Aggregates Manager April 2015

191414 Review Intermat equipment

debuts

19 Plan for a safe spring start-up

Prepare for MSHA’s fatality prevention focus Prepare for MSHA’s Prepare for MSHA’s fatality prevention focus fatality prevention focus Prepare for MSHA’s Prepare for MSHA’s fatality prevention focus fatality prevention focus 36

Dredging Up Profits... Cajun Style

April 2015 www.AggMan.com

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With the all-new 1050K, you’re not just getting a long-overdue choice in dozers this size. You’re getting the incredible pushing power of a proven hydrostatic drive. And Eco mode to reduce fuel consumption by up to 25% without limiting productivity. Deere designed. Deere manufactured. And backed by a robust service and parts program dedicated exclusively to the production-class market. The choice is yours. Bet you haven’t heard that in a while. For details, visit your local dealer or our website.

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CONTENTS

On Our Cover: Trinity Materials safely mines sand in former gravel pit, despite being in ‘gator territory.Cover photo by Kerry Clines.

31 A radial conveyor’s ability to create high-volume, fully desegregated stockpiles is one consideration when investing in a new system.

9 Terex MPS expands its portable plant line with a new screen plant, the Terex Cedarapids CRS620S.

COLUMNS & DEPARTMENTSFEATURE ARTICLES

19Spring SafetyBetween the impact of winter

weather on an operation and employees performing tasks they don’t regularly handle, be sure to focus on safety during the spring start-up.

APRIL 2015 VOLUME 20, NUMBER 4

OPERATIONS ILLUSTRATED

14 Equipment Takes the Stage at Intermat Paris show highlights the international debut of

excavators, portable plants, haul trucks, and more.

24 Diggin’ Cajun Style There’s a method to the madness of mining sand and

gravel in the marshy areas of southwest Louisiana.

31 A Stronger Side of Material Handling When evaluating stacking conveyor systems, consider

their impact on material specifi cations, safety, and ease of maintenance.

34 Washed and Separated Today’s washing and classifying equipment can help

operators capture and and clean more saleable material.

3 EDITORIAL Transportation funding: Should we laugh or

cry?

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

7 DATA MINING The latest stock and fuel price trends impacting the industry.

9 ROLLOUTS Dyno Nobel’s new blasting system, and other new equipment for the aggregate market.

36 ROCK LAW Following a spike in metal/non-metal fatalities, underlying causes will be scrutinized in future MSHA inspections.

38 ADVERTISER INDEX See who’s who and where to fi nd their products.

39 CLASSIFIED ADS Aggregate industry classifi eds.

40 CARVED IN STONE It took a combination of channel drilling and geology to mine granite in Barre, Vt.

TOC_AGRM0415.indd 1 3/18/15 10:44 AM

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AGGREGATES MANAGER April 2015 3

by Therese Dunphy, Editor-in-Chief [email protected]

LAUGH OR CRY? I

n March, John Oliver brought a new approach to the age-old debate over infrastructure spending — humor. In a 21-minute “Infrastructure” segment of his HBO show Last Week Tonight, Oliver had a unique, but accurate, perspective on why it’s so difficult to make progress on infrastructure investment. “Infrastructure

isn’t sexy,” he declared.“If an alien culture judged humanity by our most popular movies, they’d think we

were furious with asphalt all the time,” Oliver joked, noting that infrastructure was “basically anything that could be destroyed in an action movie.”

While his approach was amusing, he shared some important points with his audience.

- America’s dams are an average of 52 years old and many have problems that stem from their original construction. In 2007, Texas had seven inspectors responsible for inspecting 7,400 dams and had only inspected 239 of them that year. Alabama had no inspectors.

- The American Society of Civil Engineers gave the nation’s infrastructure a grade of D+, while the World Economic Forum ranks the United States as 16th in the world.

Oliver highlighted a recent segment of 60 Minutes, “Falling Apart: America’s Neglected Infrastructure.” It showed the Liberty Bridge in Pittsburgh, which has a structure built beneath it to prevent falling concrete from hitting motorists. It is one of 15 structurally deficient bridges along a 22-mile stretch of I-95. “They built a bridge under the bridge. That’s a college sophomore’s approach to structural engineering,” he said.

“We only seem to talk about infrastructure when something tragic happens,” Oliver added, “and the scope of this problem is scary.” While both sides of the aisle agree on the need to invest, Oliver hypothesized the reason why politicians haven’t taken action is because maintenance isn’t as exciting as building something new. They like to bring out the big scissors for ribbon cutting ceremonies, but filling potholes and expanding lane miles don’t garner photo ops.

Oliver drew attention to the problem. Now, let’s continue the push. The public needs to understand that infrastructure may not be sexy, but safe travel merits their support. Current statistics show that one-third of highway fatalities are due to unsafe road and bridge conditions. It’s not acceptable.

Politicians need to be reminded that it’s not all about the big scissors and photo ops; it’s about investing in the nation’s future. We need the kind of political leadership that built the National Highway System, not one that relies on short-term extensions and lacks the political will to develop dependable funding.

As MAP-21 expires (again) this spring, we need a six-year bill. And, if Oliver’s segment sparks action on infrastructure investment, it will go to show that laughter is, indeed, the best medicine.

April 2015 Vol. 20, No. 4

aggman.com /AggregatesManager

@AggMan_editor

Editorial Editor-in-Chief: Therese Dunphy

Editorial Director: Marcia Gruver Doyle

Online Editor: Wayne Grayson

[email protected]

Design & ProductionArt Director: Sandy Turner, Jr.

Production Designer: Timothy Smith

Advertising Production Manager: Linda Hapner [email protected]

Construction MediaVP of Sales, Construction Media: Joe Donald

[email protected]

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For change of address and other subscription inquiries, please contact: [email protected].

Aggregates ManagerTM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2015. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

Editorial_AGRM0415.indd 3 3/18/15 10:00 AM

State &ProvinceProvinceNEWS

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

by Therese Dunphy, Editor-in-Chief [email protected]

AGGREGATES MANAGER April 20154

CaliforniaLas Pilitas Resources is appealing a decision from the San Luis Obispo County Planning Commission, which rejected its proposed project for a 41-acre mine near Santa Margarita, The Tribune reports. According to the newspaper, the operator contends the “planning commission’s reasons for rejecting the project were not supported by the facts in evidence.” It also says that the commission did not consider the importance of the mine’s aggregate supplies to the region. The appeal will be heard by the San Luis Obispo County Board of Supervisors. The county environmental coordinator told the newspaper that it would take the planning staff several weeks to respond to the issues raised in the appeal. A hearing date had not been set at Aggregates Manager’s press time.

IndianaThe Indiana Mineral Aggregates Association (IMAA) named Brad Powell, of VCNA Prairie, Inc., as its 2014 recipient of the “Miner of the Year” award, it reports. IMAA Executive Director Robert Jones presented the award during the association’s Winter Workshops. Powell joined the aggregates industry in 1976 as a laborer for Rogers Group and is currently the Indiana area manager for Prairie Aggregate. He has served on the association’s Plant Operators Committee, where he organizes and teaches about equipment safety and employee relations. Two of his operations have gone more than 12 years without a lost-time accident, while two more have been without lost-time accidents since they opened.

IllinoisIn observance of National Flood Awareness Week, DuPage County Stormwater Management planned tours of the Elmhurst Quarry Flood Control Facility on March 21, The Elmhurst Patch reports. Residents were expected to be able to tour the quarry to learn how the county uses it to manage fl oodwater. The quarry is the largest of four mechanically operated fl ood control facilities in the county. The tours were sponsored by DuPage County Stormwater Management, Elmhurst Historical Museum, and Elmhurst Park District.

MassachusettsAll States Materials Group hopes to develop a solar farm on 20 to 30 acres of its Trew Stone property, The Recorder reports. Chicago-based Lake Street Development would lease land from the operator and retain ownership of the 6-megawatt solar farm, if built. Local offi cials appear to support the project. Department of Energy Resources, Selectmen’s Chair Carolyn Shores wrote that the town supports the project. She notes the land on which it would be built is not zoned or suitable for residential development, and it is not a particularly attractive site for commercial or industrial use.

KansasPerry-based Hamm, Inc. received the 2014 Governor’s Mine Land Reclamation Award for its efforts at the Overbrook Quarry in Osage County, the Kansas Aggregate Producers Association (KAPA) announced. The award, which is administered through the Kansas Department of Agriculture, is presented to a company that demonstrates excellence in executing a reclamation project and sharing a positive image of mining in the state. Hamm’s reclamation project included the construction of several ponds, including a fi sh habitat. In addition, the land was graded and fenced for future hay production. The award was presented at a KAPA meeting.

KansasFinding the right greenfi eld site isn’t just a challenge for aggregates producers; government agencies that own their own sites go through some of the same challenges when fi nding the right location. According to The Fort Scott Tribune, the Bourbon County Public Works Department is currently trying to locate an appropriate site for a new quarry. After taking core samples at two locations, however, it has not found consistent enough rock quality to merit development. Unlike operators, the county government has a relatively low budget for the project. It has $50,000 budgeted to open a new quarry and has spent between $2,000 and $3,000 on exploration.

IllinoisNorthwestern University researchers resumed monitor-ing of blasting at the Hanson Material Service’s quarry in McCook. According to The Chicago Tribune, data collec-tion stems from a 2013 event when a quarry blast was followed seven seconds later by a 3.2-magnitude seismic event. Analysis by Northwestern, the U.S. Geological Survey, and the Illinois Department of Natural Resources did not determine a causal relationship between the two events. Despite the results of that research, area residents, including U.S. Rep. Daniel Lipinski, called for more research. The data collection and analysis contin-ues to explore the cause of the 2013 events and whether geologic or weather factors could infl uence future events.

StateNews_AGRM0415.indd 4 3/18/15 10:54 AM

5AGGREGATES MANAGER April 2015

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MichiganLafarge North America’s Presque Isle Quarry received the 2015 Alpena Regional Medical Center’s Health Leadership Award during the Alpena Area Chamber of Commerce’s recent annual dinner. According to Lafarge, the award recognizes businesses that promote health, encourage other businesses to adopt similar programs, and support the hospital by promoting it throughout the community. The quarry had several wellness initiatives including a family 5K quarry run that raised more than $35,000 for the center. It also provides wellness opportunities for its staff such as smoking cessation programs, nutrition programs, weight- loss programs, fi rst aid/CPR training, and fl u shots. “Achieving the utmost health and wellness for our employees is something every Lafarge plant strives for,” said Allan Idalski, quarry manager, in a company press release.

MinnesotaIn an about-face, the Houston County Board voted against a permanent ban on frac sand mining. According to The StarTribune, the board gave a unanimous preliminary vote on the band, following a three-hour public meeting full of residents who voiced concerns about frac sand mining. When the temporary ban expires, rules revert to the existing ordinance, which does not specifi cally mention silica sand. Currently, there are no silica mines in the county, however, there are nine active sand mines.

New JerseyIn a bizarre turn of events, the Bernards Township Committee voted in late February to deny the renewal of the operating license for the Millington Quarry. The Bernardsville News reports that the annual operating license was rejected by a 3-2 vote. The town and operation had a history of litigation, which appeared to end last April when a settlement agreement allowed the operator to import soil to prepare it for future reclamation. Two days after the initial vote, a township clerk sent out a notice that the committee would hold a second meeting to “discuss, and possibly reconsider” the denial. That meeting had not taken place at Aggregates Manager’s press time.

OhioFourth graders from Danbury Elementary School recently saw a historical presentation about limestone quarries on the Marblehead Peninsula. According to The Beacon, Gretchen Curtis, from the Lakeside Heritage Society, showed students historic photos that depict quarry workers in the early 1900s working in diffi cult conditions and without safety equipment. After the presentation, students were asked if they would have liked to work in the Marblehead Quarry 100 years ago. Only three students answered affi rmatively, noting that the job offered steady wages, the ability to work with dynamite and machines, and friendships among the crew.

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7AGGREGATES MANAGER April 2015 7AGGREGATES MANAGER April 2015

Data

Company Ticker Current 52-Week 52-Week Value High Low

Cemex, S.A.B. de C.V. CX $9.182 q $13.81 $8.72

CRH plc CRG $25.532 q $27.02 $16.19

Eagle Materials Inc. EXP $80.43 p $105.69 $68.54

Granite Construction Inc. GVA $31.702 q $40.55 $30.44

Heidelberg Cement AG HEI $74.242 q $77.49 $51.29

Holcim Ltd. HOLN $73.232 q $85.62 $56.22

Martin Marietta Materials, Inc. MLM $137.622 q $146.21 $103.09

MDU Resources Group, Inc. MDU $20.402 q $36.05 $20.36

United States Lime & Minerals, Inc. USLM $63.352 q $76.98 $53.01

U.S. Concrete USCR $32.04 p $32.47 $21.22

Vulcan Materials Co. VMC $82.43 p $85.80 $54.10

3/9/2015 One Week One Year

United States $2.944 +0.008 p -1.077 q

East Coast $3.105 +0.022 p -1.053 q

New England $3.332 +0.041 p -1.030 q

Central Atlantic $3.333 +0.040 p -1.020 q

Lower Atlantic $2.884 +0.004 p -1.090 q

Midwest $2.852 +0.002 p -1.161 q

Gulf Coast $2.795 -0.001 q -1.019 q

Rocky Mountain $2.801 +0.022 p -1.199 q

West Coast $3.096 -0.001 q -0.946 q

West Coast less California $2.934 -0.008 q -1.034 q

California $3.233 +0.004 p -0.879 q

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 3/10/2015.

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

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by Therese Dunphy, Editor-in-Chief [email protected] Your complete guide to new and updated equipment

and supplies in the aggregates industry.

Improved blasting systemDyno Nobel and its joint venture partner, DetNet, offer the new DigiShot 300 RF system, which is designed to improve safety of blasting operations. The system is designed for single-box firing with the capability of firing up to 450 detonators at a distance of 3,281 feet. It will also support box synchronization of two boxes when firing in hardwire mode. The software allows the machines to be configured as either a bench box or base station, while smart key technology improves safety and security.

Dyno Nobel | www.dynonobel.com

Versatile screen plantTerex Minerals Processing Systems expands its CR Series portable plant line with the Terex Cedarapids CRS620S screen plant, which features the patent-pending LJ-TSV screen. The screen is said to increase production and application opportunities through the combination of the El-Jay high G-force oval stroke motion and adjustable slope operation. Hydraulics can change the screen slope in 2.5-degree increments up to 7.5 degrees, as fits the application. Screen openings are available up to 6 inches. A patent-pending “slant spring” screen suspension provides stability at all slopes. A 48-inch-wide fines conveyor with elevated discharge and two 30-inch-wide reversible cross conveyors extend up to 42 inches beyond the main frame to feed off-plant conveyors. Roll-away blending chutes and extended walkways allow easy access to screen cloth.

Terex MPS | www.terexmps.com

Tier 4 Interim excavatorHyundai Construction Equipment Americas, Inc. announces its newest crawler exca-vator, the R220LC-9A. The mid-size excavator features a Tier 4 In-terim engine upgrade, improved hydraulics, and increased op-erator comfort. The unit is powered by a 157-horsepower Cum-mins QSB6.7 engine,

which is complemented by a patented VGT Turbocharger, which continuously varies the airflow boost to match engine RPM and load demands for optimized performance. The unit’s variable speed fan clutch, two-stage auto deceleration system, and econ-omy mode reduce fuel consumption. The excavator has an oper-ating weight of 49,640 pounds, a maximum digging depth of 20 feet, 5 inches, and a bucket breakout force of 29,980 pounds.Hyundai Construction Equipment Americas, Inc. | www.hceamericas.com

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Drill features digital displayVermeer upgrades its D100x140 Navigator horizontal directional drill with a Tier 4 Final engine and additional features. The D100x140 S3 features a 275-horsepower Cat diesel engine that provides 100,000 pounds of thrust/pullback and 14,000 foot-pounds of rotational torque, plus increased rotational speed of 203 rpm. It is also available with the InSite asset management system, which delivers data across multiple platforms. In addition, the DigiTrak Aurora touch-screen interface provides real-time lo-cation information and enhances the operator’s ability to monitor drill performance. It has two Firestrick drill rod options: 15 feet or 20 feet. Stackable rod boxes with a single-pin design and patent-pending auto-lock allow an additional rod to be loaded from an upper rod box.Vermeer | www.vermeer.com

Tier 4 Final ADTKomatsu America Corp. introduces its HM400-5 articulated dump truck. Featuring a net 469 horsepower, it is powered by a Komatsu SAA6D140E-7, Tier 4 Final engine. With a 44.1-ton payload and gross vehicle weight of 165,633 pounds, the truck maintains the productivity of its predecessor while improving fuel efficiency. The low 10-foot, 5-inch loading height matches with 40-ton to 60-ton hydraulic excavators or 5.5-cubic-yard to 7.5-cubic-yard wheel loaders. The Komatsu Traction Control System automatically provides traction in soft ground conditions, while K-ATOMiCS — Komatsu Advanced Transmission with Optimum Modulation Control System — offers a six-speed, automatic transmission that eliminates shift shock and torque cutoff to improve operator and engine efficiency.Komatsu America Corp. | www.komatsuamerica.com

Economical breaker attachmentsAtlas Copco adds three new hydraulic breaker attachments to its Es-sential Case-Mounted (EC) range to fit 22- to 49-ton carriers. The new breaker attach-ments include the EC 140 T, EC 150 T, and EC 155 T. They feature box-style mount-ing systems, which eliminate the need for external fasteners to access components such as bushings and seals. The attachments are as light as 4,000 pounds and generate impact rates as high as 800 blows per minute to deliver impact en-ergy to the breaking surface.Atlas Copco www.atlascopco.com

Vehicle scale conversion kitsMettler Toledo announces its solution to scales that use outdated analog technology, which, it says, are prone to downtime and weighing errors. It can now replace existing load cells in other manu-facturers’ scales with Powercell PDX load cells. Conversion kits are designed for the specific brand of scale the operator owns, to allow for conversion with minimal downtime. In addition, the load cells operate without junction boxes.Mettler Toledo | www.mt.com

ROLLOUTS


Gallon per gallon, Volvo continues to lead the industry with guaranteed wheel loader, excavator, and articulated hauler fuel efficiency. And those gallons — and dollars — add up. Want proof? A Volvo wheel loader with OptiShift technology can save you up to $15,000 in fuel in a single year. So instead of money out the exhaust, it’s money back in your business. Make every gallon count at volvoce.com/smartquarry.

You put an extra $15,000 in your pocket this year.

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Quick release manifold bracketDust Control Technologies introduces a quick-release manifold bracket, engineered to limit worker exposure to harsh service environments and potential safety hazards, while minimiz-ing process downtime. Designed to fit all fan-driven models of DustBoss atomized mist dust suppression equipment, the new bracket design allows removal and replacement of the manifold in about five minutes, with no tools required. The stainless-steel bracket and pin mounting system secure the manifold in place, allowing maintenance personnel to quickly remove and replace for routine cleaning or other service.Dust Control Technology | www.dustboss.com

Backhoe tireMichelin announces the availability of its Bibload Hard Surface radial tires throughout North America. Its new tread design is non-directional and optimized to provide superior tread life when used in hard surface applica-tions. It is the first tire with diamond-shaped tread blocks made up of beveled facets, which offer six differ-ent grip angles.Michelin | www.michelin-us.com

Upgraded face drilling rigAtlas Copco ‘reloads’ its Boomer M-Series drill rigs with a series of enhancements designed to make them stronger, cleaner, safer, and easier to operate. Design improvements include stronger booms, a new filtration system, increased safety features, and the company’s rig control system. The BUT 36S booms are said to provide steadier articulation, and faster, more accurate positioning, while the filtration system keeps lubrication air and hydraulic oil free from water and fine par-ticles. The rigs are equipped with COP 1838HD+ rock drills.Atlas Copco | www.atlascopco.com

Vertical turbine slurry pumpWeir Minerals Floway Pumps offer the Floway VTSP — vertical turbine slurry pump — to address demand for a longer-lasting, abrasives sol-ids handling vertical turbine pump. Following several years of design, research, and testing, Weir says the unit has been demonstrated to last four times longer in solids handling services when compared and tested with the Floway verti-cal turbine pump bearing assembly. The patented bearing design allows for continuous operation in services with a maximum solid content of 10 percent by weight and excursions of 20 percent by weight during tempo-rary upset conditions. Weir Minerals Division | www.weirminerals.com

ROLLOUTS


CAPTURE PROFITAdvantages of a Terex Canica VSI in Your Operation:

Shaping: Produce highly cubical productsBeneficiation: Soft stone elimination/improved soundnessFine Crushing: Closed circuit down to 1 mm - create sandGradation Consistency: Minimal variance throughout parts lifeHigher Product Yield: High reduction ratio/low recirculating load - no CSSHigher Fracture Face Count: Produce in-spec products from round stoneSimple Maintenance: Only basic tools and skills requiredHigh Capacity: From 50 TPH up to 1000 TPH modelsAccepts Wet Feed: Handles various applicationsHighly Versatile: Portable, stationary and combination configurationsLower Capital Cost: In comparison to compression crushers

Take Your Operation’s Profits to the Next Level with a Terex® Canica VSI.

Terex, the Terex Crown design, Works For You, Canica, and Cedarapids are trademarks of Terex Corporation or its subsidiaries. Copyright 2015 Terex Corporation.

The Terex® Canica Vertical Shaft Impactor (VSI) offers numerous advantages for improved profitability. Our robust VSI is a vital tool for producing highly cubical products in small sizes and eliminating soft material. With the widest range of models and the most internal configurations available on the market, we will custom fit a VSI to your specific needs.

Shoe and Anvil ConfigurationLarge Feed, Mild to Medium-Abrasive Materials

Rock On Anvil ConfigurationHigh Reduction in Medium Abrasive Materials

Rock On Rock ConfigurationAll Rock Types and the Most Abrasive Materials

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

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Journalists attending an Intermat pre-show event got a sneak peek at many of the products to be featured at the show, which will be held April 20-25, in

Paris, France. Intermat is one of a trio of inter-national construction equipment shows held on a rotating basis, along with Las Vegas-based ConExpo-Con/Agg and Munich, Germany-based Bauma. The show is expected to draw 1,300 exhibitors from around the world and approxi-mately 200,000 attendees.

The show will mark the fi rst appearance of the newest company to join the Wirtgen Group: Benninghoven. Now part of Wirtgen Group’s Materials Technologies sector — which is also home to the Kleemann brand — the company specializes in the manufacture of asphalt plants. Wirtgen says the company now “comprises fi ve cutting-edge product brands, offering one-stop integrated solutions that encompass all process steps from rock process-ing and asphalt mixing to paving, compaction, and rehabilitation of all kinds of roadways.”

Also under new ownership is Terex Trucks, which makes its fi rst international appearance since coming under ownership by Volvo CE. “As a standalone company, but with the resources and expertise of a global leader in the construc-tion industry, Terex Trucks is now stronger to-gether as part of Volvo Construction Equipment,” says Paul Douglas, Terex Trucks managing direc-tor. The company will showcase the TA300 and TA400 articulated dump trucks, which debuted in North America last summer, as well as the previously released TR60 rigid dump truck.

A high-light of the pre-Intermat event was the introduc-

Paris show highlights the worldwide de-but of excava-tors, portable plants, haul trucks, and more.

by Therese Dunphy, Editor-in-Chief

Whether in re-handling or load-and-carry applications, operator skill has a big impact on an operator’s bottom line.

Equipment Takes the Stage at Intermat

Autom’elec was recognized with an Innovation Award for its TAMIsoft system, which carries out contact-free measurement of aggregate granulometry on a conveyor.

SpecialReport_AGRM0415.indd 14 3/19/15 2:42 PM


SPECIAL REPORT

tion of the Innovation Award winners, which featured some of the most interesting new products to be on display during Intermat. A total of 78 products were submitted for the com-petition, with 29 semi-finalists and a dozen award winners. Among the winners, one pertained specifically to the aggre-gates industry. French company Autom’elec took the silver award in the Digital Applications category for its TAMIsoft gran-ulometry measurement system, which allows for contact-free

measurement of aggregate sizing at various points throughout the production chain. It uses optical triangulation from a laser module, a video camera, and software to statistically model material size, distribution, and movement. At present time, it is not available in the United States. Following is a roundup of additional equipment highlights. (Editor’s note: Only prod-ucts available in North America are included. Web sites show American counterparts for some European exhibitors.) AM

Quick coupler control systemGeith will introduce a new control system for its couplers. It says its simple and safe operating sequence satisfies present and developing safety requirements (ISO 13031). Features include easier installation and improved performance; a dust and water resistance rating of IP65; a bypass button; and plug-and-play installation with a suction pad holder. It also can be used to power LED warning beacons and audio devices for additional safety features.Geith | www.geith.com

New generation of excavatorsCase Construction Equipment will launch its generation of Tier 4 Final D Series crawler excavators, with operating weights ranging from 27 to 44 tons (U.S.). The D Series — including the CX250D, CX300D, CX350D, and CX370D — feature the Case Intelligent Hydraulic System for controllability and performance, with further improvements that increase cycle times up to 12 times faster than that of prior generations. In addition, breakout force is improved by up to 6 percent over the C Series. The pressurized cab is said to be among the quietest in the D Series class. A large monitor accommodates a continuous camera view, as well as performance data. In addition to the excavators, Case will introduce two models of its first grader line, the C Series.Case Construction Equipment | www.casece.com

50-ton artic prototypeBell Equipment will showcase the prototype of its B50E articulated dump truck, the successor to its B50D, which it describes as the world’s first 50-tonner. Through the second phase of its E Series development pro-gram, Bell will upgrade its trucks in the 35-, 40-, 45-, and 50-ton pay-load classes. The operator cab on the E Series features clean ergonomics, low noise levels, a color driving screen with reverse camera, B-drive automotive-style mouse navigation of the display screen, and numerous storage areas. It features a Mercedes Benz engine to meet Tier 4 Final emission standards. The changes to the E-Series also lower the truck’s cost per ton, Bell says. The prototype is expected to be in production by late 2015 or early 2016.Bell Equipment | www.bellequipment.com



Clean sheet design excavatorsHyundai Heavy Industries will present the first six models in a new range of excavators, including the HX220 L, HX260 L, HX300 L, HX330 L, HX380 L, and HX520 L. Engineers used a clean sheet design to develop the Tier 4 Final machines, which use a combined solution of EGR and SCR technologies. All but the HX520 units are equipped with Cummins engines; the top-sized model has a Scania engine. The new cab has improved front glass and is 10 percent larger than prior models. A larger, 8-inch monitor is easier to read and offers more functions. At the same time, fuel consumption has been reduced by 3 to 6 percent. All six units will be available in North America, Hyundai says.Hyundai Heavy Industries | www.hceamericas.com

Compact mobile screenPowerscreen will debut its newest mobile screen, the Pow-erscreen Warrior 600. The unit is said to be the most com-pact heavy-duty mobile screen in the Warrior range, making it easy to transport. It is designed for operators who need versatility, maneuverability, and transportability. The screen is also said to be highly versatile with a simple conversion from three-way split mode to two-way split mode, which can be completed in minutes. The unit features an 8- by 4-foot, high-amplitude, two-bearing screen box capable of 6 G of acceleration.Powerscreen | www.powerscreen.com

Versatile hydraulic drifterMontabert will launch the HDC95 multi-purpose drifter, which is available in three models, including the HC95 LQ designed for surface drilling operations in the quarry mar-ket. In addition, the HC95 LA can replace another drifter already installed on a drilling machine to optimize perfor-mance. The multi-purpose unit was designed to allow it to be swapped for another with minimum intervention. The third model is the HC95 M, which is designed for underground drilling operations. It includes hammering with hydraulic reverse percussion as a standard feature.Montabert | www.montabert.com

Aggregates-specific excavatorLiebherr will unveil the R 946, its first crawler excavator to meet Tier 4 Final emission standards. The R 950 SME (Super Mass Excavation), devel-oped using the R 9446 base specifically for quarry applications, will also debut. The R 946 has an operating weight of approximately 44 tons (U.S.) and a 272-horsepower engine. The six-cylinder Liebherr engine inte-grates a new Tier 4 Final exhaust gas treatment system, which features a SCR system using urea injection to post-treat exhaust gases. Liebherr says the unit has a robust steel structure to ensure reliability in tough appli-cations. Through a smart system, which uses sensors placed in strategic locations around the excavator, the machine can optimize the operation of the engine and hydraulic system to maximize fuel usage.Liebherr | www.liebherr.com



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3-D mobile mapping systemTopcon Positioning Group will feature the IP-S3, the latest technology in its line of 3-D mobile mapping systems. The fully integrated high-density digital imaging sys-tem is more compact, lightweight, and designed to scan at a rate of up to five times faster than previous models. Scanning at 700,000 points per second, the system is designed to offer data-rich results with its 30 megapixel panoramic imagery. The 39-pound unit is designed for simplified installation and pairs with Topcon Master Office software.Topcon Positioning Group | www.topconpositioning.com

Redesigned enginesVolvo Penta will debut two newly redesigned 5- and 8-liter engines, as well as a complete range of common-platform units spanning all emission levels. The com-pany will also focus on OEM support, says Peter Karlsson, head of Volvo Penta’s industrial segment in Europe. In addition to the Tier 4 Final 5- and 8-liter engines, the company will show its Tier 4 Final D11. All of the engines share a common footprint and have components such as the turbocharger located in the same place. The range also shares a common electronics platform that allows them to communicate using the same protocol. Displacement has been increased, com-pared to previous versions, reducing fuel consumption by as much as 2.5 percent.Volvo Penta | www.volvopenta.com


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Untitled-7 1 3/10/15 1:13 PM

52

PULL-OUT GUIDEPULL-OUT GUIDE ILLUSTRATEDOPERATIONS

Spring safety training should re-familiarize workers with best practices.

Safe behavior is as important as safe conditions.

Be aware that winter freeze/thaw can affect geology.

Exposure to elements can compromise the integrity of stationary equipment.

Spring Safety

By Mary Foster, Contributing Editor

OpsIllustrated_AGRM0415.indd 19 3/18/15 10:50 AM

Spring Safety

OPERATIONS ILLUSTRATEDSpring Safety

It’s no coincidence that the Mine Safety and Health Administra-tion (MSHA) supports Spring Thaw safety workshops, which

typically occur for metal/non-metal mines around the country from March through May. These are the months when many operations that have been dormant for the winter begin to produce again — and often with new employees who have never worked in a mining environment.

“For our industry, winter has a huge impact on geology, machin-ery, and the humans that work around both,” notes Joe Casper, vice president of Safety Services for the National Stone, Sand & Gravel Associ-ation (NSSGA). “They’re encountering the use of equipment for the fi rst time in three to four months — or the fi rst time ever. And then there is the impact of freeze/thaw on ground control,” he adds, explaining that the change in seasons can also change the geology of highwalls, haul roads, berms, and quarry fl oors.

Matt Bunner, safety manager for Tell City, Indiana-based Mulzer Crushed Stone, agrees. “This time of year, most operations in our part of the country typically are dealing with equipment and plants that have been sitting in the elements for weeks. Through exposure to the environment, structural integrity can be compromised. Workers need to be observant.”

“Observant” is a key word that belongs in any safety program, any time of year.

Miners are familiar with MSHA’s citable standards, created around

unsafe conditions. And MSHA must focus on conditions because a con-dition is something an inspector can see and record. For instance, a moving machine part that lacks required guarding is a citable condition. Lack of working horns or backup alarms is a condition. A non-working set of brakes is a condition.

But regardless of how many ma-chine guards and safety features an operation can place on its equipment, human behavior is going to play a substantial part in the success of its safety program. When employees begin to work from habit, and are not aware of the risks around them — are not observant of what might happen — that’s when accidents happen.

“It’s human nature,” Bunner says. “We’re built to take shortcuts. If you have to go get a ladder or use an available chair to change a lightbulb, we choose the chair. If both are avail-able, we choose the ladder because it is the right tool and safer.

If we’re hanging Christmas lights, and we have to get down to move the ladder, we’re going to lean over just a little bit more to avoid moving that ladder so many times.”

Bunner says this is the problem that MSHA runs up against. Un-safe conditions only cause about 5 percent of the accidents that occur in aggregate operations. “It’s the unsafe thoughts between people’s ears that cause incidents and fatalities,” he says.

What is the answer? Education and discipline. And both require buy-in from management on down to create an effective safety culture.

AGGREGATES MANAGER

In climates where there is a great deal of freeze/thaw, producers must pay attention to winter’s effect on ground control. Changes to a site’s geology over the winter months can include sloughing of highwalls, affecting the way the product is extracted, as well as softened road conditions and berms, which can affect the patterns and steering of mining equipment.

Inspections and enforcement of regulations are part of operational safety, but education must reinforce safe behavior. Unsafe conditions account for only about 5 percent of all incidents and accidents in aggregate operations. It is human nature to take shortcuts. Min-ers must be educated about the importance of doing their jobs in a safe and healthful manner — and how to do so.

1 What the thaw leaves behind 2

4 The human factor 5


OPERATIONS ILLUSTRATED OUREXPERTS

Spring Safety

April 2015

Joseph Casper has been vice president of safety services for NSSGA since 2008. He previously had established regulatory and political affairs programs for the Brick Industry Association (BIA). Prior to his time at BIA, Casper worked for the Point-of-Purchase Advertising Institute, BMW of North America, the U.S. Department of Commerce, and the offi ce of then-vice president George Bush. He holds a bachelor’s degree from Georgetown University and a master’s in business management from John Hopkins University.

In climates where there is a great deal of freeze/thaw, producers must pay attention to winter’s effect on ground control. Changes to a site’s geology over the winter months can include sloughing of highwalls, affecting the way the product is extracted, as well as softened road conditions and berms, which can affect the patterns and steering of mining equipment.

Safety must be a commitment from every member of an aggregate operation. And if it is done right, a good safety program will not impede quality production. In fact, many of the most profi table companies in the industry also have the best safety records. A CEO who signs the NSSGA Safety and Health Pledge demon-strates safe practices himself in every operation and shows that he not only talks the talk, but also walks the walk.

There are probably three top best practices that ev-ery miner should keep in mind. 1. Keep eyes open throughout a shift to note hazards, hazardous behav-ior, and areas for improvement. 2. Conduct proper pre-shift inspections of all mobile and stationary equipment. 3. Prior to handling any task, conduct a two-minute evaluation, asking, “What could go wrong? What is the safest manner in which to handle this?”

Spring training2 3 Winter’s effect on equipment

5 Company-wide buy-in 6 Best practices

Matt Bunner has been the safety manager for Mulzer Crushed Stone since early 2000 and has more than 20 years of safety experience. He graduated from Western Kentucky University with a bachelor’s degree in indus-trial technology (safety core) in 1994. He has worked in construction, manufacturing, and mining, all in the safety fi eld. Bunner holds his certifi cation/designation of CSP and CMSP. He currently serves as chairperson of the Safety Committee for the Indiana Mineral Aggregates Association and is a past president of Audubon Chap-ter of the American Society of Safety Engineers. Safety is more than his job, it’s his passion.

While spring generally ushers in a number of new hires for training, operations should take advantage of this time to re-familiarize all employees with best safety practices. Some aggregate operation hazards are unique to spring startup, such as geology and maintenance/operation of equipment that has sat dormant for several months. But most spring safety training revolves around hazards miners encounter every day.

Winter cold and moisture can have a huge effect on equipment as it sits during the months of shutdown. For stationary equipment, such as conveyors, structural integrity may be compromised with rust and erosion through exposure to the elements. Additionally, miners must be on high alert as equipment is prepared for start-up, and must adhere to proper lock-out-tag-out rules.


AGGREGATES MANAGER

Voices of Experience

Matt Bunner

Joseph Casper

t

t

W hat are some of the hazards in aggregate mining that are unique to spring startup? In addition to changes in geolo-gy and cold, wet weather’s effects on equipment, miners are often tasked with work that doesn’t normally fall under their job descriptions, says Matt Bunner, safety manager for Mulzer Crushed Stone, based in Tell City, Indiana.

“The first full week of operation after winter, we go through spring cleaning,” he explains. “And this often requires workers to handle jobs they aren’t used to doing. For instance, a haul truck driver might be helping out in the plant. There’s a greater risk when workers are exposed to hazards that they’re not familiar with.”

Bunner says spring is also the time of year that many operations go through their greatest hiring efforts. These miners must undergo new miner training, and they are exposed from day one to new tasks and hazards.

Bunner says that each operation is different, and each miner is different. And he has found a miner’s age makes a difference in the way that person learns. “Younger workers learn better with interactive opportunities. Older workers do better in a classroom setting, where you provide examples,” he notes. “Millennials want access to what’s happening in the outside world concerning their jobs. I never would have thought that Twitter and Facebook would become part of the mining world, but they have.”

Education is key, but discipline also plays a part, he notes. “We have a strict discipline policy, with no ifs, ands, or buts if it is violated. If a worker violates lock-out-tag-out, he or she gets a minimum of three days off without pay. Discipline such as this puts workers on their guard for the next time. They think twice,” says Bunner, adding that some safety violations may require retraining — or the employee may have to discuss the violation and what led up to it at a safety meeting.

Bunner says he sums up most safe behavior with three basic tenets. 1. Workers must always be observant and look at conditions throughout their shifts — and not just because the law says so. Always look at the workplace and observe where there is room for improvement. 2. Conduct thorough pre-shift inspections prior to starting up any piece of equipment. 3. Evaluate each task before starting, asking, “What could go wrong?”

“If you do those three things, you will get your biggest bang for your buck with safety,” Bunner says.

O n Feb. 25, 2015, MSHA held a stakeholder webinar meeting that discussed a new fatality reduction initiative for metal/non-metal mines. The enforcement agency is focused on an upswing in fatalities in metal/non-metal between October 2013 and Jan. 26, 2015.

“In line with MSHA’s current focus on fatalities that have occurred in metal/non-metal over 16 months, they will begin stricter enforcement of the old ‘Rules to Live By’ program,” says Joseph Casper, vice president of Safety Services for NSSGA. “Under this heavier enforcement, if they find certain facilities that have a higher number of citations against the Rules to Live By standards, those facilities will be subject to additional ‘impact’ or spot inspections. MSHA has also rolled out new online compliance monitor-ing tools that operators and miners can use to track their compliance history, and compare it against other mines.”

Casper says, while MSHA is an enforcement agency that must focus on conditions, the MSHA-NSSGA Alliance was established to forge a public/private partnership to encourage training and education that may help operators better safeguard workers. “NSSGA encourages education. And Joe Main (assistant secretary of labor for MSHA) has been traveling the country, talking to stakeholders about mine safety. Unfortunately, not all aggregates companies are members of NSSGA, so — depending on the facility — we may not be able to connect with every quarry to stress the importance of safety and compliance.

“Accordingly, when Mr. Main or an MSHA inspector shares educational information and materials with a mine, they are some-times reaching an operation that we aren’t reaching,” Casper says. “This is a good thing.”

The best tool NSSGA has to encourage safe facilities, says Casper, is the Safety and Health Pledge, which calls for signers to commit their companies to helping the industry reduce its injury rate by 10 percent for five consecutive years. A majority of NSSGA member CEOs have signed the pledge.

“No safety program will go far until workers realize that management is genuinely for it,” Casper says. “A signed pledge shows that the CEO is supporting safety and health for that operation.” He says that when a CEO then walks a plant in proper safety gear and is adhering to safe practices, the message is reinforced in a powerful manner. “Workers need to realize that management is not calling for shortcuts or higher production to save dollars at the risk of safety. Management must walk the walk, not just talk the talk,” he adds.

For companies that still might consider taking shortcuts to push production or lower costs, Casper says there is an additional consideration. “Taking into account the costs for non-compliance and incidents — MSHA citations, hospitalizations, worker’s comp — it makes no sense to not be fully committed to safety in your operation.”


Be Concrete

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an event byINTERMATc/o IMEX Management, Inc.Tel: 704.365.0041 - Fax: 704.365.8426Email: [email protected]

In te rna t iona l Exh ib i t ion fo r Equ ipment and Techn iques fo r Const ruct ion and Mater ia ls Indust r ies .

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Southwest Louisiana is dotted with

lakes, swamps, and bayous, and

boasts a very healthy ’gator popula-

tion, but it is also an area where

large deposits of sand and gravel can be found,

thanks to the meanderings of the Mississippi

River. Most of these deposits have been mined

for years and some have even been mined out

of materials that were in demand in the past.

However, Trinity Materials’ Indian Village Plant,

located about 20 miles north of Lake Charles,

has turned what previous miners left behind

into a valuable product.

In the beginning…Aggregate production began at Indian Village

Plant about 65 years ago when Gifford-Hill Co.

built the original processing plant on the site.

There was a large sand and gravel deposit in

the bottom of a small lake, so the company

brought in a dredge and began pumping it out.

At that particular time, there was not much

of a market for sand, so once the gravel was

screened out, the sand that would not sell was

pumped back into the lake.

In 1989, after most of the gravel had been

removed and Gifford-Hill ceased operations,

Lafarge came in and built a new plant. Trinity

Materials, Inc. bought the plant five years later

and started processing the sand that had been

pumped back into the lake years earlier. Now,

with southwest Louisiana caught up in the latest

oil and gas boom, that sand has found a market.

“Right now, southwest Louisiana is booming

all the way to Baton Rouge, but more so here,”

says Ezra Young, area manager for Trinity Ma-

terials, Inc. Young has been in the aggregate

business for 33 years and manages Indian

There’s a method to the madness of mining sand and gravel in the marshy areas of southwest Louisiana.

by Kerry Clines, Contributing Editor

Trinity Materials’ Indian Village Plant dredges and processes sand from a small lake in southwest Louisiana where the recent oil and gas boom has brought new life to the construction industry.

Diggin’ Cajun Style

PlantProfile_AGRM0415.indd 24 3/19/15 2:48 PM


PLANT PROFILE

Village Plant, along with another dredg-

ing operation in southwest Louisiana

and one right across the border in Texas.

“Lake Charles is not what it was 20 or

30 years ago,” he says. “Every corner

you turn, someone is building something.

It all has to do with oil and gas.”

The processRemoving and processing the sand be-

gins with the 75- to 85-foot deep de-

posit and an electric dredge. “We rebuilt

the dredge back in 2009,” Young says.

“Trinity Industries in Dallas built a new

hull and outriggers to replace the old

dredge that was here when I came to

work 32 years ago. We used the same

pump frame and bearing table, and re-

build the old parts as they wear out.”The discharge pipe runs up the side of the processing plant, depositing the material into the top of the screen tower.

Diggin’ Cajun Style



The electric power, which is provided

by the local power company, is run out

to the dredge by a power cable, which

floats on styrofoam blocks to keep it

out of the water. Young says a super

ground fault system is necessary for the

2,300 volts of power running through

the cable.

The dredge operator is able to track

everything from the control room inside

the dredge. A couple of gauges show

how much pressure is on the line and

how much sand is being pumped at all

times. The dredge operator can regulate

the amount of vacuum to control the

amount of sand being pumped up to

the processing plant.

Material is sucked up from the bot-

tom of the lake through a 12-inch pipe

and sent to a pivot point on the bank

through a 10-inch discharge pipe. “We

pump down so that, as we remove the

deposit, the material in front

of the dredge will cave in

and come with it,” Young

says. “You want the deposit

to flow to you. We pump all

the way across the lake and

then pump all the way back. It’s what

we call back pumping.”

Each pass the dredge makes across

the lake can take three to four months.

Once the dredge has pumped across

the lake and back again, it is pushed

out by adding a joint of pipe, and the

process is repeated. Young notes that if

the dredge is pushed out before pump-

ing back across the lake, any sand

that might have caved in after the first

pass would be left on the bottom of

the lake.

The material pumped out of the lake

flows through a pipe to the bank. “We

pivot from that point on the bank,”

Young says, explaining that the pivot

point stays in place forever. A second

pump located on the bank, called a

booster pump, pushes the material the

rest of the way to the processing plant.

The material is carried through the

pipe to the top of the screen tower

where a deck of gravity screens removes

any rock or gravel. “Gifford-Hill got most

of the gravel out of here,” Young says.

“What little bit of 3/8-inch pea gravel we

get is generally sold before it’s washed.

We never have a stockpile of that.”

From the screens, the water and

sand flow into a classifier where the

sand is separated into mason and

concrete sand. The finer mason sand

passes through a dewatering screw

and is dropped into a pile beneath the

plant to dry. The concrete sand goes

through a different, larger dewatering

screw and is carried by conveyor belt

to a radial stacker where it is stock-

piled. The radial stacker has two con-

trol panels, one in the control tower

and one at the base of the stacker,

which allows it to be controlled from

the ground or the control room. A

beater roller beats the fine sand off

the conveyor belt as it returns to the

plant, limiting carryback.

Although a small supply of mason

sand is available, most of the sand is

used in concrete and is sold to local cus-

PLANT PROFILE

After gravel is screened out, the water and sand flow into a classifier where the sand is separated into mason and concrete sand.

The radial stacker used to stockpile the concrete sand has two control panels, one in the control tower and one at the base of the stacker, which allows it to be controlled from the ground or the control room.



PLANT PROFILE

tomers for use on construction projects,

such as the Interstate 210 bypass in

Lake Charles. Once the customer trucks

are loaded by a wheel loader, they pro-

ceed to the scale house for weighing.

“Four cameras at our scale house

allow us to see inside the customer

trucks when they pull on the scale so

we can verify what they have,” Young

says. “We still print and hand-deliver

tickets, giving us one last chance to in-

teract with customers.”

Safety firstSafety is a big deal at Indian Village

Plant, which is why it has such a great

safety record. It has received several

safety awards from the National Stone,

Sand and Gravel Association over the

years. The most recent award came in

2014 for 32 years without an accident.

Weekly safety meetings are held on

Mondays, but if a fatalgram is received

from the Mine Safety and Health Admin-

istration during the week, all work stops

at the plant to talk about it. “Anything

that alarms me or that I’ve never seen

before or talked about that I think is a

problem and could happen to us, I want

the guys to know about it,” Young notes.

“Safety is an everyday job. It’s not just a

Monday morning thing. It’s got to be an

all week thing for us to be safe.”

The employees do a walkaround on

mobile equipment every morning to

make sure all the lights, horns, and

back-up alarms are working, and check

all the brakes before any trucks are

loaded. In the plant, the safety guards

are checked to make sure they are all

in place, and the dredge gets the same

scrutiny.

The radial stacker was custom-made

for the plant. Young had it built with a

walkway on both sides of the conveyor.

“You won’t see that anywhere else,” he

says, “but we spent the extra money

to make it safer for those who have to

work on it.”

Young says he has seen safety get

better and better over the years. “That’s

a plus to all of us,” he says. “We focus

on teamwork, being safe, and com-

municating. Everybody on the plant

has a walkie talkie, everybody has a

cell phone, and we’ve got a CB radio

on the dredge. Nobody goes out to

Once the customer’s truck is loaded, the driver proceeds to the scale house to have the load weighed and get a ticket.

SCALEISO CERTIFIED


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Untitled-3 1 3/24/13 12:21 PM


PLANT PROFILE

Equipment List• J-36 Thomas electric pump• Powerscreen Commander

510 wash screen• Eagle Iron Works 54-inch

coarse material screw• Eagle Iron Works 24-inch fine

material washer• Eagle Iron Works 10-foot x

40-foot 11 station classifier• Caterpillar 980c wheel loader• Caterpillar 980h wheel loader• Caterpillar 230E L excavator• Caterpillar 12G motor grader• Ford water truck• Berkley electric water

pumps (2)

Sand and water flow from the screen tower into a classifier. Concrete sand is separated out and run through a dewatering

screw, then carried by conveyor belt to a radial stacker for stockpiling.

perform physical labor alone, there are

always two of them. The dredge opera-

tor doesn’t leave the dredge without

somebody knowing about it. When

our safety manager goes to make his

walkaround, he takes another employee

with him. No matter what you’re do-

ing, you can lose your life doing it, so

you’ve got to do it right.”

The crewLike most aggregate operations these

days, Indian Village Plant deals with the

issue of finding and keeping good em-

ployees. Four people at the plant have

retired within the last 10 years. “That’s

good, they deserve to go and enjoy their

life,” Young says, “but I have to bring

new people in and train them. The only

way we’re going to survive in any kind

of business is training people the right

way, and safety’s a big part of it.”

Choosing the right person for the job

can be challenging in a small town,

however. It can be difficult, if not im-

possible, to find someone with any

mining experience, so Young says he

looks for someone who wants to learn.

“I don’t think you can take just any-

body off the street and make a miner

out of him, but you know what you’re

looking for, and sometimes you just go

on a hunch,” Young says. “My dredge

operator was running a front-end load-

er for a contractor the first time I ever

saw him. I watched him load trucks

for a while. He was running a horrible

piece of equipment, and I thought, ‘this

guy’s really trying or he wouldn’t be on

that thing…I’m going to talk to him.’

It has been nine years now. I think

I made a wise decision to stop and

watch him and talk with him. That’s

how you get good employees.”

All new hires at the plant receive

eight hours of training before they ever

leave the office. The training includes

verbal instruction, as well as videos on

what to do and what not to do. As time

goes on, the employee receives training

on different jobs in the plant, but the

focus is always on staying safe.

“You really need to get the attention

of new folks nowadays,” Young says.

“My first day in the business, the old

man who trained me said, ‘Come with

me, I want to show you all the places

you can die out here.’ He really got my

attention when he told me that, so I

use that same speech with all our new

hires. It worked for me, and it works for

them.” AM

Trinity Industries in Dallas built a new hull and outriggers to replace the old dredge in 2009.


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EQUIPMENT MANAGEMENTTrinity Materials’ Indian Village Plant keeps dredges and processes sand from a small lake in southwest Louisiana where the recent oil and gas boom has brought new life to the construction industry.

EQUIPMENT MANAGEMENTTrinity Materials’ Indian Village Plant keeps dredges and processes sand from a small lake in southwest Louisiana where the recent oil and gas boom has brought new life to the construction industry.

A Stronger Side of Material Handling

by Carol Wasson

The outer truss section of the mast-type stacker is solely supported by a wire rope suspension system.

Conveyor systems vary widely in

overall quality and efficiency. Con-

sider that operations may obtain

conveyors from a variety of sources

— from in-house or local fabrication operations,

to used equipment outlets, to opting for the lat-

est technologies from major manufacturers. No

matter the source, producers should ultimately

evaluate each material handling system and

component — not just on price or immediate

availability — but based upon performance,

safety, and ease of maintenance. Examining

the latter criteria is the basis of a long-term

and forward-thinking approach to choosing any

piece of equipment.

Case in point: A recent industry water-cooler

discussion focused on evaluating the differen-

tiating factors between mast-type stackers and

telescoping radial stackers. Is one type more ad-

vantageous than the other? How does each rate

based upon the key criteria? Arguably, there are

a number of varying opinions as to using either

stacker type. Lafe Grimm, chief engineer for por-

table projects at Superior Industries, shares his

take on how the two systems stack up.

Safety firstDesigned with an outer truss section that’s

hinged to an inner section, the mast-type stacker

assembly is supported by a massive mast or

tower structure that extends well beyond the

hinged interconnection. This mass and height

is required to support a wire rope suspension

system that raises and lowers the outer section

during conveying and stockpiling. The wire ropes

are the sole support of the outer section.

“Wire ropes can deteriorate over time. If left in

service long enough, they will break – causing

the potential of serious injuries, and costly equip-

ment damage and downtime,” Grimm says. He

explains that the fiber strands in the wire ropes

are susceptible to deterioration due to overload-

ing, extreme heat, and damage due to bending,

flexing, and kinking. These effects are acceler-

ated in a system that involves sheaves and a

moving cable. “Also, with the higher profile of the

mast-type stacker’s tower, the unit is more sus-

ceptible to wind load pressure,” he adds.

Alternatively, the telescoping radial stacking

conveyor consists of a stinger conveyor mounted

inside an outer conveyor of similar length. The

When evaluating stacking conveyor systems, consider their impact on material specifications, safety, and ease of maintenance.

EquipmentManagement_AGRM0415_v2.indd 31 3/19/15 3:20 PM


stinger conveyor has the ability to move linearly along the

length of the outer conveyor, thereby varying the location of the

discharge pulley. The height of the discharge pulley is variable,

as well as the radial position of the conveyor. The undercarriage

design also delivers support and rigid lateral stability.

“We adhere to some very rigorous steel structure codes;

and the load sharing hydraulic cylinders add even greater

structural support and stability,” Grimm says. He adds that the

cylinders used to raise and lower the stacker are specially de-

signed for safety, as a counterbalance valve keeps the “raise”

cylinders from lowering should there be a hydraulic failure.

Also, he explains that, in extreme weather situations (such as

hurricane winds), safety and loss prevention are aided by the

ability to quickly and easily adjust the stacker by retracting the

stinger conveyor and bringing the unit into a low profile.

Performance pointsAccording to Grimm, some mast-type stacker manufacturers

describe the wire rope suspension system as allowing the dis-

charge point of the stacker to remain slightly above the top of

the pile, thereby decreasing material segregation and degrada-

tion. “In truth, mast-type stackers are not known for precise

control and increased range of movement. As such, they are

prone to deliver higher material segregation within the finished

stockpile,” he says. To mitigate this situation, some operations

have added spray systems or specialized chutes to reduce seg-

regation issues and minimize particulate matter in the air.

“An automated telescoping radial stacker is the only solu-

tion to creating a fully desegregated stockpile,” Grimm says. “It

stockpiles in very thin lifts or layers, with each layer consisting

of a series of windrows of material. To accomplish this, the

conveyor is in motion continuously, and the three-axis varia-

tion of the discharge pulley is essential in making the layered

pile that overcomes segregation.”

Telescoping conveyors can also be programmed to create

higher-volume stockpiles of many different shapes, sizes, and

configurations. Grimm points to the fact that some site foot-

prints are more suited to a rectangular or pie-shaped pile; or a

producer may want to stockpile inline over a reclaim tunnel for

more live storage. This stockpiling flexibility can result in high-

er production capacity at a lower cost, he says, adding that

these advantages are particularly important to the portable op-

erator who wants to build the largest stockpile possible before

relocating or to the producer who wishes to maximize stockpile

volume on a site with limited space.

Portability is another consideration, he says. The telescop-

ing radial stacker has three styles of road or radial travel axles

from mobile, to in-pit portable, to fixed radial stacking. “Mast-

type stackers require a lot of clearance and are very expensive

to move,” Grimm says.

Ease of maintenanceThe wire rope used on mast-type stackers requires frequent

and meticulous inspections by a designated competent per-

son. Guidance on these inspections can be obtained from the

American National Standard for Wire Rope for Mines; the Oc-

cupational Safety and Health Administration; and from the wire

rope manufacturer’s specifications, which indicate the number

of allowable wire strand breaks per equipment type. The

number of broken wires on the outside of the wire rope is an

indication of its condition and whether it must be considered

for replacement.

An automated telescoping radial stacker can create high-volume, fully desegregated stockpiles in an assortment of configurations.



EQUIPMENT MANAGEMENT

Grimm stresses that these types of inspections can be pains-

taking and time-consuming, while often placing the inspector

in perilous positions on lifts, or under the machine itself. Wire

rope can also be very costly to replace. As a result, inspections

may not be conducted as often as they should be — leading to

potential hazards.

“The hydraulic systems on the telescoping radial stackers are

far simpler to maintain; however they do require

routine maintenance that includes monitoring

fluid levels and cleanliness, changing oil filters,

and checking for potential leaks,” Grimm says.

Ever-changing technologiesGrimm says that conveyor technology is al-

ways changing, and always being fine-tuned.

“The mast-type stacker was far more common

decades ago. That was when wire rope was

used in all kinds of equipment — such as the

early bulldozers — a time before the advent of

hydraulic technology, which is safer and more

reliable,” he says.

Unlike the fabrication of yesteryear, Grimm

says, “Today’s telescoping radial stacking conveyors meet

the criteria of safety, performance, and ease of maintenance.

They are PLC-controlled, automated systems that significantly

streamline material handling functions and are designed with

key standard safety features at the forefront.” AM

Article courtesy of Superior Industries.

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Untitled-34 1 12/18/14 10:56 AM

An automated telescoping radial stacker can create high-volume, fully desegregated stockpiles in an assortment of configurations.


SupplySupplyby Therese Dunphy, Editor-in-Chief [email protected]


WASHED AND SEPARATEDToday’s washing and classifying equipment can help operators capture and clean more saleable product.

Designed to remove large volumes of excess water from feed material, EIW Classifying Tanks smooth out feed fluctuations and remove excess sand particles for a consistent in-spec product. Recently, the MARK VI computerized sand re-blending control system was introduced for this equipment. It is said to make stockpile calibration easier and faster, al-lowing for a varying number of controlled products, as well as calibrated tons per hour forecast of the products produced. Producers using the system maintain tighter control of their products’ Fineness Modulus (F.M.). Eagle Iron Works says it can handle up to two tanks simultaneously and makes calibration simple.Eagle Iron Works | www.eiwllc.com

McLanahan says its Ultra Sand Plants help producers increase sand production, produce a drier product, and improve product consistency. Ultra Sand Plants combine separators, dewatering screens, and a slurry pump to provide an estimated 3 to 5 percent higher product yield over traditional fine material screw washers. They produce a drier product and do not have the inherent inefficiencies of screw washers, the com-pany says. The units send unwanted fines to waste streams, keeping product-sized fines in the product piles. They also have the ability to separate and combine sand fractions, allowing the user to blend coarse/fine sands as needed to meet product specifications.McLanahan | www.mclanahan.com

KPI-JCI and Astec Mobile Screens has added a new S9000 Dewatering Screen to its Series 9000 family of products. Capable of reducing moisture content of washed sand down to as low as 8 to 15 percent, the screen is available in multiple sizes, ranging from 2 feet by 7 feet up to 8 feet by 16 feet. The screen’s 1/4-inch stroke operates at 1,200 rpm, providing high G force action to separate water from the material. It is equipped with urethane media, has an adjustable incline from 0 to 5 degrees, and can be pack-aged in portable, semi-portable, and stationary systems. KPI-JCI and Astec Mobile Screens | www.kpijci.com

Classifying tanks with updated control system

Drier, more consistent sand production

New series dewatering screen

SupplyLines_AGRM0415.indd 34 3/18/15 10:52 AM

Supply


WASHED AND SEPARATED

Metso says it can make the wash screen in an aggregate wash-ing and classifying system more efficient. Its factory-installed spray system provides 3 to 5 gallons per minute per ton per hour of feed material. Additionally, a grease-lubricated vibrator, such as its MV vibrator, works best in wet applications to prevent water and dirt contamination and provides a no-leak lubrication system. Metso says its feeders and screens deliver optimal up time and the lowest total cost to operate with trouble-free, reliable designs.Metso Minerals Industries, Inc. | www.metso.com

Superior Industries, Inc.’s Aggre-Dry Dewatering Washer includes a newly patented washing fines recovery system. The washer is a single machine integrating a fine material washer and a dewater-ing screen. The patented technology reroutes -25 mm fines from an onboard dewatering screen back to the integrated sand screw. Rather than losing these fines to waste ponds, they are recovered as saleable material. Sand processed through the equipment is said to be stockpiled with moisture content of 8 percent. Washers are avail-able in single- or twin-screw configurations and in screw sizes of 36 to 60 inches. The twin-screw 60-inch model can process up to 800 tons per hour. The maximum material size that can be processed through the unit is 3/8 of an inch.Superior Industries, Inc. | www.superior-ind.com

Enhances washing and screening systems

Patented fines recovery systemDrier, more consistent sand production

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Experience: Retired November 2011 following 41 years with the U.S. Geological Survey

Services Offered: Applied geology and geological research for construction rocks

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Contact me at: [email protected]

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• Resource evaluation• Expert testimony

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• USGS Aggregate Resource Geologist 1977-2011• Past Chair and Distinguished Service Award recipient, Society for Mining, Metallurgy, and Exploration, Industrial Minerals and Aggregates Division• Author of ASBPE award-winning columns - Carved In Stone, Aggregates Manager, 1998-Present

BillLanger_AGRM0115.indd 1 12/16/14 1:21 PM

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AGGREGATES MANAGER April 201536 AGGREGATES MANAGER April 201536

RockFollowing a spike in metal/non-metal fatalities, underlying causes will be scrutinized in future inspections.

FATALITY PREVENTION

by Dana M. Svendsen

Dana M. Svendsen is a member of Jackson Kelly, PLLC’s Denver practice. Her practice is focused on occupational safety and health and mine safety and health. She can be reached at 303-390-0011 or via email at [email protected].

MSHA Inspection Focus:

The Mine Safety and Health Ad-ministration (MSHA) recently an-nounced a fatality prevention initiative in response to increased

fatalities within the metal and non-metal sec-tor, which has recorded 37 deaths from Octo-ber 2013 to January 2015. MSHA announced its fatality prevention focus in a Jan. 30, 2015, letter to stakeholders regarding increased efforts to prevent fatalities at metal and non-metal mines. MSHA also held outreach calls with stakeholders in January and February 2015 to discuss methods that operators can use at their sites to prevent fatalities.

Common factors in the fatalities analyzed by MSHA have included deficiencies in train-ing, especially task training, and examinations of workplaces and equipment. MSHA officials also noted increases in fatalities that involved independent-contractor employees, and an in-crease in fatalities at sand, gravel, and cement operations.

So what can operators do to prepare for MSHA’s fatality prevention initiatives? Opera-tors in the metal and non-metal sector can expect additional emphasis and educational efforts by MSHA inspectors to assure compli-ance with “safety fundamentals.” MSHA has identified several areas as “safety fundamen-tals” that have played a significant role in the

metal/non-metal sector fatalities:• Workplace exams;• Corrective actions taken in response to

exams;• Training, particularly task training;• Using proper personal protective equip-

ment;• Lockout/tagout procedures; and• Pre-operational equipment checks, par-

ticularly for mobile equipment.MSHA provided guidance to the industry

on task training compliance and management considerations when working with indepen-dent contractors. Implementation of these recommendations at your mine site could go a long way to help with MSHA compliance and fatality prevention. Additionally, it is wise to review this information with miners, supervisors, and contractors, so that they will be comfortable discussing these topics with MSHA inspectors.

Task trainingTo comply with MSHA task training require-ments, operators need to ensure that miners have received task training for all new tasks. Operators must also ensure that all tasks have been properly assessed, and miners have the skills necessary to perform tasks in a safe manner. It is also important to consider that

RockLaw_AGRM0415.indd 36 3/19/15 3:23 PM


RockFollowing a spike in metal/non-metal fatalities, underlying causes will be scrutinized in future inspections.

MSHA Inspection Focus:

trainers have the knowledge necessary to perform adequate and sufficient task training. These topics are often best ad-dressed in a written training program.

To assess the need for task training, it is helpful to con-sider the different tasks required on all machines, for main-tenance activities, and differing job duties. Task training should be provided when there is a change to the equip-ment, process, or condition.

When determining the content for task training, it is help-ful to use equipment or job checklists, job safety analysis, or safe job procedures. The operator’s manual for a piece of equipment can also be a helpful resource to determine spe-cific hazards related to the equipment.

During completion of task training, ensure that trainees can demonstrate knowledge of company and federal health and safety procedures applicable to all tasks. Ideally, task training will be provided in a non-production setting. Task training can also be provided by supervised practice of tasks in production mode. Whenever possible, related infor-mation on safety data sheets and the mine’s hazard com-munication program should be incorporated into any task training.

Other components of task training include a demonstration of proper pre- and post-operation checks on equip-ment, proper start-up and shutdown procedures, and the required mainte-nance and service of equipment. Miners should understand how and where to report any problems or malfunctions with equipment.

To make sure your trainers are quali-fied to provide task training, evaluate the formal and informal training they have received to perform effective task training. Task training procedures should be evaluated to ensure that all health and safety aspects of the tasks are addressed in a correct and consis-tent manner. Once proper task training is completed, trainers need to ensure that adequate training records are com-pleted for all task training.

IndependentcontractorsMSHA offers the following best prac-tices when working with contractors:

• Make sure all workers are following

safety procedures;• Set safe work procedures and discuss them;• Identify and control work hazards and protection meth-

ods;• Inspect work area for hazards before performing work;• Check equipment for defects that may affect safety be-

fore the equipment is operated; and• Properly use personal protective equipment.

Take awayMSHA will focus inspections on areas where they have iden-tified increased fatalities. MSHA inspectors will be looking at the functions that miners are performing, particularly looking for proper examinations and pre-operational checks on mo-bile equipment, especially trucks. MSHA will also be looking for proper personal protective equipment use.

Expect MSHA inspectors to focus on the areas of task training, workplace examinations, pre-operational equipment checks, and independent contractors when they come to in-spect your mine sites this spring and summer. MSHA inspec-tors will want to discuss these topics with miners, supervi-sors, and contractors during their inspections. AM

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


COMPANY WEB PAGE #

Beka-Max of America, Inc. www.beka-lube.com 37

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John Deere Construction Equipment www.johndeere.com/pushback IFC

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by Bill Langer

Bill Langer is a consulting

research geologist who spent 41 years with

the U.S. Geological Survey before starting his own business. He can be reached at [email protected]

In Stone

“Stones that are very large, and which cannot with ease be removed whole [from land to be tilled], may be blown to pieces with gunpowder. They will be not only more handy for removing, but far better to put into walls. For the blow-ing of round stones will make some square and regular faces. They will often come cheaper in this way than if they were dug out of quarries.”

Samuel Deane, 1822, The New-England Farmer; or Georgical dictionary, p. 430

Up until the early 1800s, the stone quarries in Barre, Vt., were not quarries in the traditional sense. They were simply boulder fields or ledge rocks. Boulder fields were places containing many boulders that had been picked up and transported by glaciers, and deposited by the retreating ice. Ledge rocks are natural outcroppings of bedrock.

The boulders were shaped using plugs and feathers or by blast-ing with gunpowder. Ledge rock was quite easily quarried by pry-ing off layers of rock with crowbars or by blasting. Commonly, only the top few feet of granite were mined in ledge rock quarries. But as demand for Barre Granite increased, quarries began to extend downward into higher quality, stronger rock, resulting in quarries with the more familiar shape of a large hole in the ground.

The most difficult step in mining downward into fresh rock was obtaining a free face from which to work. A mass of rock 3- to 5-feet wide and as deep as the desired thickness of the quarried blocks had to be removed to provide the necessary working space.

This commonly was accomplished by a method called channeling, whereby closely spaced holes were drilled along a straight line. The thin webs between the adjacent holes were removed with a flat chisel called a broaching tool, thus form-ing a narrow channel. Four such channels were made bounding the working space. The rock between the channels was removed to provide the working area. Although channeling was more costly than blasting, some of the rock between the channel cuts could be removed in block, thus minimizing waste.

Mother Nature also provided the quarrymen with some special tools. Granite forms when molten rock cools thousands of feet beneath the land surface. The pressure of the overlying rock is “captured” in the rock as it cools. When erosion exposes the rock at the land surface, the pressure is released, and fractures form as the rock “relaxes.” The rock is also subjected to regional stresses caused by plate tectonics, which causes other fractures or planes of weakness.

These features, some obvious and some subtle, influence the directions in which a block of granite will split. Quarrymen with keen eyes can observe these weaknesses in the rock and use them to their advantage.

An ‘Old Timer’ in Barre described the planes of weakness as follows:

“We look for three kinds of grains in the rock. When it goes up and down we call it ‘rift.’ Crossways, like that, we call it ‘drift.’ ‘Hardway’ is a grain running at right angles to the other two, a bad one to work. *** Hell, I’ve talked long enough. I got to get my stone out now. Don’t worry, I’ll take it easy, all right. I’m old enough to know how to do that.”

“Old Timer,” an interview as recorded by Roaldus Richmond, 1940, Federal Writers Project

It took a combination of channel drilling and geology to mine granite in Barre.

TALES FROM AN Old Timer

Drilling holes in granite.

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Documents

Aggregates Manager April 2015