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EDITORIAL & CONTENTS
Big is good Big stuff. It is part and parcel of what so many in our joint industries do. Whether it be a big factory deconstruction, a big excavator or shredder being operated, or a big load of recycled material for export; scale is just one facet of any project. It’s still finesse and expertise that gets the real results. The companies we’re profiling on this issue’s cover – Nikau Contractors and Pedersen Group – are proof positive of that. Still, no one got anywhere of note without big goals and equally PUBLISHER
sizeable aspirations. And with these come big risks.
Cameron Officer Limited
For the scrap metal recycling industry on both sides of the Tasman, the world currently seems full of big
19 Konini Road
risks, with little looking likely to change in the forecast-able future. On the demolition side of the equation,
Titirangi, Auckland 0604
there are still big projects on offer for those with the right gear, manpower and talent.
phone: + 64 (0) 21 1606 175 EDITOR
Cameron Officer phone: +64 (0) 21 1606 175 cameronofficer@gmail.com ADVERTISING SALES
Amanda Gilroy phone: +64 (0) 22 435 5421 amanda.gilroy1@gmail.com
Diversification has become a key attribute, especially for scrap metal operators looking to survive when the market is down. That is set to be a topic of much discussion at this year’s Scrap Metal Recycling Association of New Zealand AGM in August (which we preview on p22). In Sydney, All Types of Rubbish (ATR) has looked to diversify their machine fleet with something the operator stands beside rather than sits in. It’s a remote controlled demolition robot and for multi-story deconstruction work, it gets big results despite its small footprint (see p28).
Hope you enjoy the big read.
SUBSCRIPTIONS
cameronofficer@gmail.com
News Briefs
phone: +64 (0) 21 1606 175
Goings on from Australia, New Zealand and around the world
PRODUCTION
Design: Richard Walker
On the Market
Printing: Client Focused Solutions Ltd
Metals market commentary with Jeff Harris
+64 (0) 27 255 1818
Sennebogen materials handlers Contributions are welcomed. Please contact the editor before sending them in. Articles in Scrap & Demolition
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are copyright and may not be
Multi-service providers Pedersen Group has invested in four new Sennebogen materials handlers, including the mighty 880EQ; one of the largest such machines in the world
Nikau Group’s giant jaw The name Mantovanibenne isn’t the only thing big about Nikau Group’s latest oversized attachment
reproduced in whole or in part without permission of the publisher.
New President for NZDAA
Opinions in this magazine are not
Peter Ward steps up to the executive for the New Zealand Demolition & Asbestos Association
necessarily those of the publisher.
Tyre Industry Summit 2015
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We report back from the inaugural Tyre Industry Summit, which looked at both risks and opportunities around end-of-life tyre recycling
SMRANZ conference 2015 preview Tough times, the challenges they pose and the road ahead will all be on the agenda at this year’s SMRANZ conference in Dunedin in August
Large scale fuel storage tank demolition Two large tank deconstruction projects have seen the development of a new methodology for deconstructing them swiftly and safely
World Demolition Awards It’s your last chance to get your submissions in. Find out how.
Sc
Scrap & Demolition magazine is the official magazine of AMRIA, the Australian Metal Recycling Industry Association. ISSN 2253-5063
ON THE COVER: Pedersen Group and Nikau Contractors go big.
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Husqvarna DXR140 demolition robot
26
A Sydney firm embraces the future with a hard-working remote controlled demolition robot
Hitachi high-reach Yakka Demolition runs a heavy duty Hitachi excavator with a difference
Bost Group multi-kit processor system & Advertisers Index
2 12 14 16 18 19 22 24 26 28 30 32
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NEWS BRIEF
ISRI Chairman Doug Kramer (left) presents the 2015 Design for Recycling Award to Dr. Nandhu Nandhakumar, senior vice president, LG Technology Centre of America, and Jane Kang, head of product stewardship, LG Electronics USA
LG receives 2015 Design for Recycling award from ISRI LG Electronics has received the 2015 Design for Recycling (DfR) Award from the Institute of Scrap Recycling Industries (ISRI) in the United States. The honour was awarded at a ceremony during ISRI’s 2015 conference in Vancouver, Canada. ISRI recognised LG “for advanced new television products that emphasise recycling during every lifecycle phase.” Specifically, LG was recognised for its 4K ULTRA HD OLED and LED TVs. According to ISRI, the product design for these models include the following recycling-friendly traits such as mercury-free display panels; use of recycled and recyclable plastics; inclusion of PVC- and BFR-free components; smaller and lighter packaging; ease of disassembly; and standardised materials and connection types. “ISRI is proud to present the 2015 Design for Recycling Award to LG for prioritising recyclability in the design and manufacture of its products,” said ISRI President Robin Wiener. “Commitment to sustainability serves as a core principle for LG. The initiatives they have undertaken to increase product recyclability, improve resource efficiency, and expand the use of recycled materials within the manufacturing process made LG a perfect selection for this year’s award.” Accepting the award on behalf of LG Electronics, Dr. Nandhu Nandhakumar, senior vice president at the LG Technology Center of America, said, “Our Design for Recycling initiatives represent a key element of LG’s Green Product Strategy under the company’s strategic roadmap to develop products that reduce negative environmental impacts throughout the lifecycle, especially when they are ready for recycling To be eligible for ISRI’s DfR Award, a product must be designed/ redesigned and manufactured to contain the maximum amount of materials that are recyclable; be easily recycled through current or newly designed recycling processes; and be cost effective to recycle (ie. the cost to recycle does not exceed the value of its recycled materials). Products must also be free of hazardous materials that are not recyclable or impede the recycling process; minimise the time and cost involved to recycle the product; reduce the use of raw materials by including recycled materials and/or components; and have a net gain in the overall recyclability of the product while reducing the overall negative impact on the environment. ISRI began presenting the DfR award more than 25 years ago. Previous winners include Dell, Inc., Cascades Fine Papers Group, Coca-Cola Recycling Company and Hewlett-Packard. Source: 3BL Media
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A British recycling boss who on-sold military equipment worth £12m to the Jordanian Army has been jailed for two years. Worcester Crown Court heard the scrap included Kevlar body armour, helmets and riot shields used in conflicts and that Sidney Nicholls posed a “serious risk” to national security by selling the gear, which he was originally paid to scrap. 53-year-old Nicholls was a recycling consultant working for a firm which had a contract to scrap UK Ministry of Defence equipment. Instead of scrapping the equipment, Nicholls stockpiled the items and agreed to sell them to a broker. The Jordanian Army agreed to pay £250,000, of which Nicholls would receive £100,000. But the MoD intercepted 60 pallets of stock on a ship destined for the Middle East, with Nicholls subsequently arrested. Prosecutor Peter Grieves-Smith said: “If sold outside the MoD system, it would present a serious risk to national security. “It could be possible to work out the strength of British armour and what ballistic force would be required to defeat it.” The court heard all the items were accounted for and would have been valued at £12million when bought brand new. Nicholls admitted fraud by false representation and was jailed for two years. Source: The Mirror
Victory in illegal demolition case could set precedent for Sydney councils Leichhardt council won a landmark victory in May against a property developer who illegally demolished a heritage-listed shopfront in Annandale. The NSW Land and Environment Court found the owner and director of development company Geitonia, Bill Gertos, personally liable for the illegal demolition of the Edwardian facade located next to the iconic Annandale Hotel. The court found Mr Gertos ordered the demolition of the Edwardian facade in late 2011 after the council approved a redevelopment of the building on the proviso the shopfront facade would be preserved. The ruling is a rare case in which an individual owner or director of a company has been successfully prosecuted for breaching heritage law, and could set a precedent for other Sydney councils fighting to save heritage buildings. “We wanted to send a message that heritage matters. The demolition and removal of buildings and other structures must be done within council’s planning controls,” said Leichhardt mayor Rochelle Porteous. Source: Sydney Morning Herald
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British recycling boss-turnedarms dealer sent to prison
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NEWS BRIEF
Steve Jobs and Steve Wozniak; creating future museum pieces
VINTAGE APPLE COMPUTER HANDED OVER AS E-SCRAP A recycling centre in California’s Silicon Valley made a thrilling discovery in May when it stumbled upon on a first edition Apple computer handed in as e-scrap. The rare find – a first generation Apple One – has been sold to a collector for US$ 200,000 at a private auction. But now the recycler, Clean Bay Area, is trying to get in touch with the mystery lady who dropped off her ‘unwanted electronics’. The Apple One computer was one of only 200 first generation desktop computers assembled by Steve Jobs and his partners Steve Wozniak and Ron Wayne back in 1976. What turned out to be a ‘breakthrough’ in personal computing was assembled in a garage by the tech pioneers. “We really couldn’t believe our eyes; we thought it was a fake,” says Victor Gichun, vice president of Clean Bay Area. The vintage collector’s item was hidden underneath layers and layers of computer cables and dusty keyboards; typical material that turns up at the e-scrap recycling site. Gichun recalls an elderly woman bringing in some “old things” that belonged to her late husband; she left no name or contact information. Source: Recycling Today
STOCKPILED CAR BODIES’ SIGN OF THE TIMES AS SCRAP PRICES STALL A scrap yard owner in Timaru, New Zealand says he currently has 1000 car bodies stockpiled as slowing Chinese growth keeps scrap metal prices at a six-year low. Timaru Metal Recyclers owner John Hepburn told reporters it is currently no longer economical to shred car bodies for scrap, and the
Metal recycler fined after explosion reveals health and safety failings A South Auckland metal recycler, National Steel Limited, has been fined $23,500 after an explosion on 17 July 2013 at their plant revealed a catalogue of health and safety failings. National Steel Limited was fined in the Manukau District Court in May under the Health and Safety in Employment Act, for failing to take all practicable steps to ensure the safety of employees. While there were no injuries from the explosion, it dislodged a long, heavy piece of metal ducting causing it to fall to the floor of the plant. Fire and the force of the explosion also damaged windows, cladding and machinery. An investigation revealed the company was not adequately managing a range of hazards. There was no effective inspection system for identifying gases or liquids in tanks, cylinders or other containers sent for shredding. An
Source: Worksafe Media Release company could only pile up the bodies and wait for prices to rise from their lowest levels since 2009. The Chinese economy, which "pretty much dictates [scrap metal] prices for the rest of the world", was in a period of relatively slow growth. Reported Chinese gross domestic product growth had dropped from approximately 10 percent in 2010 to about seven percent in 2014, with Chinese steel mills increasingly sourcing scrap metal domestically. Working out where prices would go requires Hepburn to pay close attention to developments in China. "Essentially we've become futures traders,” he said. Hepburn said that, although he enjoyed working in the recycling industry, prices in the last 18 months had made business difficult. He used to receive about $100 for a car body, but current prices meant it was not worth sending the cars to be shredded in Christchurch. The company employs six workers and had managed to limit the impact of the low prices by moving into demolition work. Some plastic-insulated wires could not be completely processed on-site, as the quantities of metal in the South Canterbury region were not great enough to justify buying a granulating machine to chop up the wire into reusable granules. Hepburn said some locals were not helping the situation by illegally dumping household rubbish, including couches, televisions and clothing, at its free drop-off area for whiteware, car bodies and some other metals. The company had to subsequently pay to dump the rubbish at a nearby landfill. He has since installed a surveillance camera and wanted help to catch the dumpers to ensure the free facility remained open. Source: Timaru Herald
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inspector also found a fuel tank in the boot of a car just as it was about to be fed into the shredder. There was also inadequate fencing and guarding of the hammer mill where employees fed material onto the conveyors, doors that were supposed to be kept closed couldn’t close and the conveyors fence had a gate that was left open. The conveyor drum and some of its rollers were also not properly guarded which meant that employees were at risk of dangerous moving parts. WorkSafe New Zealand’s Chief Inspector Keith Stewart says there’s no room for cowboys when it comes to working with machinery such as a hammer mill and conveyors – particularly if flammable gases are also present. It is only a matter of luck that no-one was seriously injured.
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NEWS BRIEF
Demolition of more than 1000 Canberra homes contaminated with Mr Fluffy loose-fill asbestos has begun, but a handful of residents refused to sign up to the ACT Government's buyback scheme as the June 30 deadline approached. Under the voluntary scheme the ACT Government has agreed to buy-out residents of affected properties and then demolish their homes. After that date, the Government's Asbestos Recovery Taskforce said it could offer no guarantees of compensation, meaning residents may only recoup the value of their land if they sell. Of the 1019 Mr Fluffy properties still standing at the beginning of June, most owners had already signed up to the Government's voluntary buy-back scheme. Taskforce chief Andrew Kefford said 980 residents had registered for the scheme, and the Government had issued home valuations to 920 of those. It had reached agreement with residents to buy back a total of 820
Christchurch’s old central police station imploded Christchurch’s second controlled building implosion was conducted without incident on May 31, drawing a large crowd of spectators both within the city centre and online via social media and news outlet live streams. Controlled Demolition Inc field operations manager Ray Zukowski told media the implosion of the old Christchurch Central Police Station – which required more than 500 metres of detonating cord and 55kg of explosives – went perfectly. While the 13-storey building was reduced to rubble in a matter of seconds, some witnesses questioned if the implosion had gone to plan, as about three storeys of the Hereford Street side of the building remained. But Zukowski said the building needed to fall away from Hereford Street, with demolition crews keeping that side of the building rigid to drag it away from the road. Implosion crews charged 185 holes, with 50 to 55kg of high explosives loaded into the building to bring it down. "It was a very, very well made building and it took a lot of work to get her on the ground," Zukowski said. The building – designed and constructed in the late 1960s – actually performed well in the 2010/11 earthquakes and was repairable, but it was deemed uneconomic to do so by owners Ngai Tahu Property. An implosion was chosen over traditional demolition methods because it would have less disruption to neighbouring businesses and traffic, while ensuring a shorter demolition timeframe. This was New Zealand's second building implosion after Christchurch's
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Source: ABC News
Radio Network House was demolished utilising the same method in August 2012. Principal demolition contractor, Ceres New Zealand, has spent the past 10 months removing asbestos from the building, which was stripped out to expose structural elements and to improve post-implosion debris for recycling and disposal. Read the autumn 2015 issue of Scrap & Demolition Australasia for all the details of an unusual sound and video project, which recorded the old Christchurch Central Police Station demolition process. Source: The Press
Image: Andy Periam
‘Mr Fluffy’ demolitions underway in Canberra; controversy continues
properties worth $630 million, or an average of $768,292 per home. But around 40 residents had failed to sign up to the scheme before its June 30 deadline. Some residents argued they could privately demolish and rebuild their home cheaper than the Government's proposal. But those wishing to rebuild under the so-called Go It Alone proposal claimed they were being blocked from putting their requests for compensation to the Asbestos Recovery Taskforce. Kefford said neighbours had nothing to fear during the demolition of adjoining properties. "By the time the house is being actually demolished, all of the asbestos will either have been removed and taken away, or will have been sprayed and bonded to the structure,” he said. "There is dust suppression in place which will ensure that there is no danger neighbours. There is no reason why neighbours can't be at home next door while this process is happening." At the scheme's peak, crews will bulldoze about 10 homes a week. Worksafe Commissioner Mark McCabe said local and interstate demolition contractors would be strictly monitored by inspectors while the homes were bulldozed. He said some firms hoping to take part in the billion-dollar scheme had been barred because they did not meet the Government's stringent workplace safety standards. "We've taken some recent action to suspend the licence of at least one of the licensed asbestos people [and] we're looking at a couple of others," Mr McCabe said. "We're going through a rigorous examination of the licensed professionals in this area, and making sure that only people who are capable of doing the work and committed to doing it in compliance with the law will be doing this work." While the government was expected to manage the vast majority of demolition projects, two homes had already been privately demolished to the same safety standards being demanded of Government contractors.
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NEWS BRIEF
ACT turns to rail over road to transport scrap metal
SMRANZ president Korina Kirk
Prompt reporting of metal theft gets results, says SMRANZ A Christchurch building company has successfully recovered materials valued at $7000, stolen from a property in the suburb of New Brighton recently. The success stems largely from the company’s prompt reporting of the theft to both the Scrap Metal Recycling Association of New Zealand (SMRANZ) and the New Zealand Police. Both organisations work together to operate a stolen metals reporting network. The theft was reported to SMRANZ shortly after 10.00pm on Tuesday morning in early May. At the same time the Police report came through to their office. SMRANZ then pulled photos from the building company’s website to help show the type of material that was stolen for circulation with the report. The offender presented the material for sale at Christchurch firm Annex Road Metals, at approximately 11.20am. “Mike Black of Annex Road Metals – a long-serving SMRANZ member – saw the stolen metal report at approximately 12.30pm and rung us and the Police shortly afterwards,” says SMRANZ president Korina Kirk. The building firm was then able to visit the Annex Road Metals yard that afternoon to confirm the materials presented for sale were definitely theirs, saving most of the material before it had been crushed. The matter is now with the New
Zealand Police, who will view the video evidence and driver’s licence of the alleged offender; part of the formal identification process of people presenting items for sale, as required of scrap metal dealers under the Secondhand Dealers and Pawnbrokers Act. Reports of stolen metals can be made via the SMRANZ website (www.scrapmetal.org.nz) or via a toll free number: ph. 0800 69 72 72. Reports are circulated to scrap metal operators throughout the country. “It’s our top priority to circulate stolen metals information,” says Kirk. “Our members help to fund the network with their membership subscriptions. We encourage metal theft victims to report thefts both to us and the New Zealand Police in a timely manner, because stolen metals are often presented for sale very quickly.” Market prices for metals have been falling steadily since the end of 2014, making it tough times for New Zealand’s scrap metal operators. “It is success stories like this one that help boost morale amongst our members,” concludes Kirk. The episode has had a positive spin for Annex Road Metals too; the Christchurch building company has come to an agreement to use their services when recycling metal waste from building sites from now onwards. Source: SMRANZ media release
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Fewer freight vehicles will need to use roads linking Canberra and NSW as a new strategy for the ACT's scrap metal comes into force. ACT Planning Minister Mick Gentleman has announced a new transport initiative in partnership with Access Recycling, Espee Railroad Services and John Holland Rail, formerly known as the Rail Infrastructure Corporation. As part of the project, roads to Sydney's Port Botany will see fewer B-double trucks carrying scrap metal. Access Recycling has been given rights to use the rail link to the old container terminal in a bid to improve road safety and environmental outcomes. The ACT and NSW governments have agreed to a two-year trial of the plan, which also eliminates the need for steel to travel to be processed in Sydney before export, with processing taking place at Access Recycling’s depot in Fyshwick instead. "By using the existing freight rail infrastructure we can improve road safety and reduce vehicle emissions," Mr Gentleman said. "Most freight to and from the ACT is road-based and our rail network is underutilised. The ACT Freight Strategy, due for release later this year, recognises the importance of retaining rail infrastructure for future potential use." Mr Gentleman said the ACT government was committed to
delivering efficient, safe and well-designed freight and traffic networks for passengers, goods and services to, coming to and from the territory. "With national freight projected to double by 2020, it is important that the ACT develops freight infrastructure that is efficient and can deliver productivity outcomes that are on par with the national and international freight industries." Asset Recycling director Adam Perry welcomed the announcement. "We are committed to establishing a direct-to-market export operation for our recycling business in the capital," he said. "Access Recycling has invested $3 million on metal processing and container loading equipment for our Fyshwick site. A single weekly train service will transport 50 shipping containers of processes recycled metal direct to Port Botany. This will remove five our our B-double trucks from highways each day." Espee Railroad Services corporate services manager Bruce Balin said the project would benefit the Australian Railway Historical Society ACT Division. "This is a big achievement for the society as profits from the commercial operations enable historic carriages and locomotives to be restored for the local community," he said. Source: Sydney Morning Herald
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OPINION: METALS MARKETS
ON THE MARKET A period of relative stability was countered in recent weeks for the New Zealand market especially, with a drop in the Official Cash Rate. Jeff Harris reports.
Non Ferrous During March 2015 the LME copper price pushed back above
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USD 6000/tonne and reached a high point of USD 6448/tonne during May 2015. Prices have risen as LME Inventories have fallen and physical demand for scrap in some Asian economies, such as China and Korea, has recovered. Prices have since fallen again and as we go to print, are sitting at around USD 5900/MT. The current drop is off the back of rising LME stocks and the higher USD. However the fundamentals for copper for 2015/16 are expected to remain positive; demand is robust and growth in terms of the supply from new mining projects is slowing down. The LME prices for both lead and zinc have both remained firm during April and May 2015. LME stocks for both commodities have fallen as a result of increased industrial demand, particularly in the automotive sector. The LME price for aluminium has fallen by almost USD 200/MT since the beginning of May and now stand at just over USD 170/ MT. These prices represent a four year low. While industrial demand for aluminium is increasing, the market is still very much in an oversupply situation. Official LME stocks have been declining recently but it’s estimated that at least as much stock again is held outside
“
the LME system. The LME nickel price has continued its usual roller coaster trend over the last three months. Prices have been affected by higher LME stocks and over-abundant supply. Stainless steel production continues to exceed demand and it is predicated that stainless steel scrap prices will remain flat.
Ferrous Scrap During April and May 2015 ferrous scrap prices have recovered in some areas of South East Asia. Current bulk shipment prices into Asia are seen at a level of around USD 260-265/tonne. Iron Ore prices have recovered in China to around USD 65/tonne and some of the finished steel products have also been increasing. However steel mills are in no particular hurry to increase scrap prices. One commentator has suggested that scrap pricing has reached a floor and a level of stability. It does seem that the scrap market will remain at least stable for the remainder of this year.
The Reserve Bank of New Zealand has signalled the potential for at least one more additional cut later this year, which means there is now a view that the NZD will fall further.
“
Generally speaking most metal prices have traded within a narrow range over the last few months. While some prices have softened recently in USD terms, the effect of these reductions has been offset by both the NZD and AUD being lower against the USD. So in our local markets we are seeing a period of relatively stable prices. The NZD in particular has dropped from over 0.77 in April to just over 0.70. On June 11, 2015 the Reserve Bank of New Zealand dropped the Official Cash Rate (OCR) by 25 basis points to 3.25 percent. The major banks were divided in terms of their opinions about a drop in the OCR, so the news of the drop saw an immediate reduction in the NZD/USD of almost two cents. The Reserve Bank of New Zealand has signalled the potential for at least one more additional cut later this year, which means there is now a view that the NZD will fall further. As long as metal prices at least stay stable in USD terms, then New Zealand traders at least should at least see some better prices being achieved in their local currency.
Global steel production will remain flat. For the first four months of 2015, global steel production was 544.5 million tonnes; 9 million tonnes lower than the first four months of 2014. It would seem that most suppliers of steel scrap are becoming more accepting of the fact that the prices being paid now are likely to be here for some time. Meanwhile, suppliers who held onto their scrap waiting for higher prices are now starting to sell stockpiled material.
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WINTER 2015 13 The Group
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COVER STORY
BIG GREEN GIANTS
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The introduction of four key Sennebogen material handling machines at one of the world’s largest pulp and paper facilities has helped create a more efficient operation for services provider Pedersen Group. While it might not be a scrap metal facility, there are many parallels to be drawn between a busy metal recycling operation and the workflow of the 200ha Tasman Mill near Kawerau in New Zealand’s North Island. Here, Pedersen Group provides log yard logistics, mobile plant operations and whole log chipping and debarking services for clients CHH Pulp & Paper and Norske Skog, handling log volumes of 1.1m tonnes per annum, undertaken on a seven day, double shift operation. “The decision to move to Sennebogen mobile plant was based around the relative technical abilities and robustness of the individual machines,” says Pedersen’s Kawerau Site Manager Marty Hine. “Utilising the advanced capabilities of Sennebogen allowed us to change the way we use both our fixed and mobile plant and led to us reconfiguring our entire yard for maximum efficiency.” The range of material handling hardware Pedersen implemented at their Tasman Mill operation is truly comprehensive; encompassing both the smallest and the largest materials handlers Sennebogen manufactures. At the smaller end of the scale, a static, electric drive Sennebogen 818 acts as the control centre for the debarking drum and conveyor feed into a 3000hp multi-log chipper. Being a stationary machine, the Sennebogen 818 sits upon an elastic bearing which gives the operator the flexibility to react to loads, but also has a suspension effect, cushioning the machine against shock and vibration and providing a better working environment for the operator. In almost every other facet though, the 818 is an off-the-shelf electric powered materials handler, simply sited for maximum efficiency. “The hydraulic elevating cab raises and lowers in a conventional manner so the operator has excellent vision of what’s coming from the power infeed, through the debarker and down the conveyor in front of him,” says Marty. Across the yard, Pedersen Group’s colossal electric drive Sennebogen 880 EQ is one of the world’s largest materials handling machines. Pedersen’s unit weighs in at 275,000kg with a 5m pylon, 30m boom and impressive 11m operator eye level; it is the largest machine of its type in the Southern Hemisphere. While offering all the efficiency benefits of electric power, the machine is still mobile as it sits on crawler tracks in order to travel up to 35m. The Pedersen team constructed the 35m galvanised cable trench which the power cable sits in once it unspools from the reel on the rear of the machine. Rubber belting sits over the trench in order to help keep debris out. Marty says he is impressed with the precision of the Sennebogen 880 EQ, citing the balance the machine exhibits, regardless of load, as exceptional. Even at the 880 EQ’s full reach (30m) and with total weight in the grab of 12 ton, the machine is never in danger of toppling over. This is due to Sennebogen Equilibrium design, with a moving counterweight to help keep the load centred. The long reach Sennebogen 880 EQ can unload from the trailers straight into the power infeed, or across to the store. Alongside the supersized handling capacities of the Sennebogen 880 EQ are two mid-range log handlers – twin Sennebogen 830 MTs – which have also proven real game-changers for Pedersen Group at Kawerau. The Sennebogen 830 MT is the only materials handler/log handling machine that
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Even at the 880 EQ’s full reach (30m) and with total weight in the grab of 12 ton, the machine is never in danger of toppling over. This is due to Sennebogen Equilibrium design, with a moving counterweight to help keep the load centred.
"A Sennebogen 880EQ in Germany handling scrap metal."
can tow 60 ton of logs. Project lead Bruce Hutchings – instrumental in all aspects of the project from instigation and planning to fabrication, civil works and machine implementation – says that, at the end of the day, the ability to tow log trailers gave Sennebogen a critical advantage. “The Sennebogen machines have given us good gains in terms of efficiency, operator comfort and handling capacities. Having the 830 MTs completely flexible to high-stack as well as tow log stock around the yard in larger lots – from the stack to the 880 – has really made a significant difference for us,” he says. Pedersen Group’s trailers were specially developed in-house to compliment the capabilities of the two 830 MTs and manufactured to Bruce’s specifications by Rotorua-headquartered trailer specialists Patchell Industries. “Before the Sennebogen 830s arrived we were using wheel loaders, which can’t stack as high as the 830s can. Wheel loaders can’t tow either, so we’re moving more logs and stacking them more efficiently with a bookend system. The way we use space within the yard has improved dramatically as a result,” says Bruce. Marty Hine says that the Sennebogen 830 MTs feature excellent acceleration, especially considering towing weights are up to 60 ton with the trailer. As part of the extended operational support Pedersen Group provides to Tasman Mill, the company also manages all garage operations on site – 120 items of mobile plant in total. Marty Hine says Sennebogen parts and technical support from Australasian distributor Pacific Materials Handling (PMH) has been fantastic. “PMH have really been with us every step of the way on this. Couple this support with better running costs, cheaper consumables and parts and less in the way of service costs and we’re ahead across the board. “There’s no denying this has been a big exercise for us, but it’s a no-brainer. We have great people in this company and working with some great people at PMH, we’ve engineered a solid result,” Marty concludes. Pacific Materials Handling Sennebogen Business Manager, Byron Judd echoes these sentiments. “From the initial phone call onwards, developing this plan alongside the Pedersen Group team has been a truly rewarding working partnership. We could not have asked for a better group of people to work with on this project,” he says. “The exceptional level of expertise and insight the company possesses has helped make the implementation of world class Sennebogen equipment at the Tasman Mill a seamless process from our side of the equation too.”
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COVER STORY
DOUBLE XL
What better attachment to put on one of the largest excavators in New Zealand than the largest multi-system processing jaw in the world. It’s all part of the plan for Nikau Group at the former New Plymouth power station demolition project.
It has been well-documented that there is absolutely nothing small in scale about the former New Plymouth power station demolition project at Port Taranaki. Main contractors Nikau Group has showcased some big machines to tackle the large scale work required in deconstructing this large facility; most notably a specialist demolition Liebherr R984C high reach, dubbed ‘Twinkle Toes’. And now ‘Twinkle Toes’ (or ‘TT’) is sporting an attachment to suit its size. The big white Mantovannibenne MS130 is the largest multi-system processing jaw in the world and the first in the Southern Hemisphere. The 14 tonne attachment consists of a main structure made up of a machine body, to which a variety of jaw types can be added. This means the giant jaw is versatile as a demolition attachment and metal cutter. Now work has moved onto the boiler room; the third largest structure within the decommissioned power station complex after the cavernous turbine hall and the 198m tall chimney (which isn’t slated for demolition). Nikau Group director John Paul Stil says that, with another large component of the project underway, the MS130 shear’s
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performance so far has filled his team with confidence that they’ve made the right choice in heavy duty equipment. “We originally brought the MS130 in when we were working on deconstructing the turbines,” he says. “When we exposed all the concrete plinths in July last year and removed all the steel work which housed the turbines, we found that the concrete in most areas was about 2m x 2m. We first thought that a 50 tonne excavator fitted with a rock breaker would be sufficient to demolish the plinths, but the concrete was highstrength and just had too much mass. “We then considered buying a large enough cracker jaw to do the job. I’d heard about the MS130 from Europe which goes onto a 120plus tonne machine, so we looked into this further and found that there was a supplier located in this part of the world. “Looking back, we just couldn’t have demolished the plinths using rock breakers and stayed on target with our programme.” Next on the menu for ‘TT’ was the boiler house; deconstruction began in March and – in keeping with the scale of the fleet already on-site – a 550 tonne crane from Smith Crane
& Construction was deployed in order to begin lifting sections. John Paul says some lifts were around 75 tonne, at 50m in the air. “We had to trim steel off to ensure the crane worked well within its capacity. The radius always changes so each lift is different. The demolition team had to ensure each lift was well under the capacity of the crane. “Once the crane had removed half of the height, the demolition crew would then strategically weaken the structure using gas cutting techniques and demolish the lower half using demolition excavators.” John Paul says that, rather than anything mechanical or logistical interrupting workflow, the Nikau team’s biggest challenge has been the Taranaki weather on this exposed portion of sea coast. “While the 550 tonne crane is fantastic at what it does, we’re now into winter and this part of the Taranaki shoreline is renowned for its wind. Inevitably it’s going to mean patches of downtime for us, but we’ll still get there.” So as Nikau Group enters the home stretch on this colossal project (by the time you read this they’ll be mere weeks away from completion), it begs the question; does size
matter? Does utilising big gear lead to using ever bigger gear? And how big is too big? “With reference to the MS130 attachment, there’s no denying the power is great. But the most impressive thing about the attachment
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There’s no denying the power is great. But the most impressive thing about the attachment is the opening of the jaw; at 2.5m it features extreme power.
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is the opening of the jaw; at 2.5m it features extreme power. Of course, power is only good if you can fit material in the jaw. “Reach is another great feature when using
the large scale attachment; it adds another five metres of reach to the machine. So from a Health & Safety point of view, the operator is well away from the hazard.” And while the capacities of the large scale gear suit this project perfectly, there are other peripheral considerations for the Nikau crew where smaller gear works in support of the big machinery. Of course, this being the project it is, the ‘smaller’ equipment still includes 50 tonne excavators. “We have smaller shears for our 50 tonne machines, which are too small to cut the large structural components but good enough to shear up the heavy gauge walkways and pipes. We also have a lot of smaller gear to transport the steel to the main stockpile. “The site is quite large thankfully, so there is a lot of space to stockpile on site,” John Paul concludes. “It’s one thing to have a large site to deconstruct, but it helps when you have plenty of space in which to move around the edges too.
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INDUSTRY ASSOCIATIONS
Peter Ward
CHANGES AT THE TOP FOR NZDAA It’s a case of ‘all change’ for the New Zealand Demolition & Asbestos Association (NZDAA) as members elect new president, vice president and secretary.
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area and we’re seeking to work through the key points with guidance.” In the aftermath of the Canterbury earthquakes and similar events in the Lower North Island, Ward says that a closer working relationship with New Zealand Civil Defence is another priority area. “As an industry our members are often tasked with second responder responsibilities in natural disasters. We want to ensure we’re better equipped in general, but we can also offer a lot of briefing information back to Civil Defence. “Many of our members have run the gauntlet in these scenarios and are very well placed to discuss with Civil Defence what works and what doesn’t. I think both
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We’ve identified areas where we want to focus our energy, so now it’s about stepping up and being a voice for the industry.
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Ward Demolition’s Peter Ward has been announced as the new President of the New Zealand Demolition & Asbestos Association (NZDAA), following the departure from the post of Alan Edge of Southern Demolition & Salvage. Ward is being joined in executive chair positions by Vice President Bryan Daley of Christchurch firm Shilton & Brown Demolition and Secretary Terry Coleman, of Auckland-headquartered CEDA Environmental Services. “It’s a changing of the guard and a chance for the Association to reprioritise what we’re actively engaging in as an industry body,” says Peter Ward. Ward says there are three key areas where the NZDAA will be active in the coming months. “Worker training is a part of our industry that certainly needs looking at. Good people are hard to find; that’s a sentiment that is echoed by a lot of our members. But in light of the forthcoming changes to Health & Safety policy in New Zealand, our members really need to understand their responsibilities and the responsibilities on the shoulders of the guys working for them. Things are changing fast in this
organisations could learn a lot from each other.” The third area the NZDAA executive will be leading activity on also relates back to changes in Health & Safety policy with particular emphasis on asbestos removal.
Terry Coleman
NZDAA Secretary Terry Coleman was the first demolition contractor in New Zealand to produce a written Health & Safety system 30 years ago and says that today, with the proposed changes to legislation, education requirements around asbestos are greater than ever. “The previous legislation from 1988 around handling asbestos ran to 12 pages. The new law is currently 98 pages, so as you can imagine the duty of care requirement on everyone will be huge,” says Coleman. “We’re an industry body at the
frontline of asbestos removal, so we need to take the lead on this.” Peter Ward says that over and above the key issues he and his executive team are looking to further develop in the coming months, the NZDAA will continue to uphold the objectives it has long supported as a body. These include continuing to improve the overall operating environment of both the demolition and asbestos industries for all member organisations, continuing to manage Best Practice guidelines in accordance with statutory obligations and standards, to keep improving the overall quality of service by member organisations to industry clients and by continuing to act as a channel through which authority agencies, clients, suppliers and the general New Zealand public can effectively communicate with the industry. “We have around 50 members so we have a lot of collective ability,” he concludes. “We’ve identified areas where we want to focus our energy, so now it’s about stepping up and being a voice for the industry.”
EVENT
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TYRE INDUSTRY SUMMIT 2015 Science, politics, entrepreneurism and the environment all came together across the space of two days in Auckland recently when the inaugural Tyre Industry Summit was held. End-of-life tyre stewardship was the key theme. New Zealand’s inconsistent track record in dealing with end-oflife tyres (ELTs) was under the spotlight in Auckland recently where the country’s inaugural Tyre Industry Summit was held. The collaborative industry event was held across two days and featured a comprehensive roster of expert speakers and industry commentators, including keynote speakers from the North American tyre industry. The overriding statistics remain arresting; with around four million passenger vehicle, truck and other tyres reaching their
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A report submitted to the government in 2013 outlined a plan which the tyre industry believed would provide a robust framework to substantially improve recycling rates. But so far this has generated little comment from Wellington.
end-of-life in New Zealand each year, only a small proportion of them – less than 30 percent by some estimates – are responsibly recycled. Most aren’t, resulting in tyre stockpiles and over 50,000 tonnes of material waste annually. Adele Rose, chief executive of 3R Group, which organised both the Tyre Industry Summit and the government-funded Tyrewise product stewardship project, says that New Zealand lags behind other developed countries by some margin. “While some [New Zealand] businesses are safely recycling tyres, these are exceptions rather than the rule,” she says. By contrast in Canada, tyre recycling has been actively managed for 25 years (after a major tyre pile fire shed light on the issue). As a result over 90 percent of ELTs are diverted from waste streams. However, as Glenn Maidment, president of the Tire & Rubber Association of Canada told delegates, tyre recycling in that country has its frustrations. Recycling is mandated at a provincial level, not federally, so every province has different schemes in place, with different fees and rules. For a medium truck tyre, the drop-off fee
can vary between $5 and $13, depending on which province the tyre is being deposited in. Still, with such a high proportion of tyres being recycled and actively reused as crumb rubber in aggregate compounds, tyre-derived fuel (TDF), moulded products and blast mats for the mining industry, the Canadian stewardship programme is certainly working. “I would hope New Zealand wouldn’t wait for a major tyre fire – as we experienced in Canada – before taking positive action. New Zealand does have a scrap tyre problem, but you have a reasonable plan and you have consensus for solving the problem. “All you need now is a bit of leadership from government. It seems like an easy win-win situation from where I sit,” Maidment commented. A report submitted to the government in 2013 outlined a plan which the tyre industry believed would provide a robust framework to substantially improve recycling rates. But so far this has generated little comment from Wellington and Mike Mendonça, director of operations for the Ministry for the Environment, had little in
the way of progressive answers at the Tyre Industry Summit. He was met with a stiff barrage of frustrated questioning from the industry representatives assembled regarding the lack of progress. There has been a ground swell of activity since the summit, with the promise of continued pressure on Minister for the Environment Nick Smith, urging for further clarification of the Ministry’s stance on ELTs, along with an explanation as to why priority product declaration for tyres has not been progressed. Working with media to raise public awareness and understanding of issues regarding ELTs was also deemed important, as was the preparation of a discussion document on potential control options for Councils on a unified approach to storage of ELTs. “This Summit was absolutely critical to moving [the current situation] forward, as none of us want to wait for a harmful tyre fire to bring about stewardship for tyres here, as happened in North America,” concluded Mrs Rose.
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EVENT PREVIEW
AWRE IS BACK AND BIGGER FOR 2015 The Australian Waste & Recycling Expo returns to Melbourne in August, once again bringing together influential figures from within the waste and recycling industries for two days of innovation and insights. We caught up with AWRE’s Lisa Brown for a preview of what’s on offer. A broader scope for discussion and better opportunities to engage with industry leaders and innovators are two overriding themes at this year’s Australian Waste & Recycling Expo (AWRE). Now in its sixth year, the 2015 event promises the most comprehensive programme of seminars and events ever held under the AWRE banner. AWRE continues to attract exhibitors and industry professionals from across Australia, New Zealand, Asia, the UK and North America, looking for innovative ways to collect, sort and process waste from the municipal, commercial and construction sectors. As AWRE’s Lisa Brown explains, the key format differences that make this an exceptionally popular event remain for 2015. “We’ve always had a lot of positive feedback about the way AWRE is structured, so even though we have more activity and discussion opportunities this year than ever before, attendees will still be able to pick and choose the seminars and panel sessions they want to go to. “It’s also a very affordable event to attend and bring colleagues along to, as single session passes or all-day passes for each day are available. “We’ve recognised for some time now that it isn’t easy for people to be away from their businesses for two entire days, so the modular framework we use to structure the entire AWRE event is designed with these considerations in mind.” This year the AWRE has been organised in conjunction with the Waste Management Association of Australia. As a result two seminar streams will be running concurrently, giving attendees access to a host of credible influencers within the industry. “We have very senior representation from the Victorian Government attending panel discussions, which will be of strong interest to those in the waste and resource recovery sectors,” continues Lisa. “In fact it’s a real credit to the Victorian Government that they have made senior staff available for such industry discussion.” Stan Krpan, CEO, Sustainability Victoria (SV), Kate Houghton, Executive Director, Department of Environment, Land, Water and Planning, Rob Millard, CEO, Metropolitan Waste and Resource Recovery Group and Nial Finegan, CEO, Victorian EPA will jointly discuss the Victorian government’s environmental agenda in a panel session at AWRE, with specific reference to current works programs and commitments in the waste sector. The four leaders will be available to answer questions from the audience and give clarity to policy and programs impacting on the waste and resource recovery sector. Another key topic will be the Victorian Government’s proposal to ban e-scrap from landfills. What implications such bold legislation might have for materials handlers remains to be seen; Assistant Victorian Environment Minister Anthony Carbines will be updating attendees on this topic. Elsewhere, an Innovation in Victoria seminar will showcase success stories from four new waste processing and recycling facilities in the host state, including an automated mattress recycling plant, a new hazardous
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waste processing facility run by Veolia, a thermal treatment plant for contaminated soil and the Southern Hemisphere’s first municipal street sweeping recycling facility. “There are also more opportunities to socialise and network at this year’s event,” says Lisa. “For the first time, we will be hosting an official AWRE conference dinner to supplement the always popular networking cocktail party. “We realise that for a lot of people in the industry – especially interstate and international attendees – AWRE is an opportunity to catch up and engage with contacts from different states and sectors. We’re very proud we can continue to help facilitate that.” AWRE 2015 is being held August 12-13, 2015 at the Melbourne Convention & Exhibition Centre. Visit www.awre.com.au for programme details, exhibitor information, the latest news updates and more.
TECHNOLOGY
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TIREANGEL PROVIDES TRAILER YOUR DUST MITIGATION SOLUTION ON-SITE INTELLIGENT TYRE PRESSURE MONITORING The new DustBoss DB-60 Fusion is a versatile and transportable atomised mist unit, combining powerful electric dust suppression design with a 45kW generator set, which can be hauled onto job sites that lack a convenient power source. The innovative DB-60 Fusion forces water through a circular stainless steel manifold with 30 atomising spray nozzles, then launches millions of tiny droplets with a powerful 25hp fan that produces 30,000 CFM (849.50 CMM) of air flow. The atomised mist droplets are thrown out in a 60m cone at an adjustable 0 to 50° elevation angle, capturing airborne dust particles and dragging them to the ground. In all the DB-60 can deliver up to 5834m² of coverage. The Fusion presents a great all-rounder package, being highly mobile on a trailer base and with its own power source, meaning it can be easily towed to the job site, and then anywhere access allows once it’s there. Visit www.dustboss.com for more details.
Okay, tyre pressure monitoring systems (TPMS) are nothing new. But the comprehensive TireAngel system certainly ups the ante in terms of failsafe abilities, especially for scrap and demolition companies running trucks that are constantly traversing ground containing potential tyre puncture hazards. Not only does TireAngel alert the driver to low tyre pressure or abnormally high tyre temperature, but notifications are also sent to the company head office, operations manager, or telemetrics monitoring service. Even while the vehicle is switched off, Tire Angel Link continues to operate 24/7 using its own power supply and enabling continual tyre pressure and tyre temperature monitoring. The system connects to any Android mobile device, tablet or laptop via an app and allows users to connect simultaneously. The sensors, which fit unobtrusively inside each wheel on the truck and trailer, are robust, small and engineered to be easy to install and monitor. Visit www.carcam.co.nz or www.tireangel.com for more details.
The system connects to any Android mobile device, tablet or laptop via an app and allows users to connect simultaneously.
LABOUNTY RELEASES ALL NEW MSD4000 SHEAR LaBounty has recently introduced three new models to their shear range, with the all new LaBounty MSD4000 shear boasting the highest power-to-weight ratio available on the market. The trusted North American manufacturer also introduced the LaBounty MSD800 for use on excavators as small as seven tone, along with the LaBounty MSD2250 for use on bigger excavators within the 20 tonne to 25 tonne range. These new models offer Labounty customers’ savings on excavator running costs for shears with the sort of capacity previously only available when used on larger 30 tonne excavators. The MSD800 and MSD2250 are ideal for scrap processing in smaller regional yards and are easily transported. Visit www.embreyattachments.com.au for more details.
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EVENT PREVIEW
AN ENDURING INDUSTRY TO BE CELEBRATED AT SMRANZ ANNUAL CONERENCE Tough times these might be, but Scrap Metal Recycling Association of New Zealand president Korina Kirk says this year’s annual general meeting and conference will still celebrate the positives, as much as it will ponder an uncertain future. It’s an ‘in-between’ year as far as the scale of 2015’s Scrap Metal Recycling Association of New Zealand’s yearly conference goes, but that certainly doesn’t mean there’ll be any less interest from association members in attending this year’s 47th Annual General Meeting. “I really want to encourage as many members as possible to make the journey to Dunedin in August and get involved,” says SMRANZ President Korina Kirk. “I’m looking forward to catching up with our members and discussing their thoughts and opinions on both the industry and the Association. “This is also an opportunity for our members to tell us how we can support them more, and of course a look at what changes can be expected in the year ahead.”
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The 2015 conference’s theme is ‘Hard as Steel’; a reflection of both the hard times the industry faces at present, but also a profoundly positive nod to the resilience of New Zealand’s operators in such tough economic times. “The past year has been one of the most difficult for our industry, and to say times have been hard for operators does not do justice to the current climate. “Now more than ever we need to remember that, when we are facing our toughest times, there is strength in numbers. Together we can achieve great things for ourselves and our industry.” The conference will kick off on Friday, August 7 with a networking reception, with the Annual General Meeting taking place the following morning. Attendees will be able to enjoy a presentation by Doug Kramer, National Chair of the Institute of Scrap Metal Recycling Industries, Inc. A well-known identity within ISRI and the North American scrap recycling industry, Doug is also president of Kramer Metals in Los Angeles (his family business, which boasts over 70 years of history in the region) and which also owns and operates several other specialised business units, including Joseph Levin and Sons and Heavy Burning Co. Additionally there will also be much discussion of the current state of the market and the challenges posed to New Zealand operators; not least the new ruling from India’s Directorate General of Foreign Trade (DGFT) which has laid down restrictive pre-shipment inspection processes for metal exports heading to the Sub-Continent. “There is certainly much to discuss, and I am pleased to welcome members to come together as an industry to share ideas, catch up with colleagues and ponder our challenges,” Korina Kirk concludes. “Change is looming and it is important that we pull together as an industry to find the best way forward in tough times. Like steel, our industry may be tough and unforgiving, but it is also strong and enduring.” The 2015 SMRANZ conference is being held August 7-8, 2015 at the Scenic Hotel Southern Cross, Dunedin. Visit www.scrapmetal.org. nz for more detail.
PROFILE
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ALAN YARKER Alan Yarker has already been profiled on New Zealand television as a “Good Sort”. He’s also a good sorter... of scrap for his community. Words and images by Peter Owens
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Alan arranged for Sims Pacific Metals’ Invercargill branch to send a truck and trailer to Tapanui once a week to take delivery of the scrap metal Alan and his mates would be collecting for the cause.
Alan Yarker with scrap metal.
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Alan Yarker is a “good sort” and became well known to Kiwis as such back in 2013 when New Zealand’s One News featured him on its regular show highlighting people giving back to the community. Alan has lived most of his life in the small West Otago town of Tapanui in the South Island. It’s the sort of rural community that rarely makes the news. In fact its only claim to fame for many years was that the national virus was known colloquially as ‘Tapanui ‘Flu’, after it was first identified by the town’s long-standing and highly regarded GP, Dr Peter Snow. Funnily enough, many years later it was also matters of health that led Alan down the road to collecting scrap metal for a good cause. Like many rural communities in New Zealand in the mid-’90s, the economy of Tapanui (and indeed of rural West Otago) were hit by the rural downturn. The double whammy arrived at that time with the closure of a major timber processing plant as well, which employed significant numbers of locals. When the Dunedin-based district health board demolished the existing hospital in the 1990s, Alan Yarker thought it was time to stand up and be counted. In 1995, he and a friend organised $1700 from the collection and sale of scrap metal, for the learned opinion of a prominent Dunedin-based QC, to determine the legal status of the land on which the hospital had stood. The QC made it quite clear that the land actually belong to the community and it was not the district health board’s to sell. Shortly after this, the land and buildings were returned to the people of West Otago. The closure of the Tapanui hospital was the catalyst for the community to become more actively involved in the delivery of health services to itself. This led to the formation of West Otago Health Limited - a charitable company in 2002 to run the day to day business. The company provides a comprehensive range of community health services (district nursing, home help, physiotherapy, occupational therapy, speech therapy and meals on wheels) and 24 hour, seven day general practice services. In 2009 the community of West Otago set about raising the funds to build and staff a community health centre and a rest home facility; the 1150sq m George and Caroline Edgar Memorial Building, which houses the West Otago Medical Centre and Ribbonwood Country Home. Combined the centre provides health services to more than 2000 people in West Otago and outlying areas. The community began raising the $3.6 million for the building in 2009. And that’s where Alan Yarker came into the action.
Cottages for visting health professionals at Tapanui Health Centre and Retirement Home.
He called on the committee of West Otago Health and told them he could raise a large sum for the new medical and rest home facility from the collection of scrap metal. “They asked me where my supporting committee was. I told them it was just me.” Alan knew from his work as a plumber where to find scrap metal on West Otago farms. He organised the collection very carefully and contacted likely sources. As one farmer puts it, “It was my junk, but it was definitely another man’s treasure.” At the same time Alan arranged for Sims Pacific Metals’ Invercargill branch to send a truck and trailer to Tapanui once a week to take delivery of the scrap metal Alan and his mates would be collecting for the cause. Alan Yarker ensured that all payments for the scrap were paid directly into the organising committee and refused any payment other than for fuel for the truck. Earlier this year Alan realised he was just too pressed for time and couldn’t continue with the scrap metal collection. Although when he finished it was realised that by his own efforts, he had raised about $110,000 for the facility. This ‘good sort’ really can sort... scrap metal, that is.
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NEW ZEALAND DEMOLITION PROJECT
TANKS FOR THE HARD WORK Two large tank deconstruction projects in Wellington and Dunedin late last year saw main contractor Macaulay Metals develop a new methodology for bringing them both to the ground. The accepted traditional method for deconstructing large tanks has always centred on workers with gas torches cutting sections, with cranes assisting them to remove the structure plate by plate. When Macaulay Metals got the job of removing a large steel tank in Wellington, national project manager Justin Stevenson and his team figured there must be a faster way to take the tank down, without the added health and safety complexities of requiring multiple team members to be on the structure. The methodology they came up
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with was successful enough to use as a blueprint for subsequent steel tank deconstruction work. That initial structure was Exxon Mobil tank number 87 at Seaview in Wellington. The steel tank was 27.44m in diameter and 14.63m high, with an approximate weight of around 100 tonnes. A fuel storage tank, it was constructed around 20 years ago but had never been used and was beginning to deteriorate. With the risk of self-collapse increasing, the decision was taken to remove it from the site. In order to deconstruct the tank,
the Macaulay Metals team used the ‘horizontal tear’ method. A section of the tank wall is cut and torn to create a horizontal separation at around approximately 180 degrees, forcing the roof to collapse. The tank is then slowly sheared and torn down to ground level, with the excavator walking out, dragging the shorn strips to the ground as it goes. The material is then sheared up into smaller pieces and trucked away from site for further processing. “Not only did we have to come up with the working method, we also had to fabricate a specialised
tool with which we completed the work,” says Justin. “First we used a rotating shear with a piercing tip to stab a hole in the tank wall. Then with a beak-and-hook extension on the excavator dipper arm we made vertical cuts into the wall. “This came about from a combination of techniques, but our team was instrumental in fabricating the hardware to do the job, which is a real credit to them.” Tank 87 was the largest tank ever demolished by Macaulay Metals. The proposed methodology worked well with
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Not only did we have to come up with the working method, we also had to fabricate a specialised tool with which we completed the work.
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some minor variances. The initial tear to open the face of the tank skewed off line due to significant rust and the failure of welds, which resulted in some minor wall-buckling in places. This strengthened the wall and slowed the collapse, so some additional shear work was required to bring the tank to ground. Other complexities at this site required particular care and attention from the Macaulay Metals team as well. Aboveground pipework close to the tank required protection with scaffold frames while the subterranean liner around the tank needed to be protected using a layer of GAP65, filled and compacted over the area where the excavators were operating. “These considerations only slowed the process for a few hours before the controlled tank collapse was completed though,” says Justin. “No part of the tank fell outside of its intended area and the protective base course layer worked very well. There was a risk of steel being forced into the ground and piecing the tank membrane, but expert machine control from our operators and a careful watch on the entire process from the supervisor ensured this didn’t happen.” The Macaulay Metals team ended up taking the same game plan to another tank deconstruction project mere weeks later, when they subcontracted to Christchurch’s Ewing Construction in bringing down tank number D4 at BP’s Dunedin terminal. This tank provided additional challenges as it had a floating roof structure which is designed to move up and down depending on how much liquid is in the tank. When empty the roof sits
at a height of only two metres off ground level and is only supported by minimal light structural work underneath. “There was the added complication of asbestos coatings on tank D4. A methodology was developed in consultation with all of the various teams involved in the
project. This involved constructing a system to wash down the tanks and collect the contaminated water as tank D4 was demolished. “We set up spray nozzles on the digger and had an asbestos contractor come in and remove the material.” In the end the actual demolition
and disposal of the tank took only three days, with in excess of 50 tonnes of steel recovered for scrap. “I reckon I have the best job in the world,” concludes Justin. “There’s nothing like taking a giant structure and working out the best methodology for pulling it apart, like a reverse Rubik’s Cube.
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CONFERENCE CREATED AND ORGANISED BY
A WA R D S
NETWORKING
WORLD
DEMOLITION S U M M I T 2 O1 5 AMSTERDAM, THE NETHERLANDS AMSTERD
IN W O N TH ITS 7 R YEA
6 NOVEMBER
The seventh year of the majo major international
Full day Conference and Gala Awards dinner
event celebrating exc ce excellence and
NH Grand Hotel Krasnapolsky, Amsterdam
innovation within the demoli ition industry demolition
SAVE THE DATE
6 November, 2015
6 Novembe November er 20 2015
Deadline for entering the awards is 31 July 2015
CONFIRMED SPEAKERS
Download entry forms from the website HEADLINE SPONSOR
KEYNOTE ADDRESS: David Sinclair
SILVER SPONS SPONSOR SOR
IN PARTNERSHIP WITH
Clinton Dick Liberty Industrial
Henrik Bonnesen COWI
Peter Craven CDE Global
William Sinclair Safedem and Immediate past president of the NFDC
Dennis McGarel Brandenburg Industrial Service
ENDORSED BY
For further information or to book your place visit:
www.demolitionsummit.com
PROMOTION
CALL FOR ENTRIES FOR THE 2015 WORLD DEMOLITION AWARDS The best of the best will be on show at the 2015 World Demolition Awards. Demolition companies throughout Australasia are urged to get entry submissions into the judging panel by July 31st, 2015. The 2015 World Demolition Awards will once again celebrate the best that the demolition industry has provided its clients in the construction sector, this time during the period June 2014 to June 2015. The basic criteria is simple – the judges require all entrants to tell them why they think their company, project or product is special, and why it should be selected as a winner. The Awards are open to any demolition contractor from
anywhere in the world and there is no requirement for membership
of any professional body, although the event itself is endorsed by many of the leading national and international demolition associations and federations. Entries for the 2015 Awards should cover demolition and related work that either started or was completed during the period July 2014 through to June 2015. Entries can be made for contracts that began before July 2014 provided they were completed during the required timeframe. Entries can also be made covering contracts begun during this timeframe where work is currently still on-going but the basis for the entry must be for elements of the contract that have already been completed. Companies can submit entries for more than one award, and more than one entry per category, should they so wish. However, specific projects may only be
entered for one category, i.e. Contract of the Year or Urban Demolition Award, not both. There is no charge for entering. The prestigious venue for this year’s awards will once again be NH Grand Hotel Krasnapolsky in Amsterdam, with winners announced at the gala evening Von November 6th, 2015. Deadline for entering the awards is July 31st, 2015.
FOR MORE INFORMATION AND TO ENTER, VISIT WWW.KHL-GROUP/EVENTS/DEMOLITION-SUMMIT/AWARDS
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AWARD CATEGORIES Contract of the Year over US$1 million • Contract of the Year under US$1 million • Safety and Training Award • Collaboration Award • Explosive Demolition Award • Urban Demolition Award • Industrial Demolition Award • Civils Demolition Award • Recycling and Environmental Demolition Award • Manufacturers’ Innovation Award: Plant and Equipment • Manufacturers’ Innovation Award: Tools and Attachments
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MACHINE PROFILE
WALL-EAT
Husqvarna’s DXR 140 demolition robot has seen Sydney-based ATR thinking smaller; especially when their teams head indoors or onto upper floors.
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suspended surfaces thanks to its 985kg weight (or 1133kg with hammer attachment). “It’ll fit through a standard doorway and, perhaps even more crucially, into most lifts. A lot of our demolition work takes us into multi-storey environments, so the way the machine compacts down when not working, combined with its light operating weight, means it has fast become an essential tool for our team when they’re above ground level.”
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Because we can get the robot into the sorts of tight environments even a small digger can’t reach, it frees up our guys to move onto other aspects of the project.
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While much of this issue has focused on larger equipment, think of the Husqvarna DXR 140 as a plucky mouse in comparison to the elephantine proportions of the other machinery we’ve taken a look at. And you know never to underestimate a mouse... Husqvarna’s DXR 140 is a compact remote-controlled demolition robot. The most compact machine in Husqvarna’s five model DXR range, the DXR 140 features a 360 degree rotatable arm with an extra ram, 15kW of power and low weight for extra manoeuvrability in the most confined environments. Sydney-headquartered firm All Types of Rubbish (ATR) specialise in commercial and residential demolition work, as well as rubbish removal and asbestos handling. In order to supplement their machine fleet with an extra unit, company director Steve Hardy took an outside-the-box look at their requirements and decided that, rather than opt for a supplementary larger excavator, they needed to think smaller. “There is often a need for high powered demolition equipment for use in multi-level structures,” explains ATR’s safety and training manager, James Willis. “Conventional plant isn’t an option for this sort of work, so a market exists for smaller, light weight machines that can still pack a punch. The Husqvarna DXR line-up really stood out to us.” James says that the demolition robot’s dimensions mean it can be used anywhere, with the DXR 140 in particular being perfect for working on
Operator Bryan McLaughlin says that, because of the machine’s threephase electric power pack, the DXR is the perfect indoor tool. “You can work on deconstructing an interior space all day alongside the robot and it isn’t a health and safety issue. You simply couldn’t work on an interior – no matter how reasonably sized – all day alongside a conventional
excavator putting out exhaust fumes. “The idea that this is a demolition robot really comes into its own when you consider that we’re essentially using it to replace the sort of work that can tie guys up on manual labour for long periods of time; because we can get the robot into the sorts of tight environments even a small digger can’t reach, it frees up our guys to move onto other aspects of the project.” Despite its dimensions, the Husqvarna DXR 140 offers a lot more than a light touch. Hammers, crushers and steel shears can all be attached. In fact Bryan says the DXR 140 features enough power to run sizeable attachments. “We’ve just finished running the robot with an Atlas Copco hammer attached which would suit a larger excavator – such as a three ton machine – perfectly well. But the robot features pumps that have the power; we work it hard and it never shows signs of running out of puff.” Bryan says the machine is completely intuitive to use and, for anyone who has operated a mini excavator in the past, the basics are very familiar to grasp. “Because the DXR features an Industrial Bluetooth enabled class 1 remote control terminal, the operator can stand as close or as far away from the machine as they need to. I haven’t needed to yet, but apparently the operator can stand up to 100m away from the unit while it’s working,” says Bryan. “This gives me a lot of flexibility, as I can stand to the side of the machine while it’s working which gives me a clearer view of what’s happening at the pointy end. I can even stand at 90 degrees to it if room allows, which theoretically gives me a better view than even a digger driver can hope for.” The DXR is also perfect for working in areas where potential hazards mean team members can’t tread, such as at the edge of drop-offs or around suspended beams. Its 3.7m reach means it can get to difficult-to-access surfaces too. “At the end of the day, we used to pay for specialised contractors to do sections of our jobs using robotic demolition units,” concludes James. “We saw this as not only a way to remove an additional cost burden, but as an opportunity for us to enter and compete in a niche market. We haven’t looked back since.”
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MACHINE PROFILE
HIGH REACHING HITACHI Auckland contractor Yakka Demolition has ensured its covered for both the highs and lows of demolition work with this heavyweight Hitachi. It even features a neat trick up its sleeve – or up its boom, as it were...
The opportunity to invest in large gear is always something to be approached with caution. As far as Yakka Demolition director Bruce Levien is concerned, the more flexibility a big machine gives his crews, the better justified that investment is. Bruce imported his 2005 model Hitachi ZX500SLD from Germany recently because it offers both excellent horsepower for the hard yards on various demolition projects, as well as the ability to quickly convert between high-reach and standard boom configurations. “Having the quick hitch assembly on the boom works really well for us, as it means we can move from high rise demolition work to lower lying deconstruction work within the space of minutes rather than hours.” The system – developed in Germany – enables the excavator operator to swap out a standard boom for the high reach attachment from the cab. An onboard computer connection ensures all lines are decoupled and reconnected automatically. With the entire changeover process able to happen rapidly, Bruce says the biggest consideration he and his team have to make is having the ability to
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store whichever boom isn’t being utilised on-site. “A machine of this size is only ever going to be used on certain sized jobs, so generally speaking there should always be space to make the changeover and house the supplementary boom when we need it.” The ZX500SLD weighs in at 50 ton, although is closer to 75 ton with the high reach fitted. Bruce says this is the biggest excavator he has on his fleet and – like his other frontline demolition gear – was purchased second hand for a practical reason. “I can’t stand seeing new gear beaten up in the demolition game. We have a civil construction arm of the company too and, while I prefer to purchase new equipment for that type of work, no one wins a prize in the demolition business for the shiniest machine. “Any frontline machine is going to suffer bumps and scrapes as a matter of course, so good, reliable machinery with some hours on the clock is what I look for.” When Scrap & Demolition Australasia visits, the ZX500SLD is busy demolishing support pylons from an old freestanding canopy at a large
Yakka Demolition director Bruce Levien
industrial site in Onehunga, Auckland. With a shear attached the machine makes short work of chewing its way through the concrete towers, even with large amounts of reinforcing steel in each one. It’s the final component of a big job on the site that reinforces to Bruce why he opted for such a large machine. “The Hitachi will do anything; the whole quick hitch system is great but I know that it’ll never be working at peak power to get through hard stuff. There’s never any huge effort required because it boasts such great reserves of grunt.” Bruce says Yakka Demolition will have more high-rise work in store for the Hitachi over the next few months. In the meantime it’s good to know it remains a useful high capacity machine in between such specialised work. “The Hitachi is a big unit to shift – it costs money to move – but the added flexibility it gives our guys on site makes it worth having. Because I can put a regular boom on it, we can use it to load the crusher when it isn’t needed elsewhere, so it’s always working.”
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INNOVATIONS – BOST GROUP
Changing it up The result of years of careful research, Bost Group’s MK Series Multi Kit Processor system has been designed with total tool flexibility in mind. Bost Group’s extensive range of heavy duty attachments features a number of new innovations which have already proven popular within the Australian industry. The new MK Series Multi Kit Processor is an incredibly comprehensive system enabling operators to run multiple tools from one fully rotating head thanks to an innovative new hydraulic quick-release system. Bost Group says change out times on tools can be decreased down to less than 10 minutes as a result of this innovative system, saving busy demolition and recycling contractors’ valuable time retooling between specific tasks. Meanwhile Bost Group’s 3V Premium Line HC Series primary crushers and Premium Line MK Series Multi Kit pulverisers feature another innovation; Impact
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Booster technology. During the processing of hard material, if the available hydraulic pressure of the excavator the attachment is affixed to isn’t great enough to create a break, the 3V Premium Line’s Impact Booster activates automatically, increasing the operating pressure from 250 bar up to a cylinder peak pressure of 750 bar. A true concentration of technology, Impact Boostercapable attachments allow the operator to multiply the hydraulic pressure available to them when the going gets tough. Not only does this help keep productivity in line, it also ensures the machine works at a lower operating pressure and lower flow, helping to keep fuel consumption in check and reducing cycle times. Impact Booster technology is also a feature of Bost
Group’s Premium Line FR Series rotating pulverisers and Premium Line F Series secondary pulverisers. Manufactured in Italy, Bost Group’s extremely robust, high quality attachments are engineered for long life. Globally the company puts a lot of merit in fostering long term relationships with its many and varied customers; something the team at Bost Group in Australia wholeheartedly believe in too. The range of attachments Bost Group offers is extremely comprehensive. However if a client requires something more specialised, Bost Group’s technical advisory team will work with the client to create a bespoke attachment solution that will help gain them that competitive edge.
ADVERTISER INDEX Alert Engineering..........................P3 Bost Group ....................................OBC Embrey Attachments ..................P7 Jones & Rickard.............................P9 Liebherr .........................................P13 Nikau Group...................................IFC Pacific Materials Handling...........P11 Ocean Wide Group.........................P5 World Demolition Awards............P26
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SCRAP & DEMOLITION AUSTRALASIA
WE’RE ALSO ONLINE!
The main message to government from India’s scrap metal recyclers is an urgent need to remove what is seen as a crippling import tax on steel scrap. The call to abolish the duty came during the Metal Recycling Association of India (MRAI) 2015 international conference in Mumbai. Under current regulations – and despite free trade agreements being in place between India and several countries – semi-finished products can be imported duty free into the country, but there exists a five percent import duty on steel scrap. India is the only country in the world to have such an import tax and, as a consequence, recyclers are struggling with profitability, says MRAI president Ikbal Nathani of the Nathani Group
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