, and

shoulder harnesses is that the micro-

dust data files taken at this operation.

phone for the dosimeter was attached

All files were provided a name as-

to one shoulder harness, and the 10-

signed by Vulcan that could be used to

mm Dorr-Oliver respirable dust classi-

distinguish between the different min-

fier was attached to the other (Figure

ers. When using the EVADE software,

2). Duct tape was then used to secure

this same naming system was used

all the cables in order to provide a sig-

to ensure that the correct video files,

nificant level of safety to the worker to

dust data files, and dosimeter data files

minimize the possibility of them being

were linked together in the analysis

caught or tangled on anything while

software program.

performing their work.

The video camera lens was attached to

Next steps

Disclaimer Mention of any company or product does not constitute endorsement by the National Institute for Occupational Safety and Health. The findings and conclusions in this report are those of the authors and do not necessarily represent the views of the National Institute for Occupational Safety and Health.

Andrew Cecala, lead mining engineer, and Amanda Azman, research audiologist,

the worker’s hardhat using a holder for a

With the Helmet-CAM technology being

are both researchers with the NIOSH Office

small flashlight clip. The video unit was

successfully used in the United States

of Mine Safety and Health Research in

turned on, and the lens was adjusted to

and internationally to identify and con-

Pittsburgh, Pa. Kelly Bailey is the corporate

ensure that it was recording in a hori-

trol respirable silica dust exposures, the

director of safety, health, and environ-

zontally aligned manner. The aligned

intent is to now expand this technology

mental services for Vulcan Materials Co.

AGGREGATES MANAGER September 2015

37

Rock MSHA uses policy to substantively revise workplace exam standards.

by Patrick W. Dennison

Who Needs

RULEMAKING?

A

Patrick W. Dennison is an associate in Jackson Kelly PLLC’s Pittsburgh office, practicing in the Occupational Safety and Health Practice Group and the Coal and Oil and Gas Industry Groups.

He can be reached at 412-434-8815 or via email at pwdennison@ jacksonkelly.com.

38

major focus of the Mine Safety and Health Administration’s (MSHA) fatality prevention initiative, announced on Jan. 30, 2015, is workplace examinations required under 30 C.F.R. §§ 56/57.18002. But MSHA’s attention to workplace examinations was first publicized in the November 2014 Regulatory Agenda (Agenda) for the year 2015, which included a “prerule” intent for a “Request for Information” (RFI) “on the examination of working places in metal and non-metal mines to determine the adequacy of the Agency’s existing standards.” MSHA stated that it would seek information regarding: persons conducting the examination; the quality of the examination; and the recordkeeping provision, among other provisions. The RFI was slated for June 2015. However, as a hint of things to come, the Agenda stated, “MSHA also is considering whether issuing guidance or disseminating best practices regarding the existing standards would effectively accomplish the Agency’s goal of providing miners a safe working place.”

On May 21, 2015, the 2015 Spring Unified Regulatory Agenda for the Department of Labor was released, and it included the same

AGGREGATES MANAGER September 2015

RFI for workplace examinations described above, this time with a proposed date of September 2015. But now, rather than seeking information through an RFI, MSHA issued so-called “guidance” regarding workplace examinations. In early July 2015, MSHA briefly posted Program Policy Letter No. P15-IV-01 (PPL), pertaining to examinations of working places, on its website. The PPL had an effective date of July 9, 2015. However, shortly after posting the PPL to its website, MSHA removed it, indicating that it would be reintroduced at a stakeholder meeting set for July 22, 2015.

At the stakeholder’s meeting on July 22, MSHA “re-issued” PPL No. P15-IV-01. The PPL’s stated purpose is “to clarify that the examination of working places required under 30 C.F.R. §§ 56/57.18002 includes the requirement that the operator shall examine each working place at least once each shift for conditions which adversely affect safety or health, that the examination must be conducted by a competent person, and that a record of the examination must be maintained and made available for review by the Secretary or his authorized representative.”

And while MSHA’s Neil Merrifield has stated

ROCKLAW

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there is “nothing new” in the PPL, the PPL does more than simply clarify the standard — it substantively changes it.

Most notably, the PPL changes the definition of “working place.” While the term “working place” is defined as “any place in or about a mine where work is being performed” (see 30 C.F.R. §§ 56/57.2), the PPL states that “working place” includes “areas where work is performed on an infrequent basis, such as areas accessed primarily during periods of maintenance or clean-up” and that “all such working places must be examined by a competent person at least once per shift.”

Thus, areas or places not normally traveled or accessed would, at least according to the PPL, require a workplace examination at least once per shift. Set aside the fact that no one may work in the area during that particular shift — as the PPL suggests — the area would still require examination by a “competent person.”

Besides the impracticality of such requirement, the PPL makes a workplace examination more onerous than preshift or onshift examinations conducted in underground coal mines. Preshift and onshift examinations are only required when persons are or will be working and only include areas where persons regularly work or travel. Areas of underground coal mines that do not meet such requirements are examined weekly.

The PPL also states that a “best

practice” for conducting workplace examinations is for a foreman or other supervisor to do so, which ostensibly increases the operator’s exposure to heightened negligence designations such as “unwarrantable failure.” Moreover, the PPL specifically states that a failure to identify safety hazards “may indicate that task training as required under parts 46 and 48 was inadequate or did not occur,” resulting in a “basis for MSHA to require training plan revisions under part 46 (30 C.F.R. § 46.3(a) and (b)(3)) or part 48 (30 C.F.R. §§ 48.3(c) (8)/48.23(c)(8)).” What operators can expect, then, is for MSHA to have the ability to write three violations for one condition: one for the condition found, one for an inadequate workplace examination, and, potentially, one for a task training violation.

The workplace examination PPL is indicative of MSHA’s rulemaking without input from the industry.

Clearly, as indicated in the regulatory agendas, such rulemaking was in MSHA’s sights. But rather than conducting rulemaking, it has attempted, through the use of policy, to shoehorn requirements into a standard that does not fit the language or the intent of the standard.

Until the courts decide to hold such rulemaking in check, one can expect to see increased instances of substantive changes to laws without the use of procedural safeguards afforded by proper rulemaking procedures. AM

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IFC

NSSGA Membership

www.nssga.org

26

Petersen Industries

www.petersenind.com

12

Progressive Commercial Insurance

www.progressivecommercial.com

31

Pugmill Systems, Inc.

www.pugmillsystems.com

41

Rice Lake Weighing Systems

www.ricelake.com/truckscales

BC

Rock Systems, Inc.

www.rocksystems.com

41

Sandvik Construction Mobile Crushers & Screens USA

www.construction.sandvik.com

8

Stedman Machine Co.

www.stedman-machine.com/grip

40

Sweet Manufacturing

www.sweetmfg.com

41

Terex Minerals Processing Systems

www.terexmps.com

11

Topcon Positioning Systems

www.topconpositioning.com

13

Trimble Loadrite

www.loadritescales.com

19

29, 40

40, 41

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

AGGREGATES MANAGER September 2015

43

In Stone

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

The Men

ON THE HILL

The life of a 19th century granite miner consisted of physically intense work, carb-laden meals, and impromptu entertainment.

[I]n a great number of cases, when the month’s pay comes to a single [quarry] man, he settles his board bill, squares up at the store and the livery stable, and then as for the balance, rolls it lively.

George Ellsworth Hooker, 1895, Labor and Life at the Barre Granite Quarries I have met quite a few aggregates workers in my day. I thoroughly enjoy working with and around those folks while doing my geological studies. Perhaps it is my friendships with quarry folk that led me to write this series of articles about Barre granite to learn what life was like for early quarry men back in the late 19th century.

Quarry men worked as hard as the rock they were mining. According to contemporary reports, work in Barre quarries was much more demanding than in granite quarries in Maine or in the old country. Heavy 8-pound sledges swung by two men with both hands would fall on the drill about 40 times per minute. Each man swung 20 times per minute, or When mining granite in the late 1800s, two men would swing an 8-pound sledge onto the drill every once every three seconds. Go through the motions 20 times in a minute; three seconds. It made for physically exhausting work. it is grueling. Shifting drills, driving wedges, and hitching chains varied the exercise, but the physical expenditure of energy in the nine-hour day was heavy.

Fueling this exercise took carbohydrates - lots of them. Most men could not reach home, eat in comfort, and return to work during the hour dinner break; hence the “dinner pail gang.” A typical dinner pail contained two thick slices of buttered bread, a slice of cold meat or cheese, one doughnut, one slice of cake, two cookies, two pieces of pie, and two cups of tea or coffee.

That could fuel a lot of hammer blows.

Many of the quarry men in Barre lived on “Millstone Hill” near where most of the quarries were located. To the citizens of Barre, Millstone Hill had a more familiar title of “The Hill;” conceived by many to be a terrible place.

At a time when men dressed in a coat and tie for supper (the evening meal), quarry men would go to their table in their shirt sleeves. It was said that they disfigured a hall floor pretty badly at an entertainment. They swore prolifically, gambled, and frequently got drunk. However, as it is today, it was the few who greatly discredited the reputations of the many.

Some men, especially those with a prudent wife, were quite thrifty. But after payday, many single men would end up being broke in a few days. However, quarry men always paid their debts, and there were very few men who couldn’t get credit.

Recreational opportunities were very limited on The Hill. When asked what people on The Hill do, the answer in an 1895 publication was “What do they do? Nothing as I know, ‘cept to sleep, and eat, an’ work.” Organized outdoor sports were prevented by the lack of a Saturday half-holiday, and the men had to make do with impromptu activities.

After the arrival of the stage coach from Barre and the distribution of the mail, the men would play billiards, pitch quoits, put the shot, play whist, read books or newspapers, or just sit on the fence and play the harmonica and sing songs.

On Saturday night, they might go to Barre where they would roll it lively.

44

AGGREGATES MANAGER September 2015

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