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.
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©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.
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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
Equipment List • • • • • • • • • • •
Komatsu WA600-6 pit loader Caterpillar 772 haul trucks (2) Euclid R40 haul truck Caterpillar D8T dozer Bobcat S185 skid steer Freightliner water truck Komatsu 500-7 loader Caterpillar 980H loader JLG manlift Hazemag 1615 primary crusher Deister 7- x 20-foot triple-deck
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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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. AGGREGATES MANAGER
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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
Need to find specific rock types to fill that order? Get the the most current information with the 2015 Aggregates Industry Atlas and the Atlas on CD. While the printed version of the Aggregates Manager 2015 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more. The Atlas on CD contains compete information on more than 11,000 operations in the United States in a data file as well as the entire 2015 Aggregates Industry Atlas in pdf format.
2015 Aggregates Industry Atlas
Your guide to aggregates operations, locations & ownership
Order additional copies of the Aggregates Manager 2015 Aggregates Industry Atlas on CD or the printed version of the Atlas today!
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7 15 23
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To order, visit AggManAtlas.com or call 1-800-430-4540
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
4. Incorporate visual inspection and repairs. Like vehicle
scale, looking at these and other items, and offer solutions
owners, scale owners must perform regular maintenance.
to any issues discovered.
In addition to the critical calibration component, a thorough
Most scale owners understand that it is better to repair
scale maintenance program must include visual inspection,
and address issues when they are small, rather than wait
followed by any necessary repairs. A good service company
until they are big and expensive.
should conduct a free visual inspection and have the ability to perform these minor repairs while on-site for the mainte-
5. Ensure thorough reporting. A good scale maintenance
nance visit.
program will provide thorough reporting. Each maintenance
The visual inspection should include these key items:
inspection should include a written report documenting test
•
Scale condition,
results and including both before and after calibration, as
•
Regulatory conformance issues,
well as a summary of finding and recommendations.
•
Any damages,
•
Safety,
tion can trust that its scale is capturing an accurate account-
•
Clearance,
ing of material being carried out in customer trucks. AM
•
Grounding,
•
Mud/debris build-up,
•
Use issues,
•
Corrosion, and
•
Electrical conditions.
By following these five maintenance guidelines, an opera-
A reputable service company will carefully inspect the
Russ Desilets is the regional director at Fairbanks Scales. He has been with the company since 1976, with experience as a technician, manager, and director in the manufacturing and service operations area. He can be reached at 936-203-6332.
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31
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
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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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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
53’-0”
9’-2”
SWITCHGEAR
19’-10”
17’-0”
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