Earthmovers December 2022

FINROCK is back, bigger and better, in beautiful virtual reality, on 24th November 2022 from 2pm to 8pm.

Venture through Finning Island’s seven stunning zones and interactive experiences, packed with exciting content showcasing Cat® equipment, parts and services.

Find answers to your most pressing questions. Get world-class advice from industry-leading Finning experts. Preview our new technology and innovations. Jump in the cab of a range of machines in our Virtual Showroom. Learn how to make your projects more environmentally friendly in the new Sustainability Zone. And join the excitement of the Finning Experience Zone.

Competitions, special show-only deals and demonstrations make FINROCK22 an unmissable event. Plus, FINROCK TV will broadcast fresh content from our TV studio throughout the event.

Editor Graham Black

Editor@EarthmoversMagazine.co.uk

News Editor Kyle Molyneux

Sub Editor Paul Carter

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Mid-range surprises

This issue went to press just before the giant Bauma machinery trade show opened its doors to visitors, but already there have been some unexpected announcements.

My view was that mid-range battery-powered machines were a few years away yet, but both Caterpillar and Komatsu will have prototypes of 20-tonne class electric excavators at the show.

This reflects the rapid development of battery and charging technologies, as both these global market leaders make a strategic investment in developing their own next generation of high-performance batteries.

Also at Bauma is Liebherr’s new hydrogen-fuelled internal combustion engine, powering a prototype 50-tonne tracked excavator.

Hyundai is also showcasing its hydrogen fuel cell technology, powering a prototype wheeled excavator. Meanwhile, back in the UK, JCB must be getting close to launching the first commercially-available hydrogen-powered muck-shifters, using their redesigned internal combustion engine in a backhoe loader.

Undoubtedly there will be similar announcements from other manufacturers when the show opens. Bauma 2022 looks likely to be a milestone in the decarbonisation of the construction machinery industry.

Yours till next month

Graham Black, Editor

PHOTO CREDIT: DAVID WYLIE

7 RUNNING REPORT

JOHN DEERE 672GP

Standing up to the harsh realities of winter working in Scottish forests.

15 NEWS

A round-up of the latest news from the earthmoving and associated machinery industry.

25 TECHNOLOGY

FLANNERY PLANT

HIRE

Progress report on the success of Faresin battery-powered telehandlers. 29

FIRST DRIVE

DRESSTA TD-16N

We report from the UK field trial of a prototype new 20-tonne dozer.

34 EURO FOCUS CAT OPERATOR

CHALLENGE

Report from Spain on the welcome return of the global operator challenge.

37 SITE VISIT

HS2 VICTORIA BOX

Xwatch’s slew and height restrictor makes for safe working on a busy site.

41 MARKET GUIDE PROCESSING

ATTACHMENTS

The large number of crushing and screening buckets available in the UK. 49

EXTREME MACHINE

CAT 992

Walters Group’s 105-tonne wheel loader at work in a Somerset quarry. 55

OWNER-OPERATOR

ALAN BROWNE

Hitachi excavator fan works across the UK installing drainage systems. 59 RUNNING

REPORT

DOOSAN DX420-7

Flagship excavator at Limehillock Quarries in the north-east of Scotland. 63

FLEET FOCUS EARTHLINE LIEBHERRS

Swindon-based firm’s hydrostatic dozers and CVT-driven loaders. 67

OWNER-OPERATOR

ALEX SILLIFANT

Young businessman and his Steelwristequipped Case CX130D excavator. 71

FLEET PROFILE

DOWLING BROTHERS

Family firm has invested in labour-saving machinery over many decades.

77 EURO FOCUS LANNEN

A LONG WAY TOGETHER

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ounded by Alistair and Linda McCrae and now run by their son Calum, A&L McCrae is a long-established firm operating throughout the west coast of Scotland. They work across many disciplines, including building and maintaining forestry roads, civil engineering, general contracting, haulage and plant hire.

In addition, they source and process local rock for their contracts, which is generally blasted or broken out of borrow pits, or from their own Barrachander Quarry at Taynuilt, Argyll.

Until three years ago they operated a Volvo G930 motor grader, with the traditional complex 10-lever hydraulic/

mechanical control system. When it came due for replacement and since Volvo had pulled out of this sector of the market, it was time to consider a different brand. Calum therefore spent three days at the Bauma 2019 show, on a mission to find the most appropriate grader to suit their requirements.

He said, “I visited Bauma to look at every single grader that was available, such as machines from Cat, Hidromek, Case and a few models from Chinese manufacturers. I then got into a detailed conversation with John Deere’s product marketing manager, Luke Kurth. I spent over an hour with Luke, going from front to back of the new 672GP, and was impressed with its

David Wylie travels to Argyll to see how A&L McCrae’s grader is standing up to the harsh realities of winter working in Scottish forests

Below and below left: In the market for a new motor grader three years ago, Calum McCrae bought this high-spec John Deere 672GP model off Deere’s show stand at Bauma 2019.

build quality, ground clearance and other key specifications. When I sat in the machine, the difference in cab comfort, controls and ease of operation really stood out for me.”

Calum was invited to put the Deere motor grader through its paces at the Windhagen factory of the Wirtgen Group in Germany, which John Deere had acquired 2017. During the Bauma 2019 show they announced the availability of their 672GP and 622GP graders, initially in Germany and France, through Wirtgen Group subsidiaries.

Calum continued, “During the live demo, the claims made at Bauma were brought to life, as the 672GP has more engine torque, power and more pulling performance on the mouldboard. For me, this was the number one feature, as we wanted a highly productive grader to cope with anything that we could throw at it in Scotland. This, along with the very quiet, comfortable cab’s great visibility, plus ease of servicing and good dealer back-up made for a complete machine package. John Deere products are not new to us, as we have run a number of their agricultural tractors in the past.”

NEW GRADER FOR UK

A few weeks after the Bauma show, Calum and his team were due to start on a subcontracted job to rebuild a haul route to ease the way for contractors upgrading a long stretch of electricity pylons. Believing the six-wheel drive John Deere 672GP motor grader was the best option for their work on forestry and renewable energy access roads, Calum quickly made a deal for the high-spec Bauma show machine. It is a GradePro (GP) variant, which includes dual multifunction joystick

controls, a far cry from the control layout of their older generation Volvo. The new machine’s ‘Automation Suite’ reduces the number of controls needed to perform common tasks, such as auto-articulation and blade flip, and includes operatorselectable pre-sets. In addition to a conventional steering wheel, the 672GP also features joystick steering, together with automatic return-to-straight.

The Deere motor grader is of an openarchitecture design, which allows the use of any brand of grade-control systems in the future, however all GP models come with automated cross-slope function. This makes

Left and below: We met man and machine while they were undertaking some light annual maintenance work on the Troustan Forest road line in Cowal, Argyll.

Left, above and below: One of the key selling points of this generation of John Deere motor graders is its cab, which offers great visibility and features easy-to-use multi-function joysticks, a far cry from the traditional 10-lever set-up.

SPECTACULAR SITE VISIT

We met Calum and his grader in the forests of Argyll, overlooking the stunning scenery at the head of Loch Striven. Together with a Valtra tractor pulling a vibrating roll drum, he was resetting the cambers and giving a light dressing to the decent-looking surface of a forestry road. An access route, constructed by A&L McCrae early last year, that many thought was an impossible dream.

Also on site was Stuart Hansom, general manager of Euroforest, one of McCrae’s valued customers, who explained the background to this 2.5km road line. The Troustan Forest in Cowal was an isolated block of mature commercial trees, but with no formal access in place. The requirement was to provide unrestricted HGV access to allow the timber to be harvested and transported. Local forestry contractors had been contemplating such a road line for the last decade; some reckoned it just couldn’t be done, due to the terrain and extreme ground conditions.

More recently, Gresham House, representing the current owner of Troustan Forest, approached forestry consultant Euroforest to cost the various access options. During these discussions, it became clear that Alistair McCrae not only thought that the road could be built, but his team had the expertise and machinery to undertake the job to the highest possible standard. Accessing through a neighbouring property, the final design involved building 2.5km of forest road across extremely challenging terrain.

Once the route of the new road line was marked, the trees were felled by Dick Brothers, before construction works could begin. Led by Alistair, the McCrae team deployed to site in January 2021 with three excavators: a Liebherr R926, a Doosan DX225 and a DX300 equipped with a Rammer 3099 breaker, supported by 30t-capacity Volvo articulated dump trucks. Once the formation was in place, they mobilised their Powerscreen PT400X crusher to produce the required surfacing stone, which was profiled by the John Deere grader and rolled in situ. Works were completed in April 2021.

Due to environmental constraints placed on this isolated site, timber harvesting and haulage at Troustan is restricted to the winter months, as client Stuart explained, “As a consequence, we expect to see a level of degradation in forest roads that are worked so intensively over the winter months, when rainfall levels are at their highest. I’m pleased to report this road has recently withstood 21,000 tons of timber movement by Peter McKerral and showed far less wear and tear than was anticipated. It’s a testament to the contractors that built it.

“Nevertheless, ongoing road maintenance is recognised as being a key component in the management of any large-scale commercial forest. And given the superb performance of the Troustan road to date, it was an easy decision to ask Alistair’s son Calum to return to give the road a light grade and roll, in preparation for the next round of felling works.”

JOHN DEERE 672GP WALK-ROUND

The 672GP is powered by a six-cylinder, nine-litre, Stage 5 ultra-low emissions John Deere engine, producing up to 250hp in 7th gear. The main direct-drive transmission is John Deere’s PowerShift Plus box, providing modulated shift-on-the-go and event-based shifting (EBS). The eight-speed box covers speeds from 4.0kph to 45.5kph.

It also has two independent front-wheel drive motors and hydraulic pumps, so that each front wheel station can be sent exactly the right amount of power and flow to maintain traction, virtually eliminating the possibility of wheel-spin. This results in automatic traction control and the power bias across the six-wheel drive being adjustable on the fly, to suit the steepness of the grade and ground conditions.

The motor grader’s automatic, dual-path hydrostatic drive is said to increase tractive effort and front-end control. This includes separate left and right systems, with variable-displacement pumps, axial-piston wheel motors and freewheel at transport speeds. It also includes a 15-position rotary ‘aggressiveness’ control and inching capability, together with a precision mode when the machine is propelled by its front wheels only.

The mouldboard is made from high-strength, pre-stressed, wear-resistant, high-carbon steel and features reversible end bits; its base length is 3.66m, it is 610mm high and 22mm thick. The mouldboard’s side-shift wear system includes quick-change replaceable wear inserts and a quick-adjust jackscrew system. Calum prefers to use original Deere cutting edges, as they are far more durable than other wear parts he has tried.

The mouldboard is attached to a heavy-duty excavator-style slew ring known as a circle. Calum’s machine has the standard unit, however later machines could be specified with the premium circle, which is a fully-sealed, maintenance-free bearing and pinion design that runs smoother and quieter, ideal for use with a grade-control system.

it simpler to hold a consistent slope, by allowing operators to run a single control, while the machine’s black boxes adjust the opposite side of the blade.

This 2019 motor grader represented the first item of John Deere construction machinery to be sold in the UK for around 50 years. This landmark deal kick-started the introduction of these graders into the UK market, as seen at the recent Hillhead show.

Last year, John Deere made a major investment in the Scottish market, with a new £2.5m customer service centre located in Perth. Believed to be unique in JD’s global dealer network, it supports both Deere’s forestry machines and the full range of Wirtgen Group road construction kit.

The 1300sq.m building includes a four-bay repair shop and a parts warehouse. It acts as a hub for Wirtgen’s home-based sales and technical staff and complements John Deere’s UK forestry base at Carlisle. Calum reports that he has a great working relationship with Wirtgen UK, so much so, that he helps to train new operators of Deere graders.

As for his own machine, now with over 1100 hours on its clock, Calum stated, “This Deere grader’s reliability has proved to be outstanding over the last 2.5 years. It has the highest uptime of any machine in our fleet, and it’s never missed a beat since the day we bought it from the Bauma stand back in 2019.”

OPERATOR FEEDBACK

Watching an experienced and skilled motor grader operator at work is always a joy. In the stunning landscape of the head of Loch Striven (see panel), Calum provided a master class by completing quick and accurate passes, using the mouldboard at different angles of attack to move the stone around. He said, “I tend to do a lot of grading work just using my eye in the first three or four passes. However, on the final pass, or where work has to be carried out to a very high spec, or where we are instructed to carry out a crossfall of say 5%, you just set the GradePro to this requirement.

“The system works simply and easily off the right-hand control, which cuts down three or four combinations of control inputs in order to hold the mouldboard absolutely bang on to 5%. GradePro is also extremely useful near the end of a long shift, as it dramatically lightens the operator’s workload and saves constantly looking down at the mouldboard.”

Before joining, and now running the family firm, Calum did his apprenticeship

Above and above rright: The 672GP motor grader is powered by a nine-litre, 250hp John Deere engine, driving the main PowerShift Plus eight-speed auto box, together with independent front right and left hydrostatic drives.

with Caterpillar distributor Finning, so chooses to do all the regular servicing of the grader in-house, under a service parts contract with Wirtgen. He finds the 672GP a very easy machine to work on, as it has fast drain connections using a vacuum pump and fill valves all located at ground level, as are all the filters. He particularly likes the ease with which the mouldboard wear shims can be adjusted to take up any slack, with a few quick turns of a spanner on a simple adjusting bolt and locknut design.

The 250hp, six-wheel drive powertrain provides excellent levels of traction and rim-pull and overall Calum thinks the 672GP is an extremely wellengineered machine. It includes everything from good work and access panel lights, to the diesel and AdBlue caps behind sealed doors to stop dirt and water ingress. This ex-show machine also has the optional winter pack, with extra filters and bigger mudguards. This example has also been fully kitted out to meet UK quarry regulations, with rear and side hi-vis chevrons, blue strobe lights, a reversing alarm and the

like. It has occasionally been deployed to the Glensanda super quarry, to help maintain the haul roads when the site’s own motor grader is in the workshop.

Left and right: All the routine service points

CONCLUSION

This John Deere 672GP is registered for road use and, although the standard front and rear cameras are great while working, something more was required when on a public highway. Specifically, when nosing out of narrow road junctions that offer limited side visibility, as nearly five metres of machine extend out before the cab reaches the head of the junction. To dramatically improve visibility in these situations, two side-facing high-tech cameras have been retro-fitted to the ends of the light poles on the front of the machine.

Calum said, “Our local electrician, Jason, did a fantastic job of wiring the two extra cameras into the existing screens. I can now sit in the cab confidently seeing left and right of a junction before starting the manoeuvre. And since it also has night vision capability, along with the very powerful LED work lights, it will be essential during the darker winter months.”

Calum is clearly delighted with the performance of the John Deere 672GP, which provides that much sought-after combination of high power and low fuel/

AdBlue burn. The contents of the 416-litre diesel tank last 2.5 shifts. Calculated on such forestry road jobs on a ‘metres-perlitre’ basis, Calum reckons he enjoys at least a 25% productivity gain over his previous grader.

As Alistair and Linda McCrae ease themselves into retirement, Calum concluded, “I’d like to pay tribute to my mother and father for their hard work, setting high standards and professionalism over the last 50 years. As I take on the running of the business, I hope to follow their lead and wish them a long and happy retirement.”

This John Deere grader, the first example in the UK, has performed faultlessly since its arrival in Scotland shortly after the 2019 Bauma show.

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ant NEWS

WOMEN IN PLANT

he first Women in Plant event, organised by the Scottish Plant Owners Association (SPOA), has been hailed a success. The event, which sold out in advance, took place in October at the Cromlix Hotel in Dunblane and was an open forum for all women in the plant industry. The SPOA organised the event so that women could have a platform to share their views and ultimately to use those insights to help create a more inclusive industry.

T

CAT AUTONOMOUS MILESTONE

Volvo Penta and CMB.Tech have announced a partnership designed to accelerate the development of hydrogen-powered engines for both on-land and at-sea applications. The design and testing of a hydrogen-injection system will take place at CMB.Tech’s Technology and Development Centre in Brentwood in the UK.oughly nine months after reaching the four-billion-tonne autonomously hauled milestone, trucks equipped with Cat MineStar Command for hauling have now moved over five billion tonnes. Cat autonomous trucks are on pace to eclipse previous record totals of materials hauled in a calendar year, projected to be more than 1.4 billion tonnes in 2022. Currently, more than 550 mining trucks are equipped with Command for hauling, operating across three continents.

R

VOLVO UK HYDROGEN ENGINES

DANFOSS DECARBONISING IN SCOTLAND

Global hydraulics and electric powertrain systems supplier Danfoss has secured a £400k grant from the UK government to help to accelerate the electrification of construction machinery. Danfoss plans to combine electrification with its hydraulic digital displacement technology to significantly improve machine efficiency. Reducing energy consumption by as

much as 50%, the technology can dramatically decrease the size of batteries needed to power the machines and the amount of energy needed to charge them.

A £25m Danfoss manufacturing, research and development facility is currently being built in Edinburgh. Called the Decarbonisation Hub, the facility will become operational next year.

obcat has introduced the super compact TL25.60 telehandler.

Powered by an ultra-low emissions 75hp Bobcat engine, it has an operating capacity of 2500kg, a maximum lift height of 5.91m and a maximum reach of 3.31m.

NEW MINING HAULER

Komatsu is launching the HD785-8 rigid dump truck, which boasts a new design of cab featuring a heated and ventilated, air-suspension seat. Thanks to a low-noise engine, large capacity viscous cab mountings, hydro-pneumatic suspension and independent strut type suspension on the front wheels, Komatsu says in-cab noise levels are a low 72dBA.

LIEBHERR TIMBER HANDLER

The LH26M Timber is the latest wheeled log-handling machine from Liebherr. Powered by a 125kW engine, this compact and highly manoeuvrable handler has an operating weight of between 23,500kg and 26,000kg. The all-wheel steer machine is principally aimed at sawmills and timber operations with limited space. Trailers weighing up to 60 tonnes can be towed. The new undercarriage concept, with a two-point blade support, is said to increase handling performance in trailer operations.

NEW KOMATSU RUBBER DUCK

Komatsu has introduced the ultra-low emissions PW138MR-11 reduced swing radius wheeled excavator. It boasts an integrated attachment control system for easy fl ow and pressure adjustment, while the boom slew function is now controlled from ancillary buttons on the joystick.

Irish Komatsu distributor McHale Plant Sales confi rms that deliveries of the new excavator are already underway. They also confi rm that the new trailer hitch option is available, which is rated at 3.5 tonnes.

In a league of your own

There’s nothing like watching a master at work — through years of dedication your tools become an extension of your hands. With bold vision and the right equipment, you turn every job into a masterpiece.

EXECUTIVE HIRE SHOW 2023

The next Executive Hire Show will take place on 8 & 9 February 2023 at its well-established home, now called the Coventry Building Society Arena (CBS Arena), formerly known as the Ricoh Arena. Organisers say that 85% of the exhibition space is already sold.

NEW HYDREMA WHEELED EXCAVATOR

Hydrema is launching the redesigned 14-tonne MX14 model, the smallest wheeled excavator in its range. It features upgraded working equipment that provides up to 20% greater lifting capacity and a signifi cantly higher digging speed than its predecessor.

JCB POTHOLE PROS AVAILABLE FOR HIRE

CB has struck a significant deal with plant hirer the Dawson Group for six Pothole Pro wheeled machines. Supplied by dealer TC Harrison, they are available for rent or contract hire by local authorities and contractors across the country.

CUMMINS HYUNDAI MILESTONE

By the end of 2022, Cummins will have delivered its 300,000th engine to Hyundai. Cummins has been supplying engines to Hyundai since 1990, hitting 10,000 engines supplied in 1996 and 200,000 in 2016.

LIEBHERR ROAD RAIL

he new Liebherr A924 road-rail excavator has an operating weight of 21,800kg to 25,000kg and is equipped with a 120kW (163hp) ultra-low emissions engine. The hydraulic system consists of a Liebherr variable displacement double pump with independent control circuits, while the rail travel drive is mounted on either end of the undercarriage.

T

KUBOTA FACTORY EXPANSION

HIGH-TECH 10-TONNE DUCK

Wacker Neuson’s new EW100 wheeled excavator is said to set a new benchmark in the use of modern muck-shifting technology. It includes an intelligent attachment management system, is pre-configured to use a wide variety of operator assistance sub-systems and comes with a new control system.

BOBCAT CUTTING AND LOG ATTACHMENTS

Bobcat has introduced two Brushcat rotary cutter attachments, together with a log grapple, all intended for use on its compact articulated wheel loaders. The Brushcat attachments offer cutting widths of 1118mm and 1372mm, respectively, and are the smallest models in the full line-up of Brushcat rotary cutters. The new log grapple is compatible with the L23 and L28 loaders and can also be used on the new MT100 mini tracked loader.

aterpillar has introduced two new sub-systems on its 306CR, 308CR and 309CR midiexcavators. They are an E-Fence system, allowing operators to digitally restrict the machine’s movements, and a basic 2D machine guidance system.

BATTERY BAUMA

Graham Black reports on the early machinery news from the massive Bauma trade show in Germany

As we go to press, a couple of days before the Bauma show, there has been a flurry of new product announcements. In particular, major manufacturers stating that they now have, or intend to have in the near future, or are developing, battery-powered miniexcavators. In addition, there is a flurry of new battery-powered compact wheel loaders. A full review of the rapidly-expanding electric compact equipment sector of the market will be in the next issue.

The widespread availability of electric minis was expected, but even before Bauma opens its doors to visitors, there have been a few surprises. It would seem that full-sized battery-powered machines are also on the near horizon.

This trend started as the Danish manufacturer Hydrema shocked the industry by stating that it had developed an electric dump truck. It is apparently an all-new design, which has been developed specifically to be a fully electric platform. Likewise, French manufacturer Mecalac announced batterypowered versions of its unique swing loaders and wheeled excavators, in addition to a cabbed electric site dumper.

CATERPILLAR

Over the past few years, Caterpillar has remained largely silent on the subject of the development of battery-powered construction equipment. This will all change at Bauma 2022, as electric versions of the 301.9 mini-excavator and the 906 compact wheel loader are unveiled.

Of more strategic importance, Caterpillar is also due to show prototypes of electric versions of its 950GC wheel loader and 320 excavator. This is an important development for the industry, as it signals the near-future availability of zero-emissions mainstream production machinery.

Associated with these announcements, Caterpillar is developing its own range of lithium-ion batteries that are modular in design and fully scalable, intended to power a wide range of future industrial machinery.

KOMATSU

However, Komatsu provided the most significant pre-show announcement: that a 24-tonne battery-powered excavator is due to enter production before the end of next year. It is equipped with a 451kWh lithiumion battery that has been developed by the US firm Proterra, which has been working with Komatsu on this project over the past two years.

It is reported that prototype excavators have been achieving five to nine hours of work from a single charge of the Proterra battery pack.

Above and below: The first generation of electricallydriven items of mainstream construction equipment, including 20-tonne class excavators, are making an appearance at the Bauma show.

REAL-WORLD ELECTRIC TELEHANDLER

Inset above and below: The Faresin is constantly topped up during the day, which is enough to keep it available around this busy depot for the whole shift.

In June 2020 Flannery Plant Hire trialled their first Faresin battery-powered telehandler, which was used to help establish the HS2 Tarmac Compound at West Ruislip. They now have six Faresin telehandlers on their fleet, and more are to come. The Faresin 6.26 model offers a 6m lift height and a maximum lifting capacity of 2600kg, plus a maximum forward reach of 3.1m, at which it can handle 900kg. The Italian-made Faresin is powered by a lithium-ion battery pack, of which there are three options delivering up to 10 hours of operation, sold and supported in the UK by the GGR Group.

SITE BACKGROUND

Having worked on various projects during 2021, this Faresin has been with the Morgan Sindall team for the past year to support the delivery of the new £42m bus corridor in the West Midlands. It will improve journey times and provide more reliable services linking Walsall, Birmingham and Solihull. The first section to be completed was used by visitors to the recent Commonwealth Games.

A main contractor on the project, Morgan Sindall invested heavily in its supporting infrastructure, including establishing a main depot on the outskirts of Birmingham city centre. In addition

“THESEGREENERCHOICESHELPEDUSTOSECURETHE WORKFROMTRANSPORTFORWESTMIDLANDS”

Peter Haddock reports on the initial success of Faresin battery-powered telehandlers, which have been on the fleet of Flannery Plant Hire since 2020

to offices and welfare units, it includes indoor and outdoor storage for a wide range of materials and other assets, including traffic management systems, lighting towers and generators.

The space was also used to support the planting of over 3000 trees during the project. As part of a more sustainable approach to temporary occupation of this site, Morgan Sindall invested in a fleet of electric vans, hired in the battery-powered compact equipment and used low-emissions fuels.

Senior works manager Eddie Anderton said, “For Morgan Sindall’s A45 section of the route, we were required to work in and around the new Green Emission Zone in Birmingham. So, even at the tender stage, I was working with the team on how we could deliver a greener approach. It also allowed us to have some early engagement discussions with the Flannery Plant Hire team to explore our fleet options. They provided the Faresin 6.26 telehandler and some electric excavators for this project, and for all of the other equipment we used HVO fuel.

“These greener choices helped us to secure the work from Transport for West Midlands, while also providing us with the data on carbon emissions and proven use cases for different greener solutions. This information has been monitored throughout the project and will support us in our own goals to be net zero by 2030. We installed a total of 16 charging points at our depot, including a designated charger for the telehandler. The others are used to charge our electric vehicles. They were joined by solar welfare units, lighting and battery-operated CCTV solutions.

“Working with Flannery, we could also have our equipment dashboard using the MachineMax system, which connects all of the Flannery fleet

throughout our project. The team and I could access this at any time and see where the plant was, what work it had been doing and, therefore, what carbon impact it generated. It also included information from the telehandler. I was a bit sceptical at first about the performance and longevity of the battery.

“UNLIKEADIESELMACHINE,ICANALSOUSEIT ACROSSTHEWHOLESITE,INCLUDINGINSIDE OURWAREHOUSE”

The Faresin telehandler features two electric motors, one for drive functions and one for hydraulic services.

Battery options range from 330Ah to 560Ah, which can be charged through the built-in charger, or from an external fast charger.

It quickly became very clear from the data and our operator, Happy Singh, that it was ideal for the job. We now know how impactful alternative fuelled machines can be and how we can integrate electric machines into the mix.”

OPERATOR FEEDBACK

Happy Singh used the Faresin 6.26 electric telehandler for general tasks around the depot, including loading and unloading. He said, “It took me a couple of days to get used to the controls and of course how to put it on charge in my breaks. Handling-wise, it’s very similar to a diesel-powered machine, but of course it’s much quieter. As it is all electric, unlike a diesel machine I can also use it across the whole site, including inside our warehouse. This has been very useful when we needed to protect materials from the weather.

“Because it’s electric, the power is also instant, so you have to get used to the sensitivity of the accelerator and the joystick controls, but that’s just like any new machine you get. I definitely think it’s the way forward for sites like this, where you have all the charging available in a designated area. I have never had any problems with charging and the battery on the machine is more than enough to do the tasks I need.”

THE FUTURE

Flannery’s Chris Matthew said, “Since we have been able to analyse the performance of the Faresin telehandler, we now know what type of activities and use cases are suited to the machine. With this information to hand, we have been able to show more customers how they can adopt electric machines, which has led to us increasing our fleet to six units. All of these machines are now connected assets, thanks to the work Faresin and its UK dealer, GGR Group, has done to make the data readily available to our equipment management platform provider MachineMax.

Left, far left and inset: Operator Happy Singh reports that the power is instant, but handling-wise it’s very similar to a diesel-powered machine.

MANUFACTURER’S COMMENTS

Faresin’s product specialist Nicolae Manea said, “Inside the cab to the right of the operator we have a series of buttons that control some of the key functions like the parking brake and Eco or Power operation. The operator can also control the flow, boom suspension and floating boom features, as well as the LED lights. The joystick mounted to the right-hand side of the cab has a toggle switch for forward, neutral and reverse, and these functions can also be accessed from a lever on the left-hand side of the steering column.

“Embedded into the right-hand side of the dashboard is a 7in LCD display, which shares general information on the hours worked, the charge on the battery and any alerts. It also links to the rear-view camera. Right in front of the operator we have mounted our anti-tipping system display. Using LED lights, this system automatically calculates the load on the front of the machine that is either being carried or lifted. Particularly for lifting, this system alerts the operator to ensure they keep within safe operation.

“We now have a 330Ah, 440Ah and our new 560Ah battery options. They can all be charged from our built-in charger. We have both standard and fast charger options, depending on what charging levels are required. For fast charging, you can charge the battery between an hour and two hours, depending on its size. But for Morgan Sindall on this project, they simply parked up the telehandler and plugged it in when the machine was not operational, topping up the battery throughout the day.”

“As we continue to collect and analyse more data, we will also be able to look at fleet purchasing decisions based on real-world activities. This will influence the different battery options from Faresin and, of course, decisions around the purchase of new products in its pipeline. There is definitely a place for electric machines in our fleet mix. That is why we will continue to work in partnership with manufacturers to feed back what our customers’ needs are and how future product developments can support them.”

With zero and ultra-low emissions machinery and vehicles helping to create new infrastructure, it’s fitting that National Express West Midlands has already been running the first of a fleet of zero-emissions buses on the route, which will, in the future, include hydrogen-powered vehicles.

DOZER ACCESSIBILITY

dozer

The industry first caught sight of a prototype of Dressta’s revolutionary TD-16N dozer at the ConExpo 2020 show in Las Vegas. A radically different design for a 20-tonne dozer, particularly in terms of access and visibility, it justly received praise from visitors, together with a prestigious product design award.

We can now reveal that a surprising amount of the design work for this brand-new dozer was undertaken in the UK.

The project started in 2013, when early concept

sketches were produced as a result of the combined visions of the American engineer Edward Wagner and the British industrial designer Gary Major. This world-class team then secured the services of a world-class dozer operator, golf course developer Jacob Cope, as a consultant during the design phase of the project.

Gary said, “We set out to create the very best dozer for operators, and to do this we put the operator at the centre of the machine. We literally started with the blade, the tracks and the operator, and then built everything round them, without compromise.”

What caught everybody’s attention at ConExpo was the astoundingly good access to the TD-16N’s cab. For as long as I can

Above and below: Polish-based Dressta is launching a revolutionary 20-tonne dozer on to the European market.

Nick Drew reports from the UK field trial of a prototype of Dressta’s new 20-tonne

remember, mounting a dozer has been a hazardous operation, especially during the winter when tracks are inevitably clogged in mud. In such conditions, first stepping on to the blade arms, before climbing up on to the tracks, is an accident waiting to happen.

Dressta’s new rear access system eliminates that risk, and involves just four steps while maintaining three points of contact. This takes you up to the cab platform level and straight through the door into the cab. Its simplicity is incredible and begs the question why nobody ever thought of it before.

SECRET FIELD TRIALS

It was just over a year ago that Earthmovers was invited to visit Rory Holbrook’s recycling facility, located just a stone’s throw away from RAF Lakenheath. His son Ryan was putting a pre-production Dressta TD-16N through its paces in near secrecy – a story that can now be told. Ryan had plenty to go at, as RJ Holbrook was constructing a 30m-high noise protection bund, which involved moving and shaping an estimated 2.5m cubic metres of material.

The prototype dozer was fitted with a host of diagnostic equipment to enable the team in Poland to monitor its performance during various customer applications and field trials. This prototype went on to amass over 10,000 hours, providing a huge volume of data and making new friends with the few people that have spent time in its cab.

As you would expect nowadays, this long-term test dozer was also fitted with a modern GPS machine control system. In this case it was a Leica MC13D, together with their ConX cloud-based data handling facility for machine control operations.

IN THE CAB

The Dressta R&D team have flipped traditional dozer design on its head (see walk-round panel). However, the only way to fully appreciate the significant improvement in all-round operator visibility is from the seat.

Just as I experienced in an exhibition hall in Las Vegas, being able to climb safely up to the cab of a dozer on site is just mind

blowing. To be honest, the first step was a bit on the high side for me, but it needs to be, to keep it up and clear of the ground. The subsequent steps and handrails offer a great sense of security, as I easily progressed up and then into the cab.

As the exhaust stack and air intake are located nicely out of the way to the sides of the cab, once in the seat is when the view on offer really hits home. There is no need to peer round the bonnet; from this seat you get a totally unobstructed view of the blade and the ground ahead of you. In my opinion, the two-piece bonded front screen provides the best visibility on offer from any dozer on the market today.

I got comfortably ensconced in the air-suspension seat, my feet resting on a couple of angled supports able to accommodate the largest of work boots. Immediately above these footrests is the control monitor for the Leica GPS machine guidance system. And that is it; the rest of my view was equally split between the

Right, inset and below right: The new Dressta TD-16N 20-tonne dozer sets new industry benchmarks for safe access and operator visibility.

DRESSTA TD-16N WALK-ROUND

Adam Pitman, LiuGong-Dressta’s global R&D director for dozers, was on hand at the RJ Holbrook site to give me a guided tour round the machine. Starting at the business end, this example features a six-way VPAT blade, which is 3981mm wide and has a material capacity of 4.3cu.m. To meet the most practical option under UK legislation, the blade has fold-in corners to ensure that it’s under 3m wide when sitting on a low-loader. At the rear is a three-shank ripper, capable of a drawbar pull and ripping power of some 330kN.

This is a low ground pressure variant of the TD-16N, fitted with 760mm single-grouser track shoes. With the fold-in blade, it tips the scales at 20.8 tonnes. Power is derived from a Stage 5 ultra-low emissions Cummins six-cylinder engine rated at 170hp (127kW) and providing its maximum torque of 881Nm (650lb.ft) at just 1300rpm.

In terms of the powertrain, the machine is fitted with an automatic infinitely variable, dual-path, hydrostatic transmission; driveline motor and final drives are all supplied by blue chip component producer Rexroth, as are the hydraulic sub-systems for the blade, ripper and even the joystick controls.

All the routine maintenance checks can be completed from ground level, without the need to clamber up on to the tracks, a great improvement in operator safety. The powerpack is mounted low down in the chassis, which allows the designers far more scope to sharply slope the bodywork for much-improved operator visibility. It also lowers the dozer’s centre of gravity, resulting in better stability.

The mid-section opening front bonnet provides access to the top of the engine and its ancillary components. For more in-depth maintenance and repair work, the entire cab can easily be raised. This provides great access to the drive pumps, working pumps, hydraulic valve blocks, batteries and exhaust after-treatment system.

The nose cone of the steeply sloping front bonnet is home to both the diesel and AdBlue tanks, both being extremely easy to reach from ground level. With the cooling pack and hydraulic oil tank located at the rear of the machine, this forward location also improves the machine’s overall balance.

The extremely sloping cooling pack at the rear is over-sized, which has enabled Dressta to run the fan at a lower speed, helping with fuel economy, while the reduction in noise is particularly beneficial to the operator. Locating the cooling pack at the rear of the dozer makes it less vulnerable to a build-up of dust, although a reversible fan blows out any debris that may build up.

ground ahead, the blade and the front of the tracks.

Instead of taking up critical space in the operator’s immediate field of vision, the machine’s high-resolution, touch-screen control monitor is mounted on the front right pillar of the cab. In addition to sharing the location of the monitor with modern excavators, it appears to be just as easy to navigate through the various menus and sub-systems.

“BEINGABLETOSAFELY CLIMBUPTOTHECABOF ADOZERONSITEISJUST MINDBLOWING”

The radical design includes easy groundlevel access to routine service items, together with a quickly-tiltable cab for access for more intensive works.

Above and inset: This is the sort of working environment that will help to attract the next generation of well-paid dozer operators.

The interior of the cab is clean cut and workmanlike, and the controls kept to a minimum for ease of use. On the righthand console is a 12v socket, a USB port for connecting a mobile device, the horn button and a rotary throttle dial. Towards the rear there is that absolute essential for any self-respecting operator, a cup holder.

The Bluetooth radio is located in the right-hand side of the roof, with the control pad for the air-conditioning system situated below. For those who prefer fresh air, the side windows are hinged and open outwards.

The multi-function joysticks are typical of what you would find in any modern dozer and fit nicely into the palms of my hands. The left stick controls direction and steering, while the one on the right-hand controls all the blade functions.

CONCLUSION

It’s very rare for me to operate a dozer, but I was keen to take the Dressta TD-16N for a quick spin. Cranking up the throttle, I was surprised by how quiet the machine is. It’s something that Ryan had mentioned, along with praising the visibility from the seat. Taking it really steady to start with,

I found the controls to be responsive and user friendly. It was a joy to use, even for a novice like me. The spacious cab is unlike any other dozer I have sat in, it certainly didn’t give that claustrophobic feel of some machines.

Obviously, I was only tickling a bit of soil around free-hand, but it was quite clear that this dozer could pack a real punch. As I had witnessed earlier in the day, when it was being used in anger by Ryan, who is clearly a highly-skilled operator.

Of course, the old school of dozer operators will tell you that you don’t need to see the blade, it’s all done by feel in the seat. That’s a valid statement, but with all due respect to such stalwarts of the industry, with no blind spots, this is a design with the next generation of tech-savvy dozer operators in mind, working on risk-averse sites.

I had officially gate crashed this manufacturer’s field trial to get an early look at, and take photographs of the prototype at work. Over the years, I have had many off-the-record chats with Edward Wagner and Gary Major about this project. As the Dressta TD-16N dozer enters production, I am delighted to see the work of the design team come to fruition.

EDITOR’S

COMMENTS

A factory to produce heavy tracked machinery was established in the new Polish industrial city of Stalowa Wola in 1937, initially to produce military equipment. After WW2, thanks to licence agreements with the likes of Coles Cranes and International Harvester, the site diversified into producing construction equipment. The business, known as Huta Stalowa Wola (HSW), developed into a major manufacturer of construction equipment in Eastern Europe.

Post-Cold War, with the factory now in central Europe, their range of Dressta dozers began to find favour in more countries around the world, typically with those looking for a simple and sturdy machine. Critics sometimes referred to Dressta dozers as nothing more than upgraded International Harvester designs, exactly the same words that were used by their most ardent fans!

In 2012, Dressta was acquired by the Chinese machinery company LiuGong. This major global manufacturer then made substantial investments in their new base in central Europe, including in the factory, its technical staff and the products themselves. In addition, they opened up the vast Chinese market for Dressta products, then went on to develop an expanding world-wide dealer network.

The Chinese-funded, Anglo-American designed, Polish-built Dressta TD-16N dozer is a triumph of modern industrial design, setting a new benchmark in the global market.

CHALLENGING TASKS

operator challenge

Europe’s best operators, including Bryan Williamson from the UK and Tommy Murphy from Ireland, gathered at the Caterpillar Demonstration and Learning Centre in Malaga on 5 and 6 October. They were competing for a chance to win one of three places at the Cat Global Operator Challenge final, to be held at the ConExpo show at Las Vegas in March 2023.

For some operators, it was their first time at a European final, but for Tommy Murphy, it represented a return to the competition he so nearly won at ConExpo 2020, eventually coming second to Jaus Neigum of Canada.

Caterpillar kicked off the event with a choreographed machine display, including a show stopping fireworks display. The next day it was down to business, when the four very different trials were revealed to the operators.

MAKE THE GRADE

The first challenge was entitled ‘Make the Grade’ and involved using the integrated

2D guidance system in a Cat 326 to accurately excavate a 6m-long bench in soft sand. To add a bit more to this timed challenge, the operator first had to navigate the tracked excavator to the work area round a steel drum, just using the excavator’s joystick steering system.

On arrival at the digging area, the left corner of the bucket had to be benched on a designated spot to set-up the 2D guidance system, before grading commenced. Once complete, they tracked back to the starting point, and the timed run finished when the bucket was on the ground. The judges then measured the accuracy of the work, and points were deducted for every deviation over 10mm.

PERFECT PAYLOAD

For the ‘Perfect Payload’ challenge, operators filled the skip of a quarry hauler with a Cat 982XE wheel loader, navigating tight turns and slopes in the carry part of the cycle. The aim of the challenge to was to load a specific weight of aggregate over

two passes using the 982XE’s integrated payload management system.

All the contestants opted for a big first bucketful, although some failed to keep all the contents in the bucket during the challenging carry from stockpile to hauler. The contest came down to how quickly and accurately the operators could tip off the desired weight of material in the partial second bucketful to meet the target payload in the back of the truck.

TIME TO MOVE

The ‘Time to Move’ challenge used a Cat MH3022 wheeled materials handler equipped with a grab. Contestants, sitting in the hydraulically-raised cab, needed to take full advantage of the machine’s reach of 10.2m to pick up tyres from the bottom of an open-top container. Slewing 180 degrees, the tyres then had to be placed on the branches of a steel tree-like structure.

This part of the competition was largely decided by the operators’ ability to keep the tyre in the grab at an orientation to allow

Peter Haddock reports from Spain on the welcome return of the Caterpillar global

easy placement on the steel frame. Time penalties were awarded if the tyre had to be repositioned, or fell from the grab and had to be retrieved.

CHAIN GANG

The challenge that looked easy, but proved to be the downfall of the most experienced continental European operators, was the ‘Chain Gang, which involved using a Cat 432 backhoe loader.

The challenge was devised by Cat trainer/demonstrator Simon Hill, who said, “When we devised the challenge, we wanted it to reflect the diverse capabilities of the backhoe and also challenge the skills of the operators, some of whom had never operated a Cat backhoe before.

“The first section was all about speed and control, in which two tennis balls placed on cones had to be knocked over in order by the front loader bucket teeth. We then wanted the operators to do a quick change-over to the backhoe for more precision work. This also required the

EURO FOCUS // CAT OPERATOR CHALLENGE

THE WINNERS

In

operators to gauge where to set up the machine, in order to be able to reach the next part of the challenge. Get this wrong and it becomes more difficult.

“We devised the next section to challenge both accuracy and control, with a pink hook mounted on to the backhoe bucket. The hook is required to hook a ring connected to a chain that lifts a weight. Once hooked, the weight has to be moved to connect into a specially fabricated container. It requires delicate control to slot the weight into the container, lift it and move it to a dedicated touch plate. Once this has touched the plate, the container then needs to be moved back to its original spot, the weight lifted out and replaced to its original position.

“If this is completed without any of the items touching the sand around the plate, then the operator will move on penaltyfree. Once this task is completed, it’s a race to reverse the machine back into its designated tight parking spot.”

In

Competing in excavator, wheel loader, materials handler and backhoe loader trials, there was plenty to challenge even the most experienced operators. In first place was Pontus Eriksson, a general construction operator with 12 years of experience from Sweden. In second place was Sebastian Behr, a road and general construction operator with 25 years of experience from Germany. And in third place was Lukasz Mokrzynski from Poland, a water and sewage services specialist with 15 years of experience under his belt. We wish them well, as they represent Europe in the toughest competition on earth.

Left, and below: The rounds at the European finals of the Cat Operator challenge involved making best use of an excavator, a wheel loader, a materials handler and a backhoe loader.

In first place was Pontus Eriksson from Sweden.

second place was Sebastian Behr from Germany.

third place was Lukasz Mokrzynski from Poland.

SAFETY

ritain’s new high-speed rail line, HS2, is being built from London to Birmingham, the second stage taking the line through to the heart of the rail system at Crewe in Cheshire. The project will see over 170 miles of a new high-speed rail route installed between London and Crewe. A third phase, yet to be approved, is planned to link Crewe with Manchester. Allied to other rail upgrade projects, the Government hopes that this huge investment will bring fresh life to the rail network, making it better able to serve future generations.

PROJECT BACKGROUND

Due to the sheer magnitude of the HS2 rail project, at a very early stage it was decided that it was just too large for only a single main contractor to undertake the work.

Indeed, some sections of the route would require a collaborative approach, combining the skills and specialities of different main contractors. With this in mind, several joint venture partnerships were formed to bid for, then undertake the most challenging aspects of the project.

We met SCS joint venture, one of the leading contractors on this project and comprising Skanska, Costain and Strabag. The last is a giant Austrian-based transport infrastructure, tunnelling and civil engineering contractor. SCS is delivering the southernmost section of the HS2 route, the 26.4km stretch in and out of the London Euston terminus.

A variety of new structures are required along the route, but for all practical purposes this section of the new high-speed rail link will be carried in tunnels. SCS will be running seven tunnel-boring machines (TBMs), of which five will operate simultaneously.

While the TBMs excavate the tunnels, there is a huge amount of overground work to undertake. One of these tasks is the installation and maintenance of a massive conveyor system, to transport the tunnelled material to a nearby railhead. This conveyor and train combination replaces hundreds of daily truck movements in central London, which would have been required to remove the spoil generated by a fleet of TBMs.

SAFETY FIRST

Such major public-funded projects are pioneering modern methods to organise and manage this work (see panel overleaf), which includes delivering the desired result with the highest possible levels of site safety. This ethos is clearly evident within the SCS joint venture and its principal machinery supplier, Flannery Plant Hire.

In addition to establishing a plant operator recruitment and training regime specifically to serve its work across the HS2 project, Flannery has also pioneered the widespread fitment of movement and lift restrictors across its fleet of excavators, specifically the emerging technology from

Flannery has been using Xwatch systems for two years, and was an early adopter of the XW range of easy-to-use slew and height restrictors, followed by Xwatch’s RCI (rated capacity indicator) systems. Xwatch says that its system is the only slew and height restrictor approved by Network Rail to work adjacent to the rail.

SITE VISIT

In three years of trading, Xwatch has supplied over 1500 safety systems around the world. Appropriately, the 1500th unit was fitted to a new Flannery excavator, a compact radius, 13-tonne class, wheeled Volvo EWR130E. We discovered it on site at the Victoria Road Crossover Box, near Old Oak Common in West London, which will allow HS2 trains to switch tracks underground.

Flannery has a number of these high-spec rubber ducks, which are equipped with a two-piece boom carrying a 2.4m dipper and a Miller quick-hitch, with an undercarriage configured with both blade and stabilisers. They are proving to be increasingly popular on the HS2 project and are finished with a full suite of LED lighting, hi-vis handrails, a travel alarm and additional flashing beacons.

Xwatch XW4 height and slew movement protection system fitted, handy in what can, at times, be a tight and congested working environment, particularly in view of the various roles that such a wheeled excavator is put to on such a project. Its operator, Alex Moraru, makes best use of the EWR130E’s all-wheel steer system to position the machine exactly where it’s required.

Jason Wells, the SCS manager for the Victoria Box section of the HS2 project, explained, “We take our health and safety very seriously. Having the Xwatch ensures the machines are always working safely within their prescribed zone. We have a very busy and often congested site. Any technology that can make the working day safer is welcomed by SCS.”

the British company Xwatch Safety Solutions.

Above, left, inset and below: Commenting on the Volvo EWR130E, operator Alex Moraru said, “It’s a very good machine to operate, quiet and comfortable and with plenty of digging power.”

EDITOR’S COMMENTS: CONSTRUCTION 2025

Almost a decade ago, the UK Government published its ‘Construction 2025’ document, which outlined a vision of the future of the construction industry. It set ambitious targets for lower costs and emissions, together with faster project delivery times. In turn, this would encourage growth in the wider industry, particularly on the international stage.

This was to be achieved by a variety of means, including the widespread adoption of new technologies and major changes to how the supply chain was organised. We first saw the practical results of the thinking behind Construction 2025 on major road projects undertaken by National Highways. They pioneered a far more collaborative approach between all the interested parties, in addition to introducing a range of new digital technologies, all to improve how the site and fleet assets were managed, particularly in the mass muck-shifting stage of the project.

One result of this is the change in status of the plant hire companies serving major public sector projects. Such firms are no longer just a potential source of machinery, but are an earthmoving contractor to the project. It’s a role that requires the establishment of an extensive infrastructure, particularly to train machine operators and ensure the highest standards of site safety, in addition to supporting the machines on site.

The first item in the summary of the aims of Construction 2025 includes the words, ‘An industry that attracts and retains a diverse group of multi-talented people, operating under considerably safer and healthier conditions.’

UK Construction PLC is a far safer and healthier industry than it was a decade ago, but it is still a dangerous occupation. As the single largest client of the labour-intensive industry, the UK Government is, quite rightly, demanding further improvements in site safety.

They will come from how the work is planned, undertaken and managed, but we are already seeing an impact when it comes to machinery selection and specification. For example, the A14 road project pioneered the use of cabbed site dumpers, together with a range of operator visibility and anti-collision aids. An early result of HS2 appears to be the far more widespread use of excavator height and slew restrictor systems.

“WEHAVEAVERYBUSY ANDOFTENCONGESTED SITE,ANYTECHNOLOGY THATCANMAKETHE WORKINGDAYSAFER ISWELCOMED”

POWER BUCKETS

Peter Anderson reviews the large number of crushing and screening buckets available on the UK market

Hydraulically-powered crushing and screening bucket attachments are becoming increasingly popular. A huge range is available, suitable for smaller minis to quarrying-class wheel loaders and excavators. The use of such attachments enables C&D waste to be recycled on site, while larger models play a key role in processing a variety of materials on a production level.

BAUGHANS RANGE PIONEERING ALLU

Located near Daventry, Baughans manufactures cost-effective recycling and rehandling attachments. They include a range of four crusher buckets from 400mm to 990mm wide, suitable for machines in the 1.5- to 13-tonne class. The attachments are low maintenance as the tungsten tips are inexpensive and easy to replace.

The company says its buckets are capable of crushing concrete with rebar down to 75mm fines and to 35mm fines with the addition of a choke bar. Depending on the type of material, throughputs range from a maximum of 3tph for the smallest bucket and between 10tph and 25tph for the largest crushing bucket attachment.

s one of the originators of the screening bucket concept, Finland-based Allu has gone on to develop a wide range of both crushing and screening buckets.

There are five models in their Veloci screener range, which has been developed for excavators from two to 20 tonnes. The screening stars at the heart of the mechanism create a rotating motion inside the bucket, breaking up, screening and mixing the material, producing a quality end product.

DL screening buckets are intended for compact base machines up to 12-tonne excavators and 8t compact wheeled loaders.

The 20-model Transformer D-series screener buckets have been developed for larger processing jobs, hosted by excavators from 10 to 45 tonnes, together with wheeled loaders with operational weights up to 30t.

Allu also offers six models of crusher buckets, suitable for mounting to excavators from four to 42 tonnes. They weigh from 1.75t to 5.53t and provide capacities from 0.4 to 1.22cu.m.

NEW CONE CRUSHER FROM AUGER TORQUE BAV CRUSHERS & SCREENERS

range of crusher buckets, designed for excavators from 2.5 to 16 tonnes, is available from Staffordshire-based BAV Crushers, a sister company of Digbits. They are made from Hardox steel and specially developed tungsten carbide tools. A five-model range of BAV-RS rotary screening buckets is also available, with drum diameters from 450mm to 1180mm, suitable for excavators up to 21 tonnes. They feature two sets of removable mesh screen grids as standard, enabling three grades of output to be produced.

EPIROC PROCESSING ATTACHMENTS

There are four models in the Epiroc BC crusher bucket range, weighing from 2.25 to six tonnes and suitable for excavators up to 54 tonnes. They offer load capacities between 0.5 and 1.2cu.m, offering a crushed sizes range from 20mm to 90mm for the smaller BC2100 model, and 20mm to 150mm for the three larger attachments.

They feature an automatic anti-lock mechanism, reversible running direction and quick adjustment of material size. The drive system features two hydraulic motors and a timing belt to generate the high torque

needed to power the crushing jaw.

The two bucket screeners, BS1600 and BS2200, have service weights of 1.71t and 2.45t and cater for excavators in the 18- to 38-tonne weight category. Hydraulic power is transmitted to the basket via a timing belt that doesn’t require tensioning.

According to Epiroc, the large diameter main roller bearing enables the tment of a much longer basket, while the bigger screening area gives a significant increase in performance. There is a choice of six different mesh size openings, from 20mm to 80mm.

Auger Torque is launching a new cone crusher bucket, suitable for machines in the three- to 10-tonne bracket, including excavators, telehandlers, skid-steers and compact wheel loaders. This attachment is capable of quickly repurposing rubble into usable hardcore of approximately 40 to 70mm.

LATEST FROM LLOYD

Leominster-based

Earlier this year, Lloyd launched the budget two-model StarTer range, to bring on-site screening within the reach of smaller companies and hire firms. The 135kg ST1-2 and the 181kg ST2-4 models have been designed for carriers between 1.5 and four tonnes, have working widths of 580mm and 970mm and capacities of 0.08 and 0.12cu.m.

The Rotastar bucket has a unique screening action. It rotates the material in a similar manner to a trommel screen, but has the benefit of rotating star discs, agitating and clawing at the material as it turns. There are nine models ranging from the RS2-4 up to RS20-30, suitable for carriers between two and 30 tonnes, with average outputs from 7tph to 50tph. In addition, the three-model rotary RT-series of screening buckets is available, designed for host machines from six to 25 tonnes.

LARGE ANROSS CRUSHA

The latest addition to the Anross ‘Crusha’ bucket offering is the top-of-the-range CB100 model, suitable for excavators up to 16 tonnes. More powerful rams have been tted to ensure performance and crushed material size is maintained. Outputs of between 10 and 15 tonnes per hour are achievable, depending on nominal product size and material being crushed.

TREVI BENNE SCREENERS

emolition equipment manufacturer Trevi Benne makes a nine-model BVR series of rotary screening buckets. Weighing from 110kg to 4.9t, they are intended for excavators up to 65 tonnes and have widths from 520mm to 2.12m. A perimeter kit is available, in either braided net or perforated sheet, consisting of four sections bolted to the basket and easily replaceable by the operator.

D

The full range of Trevi Benne crushing and screening buckets is marketed by Sunbelt Site Services in the UK.

Lloyd Engineering manufactures a range of screening buckets that include Rotastar, Rotary and, more recently, StarTer models.

LATEST FROM SIMEX

Two new screening bucket attachments have been introduced by Italian manufacturer Simex: the VSE2 model for mini-excavators up to 3.5 tonnes; and the VSE5 for midi-excavators up to eight tonnes. The addition of the new buckets brings the Simex range to six models suitable for machine up to 45 tonnes.

A range of five CB and five CBE rotary crusher attachments is also available from Simex. The CB buckets are designed for excavators, while the CBE models are suitable for a wide variety of other types of host machine.

MECCANICA BREGANZESE

Crushing and screening buckets produced by Italian-based Meccanica Breganzese (MB) Crushers are marketed and serviced by Cheshire-based Worsley Plant.

The 12-model crusher bucket range starts with the MB-C50 model weighing 0.75t and having a load capacity of 0.15cu, up the BF150.10 that weighs 10.5t and provides a capacity of 2.3cu.m, which can be used with machines up to 100 tonnes.

Their rotary screening buckets extend from the MB-LS170 weighing 1.45t, with a capacity of 1.10cu.m, up to the 3.75cu.m MB-S23 that weighs 3.66t, and is suitable for machines from 2.6 to 50 tonnes.

MB Crushers also produces a seven-model range of HDS shaft screeners, which can process different types of material. They are suitable for wheel loaders, skidsteers and backhoe loaders with operating weights up to 45 tonnes. The company says the HDS models are radically different from all the other systems available on the market, reducing noise levels by up to 40% when processing materials.

NEW XCENTRIC PRODUCTS

Anew series of maintenance-free crusher buckets has been developed by Spanish manufacturer Xcentric. The new eight-model XC series is still in development, but some of the models are already available. According to the company, the simpler internal

mechanism does not need lubrication, nor a drainage line. Replacement of the jaws has been made simpler since the bucket can be completely opened.

Four models make up the Xcentric XS series of rotary screeners. A 12-sided polygonal trommel shakes the material inside more efficiently aided by the hexagonal profile of the screening mesh. This provides a good balance between maximum yield and a more homogeneous finished product. A power boost system applies vibration to the turning trommel, which helps to improve production.

ROCKCRUSHER/HARTL RANGE

German attachment manufacturer Rock.Zone acquired the Austrian company Hartl in 2019. Since then, the range of crushing and screening buckets has been extended and rebranded as RockCrusher and RockScreener attachments.

The four-model RockCrusher range, available in the UK through Winchesterbased Inmalo, is suitable for excavators from 12 to 36 tonnes and offers capacities from 0.5 to 1.7cu.m. These jaw crusher buckets feature the innovative Quattro movement, which is claimed to provide high average performance rates with little wear and a quality end product, with minimal oversize material.

Other features include a central lubrication system, dust suppression, crush

VTN PROCESSING ATTACHMENTS

There are five models in the heavy-duty FB series of crushing buckets, offering capacities from 480 to 1050 litres, weighing 1.65 to 5.5 tonnes and designed for excavators from 12 to 55 tonnes. Each attachment has a fixed and moving jaw that can be set to produce sizes from 18mm to 130mm.

The SB series offers four powered riddle screening buckets with capacities from 750 to 2700 litres, weighing from 1.55 to 3.8 tonnes, and suitable for machines in the 13- to 50-tonne category. These buckets feature a selection of internal screens to produce different sizes of materials.

In addition, there are five models in the SR series of rotary screening buckets designed for fiveto 35 tonne carriers, providing capacities from 0.4m to 2.2cu.m.

For models make up the DSG series of screening buckets, designed for carriers up to 19 tonnes and offering capacities from 1 to 2cu.m. They feature screening in one direction and crushing of soft material in the opposite direction, interchangeable rollers and a centralised greasing system.

control, magnet separator and optional bucket teeth. The buckets are equipped as standard with reverse setting, which both reduces damage to the attachment when trying to eject jammed material and allows tarmac to be easily crushed on site.

The four RockScreener rotary screener attachments, which weigh between 640kg and 4.6t, are suitable for excavators from eight to 35 tonnes, offer capacities from 0.61 to 7.48cu.m. Features include mesh sizes from 20mm up to 80mm, interchangeable mesh modules, scraper brush and centralised maintenance and service console.

REMU SCREENING BUCKETS

Cheshire-based Worsley Plant also sells and supports the Remu range of screening buckets in the UK, suitable for excavators from three to 30 tonnes and wheel loaders up to 12 tonnes. Bucket volumes vary between 0.15 and 2.3cu.m.

Another product line is the XO crossover bucket, a totally new concept for the attachment sector: one bucket frame with multiple work modules, enabling a quick transition between different materials and jobs. Two models are currently available, the XO2090 and XO2150, designed for 5t and 8t excavators, respectively.

ROTAR SEGREGATOR BUCKETS

The Rotar EVB range of segregator buckets are suitable for mounting on excavators from 13 to 35 tonnes, while the RVB range has been developed for wheeled loaders in the 4.5- to 15-tonne category.

According to the Netherlands-based company, these attachments are a unique concept of a skeleton bucket used in combination with an eccentric shaft. The buckets lift the rib section independently, at a high frequency, which results in a vibrating motion of the material to be segregated. This segregation is then undertaken via the bar spacings, and the oversize material remains inside the bucket.

talian VTN Group produces crushing and screening buckets that include the FB, SB, SR and the DSG series, which are sold and supported in the UK by dealer ECY Haulmark.

DRIVING DOWN TOTAL COSTS PER TONNE

B

ased at Aberdare in South Wales, with offices across the UK, the Walters Group was founded in 1982. The group’s first Caterpillar machine was a D4D dozer, bought from local dealer Bowmakers in Cardiff. Today, Walters operates what is reported to be the largest independently-owned heavy plant fleet in the UK. Their on-going investment plan covering 2021 to 2023 is for around 300 large machines, resulting in an estimated £100m spend with Cat distributor Finning.

The Walters Group operates across many industry sectors, and some of its largest machines work in contract load-and-haul quarry applications on behalf of the UK’s major aggregate producers. The client base increasingly demands reduced emissions, improved fuel consumption, greater levels of productivity and the highest levels of site safety – all while trying to minimise the cost per tonne delivered to their crusher.

Below: The first new generation Cat 992 wheel loader in the UK is on the fleet of the Walters Group, working on their load-and-haul contract with Hanson Aggregates in Somerset.

David Wylie visits Hanson’s Whatley Quarry in Somerset to see the first 105-tonne Cat 992 wheel loader in the UK, which is owned and operated by the Walters Group

THE IMPORTANCE OF TYRE CHAINS

The new Cat 992 at Whatley Quarry has been fitted with Pewag Square Tyro 18 tyre chains, which are ideal for this limestone application. The same chain type is fitted to their old 992G and have now recorded an astonishing over 23,000 hours of use. Apparently, a few links and rings break now and again, but even with this extended lifespan they are still serviceable.

The second 992, currently being commissioned for the Walters Group contract at the Bardon Hill Quarry in Leicestershire, will be fitted with Rud FELS Granit Plus X 23 tyre chains. Walters has successfully used Run chains in this granite quarry since they started working there in December 2012.

Below, right and far right: This Cat 992 is currently consuming diesel at a rate of between 80 to 85lph, compared with 120lph from an older 992G model that previously undertook this application.

WHATLEY QUARRY

The limestone reserves in the east Mendips area of Somerset are considered a nationally significant resource, serving major infrastructure projects such as Hinkley Point C and HS2. The Whatley Quarry has been operating since the 1960s, supplying crushed limestone aggregate to local markets by road, in addition to bulk shipments to depots in London and south-east England via a dedicated rail head.

Situated between the villages of Mells and Chantry, four miles west of Frome, Whatley is Hanson Aggregates’ largest quarry, currently producing up to six million tonnes of material a year. Within the 173-hectare site there is a ready-mixed

concrete plant and an asphalt plant, where the majority of the limestone extracted on site is consumed. The quarry area itself covers some 120 hectares and holds estimated reserves of a whopping 100m tonnes.

The Walters Group was originally awarded a load-and-haul contract with Hanson for their flagship Whatley Quarry in 2013. This resulted in a significant investment by Walters in a fleet of new equipment to serve this project, including Cat 992G wheel loaders, Cat 777 quarry dump trucks, together with a Cat 390 excavator and a range of smaller auxiliary equipment. Walters’ operators used this fleet to deliver more than 5m tonnes per annum to their client’s primary crusher,

which operates on a continuous choke feed basis over two shifts. It is estimated that over the six years of this initial contract, Walters hauled over 32 million tonnes of limestone. The renewal of the Hanson contract in 2020 resulted in another significant investment by Walters. In addition to upgraded site office and welfare facilities, it included five new Cat 777G haul trucks, together with what would turn out to be the first new generation Cat 992 wheel loader in the UK.

LARGE WHEEL LOADERS

A stand-out feature of Walters’ working method at Whatley Quarry is their use of a large wheel loader in addition to a mining class excavator to feed the fleet of quarry dump trucks. In other parts of the world, including North America, a wheel loader is the preferred loading method, but it is relatively rare to see one in such an application in the UK.

The two main advantages of using a wheel loader over an excavator are much greater mobility and the reduced need for support machines. Using a wheel loader, the operator can be far more selective on how to manage a face and far more easily move from one face to another, or get quickly out of the way for a blast. More importantly, a wheel loader has the ability to clean up after itself, virtually eliminating the need for a dozer and operator to remove any spilled rocks and maintain the pit floor.

The Walters Group currently runs five 100-tonne class wheel loaders from the Cat 992 family, not only in quarry applications, but also to load hot slag in a steel works. Much consideration was given to replacing the original 992G at Whatley Quarry with an updated 992K model. However, with a brand-new design from Caterpillar on the near horizon, which promised significant fuel and maintenance savings, the decision was taken to wait until the all-new 992 model was in production.

The most significant design change in the 992 over its immediate predecessors is its working equipment. Gone is the

futuristic mono-boom, replaced by conventional Z-bar linkage arms. The working method at the face of Whatley Quarry is ultra-efficient V-pattern loading, which places much stress on the righthand side of the bucket, as the wheel loader turns into the pile of blasted material. On the mono-boom 992G, these forces act upon a single bucket pin and, more expensively, on the single boom pin. A replacement boom pivot pin for a 100-tonne Cat 992G costs an astonishing £30,000, plus rebushing and associated labour costs.

OPERATOR FEEDBACK

Walters’ operator Shane Grant has been working on this site since 2018, initially on a Cat 966 loader before stepping up to the 992G. He said, “The new 992 is a brilliant piece of equipment and the best wheel loader I’ve ever driven by far. It has amazing performance and digs really well; it has lots of power to get the job done. The cab is exceptional too, as it’s a lot bigger than the previous 992G model. It’s very well laid out for the operator and the three big LCD screens cover everything you need to know about machine health, payload management

THE RIGHT BUCKET FOR THE JOB

Both Walters’ 992s have been specified with Cat’s new 12.2cu.m bucket, which features a dual radius shell plate design, allowing the centre of gravity of the full bucket to be pulled back, providing improved stability and material retention. The standard bucket is reinforced with horizontal and vertical Hardox steel plates at Walters HQ depot at Hirwaun. Regarding wear parts on these two new loaders, Walters has progressed from the K-series to the new Cat Avensis tooth and shroud system.

Above and below: The new Cat 992 replaced a mono-boom Cat 992G model with 24,600 hours on its clock, which is now a standby machine at Whatley Quarry.

and 360-degree camera systems. The visibility through the larger front screen is outstanding, as is the smooth joystick steering and lightweight controls for the front-end equipment.”

Shane feels the new design of lift arms has actually improved his visibility, as he’s now looking down on the bucket during the dig phase, rather than looking along the mono-boom. He reports that the most noticeable performance difference is muchimproved stability at full reach: “Stability and lack of sway of the lifting arms on the new 992 is in a different class compared to the old 992G. It’s just so much better and therefore more pleasurable to drive; I absolutely love operating this new Cat 992.”

Shane explained that he received first class training from Finning’s John Blackett on the all-new 992, which has a host of features to help the operator get the best from the machine. This includes

an integrated payload management system, where the contents of every bucketful of material is weighed. This helps to achieve the optimum number of passes to consistently reach the target payload of the haulers. Shane reports that, if the shot material is well fragmented, he can load a Cat 777G hauler in just four big passes, but most of the time its 95-tonne target payload is achieved in five quick passes, taking a total of 2.5 minutes.

In addition to the 992 wheel loader, Walters’ contracts manager Jon Lisk also has a new Hitachi EX1200 excavator deployed at Whatley Quarry. Three of the five Cat 777G haulers are usually assigned to the wheel loader, while a pair serve the large excavator. However, when working with a well-fired blast on a wide bench, Jon will switch one of the haulers from the excavator to the 992, as the big wheel loader will keep four trucks busy all day long in such conditions.

DATA-DRIVEN DECISIONS

The Walters Group has 40 years of collective experience getting the most from heavy plant, but nowadays this is supplemented by a host of data.

Jon uses Cat’s MineStar system to help manage the connected fleet and monitor production from detailed daily reports and a weekly summary, which are automatically generated and sent to his laptop. In conjunction with MineStar, Cat’s VisionLink system is used to monitor machine health.

But this is just the start of the process, as the Walters management team has carried out regular appraisals of individual aspects of their work at Whatley Quarry over the years.

This covers working cycle analysis including waiting times, payload optimisation, haul road condition/ maintenance, together with plant availability and use.

The use of dynamic site modelling allows them, for example, to optimise hauler payloads according to local conditions and topography, while minimising waiting times and long-term maintenance costs.

Left, below and far right: Operator Shane Grant states that the Cat 992 is a brilliant piece of kit, which has amazing performance and lots of power to get the job done.

Such a data-rich environment also helps the management team judge the practical impact of such massive investment decisions. For example, they discovered that, in well-blasted limestone, the 992 was around 30 seconds quicker than a 992G to load a Cat 777 dump truck. Even more if the big loader is used somewhat more aggressively to four-pass load 95 tonnes. Over a multi-shift working day, this adds up to around an extra hour of productive

Below: There is good visibility to the working area from the operator’s seat, within an over-sized cab with all the latest creature comforts and productivity aids.

time that, on a long-term load-and-haul contract, is of critical importance to the senior management of both client and contractor.

Obviously, one key data set is fuel consumption from the Stage 5 ultra-low emissions Cat engines fitted to the new haulers and wheel loader. Jon is pleased to report that the new 777G haulers, delivered earlier in 2022, have an average consumption of 45 litres per hour.

CAT 992 BRIEF SPECS

As well as a radical change of front working equipment, the new Cat 992 wheel loader features a complete redesign of the front and rear frames. Together with a new cab, Caterpillar claims that only two main components are shared with the previous 992K model: the tyres and the engine block. Even the wheel rims are different, to fit on the heavier-duty axles.

The 992 wheel loader is powered by the latest Stage 5 ultra-low emissions Cat C32B engine rated at 814hp. Together with enhancements to the transmission, axles and final drive, these driveline components are designed to deliver a 20% longer lifespan between planned replacement. Naturally these days, routine service points are safely accessible from ground level.

The 105.8-tonne 992 has gained six tonnes in weight over the previous 992K model, principally thanks to more durable components, which help to better balance its increased payload for improved stability. The tipping-to-weight ratio has increased from 53% to 58% on the standard lift arms of a 992 compared to a 992K, and from 49% to 53% on the high-lift arm variant. This is because the centre of mass of the machine as a whole moved backwards, also improving the machine’s overall stability.

Over 6000 examples of the Cat 992 family have been sold since it was introduced in 1968, making it the most popular large mining wheel loader model of all time. The latest 992 model sets new standards of productivity, plus reduced maintenance costs, offering up to 48% greater payload fuel efficiency than the previous 992K model.

OPERATOR FEEDBACK:

CAT 777G

In the cab of the latest Cat 777G, (fleet number 12) is Tyler Pole who said, “The latest 777G is a really nice truck to drive and the repositioned driver’s seat, closer to the door and nearside mirror, provides better visibility for spotting the truck under the 992 loader. This new truck also has everything you could wish for and more: a quiet and comfortable cab, plenty of pulling power on the ramps and loaded with good driver aids, such as its front and rear camera systems.”

Spill boards have also been added to the skips of the new 777Gs to help obtain a more consistent 95-tonne payload in this limestone application. The Walters Group has also gone to the considerable expense and time of rubberlining the skips with 120mm-thick floor, side and headboard mats to help keep noise and vibration levels low, both for the benefit of their operators and the local community.

This represents a 15% to 20% improvement over their 2013 versions of the 777, which burn 50 to 55lph.

Now with 750 hours on its clock, it is beginning to look as if the new 992 wheel loader is living up to the rather astounding claims made by Caterpillar regarding its projected fuel consumption, which is currently an exceptionally low 80 to 85lph. This compares to an average of around 120lph from their 24,000hr 992G model, which was treated to a replacement engine at 14,000hrs. That’s a huge fuel saving on a machine that is

working 18 hours a day. A clean-burning engine that consumes less diesel also represents a significant reduction in carbon emissions.

A second new Cat 992 is currently being commissioned by the Walters Group for their long-standing load-and-haul contract at the Bardon Hill granite quarry in Leicestershire. Jon concluded, “While it’s early days, first impressions of the new 992 are good; it’s meeting our high expectations in terms of extra performance, quick duty cycles and significantly lower fuel burn than our previous Cat 992G model. Of course, one element that is equally important is we’ve got an excellent team of competent, well-trained and enthusiastic quarry face operators to extract the maximum performance from the machine, which has been well received by them.”

HITACHI

DRAINAGE FAN

Alan Browne is a man who loves his Hitachi excavators, stating that he wouldn’t have anything else. A native of County Kerry, he is based in Birmingham and works across the UK undertaking drainage work.

Supported by a small team, he has extensive experience of installing drainage systems: from housing developments to new industrial complexes, he has done them all. We first met him working for one of North Wales’s leading civil engineering companies, John Kelly Construction. He said, “John had asked us to put in all the deep drainage throughout a site in Colwyn Bay. It was a typical housing development, where we had some deep excavations to undertake in what was going to be the main road through the site, while still keeping access to the project open at all times.”

Alan and his team then completed another large project for Kelly

Construction, before undertaking similar contracts through the Midlands. They are currently looking forward to returning to North Wales to work with this company once again.

Alan undertakes and manages projects from the cab of his 2019 Hitachi 350-6, which he says is probably the best excavator that he has ever owned. In long carriage (LC) configuration, it remains planted to the ground during extreme lifting and excavation operations. For example, during our subsequent site visit, he was excavating 1050mm-diameter concrete pipes out of the ground and then lobbing them into an adjacent dumper, with apparently little effort.

He commented, “We’ve lifted some big pipes and manhole bases with her and she’s always a stable

machine. It’s also a very fast machine and there’s also plenty of power there, but this doesn’t make it undriveable, as it’s very smooth and precise.”

“WE’VELIFTEDSOMEBIGPIPESAND MANHOLEBASESWITHHERANDSHE’S ALWAYSASTABLEMACHINE”

Below and inset: AJ Browne Civil Engineers is a specialist drainage contractor running three frontline Hitachi excavators.

Paul Argent visits a key site in the manufacture of rolling stock for the HS2 project to speak to an ardent fan of Hitachi excavators

Alan has removed the auxiliary hydraulic services from the dipper stick of his 35-tonne excavator, except for the quickhitch line, to minimise its width and the potential for damage, as he explained: “It’s just too easy to snag them on a trench box. Not only does this cause damage to the machine, with the associated downtime, but there’s also the risk of contaminating the ground you’re digging in.”

SITE BACKGROUND

We later met Alan and his small team in a very different working environment to a new housing development, at the former Bombardier train works in Derby. This site has been used to build and repair trains since 1840 and has recently been taken over by Alstom, one of the world’s leading engineering companies. In a joint venture with Hitachi, Alstom will build phase one of the rolling stock requirements for the new HS2 route, and the Derby facility will play a major role in delivering this contract.

Alstom is undertaking a significant programme of upgrading works on the site, and infrastructure specialist Buckingham

Group has won the contract to deliver additional train manufacturing and testing capabilities. In the limited space between an existing maintenance facility and the busy mainline railway, a new manufacturing shed is to be constructed, along with additional rolling stock testing and storage lines.

WORKING METHOD

Working on behalf of RMF Construction Services, Alan’s first task on site is to remove sections of the existing concrete drains and associated gullies. He will then immediately replace them with new HDPE drainage elements. Working across the footprint of the new facility in this way ensures that the site doesn’t flood as the works are in progress, allowing early access for the chain of sub-contractors.

Alan said, “It would be a lot easier if we were able to rip up the existing drains and then re-lay the new. As there is a tight timescale for the project, we have to complete the works as we progress, so other trades can follow on behind us.”

Saying that, Alan’s approach to undertaking drainage work seems ideal for

such working limitations, as he deploys all three of his front-line excavators to such jobs. All Hitachi models, they include a wheeled Zaxis 145W, which on this contract is used with a hydraulic breaker and to undertake general loading and carrying work. A short-tailswing 225USLC-6 excavator with a suitable hydraulic attachment undertakes the compaction work.

Alan continued, “We have a limited amount of time to complete the works: whether on this site or any other one we work on, we have to work productively at all times. We have my Zaxis 350 doing most of the excavation and laying works, while the Zaxis 225 undertakes backfilling and compaction works.”

With Alan stirring the levers on the 35-tonner, he quickly changed buckets to allow him to excavate a new location for a manhole base. With the ground being made up during the installation of the previous pipework, he ensured there was sufficient room around the base to stop any ground from slipping in. This chamber is just over a metre below the finished ground, so trench boxes weren’t being

used. As the work progresses, deeper cuts will be required, as Alan commented, “That’s another thing I like about the 350. Even in the stickiest of ground, the digger will always have the power to lift the trench box clear.”

The Zaxis 225USLC-6 is used for compaction duties around the pipework with an Allied compactor plate, Alan said, “It’s a quicker and a far safer option than putting a man in a trench with a compactor. We know there’s going to be no issues with any of the ground subsiding around our pipework in the future. This puts our minds and those of our clients at ease.”

The 145W wheeled excavator is configured with a front blade, rear stabilisers and a two-piece boom to provide a versatile workhorse for the team. It was originally purchased for works at London City Airport, which mandated the use of the Fhoss Halo safety lighting system.

The system is great in the dark, but according to Alan is useless in the daytime: “We do wonder why these systems have to be fitted sometimes. At night, the machine is all lit up with working lights both front and

rear. Having a Halo light doesn’t help people identify the machine, it’s just another thing that detracts from using common sense on site.”

The 145W was kept busy at the Derby project breaking out the gullies and bends round the existing shed, using an OKB hydraulic breaker. Following a quick change to a bucket, the machine was then off to the top of the site to load pea gravel into the two

nine-tonne capacity dumpers. Alan hired them in for the project, saying, “We tend to hire dumpers in for each specific project, as it’s more cost-effective for us.”

As this project is on track to finish on schedule, Alan is already starting to look at other projects, including a return to North Wales to work for the John Kelly team.

He said, “We like North Wales,” and then, with a grin, “It’s like being back on holiday.”

“WEHAVEALIMITEDAMOUNTOFTIMETO COMPLETETHEWORKS;WEHAVETOWORK PRODUCTIVELYATALLTIMES”

Left, inset and below: Using the 350 for excavation and pipe-laying, the short-tailswing 225 for compaction and backfilling and the wheeled 145W for breaking and loading resulted in rapid progress.

Above, inset and right: Alan Browne loves his Hitachi excavators; he reckons that his three-year-old 350LC-6 is the best machine he has ever owned.

second-generation family business established in the north-east of Scotland in 1973, Limehillock Quarries runs a sizeable operation from its HQ at Spey Bay, Moray. Richard Murray spearheads the operation, which includes seven active quarries and gravel deposits, together with demolition work and, through other firms in the group, a wide range of associated activities.

They include LAS Plant Hire, which offers plant and tool hire, together with access platform and crane hire, from depots at Inverness and Spey Bay. In 2017, the long-established and well-respected haulage company Baillie Brothers became part of the Limehillock Group.

However, quarrying remains the core activity of the business, which produces a variety of materials from its various sites. They range from the production of common aggregates to more valuable deposits of magnesium and calcined limestone; they even operate a marble quarry. In addition to serving their own processing needs across these sites, contract crushing and screening continues to be a key activity for the firm.

BUYING DECISION

Very much a staunch JCB customer over the decades, as the British firm’s excavators and wheel loaders are in use across its various quarrying operations, Limehillock Quarries’ management

and inset: Weighing close to 45t, the Doosan DX420-7 took over primary loading duties on the Limehillock Quarries’ fleet from a smaller JCB JS370 excavator.

Below

team had a difficult decision to make last year. Their JCB JS370, with additional ballast, was working well loading a series of crushers and screeners at the face, but this application was at the top end of its performance envelope. A step up to the next excavator weight class was the obvious route to take, to get the best from their extensive fleet of tracked processing equipment.

The trouble was that such a 40-tonne-plus excavator was not available from JCB, and there was an on-going concern about the operating costs of running a larger machine, to say nothing of its purchase price.

However, after much detailed consideration, it was decided to introduce a Doosan DX420-7 to the quarry fleet, which in standard spec weighs 43.5 tonnes.

Richard said, “Previously our largest excavator was a JS370 and, even though we did decide to increase the size of the machine, it was important not to increase too much, as a larger machine would have implications for transport. This is why the DX420 strikes the right balance of capacity and still remains in an ideal size class for movement between our quarries.

“We have been using JCB machines since

1975 and they have been really great for the company. Our JS370s have been excellent and we have had no issues with service. Since Doosan have been showing around the country, we decided they deserved a closer look. That led us to ask the question: would it be worthwhile to change to a machine that is more expensive than those we would have bought?

“Of course, this can only be answered over the longer term, but for us the machine looks right and is well built for quarry work. We also saw the commitment to service from

SITE VISIT

Its large working envelope and the stability to work at full reach, enables the DX420-7 to provide a fast, comfortable and efficient way to load a mobile crusher.

The Doosan has been the flagship excavator at Limehillock Quarries for just over a year now, in the extremely capable hands of operator Gordon Souter, whose previous mount was the JS370. We met them on a contract crushing job, where the team were clearing a large site down to formation

Doosan dealer Balgownie as being a strong argument in favour of the machine. This is the fourth machine I have bought from them, the others working on the plant hire side of the business.”

“EVEN

level, to enable the construction of a whisky storage facility.

Running on narrow 600mm quarry track shoes on a standard fixed undercarriage, the width of the DX420-7 is 3.35m. A wide load, but still more practical than moving a 50-tonne-plus machine about this rural upland region. In practice, the big Doosan is frequently relocated around the firm’s various quarries without any real issues.

This somewhat over-sized undercarriage, together with the standard eight-tonne counterweight, helps to provide a high level of operational stability when working at full reach. Configured with a 6.7m mono-boom and a 3.25m long dipper, the machine also carries a Geith quick-hitch.

When feeding a crusher, the excavator is equipped with a narrow but deep bucket, which minimises the possibility of in-feed blockages. A wider digging bucket is used when it is being used for excavating and handling material in the firm’s sand and gravel deposits. This DX420-7 also has a ripper tooth in its arsenal of attachments, together with auxiliary lines to run a high-capacity hydraulic breaker.

OPERATOR FEEDBACK

Perched on a pile of extracted rock at the warehouse development site, the DX420-7 was loading a Terex Finlay J1170 crusher, a combination that had already built up a considerable stockpile of processed material. With the ability of the big Doosan to work at full reach, there is a large volume of material within its grasp, resulting in fewer relocations of both excavator and crusher.

Gordon was delivering smooth and surprisingly fast loading cycles, accumulating a full load every time, after the bucket effortlessly penetrated the pile of rock.

He said, “Even though it weighs almost 45 tonnes, its speed of operation enables it to work like a much smaller machine. It gives this level of speed without affecting breakout force, which is very impressive regardless of which bucket I’m using, and also when

DOOSAN DX420-7 DRIVELINE

This latest generation of Doosan excavator is powered by a six-cylinder, Stage 5 ultra-low emissions Scania engine. It is rated at 257kW at a modest engine speed of 1800rpm, which is much of the basis for the excavator’s decent fuel economy.

The engine drives a hydraulic system that provides an oil flow of 335 litres per minute from each of the two main pumps, all controlled by Doosan’s latest engine/hydraulic management system. It enables the operator to select between four work and four power modes, which can be further fine-tuned through the cab’s main control monitor.

From the perspective of daily checks and routine service points of this driveline, everything seems to fall easily to hand. Its operator particularly appreciates its refuelling system and the ease of access to the Ad-Blue tank.

The DX420-7 is fitted with Doosan’s Connect telematics system, the resulting service history and operating data being easy to comprehend and use.

Above: Operator Gordon Souter highly rates the first Doosan excavator to enter the Limehillock Quarries fleet, following over 40 years allegiance to JCB.

Right: This excavator is equipped with a wide array of additional LED work lights, to help with full shifts in little daylight this far north during winter months.

Routine service items are easy to get to, with good access up top, over the AdBlue tank and then past the diesel refill point, to the engine compartment.

I’m extracting rock with the ripper tooth.

“The Doosan cab is very well finished and gives a very high level of comfort, which makes it a pleasure to operate over the course of a full day. The heated air seat and working position is generally excellent, while the sense of space inside the cabin is also very welcome. The cab design provides good visibility too and a glance at the 360-degree camera system gives total awareness of everything that is going on around the machine.

“The Doosan is a first-class machine and I couldn’t find fault with anything in either its design or the way it performs. It has good digging power and is smooth to operate with a well laid-out cab and a high level of comfort. To be honest, there is nothing I would change about it.”

OTHER FLEET

The Doosan DX420-7 is part of the quarry’s production fleet, which is dominated by JCB excavators and wheel loaders, but also features Liebherr wheel loaders.

As a consequence of the number of quarry locations and the diversity of projects undertaken, when it comes to contract crushing and demolition, a number of low-loader combinations support these activities. Their flagship HGV tractor unit is a Volvo FH16 750 Globetrotter XL with an 8x4 axle configuration, ideal for heavy haulage duties. In addition to a four-axle Nooteboom low loader, the FH16 is also used with tipping trailers and step-frame units.

CONCLUSION

Over the last year or so, the Doosan has performed well across different applications and has settled well into the varied but challenging role, as Richard explained, “The DX420-7 is normally working at the head of a full train of crushers and screens and is the right size for this type of work. It wouldn’t be viable to run a larger machine in the 50-tonne class, as the greater investment involved is not in line with the application.

“The fuel efficiency has improved a lot on the machine as the months have passed and, in relation to its size class and the work it can do, it is efficient. It is a little thirsty on the Ad-Blue side though, and a filter kit to do a complete service is more expensive than we would have paid for our JCB excavators. That said, we are dedicated to using genuine filters and keeping the machine original, which can only help aftermarket value by having a fully traceable service history.

“We will be looking at all the running costs over the machine’s working life, and taking resale value into account, before we can say if buying a more expensive excavator has been a sensible long-term decision. But for now, we are very impressed by the early indications.

PROCESSING FLEET

Over the decades Limehillock Quarries has remained loyal to Terex Finlay crushers and screeners, which have been found to produce consistently high levels of output and overall reliability. Heavily reliant on mobile processing plant, Terex Finlay kit suits the operations at Limehillock Quarries particularly well. The firm runs a comprehensive fleet of crushers and screeners, to enable a machine train to be formed to suit specific production requirements.

Below and inset: The fleet of Limehillock Quarries is dominated by Terex Finlay mobile crushing equipment, together with JCB excavators and wheel loaders, plus Liebherr loaders.

“WEWILLBELOOKINGATALLTHERUNNINGCOSTSOVERTHE MACHINE’SLIFE,BUTFORNOW,WEAREVERYIMPRESSED”

TRANSMITTING FUEL ECONOMY

Paul Argent reports on the hydrostatic dozers and CVT-driven loaders on the fleet of Swindon-based Earthline

Established over 30 years ago, Swindon-based Earthline operates eight sites across the region, which offer primary and recycled aggregates, along with inert tipping facilities. With 86 eight-wheelers, the firm runs one of the largest privatelyowned fleets of tipper trucks in the area. They are used both for the distribution of aggregates from their quarrying and recycling activities, and delivering inert material back on to their sites to restore former quarry workings.

Across their sites, Earthline currently runs 65 items of operated plant, plus numerous examples of mobile crushing and screening machinery. Over the past few years, Liebherr has been steadily supplying more machines into this fleet. This has been largely driven by the need to improve fuel efficiency, something Earthline’s MD, Philip Coplestone, is eager to progress.

The first Liebherrs – three hydrostatic PR746 dozers – were delivered following a successful trial in 2017. They were replaced in 2021 by PR736 models. With a maximum operating weight of 25 tonnes, the PR736s were smaller than their predecessors, but they have more than kept up with production requirements, while delivering good fuel economy.

Above, below and inset: A batch of Liebherr L566 XPower wheeled loaders joined the fleet in 2021 and are proving to be comfortable, productive and fuel-efficient.

WHEEL LOADERS

Alongside the arrival of the PR736 dozers in 2021, Earthline also took delivery of four Liebherr L566 XPower wheeled loaders, which feature a continuously variable transmission (CVT). The transmission constantly adjusts the ratio of power diverted through the hydrostatic and mechanical elements of the box, in response to any given demand on the machine. One result is a smoother drive and seamless increases in speed and

“THEFIRSTLIEBHERRS–THREEHYDROSTATICPR746 DOZERS–WEREDELIVERED FOLLOWINGASUCCESSFUL TRIALIN2017”

power, together with an unrivalled increase in torque and almost zero wheelspin when pushing hard into a stockpile.

Another benefit of the XPower transmission is improved fuel economy, as the power demands made by the CVT system tend to result in the engine running in a lower speed band, closer to its maximum torque.

There is no doubt about it, a CVTequipped machine requires a different operating style to one with a standard transmission.

Earthline’s operators didn’t like their first few shifts in the Liebherr loaders, but within a week or so had settled into the new style. Today their feedback, partly thanks to the transmission, is that they are far more comfortable to operate than their previous machines.

They are used across both Earthline’s quarrying and recycling operations, handling a variety of materials, either feeding crushing and screening plants, or loading finished products into HGV

trucks for onward delivery.

In operation they can fill their 4.2cu.m capacity, straight-edged bucket quickly and smoothly, whatever the material they are handling. For load and carry operations, something the Earthline machines undertake on almost a constant basis, the Liebherr loaders accelerate quickly. This provides faster travel times between stockpiles, resulting in considerable productivity gains over traditional mechanical drivelines.

LATEST DOZER

Earthline has recently added a further PR736 dozer to its fleet, to help manage its inert tipping site at Shellingford. This latest Generation 8 model was specified in full low ground pressure (LGP) configuration and is powered by a four-cylinder, seven-litre Liebherr engine rated at 238hp, which drives through Liebherr’s tried-and-tested hydrostatic transmission.

In this application the three ranges

provide a maximum speed of 6.8mph in either direction. The infinitely variable hydrostatic drive is electronically controlled and automatically adjusts travel speed and drawbar pull to match the changing load conditions.

At the time of our visit, a spell of good weather had dried the tip area out nicely. Any prolonged rain can turn it into a no-go area for the constant flow of eight-wheel tipper trucks depositing their loads. In these circumstances, two dozers are required to push the material a considerable distance from solid ground to the live tipping area.

However, the tip was dry and firm, allowing the trucks to deposit their loads close to the dozer. Equipped with a 4.1cu.m straight blade on outside draft arms, the PR736 easily pushed out a full 20-tonne load in just two passes, easing the material further into the worked-out cut.

CONCLUSION

Earthline’s latest Liebherr is a 30t capacity TA230 articulated dump truck, which joins a mixed hauler fleet used to carry material from the extraction areas back to the screening and stockpiling area. It is early days yet, but indications are extremely positive. The site manager at Shellingford said, “Our prime objective is to get material out of the gate as quick as possible and get the returning trucks tipped as quickly and safely as possible. The Liebherrs have been performing exceptionally well since they arrived and have impressed us all. The loaders are more than up to the job and the dozer matches the performance of the larger machine we also have on the tip. They have plenty of grunt when it comes to digging into the stockpiles.

“We don’t keep a detailed check on the fuel consumption, but we check the number of times they are filled up in a week and, so far, the Liebherr loaders and dozer aren’t as frequent visitors to the diesel tanks. This has made a huge difference to our fuel bills following the changeover to white diesel.”

The latest Liebherr addition to the Earthline fleet is a TA230 articulated dump truck, which is already creating a positive impression.

Earthline’s latest Liebherr dozer is a 238hp PR736 LPG model, on duty spreading material on the inert material tip at Shellingford.

TRADING UP

Nick Drew reports on a young businessman and his latest excavator, a Case CX130D equipped with a Steelwrist tilt-rotator

There cannot be many who have owned a large variety of construction machines by their mid-20s. However, Alex Sillifant (26) has done just that and is continuing to expand his AMS Plant & Agri business, based in the village of Egloskerry, east Cornwall.

By the time he was 19, Alex already had considerable machinery experience. From an early age he accompanied his father to work on Saturdays. He runs a haulage business specialising in muck away, aggregates and bedding sand for local farmers. More often than not, they had to load themselves, with whatever equipment was available. Over the years, Alex became extremely proficient at loading with a range of machines.

He then undertook a two-year course on construction machinery at Duchy College. It also provided him with the necessary CPCS tickets to operate on construction sites, a sector of the industry he has managed to avoid over the years. While attending college, he also worked for his uncle,

spreading lime and sea sand on to fields. He continued to do this after leaving college and went on to work for local agricultural contractors.

FLEET FOCUS

Aged 19, Alex was ready to purchase his first machine, initially looking at eight-tonne ‘swing shovels’, as 360-degree tracked excavators are affectionately known in the West Country. However, Alex’s father suggested that he would be better buying a backhoe loader, so he could flit from job to job under his own steam, without the need for transport. Alex was also inspired by a local backhoe legend, owner-operator Johnny Littlejohns, who was something of a mentor to him in the early stages of his operating career.

Alex said, “He was one of the only guys around Egloskerry and Launceston with a backhoe loader and was, without a doubt, one of the best around. He is semi-retired now, but still takes some beating.”

Figuring out that there is always work on local farms for a wheeled digger, seven years ago Alex bought his first machine, a used Volvo BL71 Plus backhoe loader. As the workload increased, he purchased a Fendt tractor and dump trailer to work in conjunction with the backhoe.

Always looking for different ways to expand his business, Alex then considered adding a tracked loading shovel to his fleet. However,

“THEREISALWAYSWORK ONLOCALFARMSFORA WHEELEDDIGGER.SEVEN YEARSAGOALEXBOUGHT AUSEDVOLVOBACKHOE LOADER”

Above and below: This Case CX130D is equipped with a Steelwrist X18 tilt-rotator. On this job it carries an Intermercato grab, which is used in conjunction with one of their tree-shear attachments.

after a deal fell through, he reconsidered his options, coming to the conclusion that the time was right for a swing shovel, which would be a lot more versatile in the long run. It led to the purchase of a Komatsu PC130-8 tracked excavator, followed by a couple of Volvo EC140Bs, together with a Kato 1.7-tonne mini-excavator. Alex says that the Kato is a cracking little machine; he was sad to see that they only had a short time in the UK market.

After the last Volvo excavator, Alex decided to go for something a bit different, purchasing a two-year-old Hidromek HMK102S backhoe loader. He explained, “It was OK, but it did suffer from some leaks and in reality the dealer was too far away. I did like the digger, the only reason I sold that one was because a Case 590ST became available, which was five years old, but incredibly had only done 450 hours. I bought that backhoe, which made a lot of sense really, as our local dealer M&M Plant Sales is right on my doorstep.

“I later replaced it with a New Holland, before coming full circle and purchasing

another Volvo BL71 Plus, on a 10 plate, which is still with us to this day.”

CASE SWING SHOVELS

There is plenty of light-hearted comment in the local plant community about Alex’s ‘revolving door’ policy when it comes to machine selection. He clearly can’t resist a good buy, but if he can make a bit of money and trade up along the way, so much the better. More recently, Case have become Alex’s favourite excavators, having purchased and sold on a couple of CX130C models, before acquiring his current CX130D model.

Eagle-eyed readers may recognise this excavator as having been owned from new by another local plant man, Olly Swiggs,

who we featured in the June 2019 issue of Earthmovers. Olly’s business model had changed; he was venturing into the world of tracked loaders and eventually dozers, so the excavator had become somewhat surplus to requirements.

This CX130D was seen as an ideal addition to the AMS fleet, Alex took delivery of it in February this year with just 2300 hours on the clock. He has since put just over 1000 hours on it and said, “Olly’s contract with this machine was ending, so it was an ideal opportunity for me, as I needed to get through more work in a shorter time.”

Alex reports that the Sumitomo-built Case CX130D has been absolutely bomb proof since he bought it. With the dealer support just up the road for filters and service, it just works for him and his business.

As the vast majority of the work for his excavators is agriculture-related, a Steelwrist X18 tilt-rotator – an exdemonstration model – was fitted, as Alex explained: “The combination with the tilt-rotator and attachments enables me to do so much more work on my own. That is increasingly important, as it’s becoming so hard to find operators these days.”

Above, left, inset below and above right: This well-known Case CX130D was acquired in February 2022 with just 2300 hours on the clock. It hasn’t missed a beat as Alex has put another 1000 hours on it.

SITE VISIT

We recently met Alex on a mammoth hedging job a St Tudy in Cornwall, where his Intermercato grab and tree shear were being put to good use on the tilt-rotator. The landowner had received a stewardship grant to lay the hedgerows, which had been left to grow for the past 25 years. This involved Alex shearing a 4km stretch of trees, some of which had grown to over 30 feet tall.

Hedge-laying, where partially-cut woody stems are folded over, is a traditional way to form stock-proof field boundaries. On this job, a significant volume of large timber was removed from the hedgerow, which will be chipped on the farm for use in their bio burner, so nothing leaves the site.

Alex already has a further 8km of this work in the pipeline, which must be finished by 31 March 2023. He has just added a used, but tidy Case CX130B excavator to his fleet to help with this huge task, if he can find another operator.

Most of Alex’s work is for local large-scale farmers, many of whom are more than just customers, but also life-long friends, which results in enjoyable work and returning custom year in and year out. By his very nature, Alex is not one to blow his own trumpet, but he certainly puts the effort in, often working over 70 hours per week.

It was inspiring to see Alex at work in what is his natural habitat. He concluded, “I love the work, as I am generally left alone to get on with the job. If I’m honest, I really don’t think mainstream construction site work would suit me at all.”

“THECOMBINATIONWITHTHETILT-ROTATOR ANDATTACHMENTSENABLESMETODOSO MUCHMOREWORKONMYOWN”

Alex Sillifant runs the AMS Plant & Agri business based in east Cornwall, currently using a tilt-rotator and attachments to undertake large-scale hedge maintenance work.

TECH-SAVVY VETERANS

Based at Bagenalstown in County Carlow, Dowling Brothers Civil Engineering has, over the decades, evolved from its roots as a land drainage specialist, weathering economic downturns along the way while investing in the best machinery for the job. The operation, perhaps now best known for sports pitch construction work, was established in 1972 (see panel overleaf). It is run by brothers John, Billy and Michael, who inherited their work ethic and interest in plant from their late father, Thomas Dowling.

John recalls, “Our father was a carpenter by trade and then started importing axles and building trailers in the years following World War II. Based on his deep interest in all things mechanical, he then started a plant hire business in 1953. The first machine was an Allis Chalmers 25 dozer, which was a TVO machine and did a lot of work on land reclamation.

Below and inset: Although Komatsu excavators feature strongly in the fleet, Dowling Brothers’ take an open-minded approach to machine selection.

Eoghan Daly reports on a family business that has invested in labour-saving machinery over many decades

EARLY FLEET PROFILE

The Dowling Brothers’ business was established in 1972. With an interest in plant and a desire to mechanise land drainage operations, in 1976 they purchased their first trencher, a Howard Mark 5. Although its performance and reliability left much to be desired, it still represented a significant step forward from traditional labour-intensive working methods.

It was replaced in 1980 by a Bart 171 trencher, which took their operations to a new level. It was an extremely strong machine, able to cope with the challenging ground conditions, as John Dowling added, “Irish conditions are much different to anywhere else, as the ground is continuously changing. In Europe, ground conditions are more likely to be pure clay with few if any stones, making it much easier to commission and run a trencher.

“But here, we have a mix of everything, which puts a big strain on a chain trencher. The Bart trencher coped with these challenges very well and also had the added benefit of using a laser guidance system, which was much more accurate than the profiles we had been using previously.”

The Bart was replaced seven years ago by a Mastenbroek 1515 trencher, which is regarded by the brothers as the ultimate tool for intensive field drainage works.

From a fleet that was originally based on dozers and then a trencher, a number of JCB backhoe loaders were acquired, followed by a succession of Hymac excavators. The Hymacs are recalled as being effective in relation to the machine choices available at the time, but were overshadowed by Poclain excavators, most notably in operator comfort and convenience.

Although their Poclain 75 and 90 models were indeed dogged by recurring oil leaks, they were certainly not as problematic as some would suggest. Far from it, as the examples on the Downing fleet successfully completed considerable long-term service with the firm.

John commented, “The Hymac excavators may have got through a lot of work, but were not without their problems. Even though they were from the same era, once we moved on to Poclain, they were in a completely different class and really were machines that were very much ahead of their time.”

He then imported an International TD-9 from the USA, which was an amazing little machine based on the work he could do with it. It only had a 35hp diesel engine, which was started by a petrol unit. He really had a great pair of hands and had his own lathe and a fully equipped machine shop and even went on to repair clocks in his spare time.”

The young brothers had an early introduction to working with their hands and backs, as John continued, “We would go and help out after school, on jobs like laying clay pipes on land drainage. We have seen both sides of the industry, having started out with the manual side and being involved long enough to enjoy the benefits of modern technology.

“Some would say being in business with your family brings challenges, but it is a model that has worked really well for us over the years. When we go to work on a project, we all bring our own individual contribution to it and we know each part of

the job is done properly. There has never been a time that I have not looked forward to going to work. Enjoying what we do is the secret to our long-term survival as a company.”

EMBRACING CHANGE

Another element in the firm’s longevity is embracing change and taking new ideas on board: “It’s never a good idea to accept anything as being the ultimate; we always believed in being open to change and advancement from the very start. We were probably the first in Ireland to use laser guidance on a dozer, having used these systems on our trenchers since 1980.”

Komatsu remains the dozer and excavator supplier of choice for the Dowling Brothers (see panel). That is not to say that buying decisions are automatic, as several options are considered on each occasion. For example, for the past few years the brothers have kept an eye on Hidromek machines, after initially being

Above, below and above right: Dowling Brothers currently run a single dozer on their fleet, a multipurpose Komatsu D65PX configured with a six-way PAT blade and a Leica 2D machine control system.

impressed with their build quality when seen at an Intermat show. After the appointment of a local dealer, KOB Plant, 18 months ago they bought a 14-tonne class HMK140 excavator.

John said, “We had every faith in Hidromek from the very start and it has since proved itself to be just the machine we expected. Based on our experience so far, we would have no hesitation in buying another. It has great digging power and is also very smooth on the levers, which means it’s ideal for fine work.

“The only negative we see is that, when it comes to running attachments such as the mulcher, the hydraulics do not perform quite as well as some other 14-tonners we’ve run, like the Komatsu PC130. But overall, it’s still an excellent machine.”

Fitted with an i-Dig machine guidance system, the Hidromek is proving to be a simple and cost-effective means of working

to a pre-set level, as John confirmed, “The i-Dig system takes the onus off the operator and is another vital tool in our arsenal of systems to help get through the work more efficiently.”

MULI-PURPOSE DOZER

As pioneers in using precise 2D machine guidance muckshifting techniques in Ireland, a large percentage of Dowling Brothers’ current projects relate to the construction of sports pitches and the like. It’s an application where the low ground pressure Hydrema haulers come into their own, but one where the focus is very much on achieving the final grade profile.

In the past, dozers were a large element of the Dowling fleet, but today the firm runs a single multi-purpose machine, a Komatsu D65PX. It is large enough to work on civil engineering projects,

KOMATSU FLEET

When it came time to replace their last three Poclains, having good experience running Komatsu dozers, the firm also turned to the Japanese manufacturer for their excavators. It was the start of a long-term relationship with Komatsu, which continues to this day.

John Dowling said, “We began using Komatsu dozers including 60, 65, 80 and 85 models, which have brought great satisfaction, as some worked up to 32,000 hours with very few problems. On excavators we have had Komatsu 210, 222, 240 and 300 in the early years, which have also been first class machines. In the event of a problem, we have had excellent service from the different dealers over the years, starting with Tracell, then MacCandless and now McHale Plant Sales.”

The largest excavator on the fleet, a Komatsu PC360-10 is very highly rated, especially when contrasted with the Hitachi 350-3 it replaced, which experienced repeated hydraulic issues. Purchased used from McHale with just 3000 recorded hours, it never failed to deliver.

John continued, “Even though we run a mixed fleet, we continue to be big fans of Komatsu. We have run 30-tonne machines from Hitachi and Kobelco in the past, but see the PC360-10 as being in a different league. It’s an ideal machine, as it’s big enough for bulk earthworks and an ideal match for our two A35F ADTs, yet is still small enough to do a full range of other work on different site types.”

such as road construction jobs, but also versatile and able to deliver precise final grades on sports pitch developments.

This example differs from the vast majority of D65 dozers in Ireland, as it is configured with a six-way power angle tilt (PAT) blade, complete with folding outer sections to ease transport issues. Such working equipment is usually reserved for smaller dozers dedicated to finishing works.

On a 20-tonne-plus D65PX, this set-up is equally at home in intensive pushing and

Right and below: The main earthmoving fleet consists of a pair of Volvo A35F articulated dump trucks, matched to a number of Komatsu excavators.

levelling work, but also performing trimming and final grading to the strictest of tolerances.

John explained; “We were using a Komatsu D58 dozer with laser guidance and wanted to upgrade. We searched the internet and found this D65PX with a folding PAT blade in Poland, which was exactly the machine we were looking for. It was imported five or six years ago and has proved to be ideal for our needs.”

GUIDANCE SYSTEMS

No strangers to laser-based 2D machine guidance systems, after a visit to the Irish Ploughing Championships in 2019, the brothers left with a very positive impression of Leica systems, as shown by Irish dealer Levelling Equipment Services. Dowling Brothers’ first experience with Leica products was the dozer-specific iCON iGD2 2D machine control system, which was fitted two years ago to their Komatsu D65PX. They have gone on to invest in a Leica GPS rover system, which has proved to be an invaluable surveying tool and is in continual use across their projects.

John said, “The system we use on the D65 paid for itself in the first year of use. If we take a full-size, all-weather playing pitch

measuring 100 x 150 metres and just grade off 50mm too much, it is a massive extra expense for stone to build back up to the required level. Using a system like this allows us to work to specification every time. There are no surprises from additional costs and it helps us stay within budget on a project, while doing work to a very high standard.”

The 2D system on the dozer uses dual power mast laser control units. Slope and elevation grading is achieved either by manual or automatic control, and working independently of slope direction is possible. Operator Billy Dowling said, “Using this system, I can go to any part of a playing pitch development and work to grade in either cut or fill situations. The level of accuracy it can give is incredible and, when using it in automatic mode, it takes away much of the pressure from me as the dozer operator. It has proved very reliable too and needs minimal effort to set up.”

A Topcon machine control system also plays a vital part in their sports pitch construction activities, fitted to a Massey Ferguson 3625 tractor, running on super flotation turf tyres. It hosts an in-house designed and built grading box, which is

Top, above and below: An MF 3625 tractor, running on flotation turf tyres, uses an in-house grading box controlled by a 2D Topcon system.

“THEREAREWONDERFUL OPPORTUNITIESFORANYONE WITHAGENUINEINTEREST, ANDAGOODLIVINGTOBE MADEFROMIT”

a result of the Dowling family’s considerable hands-on experience. It is ideal for less demanding precision levelling of stone, especially on athletics tracks and allweather pitch bases. A key factor in the choice of Topcon was their willingness to produce a system compatible with tractor electrics, which could achieve both automatic and manual control of the attachment’s functions.

CONCLUSION

John said, “When I think back to the old dozers, things have really come a long way since our father’s time. The one regret we have is not preserving some of the older machines. Our search for an International TD-9 with the Ruston Bucyrus-type blade continues, since we would like to mark our origins in the industry.

“Much has changed over our time working in the plant and civils sector and all has been positive, apart from the big problems attracting young people into the industry. There are wonderful opportunities there for

HAULING FLEET

When it comes to articulated dump trucks, the firm runs a pair of Volvo A35F units, which are seen to offer the ultimate balance in terrain friendliness in tandem with a worthwhile load capacity. Used across the company’s projects, they have proved to be extremely reliable, as have their Volvo predecessors on the Dowling fleet.

However, when it comes to working in more confined or delicate environments, Dowling Brothers have a pair of Hydrema 912E articulated dumpers, complete with rotating 12t capacity skips and super high flotation tyres. Purchased from dealer Philip P. McCormack Plant, the 912E duo has never presented any form of major malfunction, and any issues encountered were dealt with quickly and effectively.

John Dowling added, “We have always had great service from Philip McCormack and can see the benefit of dealing with a family-run business like theirs. Hydrema really is a premium level machine, but a must for an operation like ours. Their manoeuvrability and low ground pressure mean they can work successfully in practically any application. With their enclosed cabin and low centre of gravity, they are also very safe machines. Even though all this comes at a premium price, they hold their value very well.”

anyone with a genuine interest, and a good living to be made from it. Technology has eased the work greatly, which should add to the appeal for younger people and I believe it really is an opportunity not to be overlooked.”

Above: From left to right: ADT operator Piotr Watly, John Dowling, excavator operator Kazik Zurowski, Billy Dowling and Michael Dowling.

Below and inset right: Dowling Brothers run two Hydrema 912E dump trucks, which feature rotating 12t capacity skips and high flotation tyres.

MULTI-

last reported from Lännen Tractor’s backhoe loader and dredger factory at Loimaa in the south-west of Finland in 2017.

Since then the firm has restructured as the LMCE Group (Lännen mobile construction equipment). They currently employ around 160 people, located at Loimaa and at their Lundberg wheel loader/tool carrier factory at Skellefteå in Sweden. Net sales for the group are €50m and 75% of their production, particularly their Watermaster dredgers, are exported.

FACTORY TOUR

A significant development for the Loimaa factory is that Lännen has become a contract manufacturer and R&D partner for Mecalift, a Finnish company producing heavy-duty, variable-reach forklifts. In addition, there is a similar working collaboration with Nisula Forest to produce their N6 harvester. Recent investments in machine tools at the Loimaa factory include state-of-the-art Varnsdorf milling machines.

The Loimaa facility includes a separate assembly area for Mecalift forklifts, while another section of this massive site is used to produce Watermaster dredgers.

The main assembly line at Loimaa is used to produce Lännen’s large articulated backhoe loaders, and examples of their flagship 8800M models were going down the line during my visit. These are premium products that are not churned out in vast numbers, but are rather hand crafted, usually to meet a customer’s specific requirements.

In a familiar scenario, the chassis travels down the line and the various subassemblies and components are fitted. They include Agco engines, transmissions from ZF and Dana Spicer, ZF axles and hydraulic components from Bosch Rexroth and Danfoss.

As the assembly progresses, various aspects of the hydraulic systems are tested, culminating in a full road test and a digging session on the factory’s demo plot.

Inset and below: Lännen offer three base models of large articulated backhoe loaders, plus the option of specifying a fully-integrated access platform.

The combination of blue-chip components, extremely robust-looking structures and a conscientious workforce, which seem to be given the time to do the job properly, results in outstanding build quality.

FIRST IMPRESSIONS

There are three models in the backhoe loader range, all powered by Stage 5 ultra-low emissions four-cylinder 4.9-litre, Agco engines, as used in Valtra and Massey Ferguson tractors.

In the range-topping, 13-tonne class Lännen 8800M, it is rated at a whopping 173hp (127kW), which makes it the most powerful civilian backhoe loader on the market.

Sitting on four Nokian Ground Kare 620/60x34 T459 tyres, the 8800M has an impressive and somewhat dominating footprint. These giant tyres offer excellent ground clearance and the substantial underbody guarding, together with a turning angle of 42 degrees and 400mm oscillation either way, translates to high levels of

mobility across the roughest of terrain.

The backhoe is a slewing centre-mount design with independent jack legs. The standard build is with a knuckle boom, which allows trenches to be excavated parallel to the machine. Naturally, there are a host of hydraulic services, allowing the use of a tilt-rotator or a tilting hitch on the backhoe together with powered attachments. If required, the entire backhoe can easily be dismounted to allow another form of hydraulically-powered attachment to be mounted on the rear of the machine.

Twin auxiliary hydraulic lines are fitted to the front loader arms, together with a free-flow line back to the tank. This enables the machine to run a wide variety of oil-hungry attachments on the front quick coupler; the 8800M it is capable of delivering and impressive 309lit/min of oil flow.

Then we come to the elephant in the room, as the Lännen range are not just backhoe loaders, as they are often equipped

with a third attachment in the form of a fully-integrated access platform. It provides a genuinely multi-functional machine, ideal for challenging Nordic infrastructure projects across the rail, electricity and communications sectors.

To complete the factory visit, I spent a little time in the smallest 8600M model, configured as a backhoe loader access platform. Initially driving round the yard using the left-hand joystick to steer, I found it very useful to be able to move and steer the machine while facing in either direction of travel.

After a short spell of digging on the demo plot, I was given the opportunity to take the 12-tonne/147hp 8600M for a longer period of road work to get a better feel for its speed and power. This model comes with an electronicallycontrolled ZF two-speed full powershift transmission, which provides a top speed of 46kph. I can confirm that it’s a very lively bit of kit on the road and an absolute joy to drive.

Above: The chassis frames and other structural elements look well over-engineered and able to cope with gross machine weights of over 20 tonnes.

Right: Three lots of working equipment mean there is a lot to take in, to say nothing of fettling the extremely competent base machine.

SITE BACKGROUND

The 25km Raide-Jokeri light rail project, which started in 2019, will connect the Finnish capital Helsinki with the city of Espoo. The line connects Itäkeskus in Helsinki with Keilaniemi in Espoo and is due to be in regular use from January 2024.

This project is intended to replace the long-running 550 bus service between the two cities, which is currently used more than 40,000 times every weekday, an incredibly high number of passengers for a bus route. This is projected to rise to 90,000 trips per weekday by 2030, hence the need for a tramway. The new line will be served by two-way, electric express trams with a top speed of 70kph, running at an average speed of 25kph along the entire route.

As part of an alliance agreement, contractor NRC Group Finland has been engaged in the construction of Raide-Jokeri since the start of the job. The total value of project is almost €400m.

To assist them on the latter stages of this project, last spring NRC took delivery of a bespoke road-rail Lännen 8800M, which includes an integrated access platform. This machine has been used extensively on track/electrification works of the Raide-Jokeri project. The rail lines were completed in August and the current focus is on installing the overhead power wires, which is due for completion by the end of this year.

SITE VISIT

I met up with this Lännen 8800M in the Roihupello district of Helsinki, close to the main depot that will serve the light rail project. NRC’s site manager Mikko Lompolojärvi said, “In this project we are

This tilt-rotatormounted attachment is used to raise, support and manoeuvre the overhead wires into place.

raising wires to the overhead gantries to a total of about 120km. The new trolley depot is already prepared and contains 3km of wires.

“We have been very satisfied with the Lännen combination. The original criterion for its purchase was for its multi-use ability, both on- and off-track, working rail-wheel drive and proximity to the factory with aftermarket services in mind. We use the access basket for additional on-the-spot work, for example in furnishing the poles and installing separators, and as an aid to the telehandler accommodating the overhead installation team.”

NRC’s cable-pulling team includes a road-rail Manitou rotary telehandler, used as an access platform, from which a pair of technicians install the wires on the overhead gantries. Lännen faced similar constraints to this machine when designing the rail gear for the 8800M, as the Raide-Jokeri light rail project features a track width of only 1000mm. Due to this narrow track gauge, tyre contact with the upper surface of the rail is not possible. This results in all the traction and braking forces, as well as the

entire weight of the machine, being on the hydraulically driven rail wheel assemblies, which on both machines look reassuringly stout structures.

This 8800M is configured with a Lännen L1900 personal lift with a two-person basket, which provides a maximum working height of 19m. It was also specified with a handy optional extra; hinged foot pads on the individual stabiliser legs. Operator Henri Vuorialho explained, “The track beds often start to rise sharply from the side of the track. The machine can be supported well with the independent jack legs, even on inclined surfaces, thanks to the moving base plates.”

Left and above: This tilt-rotator-mounted attachment is used to raise, support and manoeuvre the overhead wires into place.

The front attachment is a large, hydraulically-powered cable reel support and winding attachment, which provides a maximum pulling capacity of 5500kg.

For this phase of the project, the 8800M is usually configured with a Lännen overhead wire installation pole, mounted on an Engcon tilt-rotator on its backhoe. A simple-looking attachment, featuring two hydraulic extensions that provide a maximum lift height of 4950mm, which is used to raise, support and manoeuvre the overhead wires into place.

Site manager Mikko said, “It’s heavy work, so you can’t do it up there with muscle power alone. With the help of the mounting stick, the cables are supported and connected to the turning spindles.

attach the driving wires to the shafts and adjust them.”

in the

For this type of work, the front loading arms carry a large hydraulically-powered cable reel support and winding attachment. It has a maximum pulling capacity of 5500kg, adjustable by the operator from the cab. When fully loaded, cable reels weigh up to two tonnes, which pushes this road-rail Lännen 8800M up to a gross weight of around 21 tonnes. It’s a hefty item of road-legal wheeled machinery, but one that is well suited to this rail project.

Operator Henri commented, “The machine can be quickly driven on and off the track as needed. The narrow rail wheels do not get behind the tyres, which makes it easier to position yourself on the track. There is also a camera on the nose, which can be directed downwards instead of to the front loader, to show the rail wheel positioning. There are sharp bends in the track profile here, so with the articulated steering you can follow the track precisely, even in curves.”

Movements of the base machine, the working equipment including the access platform, can have their operational envelope digitally restricted, for instance when an adjacent rail line remains open to works or live traffic. On the track, more often than not this machine is driven backwards, with the backhoe operator position including all the relevant controls, together with a rail-spec sloped rear window.

CONCLUSION

This specialist road-rail application for Lännen’s flagship product demonstrates just what is possible when it comes to providing a custom solution to a customer’s specific requirement.

A key part of this equation in Finland appears to be to minimise the number of people working on the ground. This is for strong economic, climatic and practical reasons, never mind from a site safety

perspective. A crew of three was undertaking this key rail task, with not a bystander in sight.

Returning to my brief spell in the smaller 8600M model at the factory, it certainly excelled on the road. My time with it on the digging demo plot was too brief to form an opinion, but no doubt it will do exactly as it says on the box. Its long list of operational parameters is reflected in the myriad of control, customisation and diagnostics sub-systems, available to the operator via the main control screen.

The standard front bucket is a traditional Nordic wheel loader shape, which to my eyes looks very basic, on what is an extremely capable backhoe loader. Lännen has an ambition to enter the UK market, which is more likely to be successful if they offer the likes of a 6-in-1 multi-purpose bucket, which would make it a right beast.

Many thanks to Olli Paivio of Konepörssi for his assistance with this article.

EDITOR’S COMMENTS

I doubt there is yet a meaningful demand from the UK construction sector for such a large and premium-priced backhoe loader. However, with the option of a fully integrated access platform, Lännen machines offer far more than that.

Certified to work on a northern European rail project, one can assume that this is rock-solid design from a health & safety perspective. Configured with a tree shear on the backhoe, an access platform up top and a mulcher on the front, such a road-legal machine would make an absolutely stunning tool for tree surgeons and others involved in the arboriculture sector. Far superior to even the most sophisticated agricultural tractor.

The fitters

telehandler’s basket

The very useful triangular-shaped storage locker on each front mudguard is standard; the narrow-gauge rail gear is certainly not.

The road-rail Lännen works alongside a road-rail Manitou rotary telehandler configured as an access platform, the latter crewed by two overhead line operatives.

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NORTH-EASTERN BLACK GOLD TRIANGLE

ome of the largest earthmoving machines ever seen in Britain worked on the Northumbrian coastal coal belt from Amble in the north, down to Newbiggin-by-the-sea and across to Morpeth. This area was extensively worked by opencast methods, to mine the rich coal seams that were relatively easy to uncover.

Opencast coal mining in the UK started in 1942, initially as a wartime measure to supplement production from labourintensive underground mines. The coal industry was nationalised in 1946, but

continued to use independent contractors for mass earthmoving and extraction works on opencast sites. The National Coal Board (NCB) also continued with the wartime practice of importing large earthmoving machines from America, for use by contractors on their more extensive sites.

To help alleviate the dire post-war need for coal, from 1949 to 1955 the NCB imported four second-hand Bucyrus-Erie 1150-B walking draglines. Launched in 1944, the 1300-ton 1150-B was a masterpiece of wartime engineering, as it was able to compete with the largest draglines of the

time. Configured with a 25-cubic-yardbucket on a 180ft boom, a pair of these pre-owned 1150-Bs spent their long second working lives in Northumberland, initially in the Bedlington area.

These Bucyrus-Erie 1150-Bs turned out to be a good long-term investment for the NCB; from 1966 onwards they worked at sites throughout the Radar North Zone (see below). One spent its last five years at Togston, the other its last 11 years at Acklington; both were no longer used after 1984 and were scrapped a few years later.

More importantly, the NCB’s initial experience with these substantial earthmovers pioneered the way for the use of much larger walking draglines in Northumberland‘s coastal coal belt over the next few decades.

Top: One of the second-hand, 25-yard BucyrusErie 1150-B walking draglines working in Northumberland in the early 1950s. This example at Ewart Hill was operated by Sir Lindsay Parkinson & Co. Above inset: The National Coal Board invested in a succession of extremely large earthmoving machines, cumulating in the 4416-ton P&H 757 walking dragline called the Ace of Spades.

“THE

THE NEED TO UP-SCALE

With experience of using large shovels and draglines, by the mid-1950s the UK opencast coal sector had matured considerably. The sites themselves were generally better organised and site restoration standards had vastly improved over wartime practices.

As increasing volumes of lower-cost opencast coal were in demand from the government, the NCB expanded the nation’s production capacity with even larger earthmoving machines, which would also result in improved economies of scale.

The vast coal beds near the Northumberland coast proved very attractive for such surface mining methods, as the coal was of high quality and lay in relatively flat seams at reasonable depths.

After completing a few small opencast sites in the area, the NCB was ready to start operations on a scale previously unseen in Britain. In 1955 it ordered two brand new Marion 7800 walking draglines, to be used by contractor James Miller & Partners at the

Radar South site, on the coast near Widdrington. When tendering for such massive opencast contracts, companies naturally included their own fleet of machinery in the submission. However, it was the continuing practice of the NCB Opencast Executive (later British Coal Opencast) to purchase some large prime movers, such as walking draglines and electric rope shovels, which were to be used on a series of muck-shifting contracts over the following decades.

The main reason for this is that such machinery has an extremely long working life, lasting well beyond the duration of a typical UK opencast coal site.

Disaster struck only six weeks after the new Marion 7800s went to work. The 280ft boom on one of them collapsed (Pic: Peter Grimshaw collection).

“FOLLOWINGTHEBOOMCOLLAPSETHERE WASALONGINTERVAL,DURINGWHICH ARGUMENTSTOOKPLACEWITHTHE MARIONCOMPANY”

After a productive working life of 51 years, and emigrating to Canada in 1969, Marion 7800 (serial 9998) is shown parked at the Highvale surface coal site, just before being scrapped in 2010.

Therefore, contractors were not expected to carry the significant capital investment in such machinery, with no guarantee of work after it completed its first site. In addition, there was a long time lag – which could be up to several years – between placing an order and the likes of a walking dragline being commissioned on site. The NCB would therefore often pre-order such massive earthmovers, which were then included in subsequent extraction contracts under a lease agreement.

1500-TON MARION 7800

The Marion Power Shovel Company of Ohio introduced the 7800 walking dragline in 1942, at that time the largest such machine in the world. The 1500-ton class Marion 7800 remained in production until 1964, during which time 19 examples were sold. The two at the Radar South site began work a the end of 1956.

They sat on a circular base 50ft in diameter, and each walking shoe was 48ft long, providing an overall width over the shoes of 70ft; the height to the top of house was 35ft. Electrical equipment included two 500hp hoist motors, two 425hp drag motors and four 137.5hp swing motors. These DC motors received power from AC motorgenerator sets totalling 2200hp.

They were specified with 22-yard capacity buckets, suspended from 280ft-long booms, providing a total working weight of 1580 tons. The NCB organised a grand event to launch the largest digging machines ever seen in Britain, unfortunately disaster struck after they had worked only six weeks. In February 1957, the boom on one of the draglines collapsed, fortunately no one

This accident resulted in a protracted enquiry that lasted many months, during which time the second Marion dragline was also out of commission.

It was reported that, before the accident, the 280ftlong booms appeared too highly stressed and showed alarming whip, not only vertically, but also laterally. It was also noted in the report that the booms were not subject to a careful daily inspection.

An internal memo stated: “Following the boom collapse, there was a long interval, during which arguments took place with the Marion company. That went on from mid-February

This significant historical photograph was taken in 1956 during the raising of the original booms on the two Marion 7800 draglines at Radar South.

Latterly given the name Old Timer, Marion 7800 (serial 9997) is seen here at Chester House site in 1991, some three years before being scrapped (Pic: David R. Wootton).

Dignitaries were invited to a ceremony in 1956 to launch the 1500-ton Marion 7800s, the largest digging machines ever seen in Britain at that time.

until August, when the NCB called a meeting with all concerned. After the meeting, action was decided upon and eventually, after another lengthy delay, both dragline booms were rebuilt.”

When the booms were finally replaced, they had been reduced in length to 240ft and went on to work successfully with larger 30-yard capacity buckets for the rest of their days. Following completion of Radar South site, both 7800s moved over to the adjacent

and much larger Radar North site, leased to Derek Crouch (Contractors) Ltd. It was the largest opencast site in the UK at that time and yielded 8.8m tons of coal up to 1974.

After a spell at Radar North, in 1969 one of the Marion 7800 walking draglines (serial number 9998) was sold to a Canadian customer. It was subsequently used to open up the new Highvale surface mine to the west of Edmonton in Alberta. This site eventually became Canada’s

ACE OF SPADES BASIC SPECS

largest coal mine, producing up to 12m tons per year. After an extremely productive life of 51 years, the old 7800 workhorse was finally parked up in 2007, then scrapped in 2010. After its stint at Radar North, the other Marion 7800 (serial number 9997) worked at three more local opencast coal sites, Radcliffe, Togston and Chester House, before being finally scrapped in 1994.

Radar South, the initial home for the pair of Marion 7800s, was the first in a long succession of opencast coal sites in close proximity, to the extent that large draglines could be quickly and cheaply walked to their next assignment. While Radar North site was in progress, Crouch was awarded contracts for the neighbouring Coldrife, Ladyburn, Radcliffe and Acklington sites, all close to the Northumberland coast. These sites were connected by internal haul roads and the area became known as the Radar North Zone, where machines would often move from one site to another as the need arose.

ENTER BIG GEORDIE

The 1500-ton Marion 7800 sold to Canada had been replaced at Radar North by a 3200-ton Bucyrus-Erie 1550-W walking dragline, affectionately known as Big Geordie, which took over the crown as Europe’s largest dragline. Purchased by the

Above: As seen by the author in 2003, Stobswood was the final resting place of the Big Geordie, some 13 years after finishing work at Butterwell.

The 4416-ton P&H 757 walking dragline, called the Ace of Spades, worked at Butterwell from 1991 to 2004.

The two cabs of the Bucyrus-Erie 1550-W allowed the operator to select the best view, depending on which side he was dumping. Two Cat D8 dozers are used to push back the ‘roll’ in front of the machine.

Left and below: Big Geordie went to work in 1969 at Radar North, taking the title of largest dragline in Europe. By the late 1970s, Crouch had become the owner of the ex-NCB Bucyrus-Erie 1550-W.

NCB Opencast Executive and taking 12 months to erect, Big Geordie started work for contractor Derek Crouch in mid-1969. It was specified with a 65-yard capacity bucket on a 265ft-long boom (see spec panel).

Big Geordie worked at Radar North until 1973, when it was moved to the adjacent Sisters site, also operated by Crouch.

By the late 1970s, Crouch had become the owner of the ex-NCB Bucyrus-Erie 1550-W. In 1977, Big Geordie set off across country, on a specially-built four-mile-long walk road, to the new Butterwell site, just

to the north of Morpeth. It had been leased to contractor Taylor-Woodrow for the duration of their Butterwell contract, a site that yielded around 12m tons of coal until its closure in 1991.

It turned out that this was the end of the Bucyrus-Erie 1550-W’s working life, but things could have turned out differently. After it was finished at Butterwell, Big Geordie was walked to another, even larger site called Stobswood, some two miles north of Butterwell. Crouch Mining had won the Stobswood contract, so had

relocated their own 3200-ton dragline, in anticipation of a start date in 1991.

Unfortunately, negotiations to use the Bucyrus-Erie 1550-W fell through, as the NCB Opencast Executive insisted that their new flagship walking dragline, a 4400-tonne P&H/Page 757, be used at Stobswood. Big Geordie sadly remained parked with its boom lowered until it was finally scrapped a dozen or so years later.

CHEVINGTON COLLIER 1260-W CHEVINGTON

As the 3200-ton Big Geordie left the Sisters site, British Coal Opencast commissioned a brand new 1600-ton Bucyrus-Erie 1260-W walking dragline, later named the Chevington Collier, to be used by Crouch. This 1260-W carried a 32-cubic-yard bucket on a 285ft boom and was manufactured in Lincoln by Ruston-Bucyrus, the second of six such machines to be made there.

Another significant dragline to appear in Northumberland was the Rapier W2000, which spent its entire, but short life at East Chevington site. Designed and built by Ransomes & Rapier at Ipswich, this machine carried a 32-cubic-yard bucket on a 314ft boom. Named ‘Chevington Lady’, it was one of two similar machines owned by British Coal Opencast, the other worked at St. Aidans site near Leeds.

The Chevington Lady started work in 1983 and finished at the East Chevington site a decade later. With only 10 years on its clock, the expectation was that this low-hours walking dragline would easily be sold on the world market, in particularly into the Indian coal sector. It already ran 14 examples of the Rapier W2000 and would go on to purchase another six over the following years. Bizarrely, the importation of such used machinery was banned. With no other bids received for the Chevington Lady, she was scrapped in 1993.

THE ACE OF SPADES

After an 18-month erection period, in December 1991 a launching ceremony took place at Stobswood to name the P&H 757 the ‘Ace of Spades’. The giant walking dragline was designed by Page Engineering, a company that had been taken over by P&H/Harnischfeger a few years previously. The Ace of Spades had an operating weight of 4416 tons, a 310ft boom and 65-cubic-yard bucket, qualifying it as the largest dragline in Europe.

The task of the P&H 757 at Stobswood was to uncover the lower coal seams, after removal of the upper overburden and coal seams by a fleet of hydraulic excavators and trucks. All owned by Crouch Mining, these consisted of two O&K 26-yard RH200 shovels, a 17-yard RH120 backhoe and a fleet of 15 Cat 789 haul trucks rated at 195 tons.

above:

which was finally scrapped in 2009.

On completion of the Sisters site in 1980, the 1260-W moved over to the adjacent West Chevington site, which was operated by contractor AF Budge and yielded 5m tons of coal up to 1992. After that, the Chevington Collier spent four years at Colliersdean, helping to produce another million tons of coal under RJ Budge Mining (later UK Coal). It spent its last few years of life at Maidens Hall site, where it joined a fleet of hydraulic excavators including O&K RH120, RH170 and RH200 machines. The venerable Bucyrus-Erie 1260-W workhorse was nally scrapped in 2009.

The Stobswood site was active from 1991 to 2004 with a contracted 13.5m tons of coal produced. The site area covered some 1600 acres and contained 28 different coal seams, which were mined to a maximum depth of 620ft. On completion, the site was returned to agricultural use, together with woodland and wetland areas.

After completion of Stobswood, the Ace of Spades was sold to an America customer and continues to help to produce coal for its new owners to this day. It will be the subject of a separate report in a future issue. In the next part of this series, we will focus on the Radar North Zone, including the only bucket wheel excavator ever to work on an opencast coal site in the UK.

Inset

Maidens Hall site was the last home for the 1260-W Chevington Collier,

Below: Initially erected in 1983 at East Chevington, a Rapier W2000 similar to this example at St. Aidans, had a short working life, being scrapped soon after the site was completed in 1993.

Above: The Bucyrus-Erie 1260-W named Chevington Collier worked on several sites in Northumberland. Built at Lincoln, it carried a 32-yard bucket on a 285ft boom.

lot has changed since 1965 when Keith Bell founded what went on to become the KW Bell Group. Today the business has a turnover of around £90m from three divisions: Bell Contracting, Bell Plant and Bell Homes. I met Keith’s son Peter, MD of Bell Contracting, at the newly opened AccXel construction training school in Gloucestershire, which has received funding from the KW Bell Group.

Peter said, “Our growth has accelerated dramatically over the last decade, as we have changed the way in which we approach working with our customers, who are some of the major house builders in our region.

“These customers want more of a partnership approach, so we recognised we had to solidify our own approach to partnerships within our core supply chain and, in particular, the plant we use. We started to work with our local dealer, Holt JCB, and JCB Finance to look at how we could better manage our fleet and get the right equipment matched to the jobs onsite.

“The aim was to develop a better approach to managing the movement of muck that is safer and more efficient. It also involved changing our methods and how team members worked together, from engineers to surveyors, site managers and operators.

“As part of this process, we created a partnership with Leica Geosystems, combining surveying, 3D modelling and machine control as one seamless delivery model. This achieved two goals: it made our JCB machines more efficient, while also questioning why and how we moved muck.

“It has been a revolution for our business. The productivity of the jobs we are now doing is off the scale. We don’t bang pegs in the ground anymore. Everything’s built in accordance with a 3D model, which is plugged into the machine, so my operators and foreman can see what they’re actually trying to achieve right in front of them.”

SITE SAFETY

The use of digital surveying, 3D site models and GPS machine control systems dramatically improves site safety, as there is a dramatic reduction in the need for people to enter the excavation area.

Bell has also made a significant investment

in inherently safer machinery, as Peter continued: “We could have just changed our operations when new safety regulations came out, but we looked ahead. As an end user, we challenged our suppliers to help us improve our business, rewarding them with new equipment orders.

“A great example of this is how we have redefined our equipment language. Take our recent investment of well over a million pounds in the relationship we have with JCB. We have purchased a fleet of their new and safer cabbed site dumpers and called them earthmoving vehicles.

“Why is this important? Well, the old-style site dumper is one of the most abused pieces of equipment on site. Across the industry, there are not only huge costs for repair, but unfortunately injuries also occur when the kit is not properly used and managed on site.

“By rebranding the equipment, investing more in each unit and delivering proper training, we have changed attitudes, increased safety and improved the way we move muck. It’s not rocket science to see how this has increased our productivity.

“Taking full advantage of having the AccXel training school on our doorstep, the critical part of this business is finding the right people and investing in them. In my time in this industry, I have seen a huge problem in the way we attract and retain talent. This in turn has led to a real skills shortage, which we are only just properly addressing, at the same time as technology adoption is exploding. It’s now all about how we promote our sector, invest in training and all think about moving muck better, as every drop of fuel counts.”

Peter Haddock reports on Bell Contracting’s journey to find safer and more productive ways to move muck on behalf of major house builders

PRE-BAUMA LAUNCHES

Steve Downes reviews some of the latest model releases in 1:50 scale from Conrad, NZG, Motorart and Diecast

Masters

Model manufacturer Diecast Masters has introduced several ranges alongside its standard machines, such as the weathered series, a range of models supplied with a moulded base depicting equipment in a used and dirty look. This Cat 745 articulated dump truck is an interesting model, on which the mud effect looks quite convincing. The bonnet can be opened, the cab tilts to the side and the body tips.

Released by NZG, this Baljer Zembrod stationary materials handling machine has some interesting design features. It comes with both cactus and wood handling grabs, has adjustable stabilisers for a solid base and has authentically captured the range of movement of the boom. The ability to detach the cab away from the structure is a nice touch.

T Jhe L504 Compact is the smallest wheel loader in Liebherr’s range. NZG has done a fine job in producing this model as it features an articulating chassis, detailed cab interior, replicated driveshaft and fully operational loader arms, which are fitted with a toothed bucket.

With the latest generation of full-sized Liebherr wheel loaders now launched, Conrad has produced an upgraded replica of the L546 model. The update includes a lot of new tooling over its predecessor, including a new bucket, loader arms with Z-bar linkage and the new body styling, which has been implemented flawlessly.

oining the Diecast Masters Black Series range of Caterpillar replicas are a 242D3 wheeled skid-steer and a 259D3 tracked loader, both coming with a set of four attachments.

From the Diecast Masters Vintage Series is this recently-launched Cat 966A wheel loader, part of a range of packaged examples of classic Caterpillar equipment. It is fixed to a display base with an engraved nameplate and comes complete with a contemporary operator and detachable umbrella, while the rear wheels have functional steering and the loader arms can be raised.

Produced by Motorart, it is good to see a new release from K-Tec in the form of the 1237 towed scraper paired with a Volvo A45G ADT-based 6x6 prime mover. The model is a little larger than its 2014 predecessor and has more refined movements of the scraper’s bowl and apron. The coupling works well and is detachable from the A45G. An additional coupling on the back of the scraper allows a pair of scrapers to be linked together.

SITE VISIT

LONG-REACH

KOMATSU

FLEET FOCUS

PR WELDHEN

PICTURE POST

Earthmovers turn up in every corner of the world. It doesn’t matter whether they are stuck, submerged, or just plain interesting - we want to see them all. As an extra incentive (other than the obvious thrill of seeing your pictures in print), we’re offering £20 for each month’s star picture.

Tell us as much as you can about the machine in the picture, and don’t forget to enclose your name and address, and an SAE if you would like us to return your picture(s).

E-mail high-resolution images to editor@ EarthmoversMagazine.co.uk or send your prints to:Picture Post, EARTHMOVERS, Sundial Magazines Limited, Sundial House, 17 Wickham Road, Beckenham, Kent BR3 5JS.

THAT SINKING FEELING

one was hurt.

Thanks to Gary Steen from Australia for this pic, of a swamp-spec dozer finding a particularly soft patch of ground.

It is unclear exactly how the Terex articulated dump truck ended up in this position; a lesson learnt by the operator.

If you look closely, this container vessel has an underwater obstacle to navigate around, in the form of a submerged excavator.

There appears to be a minor issue with the offside rear wheel station of this massive machine, with the investigation already underway.

OFPICTHE MONTH

Sometimes you have to look on the bright side of life, this excavator was eventually recovered and no

• various mounting options

Attachable to all popular carrier vehicles.

• Cutting mechanism with replaceable, high-strength blade Easily resharpened, strong and resistant to dirt.

• synchronously closing, powerful grippers with a large opening stroke High cutting capacity for fast and safe harvesting.

• Multigrip-controller

For a safe grip, the gripper closes first, then the cutting system closes.

• made of high-strength Hardox® steel Low maintenance and wear, highly rugged and durable.