THE AUTHORIT Y ON EQUIPMENT & TECHNOLOGY

16 - 2 016
19

100
years

GOOD T0

GO
Whether processing
virgin aggregate or
recycled material,
portable plants
offer versatility

TIPS ON SELECTING
SCREEN MEDIA FOR
YOUR APPLICATION
PUTTING TOGETHER A
COMPREHENSIVE CRISIS
MANAGEMENT PLAN
AUGUST 2016
V OL . 1 0 9 NO . 2

PitandQuarry.com

WHY MOVE FOUR PLANTS

WHEN TWO WILL DO.

The home of genuine Pit Boss Equipment

www.elrus.com

TM

Self-Contained Crushing and Screening Spread

Two plants to pull
Setup & crushing in under two hours
Plant #1: 36 belt feeder with hydraulic grizzly, MS612 (6x12 3-deck) high frequency screen
Plant #2: Sandvik CH430 200 H.P. Cone with 36" in/out conveyors, control tower,
electrical switchgear and 500 kW genset

CLOSE TO OUR CUSTOMERS

CLOSE
TO
OUR
CUSTOMERS

Find out more: www.wirtgen-group.com

CONTENTS
VOL UME 1 0 9 AUGUS T 201 6 NO. 2

46 DRONES
Do it yourself
A number of considerations must
be made when evaluating drone use
and management at aggregates
operations.
BY KEVIN YANIK

48 EVOLUTION SERIES
The evolution of conveying and
material handling equipment, as
seen in the pages of Pit & Quarry the
past 100 years
BY MEGAN SMALLEY

P&Q EVENTS
PROCESS CONTROL

This system provides full

automation of a mobile crushing plant from the site or an office. PAGE 16

UP FRONT
6 AN INSIDE LOOK
Better than Red Bull

22 WASHING &
CLASSIFYING

58 MINEXPO
INTERNATIONAL 2016
On deck
Another four years have passed,
putting MINExpo once again at
center stage.
BY KEVIN YANIK

60 HILLHEAD 2016

8 UP TO SPEED

Simplified system
New equipment helps Kilgore
Companies improve fines recovery.

The latest industry happenings

EDITED BY KEVIN YANIK

P&Q TECH

26 Equipment and technology

BY DARREN CONSTANTINO

Dewatering screens, classifying

tanks, frac sand processing and
more

P&Q BUSINESS

30 SCREENING

Aggregates industry forecasts,

stocks, economic news and more

BY DARREN CONSTANTINO

10 CUTTING EDGE
The latest in equipment and
technology for the industry

12 PORTABLE PLANTS
Increased efficiencies
From more productivity to greater
fuel savings, the capabilities of a
new crusher have changed how
one Canadian producer operates
each day.
BY TOM KUENNEN

16 Equipment and technology

Portable crushing and screening
plants, including tracked models, as
well as automation solutions
2

PIT&QUARRY

June 2016
August
2016

Screen media selection

Tips for choosing the most effective
engineered screen media for your
aggregate operation.
BY STEVE FAIR

42 SCALES
Accurate weighing
Six advanced truck-scale solutions
offer aggregate producers a variety
of weighing options.

Equipment demos and more

More than 18,000 withstood the
elements to attend Englands quarry
equipment exposition.

62 BUSINESS UPDATE

64 COMMUNITY RELATIONS
Winning strategies
With ever-increasing public
concerns about blasting, a
consultant shares tips on how
to proactively handle blasting
complaints.
BY MEGAN SMALLEY

BY KEVIN HILL
Cover photo by Darren Constantino

pitandquarry.com

SIZES: 5X16 - 8X20

SEPARATE FROM THE PACK

BRAND NEW TRIPLE SHAFT GUARDIAN HORIZONTAL SCREEN
Patent pending bottle jack lifting points simplify and speed up spring replacement and improve safety.
Segmented belt guard and tailgate designs lighten load, requiring only one person during maintenance.
Bolt-fastened, hinged access doors prevent spillage and allow access for screen cloth maintenance.
Fully-enclosed belt guard eliminates pinch points while an integrated tensioner accelerates maintenance.
CONE C
RU
SH
IOT
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PA

+1 (320) 589-2406
WWW.SUPERIOR-IND.COM
I

CRUSHING
EQUIPMENT

SCREENING
EQUIPMENT

WASHING
EQUIPMENT

CONVEYING
EQUIPMENT

-S

TO

C K AVA I L A B

LI

IDLERS, PULLEYS, CONSTRUCTION

ACCESSORIES
MANAGEMENT

CONTENTS
VOL UME 1 0 9 AUGUS T 201 6 NO. 2

ONLINE
NOW
W W W. P I TA N D Q U A R R Y. C O M

P&Q HITS THE ROAD

Hillhead 2016
P&Q traveled to Hillhead 2016 near
Buxton, England, to see what was
new with the nearly 500 exhibitors
in attendance. At the event, Sandvik
Construction showcased a variety of
new equipment. Watch some of the
equipment in action at pitandquarry
.com/video.

HILLHEAD 2016

Thousands braved the rain to view nearly

500 exhibits and equipment demos at the quarry show in England. PAGE 60

Screen Machines 50th anniversary

SAFET Y
66 SAFETY UPDATE
Safety and environmental news,
including the latest from MSHA

68 MSHA & THE LAW

Negligence per se
BY MICHAEL T. HEENAN

70 CRISIS MANAGEMENT

CL ASSIFIEDS
& AD INDEX
76 CLASSIFIED ADS
79 ADVERTISER INDEX

A LOOK BACK
80 Photos from Pit & Quarrys
historical archive

Screen Machine Industries celebrated its 50th anniversary with an open

house that drew hundreds of people,
including P&Q staff, to its facility in
Etna, Ohio. Watch an exclusive interview with Screen Machine President
Steve Cohen and see some of the
companys latest equipment at
pitandquarry.com/screenmachine-celebrates-50thanniversary.

Having a comprehensive
management plan and
familiarizing your team
with it is useful in the
event of a serious or fatal
accident on mine property.

facebook.com/PitandQuarry

BY KEVIN YANIK

youtube.com/PQTV3

CONNECT
twitter.com/PitandQuarry
pitandquarry.com/linkedin
instagram.com/PitandQuarry

PIT&QUARRY

August 2016

pitandquarry.com

Terex Minerals Processing Systems

NEW LARGE MOBILE PLANT SOLUTIONS

MAKING

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TRACKS
sales@terexmps.com

www.terexmps.com

Like us on Facebook
www.facebook.com/Terexmps

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JAWS

CONES

IMPACTORS

VISIT US AT BOOTH 3379 TO FIND OUT MORE

Check out our videos

www.youtube.com/MPSTerex

An Inside Look
PITANDQUARRY.COM
North Coast Media LLC
1360 E. Ninth St., Suite 1070
Cleveland, OH 44114

BETTER THAN
RED BULL

e have heard a lot about autonomous vehicles, and have

seen demonstrations. It was reported late last year that
mining giant Rio Tinto began using dozens of these
driverless trucks at two of its mines in Australia, operating the vehicles remotely from a center more than 700 miles away.
Not only do these haul trucks run 24 hours a day, 365 days a year, they
are also the ultimate in operator safety. What better way to keep an operator safe than to have that person away from the mine, sitting behind a desk?
And while autonomous technology evolves in other mining vehicles like
wheel loaders and excavators, and slowly trickles down from enormous
mines to, someday, pits and quarries, were not there yet. In
the meantime, Caterpillar is working on an alternative
way to keep all vehicle operators safe.
Caterpillar Safety Services has partnered with
the tech company Seeing Machines to put fatiguedetection systems into mining trucks around the world.
The system uses an in-cab camera, as well as advanced detection and prevention technologies, to
track eye and facial movement in order to
monitor fatigue and distraction events,
such as microsleeps, texting and cellphone
use as they occur.
It provides for a real-time intervention
Darren Constantino
strategy, which reduces risk, improving
EDITOR-IN-CHIEF
safety for the vehicle operator and others
in the area, and it helps preserve company
assets.
The system uses
A report from Huffington Post details
an in-cab camera what happens next: When a potential fatigue event is detected, the system sounds
to track eye and
an alarm in the truck and sends a video
facial movement
clip of the driver to a 24-hour sleepfatigue center at Caterpillar headquarters
in order to
in Peoria, Ill.
monitor fatigue
According to the report, Once an alarm
and distraction
goes off in a truck, the driver becomes
much more aware of their fatigue, and is
events.
more cautious and proactive about drowsy
driving than they would be otherwise.
Seeing Machines says its technology is already used worldwide
across the automotive, mining, transport and aviation industries, as well
as by many of the leading academic research groups and transportation
authorities.
Such in-cab monitoring might be a little bit Big Brother, but until autonomous vehicles become commonplace, monitoring operators for signs of
fatigue could be a lifesaver.
6

PIT&QUARRY

August 2016

Phone: 216-706-3700
Fax: 216-706-3711
EDITOR-IN-CHIEF Darren Constantino
330-533-6804 | dconstantino@northcoastmedia.net
SENIOR EDITOR Kevin Yanik
216-706-3724 | kyanik@northcoastmedia.net
ASSOCIATE EDITOR Megan Smalley
216-363-7930 | msmalley@northcoastmedia.net
DIGITAL MEDIA CONTENT EDITOR Allison Barwacz
216-706-3796 | abarwacz@northcoastmedia.net
MSHA & THE LAW COLUMNIST
Michael T. Heenan | michael.heenan@odnss.com

AGGREGATES FORECAST COLUMNIST

David Chereb | david.chereb@sc-marketanalytics.com
MARKET INSIGHTS COLUMNISTS
George Reddin | greddin@fminet.com
Scott Duncan | sduncan@fminet.com

WESTERN U.S. CORRESPONDENT Loretta Sorensen

GROUP PUBLISHER Rob Fulop
216-706-3741 | rfulop@northcoastmedia.net
ASSOCIATE PUBLISHER Dino Vitanza
216-706-3744 | dvitanza@northcoastmedia.net
PRESIDENT & CEO Kevin Stoltman
216-706-3740 | kstoltman@northcoastmedia.net
V.P. FINANCE & OPERATIONS Steve Galperin
216-706-3705 | sgalperin@northcoastmedia.net
V.P. GRAPHIC DESIGN & PRODUCTION
Pete Seltzer

216-706-3737 | pseltzer@northcoastmedia.net
ART DIRECTOR Kim Traum
216-706-3779 | ktraum@northcoastmedia.net
GRAPHIC DESIGNER Courtney Townsend
216-363-7931 | ctownsend@northcoastmedia.net
PRODUCTION SERVICES MANAGER
Terri Johnstone

216-978-9622 | tjohnstone@northcoastmedia.net
SR. AUDIENCE DEVELOPMENT MANAGER
Antoinette Sanchez-Perkins

216-706-3750 | asanchez-perkins@northcoastmedia.net
MARKETING MANAGER
Scott Gebler | 855-460-5502, x7932

sgebler@northcoastmedia.net
MARKETING & SALES MANAGER, BUYERS GUIDE
Chloe Scoular | 216-363-7929
cscoular@northcoastmedia.net
DIGITAL OPERATIONS MANAGER Bethany Chambers
216-706-3771 | bchambers@northcoastmedia.net
WEB DEVELOPER Jesse Malcmacher
216-363-7925, jmalcmacher@northcoastmedia.net
LIST RENTAL Antoinette Sanchez-Perkins
216-706-3750 | asanchez-perkins@northcoastmedia.net
REPRINTS Brett Petillo, Wrights Media
877-652-5295 | bpetillo@wrightsmedia.com
BUYERS GUIDE INQUIRIES
216-363-7929 | cscoular@northcoastmedia.net
CLASSIFIED ADVERTISING
216-706-3744 | dvitanza@northcoastmedia.net
SUBSCRIPTIONS / CUSTOMER SERVICE
Phone: 847-513-6030 Fax: 847-763-9694
Web: www.pitandquarry.com/subscribe

pitandquarry.com

1966 Gravel Charlie

2016 VOLVO A60H

BEING THE FIRST

KEEPING THE LEAD

Since unveiling the worlds first articulated hauler in 1966 we have continued to lead
the way. Over the last 50 years our customer-focused, intelligent hauler technology
has revolutionized transport operations in the construction sector. Our latest innovation
comes in the shape of the ground-breaking Volvo A60H the largest true articulated
hauler on the market. Learn more at volvoce.com/na.
Please visit us at MINExpo in booth 10070.

UPtoSPEED
ICYMI

GOVERNMENT

FAA releases new

drone regulations

I N

C A S E

Y O U

M I S S E D

I T

SA FE T Y

The FAA says

drones must
now fly at or
below 400
ft. and weigh
less than 55
pounds, but
dont expect
the rules to
stop there.

he Federal Aviation Administration (FAA) finalized the first operational rules for routine commercial use of small unmanned aircraft
systems (UAS, or drones).
The new rule, which takes effect in
late August, offers safety regulations
for unmanned aircraft drones that
weigh less than 55 pounds and conduct
non-hobbyist operations.
Drone operators must now pass an
FAA aeronautical knowledge test, as
well as obtain a remote pilot certificate.
In addition, drones must be registered,
fly at 400 ft. or lower, be kept within a
visual line of site and flown only during
daylight.
We are part of a new era in aviation,
and the potential for unmanned aircraft
will make it safer and easier to do certain
jobs, gather information and deploy disaster relief, says Anthony Foxx, secretary of transportation. We look forward
to working with the aviation community

to support innovation while maintaining our standards as the safest and most
complex airspace in the world.
According to FAA, provisions in the
rules are designed to minimize risks to
other aircraft, people and property. FAA
is also offering a process to waive some
restrictions if an operator proves the
proposed flight will be conducted safely
under a waiver.
Under the final rule, the person flying a drone must be at least 16 years old
and have a remote pilot certificate with a
small UAS rating, or be directly supervised by someone with the certificate.
With this new rule, we are taking a
careful and deliberate approach that balances the need to deploy this new technology with the FAAs mission to protect
public safety, says FAA Administrator
Michael Huerta. But this is just our
first step. Were already working on additional rules that will expand the range
of operations.

BREAKING NEWS ONLINE

FOR NEWS AS IT HAPPENS, GO TO PITANDQUARRY.COM

PIT&QUARRY

August 2016

The U.S. Department of Labors Mine

Safety & Health Administration
(MSHA) announced that for the first
time since Pattern of Violations
(POV) reforms began in 2010, none
of the nations more than 13,000
mining operations meets the criteria
for a POV notice. The POV provision
is a part of the Federal Mine Safety
& Health Act of 1977 and is reserved
for mines that pose the greatest risk
to the health and safety of miners.
Says Joe Main, assistant secretary
for mine safety and health, of the
regulation: It is achieving its purpose to improve mine operators
compliance with safety and health
standards and enable them to monitor their own compliance.

EQUIPMENT

OLDEST ACTIVE VOLVO

HAULER LOCATED IN
CALIFORNIA

Amswede Corp., a recycling company located in Chula Vista, Calif., won

Volvo Construction Equipments
Still Hauling contest after Volvo
identified Amswede as having the
oldest operational Volvo articulated
hauler working on a North American
jobsite. Volvo hosted the contest as
part of the 50th anniversary celebration of its first articulated hauler.
Stenvall runs a 1968 Volvo DR860
almost every day at Amswede,
according to Volvo.

pitandquarry.com

PHOTOS COURTESY OF SULLY-MILLER (TOP LEFT) AND VOLVO CONSTRUCTION EQUIPMENT (BOTTOM RIGHT)

MSHA: NO MINES MEET

CRITERIA FOR PATTERN
OF VIOLATIONS NOTICE

UPtoSPEED
INFRASTRUCTURE

MANUFAC TURERS

Report details
highway systems
deficiencies

RIP, a Washington, D.C.-based national

transportation organization, produced a
report detailing how the aging U.S. interstate highway system will increasingly require
more long-term, costly repairs.
According to the TRIP report, The Interstate Highway System Turns 60: Challenges to
Its Ability to Continue to Save Lives, Time and
Money, while the interstate highway system
represents only 2.5 percent of lane miles in the
United States, it carries 25 percent of the nations
vehicle travel.
The system is increasingly congested, with
truck travel growing at a rate twice that of overall interstate travel, according to TRIP. And,
while the nations interstates tend to be in better condition than other roads and bridges, the
aging system lacks the required funding for
needed improvements and repairs.
The current backlog of needed improvements to the interstate highway system, as estimated by the U.S. Department of Transportation, is $189 billion. By 2020 the shortfall into
the nations Highway Trust Fund will be $16
billion annually.

SCREEN MACHINE CELEBRATES

ANNIVERSARY WITH OPEN HOUSE
Screen Machine Industries celebrated its 50th anniversary
with an open house celebration that drew nearly 700 dealers,
suppliers, government officials, family members of employees
and others to its facility in Etna, Ohio.
The event included factory tours, equipment demonstrations and a series of speakers, including dignitaries from the
state of Ohio. Sen. Rob Portman, R-Ohio, delivered a video
tribute to the company, saluting Screen Machine for 50 years
of service to Ohio.
Steve Cohen, president of Screen Machine, delivered remarks
along with his father, Bernard, who founded the company in
1966. The two shared memories from over the years, paying
tribute to employees, customers, dealers, suppliers and others
who helped to build and sustain the business over a half-century.
Were a unique business, Steve says. We are a family
business. Were a business that started small. Ive heard statistics that its [in the] low single digits that a company will last
50 years. Were very proud to have done so.

This Screen Machine portable plant in the companys yard during

the open house celebration is ready for transport.

MANUFAC TURER BRIEFS

PHOTO BY KEVIN YANIK

Kolberg-Pioneer manager to retire: Leon Luadzers,

who has served as regional
sales manager for KolbergPioneer for 20 years,
announced his retirement.
Luadzers held several
positions with KolbergPioneer, Johnson Crushers
International and Astec
Mobile Screens (KPI-JCI
and Astec Mobile Screens)
for the past 40 years.
According to the companies, hes been involved
pitandquarry.com

with national and state

aggregate associations. In
addition, Luadzers created
a formula for sizing and
vibrating scalping screens,
which was incorporated
into the Agg Flow program,
the companies add.

McLanahan names
global product manager: McLanahan Corp.
named Jeff High as its
global product manager for
crushing and screening.
High will work closely with

McLanahans engineering
group and global market offices to ensure the
companys crushing and
screening products exceed
customer expectations.

Kesprys growth takes it

to new facilities: Kespry,
which designs automated
drone systems for commercial use, plans to move
to several new buildings in
Silicon Valley near its current headquarters in Menlo
Park, Calif. Kespry has doubled its staff over the last

year, from 25 employees to

more than 50, a company
spokesperson says.
Superior, dealer make
announcement: Superior
Industries expanded its
partnership with RB Scott
Co., a conveying equipment
dealer headquartered in
Eau Claire, Wis. In addition
to conveyors and conveyor
components, RB Scott will
now represent Superiors
line of wet processing
equipment and portable
processing plants.
August 2016

PIT&QUARRY

CUTTING EDGE
DUST CONTROL SYSTEM INTEGRATES
POWERFUL ATOMIZED MIST DESIGN
DUST CONTROL
TECHNOLOGY designed the

HYBRID
TECHNOLOGY
BOOSTS MOTORS
EFFICIENCY
BALDOR ELECTRIC CO.S RPM XE

motors hybrid design helps it to

achieve efficient performance
levels, the company says. Using
advanced technology, Baldor says
the RPM XE platform can provide
substantial energy savings and
performance for most centrifugal load applications. The motor
starts like a traditional design B
induction motor, and it pulls into a
true synchronous speed to operate like a synchronous machine.
The motors laminated and finned
frame construction also contributes to the machines power
density and enhanced thermal
performance by providing greater
heat dissipation, the company
adds. The RPM XE platform comes
in two design configurations: a
power dense and a standard NEMA
frame. The power dense design
offers horsepower in a smaller
frame, which is best suited when
the driven equipment or machine
is limited on space. The standard NEMA frame offers a drop-in
replacement solution for traditional induction motors.

PIT&QUARRY

www.dustboss.com

SPHERICAL ROLLER
BEARINGS ALLOW
FOR EXTENDED
SERVICE LIFE
SKFS Explorer spherical roller

bearings for vibratory applications

provide ideal performance and
longer service life compared to conventional types of bearings, according
to SKF USA. Applications include vibrating screens, compactors, road rollers and other equipment that operates with high vibration and exposure
to contamination. SKF says the bearings can accommodate very heavy
radial and axial loads suiting applications where misalignment may occur.
SKF Explorer spherical roller bearings are made of tough steel and integrate a special cage design. The bearings are available in a range of bore
sizes with increased dimensional precision. According to SKF, it can also
develop custom roller bearing products to meet demanding requirements.
www.skfusa.com

www.baldor.com

10

DustBoss DB-100 Fusion

as its latest and largest
trailer-mounted dust control system. The machine
features a powerful atomized mist design with a
range of more than 328 ft.
and the ability to deliver
140,000 sq. ft. of coverage
area. Designed for large,
open-air applications, the
company says the unit
delivers effective particle control in a mobile platform that can be positioned directly at a source of dust-generating activities even on sites
that lack a power supply. The DB-100 Fusion features a 150-gallon fuel
tank, which provides about 32 hours of run time without refueling. Unlike
industrial sprinkler systems used for dust management, the DB-100
Fusion uses about 38 gallons of water per minute to help avoid pooling or
runoff, according to Dust Control Technology. The system can also be customized with alternative nozzle options for specialized applications.

August 2016

pitandquarry.com

SCREW
CONVEYOR
TRANSFERS MATERIAL
FROM FRONT-END
LOADERS

SCRAPER
TIRES PROVIDE
TRACTION IN
UNDERFOOT
CONDITIONS

The FLEXICON flexible screw conveyor with a purpose-built hopper

transfers bulk material received
from front-end loaders. Positioned
on an all-stainless steel skid with
forklifting tubes, the conveying system can be deployed in multiple indoor
or outdoor locations with a single power connection. The conveyor is rugged
enough to withstand incidental contact from front-end loaders because
of its stainless steel design, the company adds. Material is conveyed at a
40-degree incline before discharging into downstream processing equipment or storage vessels. Because the conveyor is driven at its top end with
a 20-hp variable speed electric motor and gear reducer, material exits the
discharge housing prior to contacting any seals or bearings. In addition, the
smooth tube interior and removable screw allow for a quick and thorough
cleaning, according to Flexicon.

The GOODYEAR TIRE &

RUBBER CO. debuted three

www.flexicon.com

APPLICATION-SPECIFIC BUCKETS
HAVE INCREASED CAPACITIES
VOLVO CONSTRUCTION EQUIPMENTS line of application-specific wheel

loader buckets features increased capacities and spillage-protection features to boost cycle times, according to the company. Volvos rehandling
bucket, rehandling flat floor bucket and sand bucket all fit Volvo L110 to
L350 wheel loaders. The rehandling bucket transports tougher aggregate
material best, and the company says the buckets design helps operators
to reduce fuel costs. The rehandling flat floor bucket works best for handling, stockpiling and loading processed materials such as sand, gravel and
aggregate because the bucket penetrates maximum traction on sand and
softer terrain. The sand bucket functions
best in applications where ground conditions are soft and traction is compromised. Designed for handling sand or
aggregate, the sand buckets long
floor maximizes penetration for
improved fill-factor, while its flat
design helps to maintain a clear
and level work area. All three buckets are available for both torque
parallel and Z-bar linkage on Volvo
wheel loaders.

scraper tires for construction

and mining applications: the
RT-3A, the RT-3A+ and the
RL-3J. Goodyears RT-3A and
RT-3A+ tires are designed
to offer improved traction in
underfoot conditions. Both
tires feature cool-running radial construction and aggressive
tread patterns. In addition, the
tires incorporate self-cleaning
lugs to protect them against
sidewall cutting. The RT-3A
is available in size 33.25R29,
while the RT-3A+ is available in size 40.5/75R39. The
Goodyear RL-3J, which comes
in size 37.25R35, functions well
for high-speed use on moderate-to-severe underfoot conditions. The tire features a zigzag
centerline groove to offer
superior lateral traction in hightorque applications, as well as
self-cleaning shoulder lugs for
good forward traction.
www.goodyear.com

www.volvoce.com
pitandquarry.com

August 2016

PIT&QUARRY

11

PORTABLE PLANTS

Increased

efficiencies
From more productivity to greater fuel savings,
the capabilities of a new crusher have changed how
one Canadian producer operates each day.
BY T OM KUENNEN

new impact crusher is keeping a western

Ontario aggregates producer in the black
as it processes 1-in.-minus reclaimed
asphalt pavement (RAP) particles from
chunks as big as a coffee table, with the
help of the right excavator.
The processed RAP originating from driveways and
parking lots, in addition to cold milling machines is destined
for use as fill and for top dressings for low-volume pavements
and parking lots. Asphalt millings from pavements are kept
separately for use in spec asphalt mixes for local road agencies.
The biggest challenge we have is uncertainty and variability

of the product in our production environment, says Jamie

Martelle, sales and operations manager at AAROC Aggregates.
Not every site is the same. Not all feed materials are the same.
One of the reasons we chose this mobile crusher was its versatility in being able to adapt to site conditions. For example, we
get positive production in tight quarters.
To maintain consistency of end product, AAROC separates
incoming asphalt from commercial projects from incoming
highway pavements.
Asphalt is softer than concrete, so it doesnt take much to
break it down, Martelle says. Nonetheless, we will get better
production from asphalt milled product than slab product.

PHOTOS COURTESY OF WIRTGEN AMERICA

An attached final screen returns

oversized material to the crushing
circuit, thus eliminating the standalone screen that AAROCs previous
plant had used.

12

PIT&QUARRY

August 2016

pitandquarry.com

a 44-in. crusher inlet width.

We fed the MR 110 with a smaller excavator, Ritchie says.
We started off with the MR 130 using a like-sized excavator,
but we were struggling to keep up with the asphalt.
Breakout force was lacking, he says.
We were all right with recycling concrete, Ritchie says, but
we needed more ripping power to get through the asphalt. The
reclaimed asphalt will get packed in hard, as it melds together in
the sun. Trucks back over it and the excavator runs over it, too.
AAROC is now feeding the MR 130 ZS EVO with a 2.75-cu.yd. bucket, 54 in. wide.
PRESCREEN FOR PRODUCTIVITY
An integral, double-deck, independent prescreen below the
receiving hopper improves RAP productivity and profitability for AAROC. The denotation Z in the nomenclature
of the Kleemann MR 130 ZS EVO indicates the presence of
The crusher foreman can operate
this prescreen, which utilizes an elliptical motion instead of
the mobile impact crusher from
the loading excavator cab using a
vibratory linear motion.
handheld remote.
The benefit is more product coming out of the prescreen
much cleaner, with smaller material
Thats why we control the raw mabypassing the crushing circuit or
terial as it comes in; we know the
going to the side belt as a saleable
customers and what they provide. As
product, increasing total output and
long as we have the room to keep the
reducing long-term wear costs.
stockpiles separate we can maintain
It lessens the load on the crusher
composition.
itself, Ritchie says. It lets the fines
Depending on location, in addition
pass through so they are not fed
to the 1-in.-minus RAP, AAROC will
into the crusher, causing needless
produce a 5/8-in.-minus RAP for
wear. It lightens the load overall. The
incorporation into spec asphalt mixes.
fines drop through, join the crushed
AAROC moves the crusher from
material where they are sized in the
pit to pit, or quarry, but has the option
attached final screen, and oversize
Tom Ritchie is the crusher foreman for AAROC
to move it to construction sites where Aggregates.
is returned to the crusher circuit.
demolition concrete or asphalt exists
With its Continuous Feed System
to be recycled. When visited, RAP was being processed at West- (CFS), each step the material goes through in AAROCs plant
cliff Pit, one of five locations in Ontario managed by AAROC is wider than the width of the one before it, eliminating choke
Aggregates, a unit of the John Aarts Group of Ilderton, Ont., or wear points.
which also includes J-AAR Excavating and AAROC Equipment.
The crusher is diesel direct-driven via a fluid coupler,
AAROC was crushing RAP pieces at a rate of 300 to 325 and feedback is provided from the engine to the controlling
metric tons (330 to 358 short tons) per hour, says AAROC computer, allowing indications that the crusher may be
crusher foreman Tom Ritchie.
getting overloaded. CFS manages a more equal loading of
Thats an adequate speed, he says. Anything more than the crushing area, in which the conveying frequencies of the
that will make it hard to keep up with the excavator, or you are feeder trough and the prescreen are adapted independently
having to watch the belt.
of each other to the level of the crusher, thus significantly
One challenge AAROC met in searching for a new crusher boosting performance.
was using the right excavator to feed raw material.
It lets the system know when its getting overloaded, and will
AAROC has had its new Kleemann Mobirex MR 130 ZS slow down the feed so it doesnt stall out the crusher, Ritchie
EVO impactor with 52-in. crusher inlet width since January says. Its a very valuable feature that saves us a lot of digging.
2014, but it first tested the waters with a MR 110 ZS EVO with
At the same time the exclusive CFS maintains a choke feed to
pitandquarry.com

August 2016

PIT&QUARRY

13

PORTABLE PLANTS

The new Kleemann Mobirex

MR 130 ZS EVO crusher in
London, Ontario, processes
1-in. minus RAP from slabs
and millings.

the crusher, eliminating stops and starts

of the feed system, improving production,
material shape and wear.
STAYING MOBILE
The MR 130 ZS EVO impactor from
Kleemann is the largest crusher AAROC
could obtain that still would fit on its
flatbed trailers.
Our machine is completely portable,
Ritchie says. We move it as we need it
around our pit locations. Any of them
may have a need to crush concrete or
asphalt, or a customer may request us to
come and crush.
Moving the crusher is the easy part,
Ritchie says. The worst part is cleaning it
off. We take any stones off the machine and
wipe it down, getting it as clean as we can.
14

PIT&QUARRY

August 2016

This contrasts with the plant it replaced, a primary crusher with screen
alongside, which would recirculate the
oversize back to the primary. However,
on the new plant, the screen is self-contained, attached to the loading conveyor,
and completely eliminates the standalone screen.
The attached final screen was a
major factor in our selection, Martelle
says. No matter what we are doing,
every second we run that machine we
are saving money.
Adds Ritchie: The new impactor
works in a much smaller footprint than
what we had. Its a lot easier to set up.
With the old plant, including crusher
and screen, it would take three days to
tear down and move, with a lot of labor.

But with this model we can have it broken

down and cleaned in four to five hours,
and thats from the time you stop feeding
it to the time you are ready for loading
onto the low-boy.
By contrast, the new mobile impact
crusher with an attached final screen is
moved easily, loaded in a couple of hours.
Its the biggest screen we could get that
would fit on our lowboy and still allow us
to move it around, Ritchie says. Thats
due to weight restrictions, height and
width. The final screen stays on, but we
have to lower the side conveyor and fold
the hydraulic hopper sides down, which
is easy to do. You cant beat it.
With the new plant, AAROC also
is accruing significant savings in fuel
consumption.
pitandquarry.com

Were seeing a 30 to 35 percent reduction in fuel costs with the new impact
crusher, Martelle says. It has much to
do with the diesel-electric direct drive, as
opposed to a hydraulic drive.
Ritchies hand-held remote control
allows him to operate the crusher from
within the feeding excavators cab, or
control its movement as he walks alongside it, guiding the impact crusher onto
the flatbed trailer.
We just track it up and on like any
other tracked piece of equipment, Ritchie
says. The remote controls feeder speed,
magnet belt and the tracks. It also will
raise and lower the jam door on top of
the apron lid. If you get a big piece in
the hopper, or its standing upright and
wont go in, you can raise the door and

If you like what you are doing, it aint work.

Its every little boys dream to play in the
sandbox all day. And now I have the biggest
remote control of all.
TOM RITCHEY
AAROC Aggregates

keep the flow going.

With the magnet belt, if a large piece
of steel comes out, the belt can be raised
for access, Ritchie adds.
The versatility and quickness of mobilization with the machine has allowed
us to service all of our various locations
market demand, Martelle says.
If we had our old set up, we would be
well behind on our production targets,
due just to lost time of mobilization, he
says. Because we can move the Kleemann
in the morning and be running it in the
same day, across town or 50 km (30 miles)

away, we can crush another day and a half

more than we could before.
They say If you like what you are
doing, it aint work. With the opportunity
to control a powerful crusher via remote,
and to dig piles of aggregate, Ritchie likes
what he is doing.
Its every little boys dream to play in
the sandbox all day, he says. And now I
have the biggest remote control of all. P&Q
Tom Kuennen is a freelance writer
specializing in the construction, energy and mining fields. Visit his website
at www.expresswaysonline.com.

GO ALL IN
FOR MINING
Lets unite to voice the
positive impact mining
delivers throughout the world.
Join us at MINExpo in Las
Vegas to say youre ALL IN
for mining.

Learn more at
miningallin.com

pitandquarry.com

August 2016

PIT&QUARRY

15

PORTABLE PLANTS
Impactor, screen plant offer versatility
The Terex Cedarapids CRH1313R portable impactor and screen plant delivers on users production needs, according to TEREX MINERALS
PROCESSING SYSTEMS (Terex MPS). The machine is a standalone,
closed-circuit unit with three
product capabilities. It has
the versatility to handle rock
crushing, concrete recycling
and asphalt recycling. The
CRH1313R comes with a
Cedarapids IP 1313 impactor with a three- or four-bar
50-in. rotor powered by a
Tier 4-compliant 450-hp
diesel engine, direct drive to
the crusher and a 200-hp
generator. The CRH1313R
also includes a heavy-duty
under-crusher pan feeder that protects the conveyor belt from damage by
absorbing high-velocity discharge from the crusher. According to the company,
the CRH1313R plant is simple to operate, quick to set up and easy to transport.
www.terexmps.com

Plant design provides

easy access to maintenance areas
MCLANAHAN CORP.S portable jaw crusher series provides the aggregates
industry with plants that are movable with easy-to-access maintenance
areas. McLanahans portable plant starts with a Universal jaw crusher, which
can handle anywhere from 100 to 1,000 tph of material. The crusher offers
a compressive stroke that is nearly equal at both the top and bottom of the
chamber, producing more spec material at a lower cost per ton, according to
the company. The machines conveyor design uses a fabricated construction,
which makes it easy to perform maintenance, as well. Both hydraulic and
shim adjustment are available on this crusher, which comes equipped
with a severe-duty vibrating grizzly feeder.
www.mclanahan.com

16

PIT&QUARRY

August 2016

Business solution
automates
crushing plants
WORLD TECH SOLUTIONS INC.S
aggregate processing control system
serves as an end-to-end business
solution for mobile aggregate crushing plants. The system provides full
automation of a plant and enables
remote-control operation from a loader,
on the ground or from an office. Once
installed in a new or retrofitted plant, the
system records all relevant information
about plant operations, in order to allow
the owner to analyze fuel usage, power
consumption and motor runtimes with
precision. The tool also includes business management functions, with modules for equipment maintenance, time
cards and fuel management. This addition helps plant owners to understand
their costs better.
www.wtsolutions.com

pitandquarry.com

MAINTENANCE
PORTABLE
PLANTS
Vibratory feeder,
compact size
enhance crushers
productivity
A high-performance vibratory feeder and
the compact size of KLEEMANNS Mobicat
MC 100 Ri EVO jaw crusher help to boost its
productivity levels. With a vibrating feeder
7-ft.-long by 3-ft.-wide and an integrated
slotted grizzly and screen mesh below, the
machines feed system receives product as
large as 36-in. x 20-in., with raw feed capacity of 221 tph. The machine excels in processing demolition
materials, limestone, granite or basalt. In addition, the MC
100 Ri EVO is very easy to transport, making it ideal to move
from jobsite to jobsite, pit to pit or quarry to quarry. Since the
feeding unit is integrated in the chassis, there is no need to
fold the hopper walls, which speeds up setup time. With the
crushers leveled transfer, material tilts into the crushing
area with no restrictions. The MC 100 Ri EVO is Tier 4 Final
emissions-compliant. Its economical diesel-electric direct

t he
us at
Meet po show
28
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d 17
MinE Hall Stan
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Nort .09.2016
8

.
6
2 2

drive is powered by a Deutz engine at 208 tph, which allows

for crushing volumes from 80 to 143 tph, depending on the
adjustable closed-side setting.
www.wirtgenamerica.com

Dual-slope screen enables

high screening capacity
METSOS Lokotrack LT1213S mobile impactor plant features a high-capacity, single-deck screen and a return conveyor. The machine transports as a single unit on a low-bed
trailer. The dual-slope screen and radial return conveyor
provide high on-board screening capacity, which makes
the Lokotrack LT1213S easy to operate in both closed and
open circuits. The screening unit can be docked in a matter
of minutes. The LT1213S can be customized for aggregate,
quarry or recycling applications. The unit offers features
such as a vibrating grizzly or pan feeder under the crusher.
In addition, the LT1213S includes an advanced gearbox as
standard. The optimized hydraulic circuit with an independent fan and standby function provides up to 20 percent lower
fuel consumption, as well as more power for the crusher, the
company adds. The machines standby function also helps to
reduce noise levels when its idling.
www.metso.com

NORDIC CENTAURUS
LED N4601 QD
7200lm Operational
Quake Dampening
Heavy Duty Construction

18

PIT&QUARRY

August 2016

pitandquarry.com

CUTTING DOWN
ON EXPLOSIVES
INTEREST IN SURFACE MINING MACHINES FOR QUARRIES
GROWS ALONG WITH DRILL AND BLAST REGULATIONS

IF YOU ASK PEOPLE WHO RUN QUARRIES WHAT THEIR BIGGEST

PAIN POINT IS, THEYRE LIKELY TO SAY TRANSPORTING THEIR
PRODUCT. ITS EXPENSIVE AND LOGISTICALLY CHALLENGING.

Because those products are mostly used as

building materials, the goal usually is to locate
quarries near where road and other construction
projects occur. This is typically in urban areas.
And that is becoming an even bigger pain for
mining companies because a major trend in the
industry worldwide is increasing regulations
on drilling and blasting methods due to
environmental and safety concerns, especially
in populated areas.

a 600-horsepower (447 kW) engine and can cut

a swath up to 27 inches (68.6 cm) deep and 12
feet (3.7 m) wide in a single pass.

More and more quarries are turning to surface

excavation machines as a solution. They have
numerous advantages over drilling and blasting:

Mining companies are benetting from these

features. Theres a Vermeer customer that
chose not to use a primary crusher because its
Terrain Leveler SEM could consistently produce
a 6-inch (15.2 cm) minus particle size.

THEY can be used in parts of surface mines

that explosives cannot.
THEY cause less noise, dust and vibration.
THEY cut more precisely.
THEY produce a smaller, more consistent particle size.
THEY can take steps and equipment out of the
mining process.
THEY can also be used for site preparation
and haul road construction.
As a surface excavation machine moves on its
tracks, its cutting drum rotates and the teeth
on the drum mechanically excavate material.
To give an example, the Vermeer T1255 Terrain
Leveler surface excavation machine (SEM) has

It can be equipped with an optional GPS for precision cutting, allowing an operator to use the
full length of the drum and minimize the overlap
with each pass. Additionally, a survey can be
taken of a quarry to create a itch plan, which
can be uploaded to a computer on the machine.

Another customer had a million tons of mineable product but could no longer drill and blast
because of nearby pipelines, powerlines and
roads.
The surface excavation machine is getting that
last remaining bit of aggregate, says Patrick
Robinson, senior commercialization manager
for mining at Vermeer. The site is already permitted, but if not for the surface excavation machine, it would probably be abandoned because
drill and blast is no longer an option.
It may go without saying, but surface excavation
machines are quieter and create less vibration
than explosives. As for dust suppression, the

Vermeer Terrain Leveler SEM offers an optional traditional water spray bar or an optional
dust-collection system that uses vacuum technology instead of spraying.
The smaller, consistently sized product wastes
less space than the larger material from drilling
and blasting, which may allow more material to
t into haul trucks and loaders or possibly allow
for the downsizing of equipment, which in turn
can lower expenses.
A surface excavation machine also could
potentially let a quarry get to market faster. The
infrastructure and planning needed for drill and
blast conveyer systems, purchasing and setting up large pieces of equipment like primary
crushers, permits can take years.
Many of the mining companies interested
in surface excavation machines usually are
forward-thinking in terms of how they adopt
technology, their processes and their process
control, Robinson says.

Visit Vermeer
at Booth #8401
at MINExpo.

Vermeer, the Vermeer logo, Equipped to Do More and Terrain Leveler are trademarks of Vermeer Manufacturing Company in the U.S. and/or other countries. 2016 Vermeer Corporation. All Rights Reserved.

PORTABLE
PLANTS
MAINTENANCE
Screening plant handles
dirty, sticky aggregates
The Chieftain 2200 triple-deck portable screening plant features two
screen boxes and offers high performance levels with tough aggregates, according to POWERSCREEN. The machines screen boxes
can handle dirty, sticky material with ease, the company says. The
Chieftain 2200 can be set up in less than
30 minutes as a result of hydraulically
folding conveyors and track mobility,
Powerscreen adds. The machine is
designed for operators who require large
volumes of high-specification products
with maximum versatility. It has a capacity of up to 770 tph. With a four-bearing
box, the efficiency of the screen can
drop as the box length increases. The
Chieftain 2200 can screen with a 20
percent increase in g-force compared
to similar screens with the same surface area. The machines two versatile
triple-deck screen boxes provide a total
screening area of about 64 sq. ft.
www.powerscreen.com

Track-mounted
crusher offers
energy savings,
reduced costs
Ball Bearing Idlers
Inventory in Stock for Quick Delivery

Interchangeable Idler Assemblies

Maintenance Free Sealed Ball Bearings

Custom Powder Coating

Value Priced with CEMA C

Performance Ratings

Extra Heavy Duty Frame (CEMA D)

for Longer Life

Proven Engineered Products Complete Material Handling Solutions

800.356.4898 | www.syntronmh.com

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www.syntronmh.com

PIT&QUARRY

August 2016

KOLBERG-PIONEERS track-mounted
GT125 Vanguard jaw crusher offers
increased energy savings and reduced
costs, according to the company. The
GT125 is an ideal mobile crusher for
aggregate production, mining, recycling
and concrete applications. Its large,
dynamically balanced, heavy-duty flywheels produce up to 33 percent more
inertia than competitive models, leading
to a reduced cost per ton over the lifetime of the machine. The GT125 features a 27-in. x 42-in. jaw crusher with
hydraulic drive and reverse capabilities.
Additionally, the crushers fixed hopper
design enables rapid setup times, while
a grizzly feeder cassette allows for the
replacement of the grizzly section without removing hopper sides. An ultra-sonic level system provides continuous feed
to the crusher in order to reduce surges
and lower wear costs.
www.kpijci.com

pitandquarry.com

A WIRTGEN GROUP COMPANY

POWERFUL PERFORMANCE.
JUST TAKE YOUR PICK.
MOBICAT MC 110 EVO

MC 110 R EVO I MC 110 Z EVO

Visit us at
MinExpo
Booth
8801

EFFICIENT HIGH ACHIEVERS IN TWO VERSIONS. Whether you opt for the MC 110 EVO Z with its
independent double-deck prescreen, or the R-version with its vibrating feeders and integrated slotted
grate the crushing unit with its elevated crushing jaw ensures optimal material feed and an impressively
high crushing capacity of up to 330 t/h for both systems. Combined with their innovative and cost-effective
diesel-direct-drive concept and exceptional transportability, powerful performance is guaranteed. The
MOBICAT MC 110 EVO. Visit us at MinExpo Booth 8801.
www.wirtgen-group.com/america

WIRTGEN AMERICA, INC. 6030 Dana Way Antioch, TN 37013 Telephone: 615-501-0600

WASHING & CLASSIFYING

SIMPLIFIED

system

22

PIT&QUARRY

August 2016

pitandquarry.com

New equipment helps Kilgore Companies

improve fines recovery.
EDI T ED BY K EV IN YANIK

SOLUTIONS
To improve sand recovery, Kilgore reached
out to McLanahan Corp., which tested
samples at its in-house laboratory to determine how much product size sand was
in the material. As a result, McLanahan
engineered a system that fit Kilgores
pitandquarry.com

existing screw washer and sump without

forcing the company to greatly increase
its physical and environmental footprint.
The new system, which became operational in mid-2014, includes a McLanahan
pump, a separator and a dewatering screen
at the screw washers product discharge
chute. McLanahan engineered the system
to utilize the customers existing sump.
Overflow from the screw is collected in
the sump, from which the rubber-lined
pump feeds the separator.

Kilgore is now able

to retrieve more
saleable material
instead of sending
it to ponds.
The separator then makes a cut at
200 mesh and discharges the recovered
solids of +200 mesh back into the sand
product on the dewatering screen, further
dewatering the screw washer product
and separator product and producing a
drip-free sand.
McLanahan engineers also took into
consideration Kilgores need to produce
two different spec products. The result is
a plant that can easily change spec sizes
with the turn of a valve on the separator
overflow pipe.
RESULTS
Since the startup of this new fines recovery
product scavenger system, Kilgore has seen
a number of benefits and improvements
to its operation.
August 2016

PIT&QUARRY

23

PHOTOS COURTESY OF MCLANAHAN CORP.

ilgore Companies, a subsidiary of Summit Materials, was formed in 2010

through the merger of
Harper Contracting, Altaview Concrete, Kilgore Paving, EnerCrest
Products and Triple C Concrete.
Combining these companies led to
a significant presence for Kilgore in the
western United States. At its site in Bluffdale, Utah, just south of Salt Lake City,
Kilgore processes two types of concrete
sand, as well as stone and gravel. In total,
the company makes about 750,000 tons
of aggregate each year selling it to users
throughout the Salt Lake Valley.
Like so many other sand-and-gravel
operations, Kilgore uses a wash plant to
process the raw feed material and make
a concrete sand product. However, it is
losing a lot of potential product, including
product-sized sand, through the overflow
of an existing screw washer.
We were losing a lot of our fines into
our pond instead of being able to capture
that and make it a sellable product, says
Mike Sosa, foreman at Kilgore.
The loss of this sand product meant
the company was losing out on potential
profits. To combat this issue, the decision
was made to look for a solution that would
allow Kilgore to do more with the material.

WASHING & CLASSIFYING

Kilgores new system includes a

McLanahan pump, a separator and a
dewatering screen at the screw washers product discharge chute. Below is
company foreman Mike Sosa.

24

PIT&QUARRY

August 2016

The company has been able to increase

the tonnage on the belt by more than 30
tons per hour, and its producing a drier
product at 85 percent solids about 10
percent less moisture in the product.
Kilgore is also able to retrieve more salable
material instead of sending it to ponds,
helping to increase product yield and
profitability.
Kilgore wanted to be able to utilize
the waste product for a salable material,
Sosa says. Also, with us making our two
different specs it helps to be able to control
that bottom end a lot better.
Increasing its product yield by 10
percent means less solids reporting to the
pond. As a result, Kilgore employees now
spend less time cleaning out their pond.

At Kilgore, what weve done in the past

is dug it out, usually with some sort of a
long-reach track hoe, Sosa says.
He says the new equipment means
they dont have to do it as often.
Instead of having to clean out our
ponds once a week, were now doing it
once every two weeks.
Kilgore also finds the system is easy
to operate and maintain.
The McLanahan system is quite
simple maintenance wise, Sosa says. You
have very few moving parts and the parts
you do need to service regularly are easily
accessible. P&Q
Information for this article courtesy
of McLanahan Corp.

pitandquarry.com

Severe Duty Bearings

BRANDS You Count On,

PEOPLE You Trust.
NTNs ULTAGE series bearings provide
maximum possible output and durability in
the most severe applications. These largebore taper, cylindrical and spherical bearings
are built to withstand the environmental risks
that heavy-duty surface mining equipment
demands. NTN ULTAGE combines special
alloys with an optimized roller complement
and retainer designenabling the highest
load capacity and allowable speed for a
given bearing type and size.
And, you can find NTN ULTAGE series
bearings at your local Motion Industries
location. Our local sales and service
specialists are experts in application and
technical support, providing the parts and the
know-how you need to stay up and running.

Learn More
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The BRANDS you count on from the PEOPLE you trustthats NTN and Motion Industries.

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

2016 Motion Industries, Inc.

WASHING &
CLASSIFYING
Design minimizes
time needed to
dry stockpiles
The Aggredry wash plant from
SUPERIOR INDUSTRIES decreases
the amount of time it takes to dry
stockpiles, the company says. The
wash plant includes a twin 36-in.
Aggredry dewatering washer, and
it features a Guardian triple-shaft
horizontal screen. The machines
dewatering washer helps the wash
plant to produce sand with a moisture
content that is as low as 8 percent,
according to Superior. The low-moisture sand requires no additional
drying time in the stockpile, making
it instantly salable material. Superior
designed the dewatering washer to
integrate a fine material washer and
a dewatering screen into one processing component. The dewatering

screen is designed with replaceable

snap-deck urethane screens featuring bolt-on urethane liners. Also, the
wash plants fine material screw has
a 1-in.-thick rubber wear shoe, which
makes it last longer than non-rubber
wear products, according to Superior.
Additionally, the machine comes
with a fines-recovery system, which
re-routes minus-25-mm fines from
the dewatering screen back to the
integrated sand screw. Too often,

Superior says these fines are lost to

waste ponds; however, the recovery
system processes this material into a
salable stockpile. The company estimates users can prevent about 3 percent of the material from streaming
to a waste pond through this function.
Depending on production rates, the
extra material can add up to thousands of dollars to a sand producers
bottom line, Superior says.
www.superior-ind.com

Sand plant offers improved

product consistency
MCLANAHAN CORP.S Ultra sand plants help producers to increase
sand production, produce a drier product and improve product
consistency. Ultra sand plants integrate McLanahans separators,
dewatering screens and a slurry pump to provide a 3 to 5 percent
higher yield over fine-material screw washers. Also, the machines
dewatering screen combines the right g-force and amplitude to
provide the best product dewatering. The company says the plants
dewatering screen can withstand high loads and provide maximum
wear life. The Ultra sand plant makes products that contain about
50 percent less water than screw washer products, McLanahan
adds. Typically fed by a wash screens bottom-deck discharge,
Ultra sand plants send unwanted fines to waste streams, keeping
product-sized fines in product piles. Material is fed onto a dewatering screen, allowing screen media to separate the coarse fractions
from the water and fine sand fractions. Any material that passes
through the screen area is pumped to a cyclone or separator where
classification occurs. The machine can separate and combine sand
fractions, allowing users to blend coarse and fine sands as needed to meet product specifications. Unwanted silts and fines can
be removed, while product-sized fines are discharged back to the
dewatering screen to remove extra moisture.
www.mclanahan.com

26

PIT&QUARRY

August 2016

pitandquarry.com

[kleen]
verb
to

RID of UNDESIRABLE MATTER

See the Hydro-Clean, and learn more about our other innovative
products and services, at booth 12050 during MINExpo.
PROCESSING

STORAGE

MIXING

PACKING

FILLING

1-800-325-5993
www.havercanada.com

PALLETIZING

LOADING

MAINTENANCE
WASHING
& CLASSIFYING
Walkways provide easier access to screens
The TEREX MPS Simplicity TXW516S portable
inclined screen wash plant for the aggregates industry features a 5-ft. x 16-ft. triple-deck inclined screen
for high production. The plant includes a heavy-duty 3-ft.
x 25-ft. dewatering screw to maximize screen capacity.
An I-beam main frame with two manual landing jacks and
four cribbing legs allows for stable operation and easier
mobility. Walkways around the three sides provide convenient access to the screen. Additionally, water amounts can
be adjusted for various applications because of the water
manifold and splash style spray bars on the TXW516S.
www.terexmps.com

Dewatering screen reduces moisture

KOLBERG-PIONEERS S9000 dewatering screen reduces the moisture content of washed sand. The S9000 can
reduce moisture content in washed sand down to as low
as 8 to 15 percent. The screens -in. stroke operates at
1,200 rpm, providing high gravitational force action to separate water from material. The dewatering screen comes

WABASH MPI Proppant

Crush Test Press
Compatible with ISO 13503-2:2006
For use with frac sand, resin coated sand
and ceramic proppant

This Genesis Series press

meets the critical demands
of ISO 13503-2:2006 with
unsurpassed cycle repeatability. The proportional
hydraulic system is capable of
applying a constant rate of 13.8
MPa/min. (2000 PSI min.) from
2 ton to 28 ton clamp force
within a 2.5% deviation.
The operator interface allows
easy setup of press control
parameters and includes ample
recipe storage.
Visit our website or contact
us for more information.

ISO 9001:2008
Certified

www.wabashmpi.com
Tel: 260-563-1184
wabashmpi@acscorporate.com

with urethane media, has an adjustable incline from 0 to 5

degrees and can be packaged in portable, semi-portable
and stationary systems. The S9000 is available in sizes
ranging from 2-ft. x 7-ft. to 8-ft. x 16-ft.
www.kpijci.com

Control system update

on classifying tank
EIW classifying tanks smooth out feed
fluctuations and remove excess sand particles for a consistent in-spec product. The
Mark VI computerized sand re-blending
control system included with EIW classifying
tanks makes stockpile calibration quicker,
allowing for a varying number of controlled
products. Producers using the Mark VI system maintain tighter control of their products fineness modulus. It handles up to two
tanks simultaneously to make calibration
simpler.
www.eiwllc.com

28

PIT&QUARRY

August 2016

pitandquarry.com

MAINTENANCE

PUMP IT.
PIPE IT.
Modular
frac-sand plant
TEREX WASHING SYSTEMS (TWS)
offers the FracStac, which the
company says is the worlds first
modular frac-sand plant. The
FracStac can produce up to three
grades of frac sand. TWS also offers
the AggreSand 206 wash plant for
industrial, construction, recycling
and mining applications. It nearly
doubles the capacity of the companys AggreSand 165 model. The
wash plant includes full containerization of the machine to help with
transportation and set-up time,
and it comes with pre-wired and
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automated control system.
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And, both companies excel in professional consultation and
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Make the call for ISCO.

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pitandquarry.com

August 2016

PIT&QUARRY

29

SCREENING

Screen

media

selection
Tips for choosing the most effective engineered screen media
for your aggregate operation.

he federal governments
$305 billion approval in
surface transportation
funding through the
FAST Act is increasing
the demand for aggregates in the United
States as more construction projects get
the go-ahead. This growing demand can
lead to increased profit for an aggregates
operation that is, if it can keep up and
maintain maximum efficiency. Thats
why its important for producers to use
the best tools for the job. The right choice
is especially important when choosing
30

PIT&QUARRY

August 2016

screen media for vibrating screens.

Many mining and aggregates operations have used traditional products, such
as woven wire cloth, for years with great
results. But for operations experiencing
high wear and frequent screen changeouts,
its worth looking into engineered screen
media. Materials such as polyurethane,

rubber and perforated steel plates often

handle heavy and abrasive materials better
than woven wire. But operators need to
know how to choose the best screen media
for their operation.
The difference between using goodenough screen media instead of the
optimal screen media for the application

Shutting down a vibrating screen for

an hour to change one screen media
section is costly.
pitandquarry.com

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BY STEV E FAIR

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SCREENING
can be unwanted downtime and expense.
Consider three things when selecting
the best-engineered screen media for an
application. First, look at all aspects of
an aggregates or mining operation and
any challenges to increasing production
rates and profitability. Second, look at
the composition of the material going
through the vibrating screen and consult
an expert from a reputable company to
match the best screen media to the application. Finally, learn to properly install
and maintain the screen media.
HAVE A LOOK AROUND
The first step toward selecting the most
productive screen media involves answering several questions. What material is
being processed? Is the screen media
reaching a suitable lifespan for the operation? And what sorts of challenges are

occurring with the current

screen media?
Consider the types of
materials going through
the vibrating screen. Factors such as material size,
weight and abrasiveness
all come into play during the
selection process. For example, screening
gravel typically requires media with higher
wearability to handle the materials abrasiveness. Materials with top sizes as large
as 10 in., on the other hand, require more
durable screens because of the constant
high impacts.
Next, look at the vibrating screen itself
and complete a vibration analysis. Some
analysis systems are designed to safely
monitor vibrating screen performance in
real time and detect irregularities before
small problems lead to diminished perfor-

Besides having longer service life,

polyurethane and rubber engineered
screen media dampen noise levels.

mance or bigger issues. In some cases the

machine may be running perfectly, but
changing the screen media can prevent
screening irregularities and the resulting
damage.
Consider the three phases material goes
through within the vibrating screen, from
layered to basic to sharp. Producers can

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SCREENING
customize the screen deck with various
types of screen media through each phase
by accounting for open area and wear life
to maximize productivity in each phase.
In the layered phase, as material of
all sizes hits the screen deck, the media

should handle a deep bed

depth, high impact and a
mix of coarse and fine particles. Material should stratify
in the middle of the deck
during the basic phase, and
Engineered screen media allows operators
to solve problems or address unique
situations using customized panels.

near-size and oversize particles should be

at the top of the material being screened.
Virtually all undersize material should
have fallen through the screen media by
the time it reaches the sharp phase at the
discharge end, where near-size and oversize particles should be in direct contact
with the media.
A vibrating screen operator should
also examine wearability to determine
whether media in the three phases is
reaching maximum potential. If it seems
like screen media has to be changed too
often, consider switching to something
more durable.
Next, look at the screening challenges.
Examine discarded screen media for
signs of problem areas, such as broken
wires, wear areas, pegging or blinding.
Common screening issues are premature
wear due to heavy material along with
large amounts of abrasive fines. Screening
problems can cause carryover or contamination, resulting in unwanted material
in the screened pile, or the added cost of
rescreening. Also, broken screens mean
costly unscheduled changeouts. All of
these signs indicate theres likely a better
screen media option for at least one phase
of screening, if not all three.

Booth 4715

34

PIT&QUARRY

August 2016

SCREENING A SOLUTION
An operation can see increased maintenance costs and downtime as a consequence of using the wrong screen media.
If a vibrating screen continues to operate
while having issues with pegging, blinding,
broken screens or screen media with
incorrectly sized openings, the screened
pile will likely be contaminated and might
pitandquarry.com

Well Keep You Moving Forward.

Producers agree...whatever the materials, the process or the conditions Unified Screening & Crushing
has the products and expertise that make operations more productive across the USA.

SUPERFLOW
SCREENS

Porterville Rock
& Recycling
I saw a reduction
in the number of
change-outs, screen
cost savings and
production increases.
Mitch Brown, President

CRUSHER
WEAR PARTS

CANOE LINERS

TUFFLEX WIRE

Fisher Industries
This product does
very well in high
impact and high
abrasion applications.
Wear-life is
substantially greater than skirt-board
(flashing) rubber and it has a much simpler
installation.
Curt Kittelson, General Manager

Kraemer
Mining &
Materials
We more than
doubled our
wear-life.
Mike Strom, Quarry Supervisor

Canoe Liners

CLEAN
SCREENS

Easier to
install in hard
to reach places
Canoe Liners

Haas Sons, Inc.

We increased our
throughput 20%.
Phil Haas,
President

Overall the Unified

Canoe Liners
consistently
outperform any
Flashing or
Skirt-board Rubber.
Delmar Meier,
Shop Superintendent/ Production

Yahara
Materials
We experienced
a 15%
increase in
ourproduction.
Nick Cady, Superintendent of
Operations

Unified products deliver job-inspired performance because theyre all designed to solve tough, real-world
production problems. See what producers are talking about. Go to www.unifiedscreening.com, then view
the left column and click on Press Room Customer Application Stories, select your favorite success story.
Increase your throughput and boost plant productivity with help from Unified.

For more information, call 866-968-3697, or email info@unifiedscreening.com. www.unifiedscreening.com

SCREENING
costly problems are unscheduled changeouts. It takes about an hour to shut down
a vibrating screen and change one screen
media section. While at first glance, an
hour may not seem like a long time, the
lost production to a mining operation,
for example, will result in thousands of
dollars off the bottom line.
Engineered screen media, by itself
or combined with woven wire cloth or
self-cleaning screens, solves many common screening problems. The screens
generally offer a longer service life than
wire alternatives, and their durable qualities address screen breakage from heavy
bed depths. In addition, polyurethane
and rubber resist premature wear from
abrasive materials.
Besides the longer service life, polyurethane and rubber engineered screen
media dampen the noise level of screening

36

PIT&QUARRY

August 2016

when compared with metal

screens. This allows for more
operational hours in areas
with decibel limits during
certain times of the day.
Engineered screen media
is versatile. It allows operators to solve different
problems or address unique
situations by ordering customized panels. Some screen
media manufacturers, for
example, offer dual durometer screens
with softer polyurethane on the top layer
and more rigid polyurethane on the
bottom.
This combination works well for
hard-hitting applications requiring
openings greater than 2 in., and, especially when used with tapered openings,
helps eliminate pegging and blinding by

Engineered screen media helps address

premature wear from too many abrasive
fines; breakage from heavy bed depths;
pegging and blinding.

allowing larger particles to better screen

or reject near-sized particles.
Some screen media manufacturers
address high-impact applications and
improve wear life by supplying screens
with solid areas to withstand the heaviest

pitandquarry.com

TO HELP GET THE JOB DONE.

Day in and day out operations
around the world demand efficiency
and reliable systems to keep the
business profitable and running at all
times. Whether your challenge is belt
tracking, wear or cleaning issues,
PPI has a full line of problem solvers
that will give you quality, reliability
and a team that stands behind you.
WE KEEP IT MOVING.

USA | CANADA | CHILE

www.ppipella.com | sales@ppipella.com

SCREENING
of materials. Engineered medias versatility addresses not only the materials
composition, but also its temperature.
Manufacturers can create polyurethane
products to withstand high-heat applications, such as when screening silica
after running it through a drying drum.
Operators can also ask for additionally
customized screen media for unique and
challenging applications.
A LOT TO CHOOSE FROM
Manufacturers create engineered screen
media out of several different types of
materials, such as polyurethane, rubber
and perforated plates. Polyurethane offers
a long lifespan and durability. Look for a
polyurethane screen media manufacturer
who blends their own material and who
pours their polyurethane open cast rather
than injection-molded. The open cast
process takes about 9 hours to complete
and typically lasts about 1 1/2 to two times
longer than injection-molded products.
In addition, open-cast polyurethane
permanently hardens when cured to
maintain its chemical properties, so it
resists wear and tear. Injection-molded
screens, though faster to manufacture,
can soften when the temperature rises
during screening, resulting in less wear life.
Engineered screen media is made with
thicker material for increased durability,
but this results in less open area. This is
ideal for screening many small aggregates
materials or for decks with mixed media.
Hybrid screens are an option that combine
woven wire with polyurethane to achieve
open area closer to wire cloth but with
four to six times longer wear life while
weighing less than woven wire. Other
polyurethane screens achieve additional
durability with thicker wire to hold up
to deep bed depths, large top sizes and

wide bar rail spacing. There are misconceptions that polyurethane is strictly for
dry applications, whereas there are others
that it is only for wet applications; in fact,
it works well in both.
Look for rubber screen media when
screening material with a top size larger
than 12 in., or when an application requires
an opening bigger than 4 in. Manufacturers can create rubber screens thicker than

PIT&QUARRY

August 2016

MAINTAINING LONGEVITY
After determining the best combination of
materials, open area and opening size and
shape, think about how the screen media
will be installed. If a vibrating screen has
a cambered deck, switching to a modular
system can cost $5,000 to $15,000.

Some vibration analysis systems allow operators to safely monitor vibrating screen
performance in real time.

polyurethane for improved durability.

The screens also dramatically reduce
noise, handle high-impact applications
and resist abrasion.
Consider perforated steel plates for
heavy-duty operations that require a large
amount of open area. Some manufacturers
customize each plates thickness to a customers application and can create almost
any size opening. The screens should be
manufactured with tapered openings to
resist pegging. Many perforated plates
come in different abrasion-resistance

Look for rubber screen media when

screening material with a top size
larger than 12 in.
38

levels, so be sure to choose a plate appropriate for the application.

Look for a manufacturer that offers

tensionable screen sections that hook for
a cambered deck to eliminate the need for
a costly deck conversion. This allows an
operator to test the media on a vibrating
screen with no additional costs or commitment, as well as the option to blend
engineered media with woven wire cloth
or self-cleaning screens. Engineered screen
media products also come in modular
panels for flat decks.
Also, be aware that engineered screen
media is often heavier than woven wire
cloth, so the weight of a vibrating screen
may change.
Calling a screen media expert is a fast
way to assess an operation and find the
most effective screen media choices for
an operations specific needs. Look for a
pitandquarry.com

mellottcompany.com

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SCREENING
company that offers certified technicians
with years of experience in vibrating
screen media selection and maintenance.
Some manufacturers not only offer
consultations to help an operation find
the best combination of screen media but
also provide on-site training to make sure
the entire team knows how to properly
install it to maximize wear life.
Ask the manufacturer to do a vibration analysis before and after installing
the engineered screen media to ensure
everything runs correctly. Its a good idea
for producers to complete an inspection
of screen media weekly. Inspect square
holes carefully.
Wear becomes apparent if the openings in engineered media begin to round.
Also make sure tensioning remains correct by checking screen tension weekly.
Look for a manufacturer that provides

Material composition should be

a consideration when selecting
screen media for an application.
ongoing support, too. Find a company
that follows up to make sure the screen
media works well once in use. Some
companies employ service technicians
who can be on site within 24 hours to
find, diagnose and fix problems.
MAKE THE BEST CHOICE
If an operations manager finds traditional screen media isnt working and
unscheduled changeouts are eating into
profits, it might be time to consider a
polyurethane, rubber or perforated
plate product.
Engineered screen media has the

advantage of being versatile while

bringing improved durability and longevity to a range of applications.
Perhaps most importantly, look for a
company that takes pride in its work and
provides great service and has integrity.
That, too, will save time and money.
Following these tips will improve an
operations screen media life, profits
and satisfaction for years to come. P&Q
Steve Fair is the Tyler engineered
media manager at Haver & Boecker.
He has more than 21 years of industry
experience. www.havercanada.com

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40

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August 2016

pitandquarry.com

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SCALES

Accurate

weighing
Six advanced truck-scale solutions offer aggregate producers
a variety of weighing options.
BY K EV IN HILL

rucks are used in almost every

industry that transports
goods from one place to
another. In the past, trucks
had to be weighed at truck
weighing stations to make sure that the
overall weight was within the required
limits. Overweight trucks often had to pay
huge fines. To overcome various weighing
issues, industries have been investing in
dependable and accurate truck scales
that are backed by technology.
Let us look at some of the most commonly used advanced weighing technology being incorporated by the aggregate
industry.

1) Full-length truck scales: Known to be

the most dependable truck scales, they
provide accurate weights and are used
primarily in the mining industry and
other applications where heavy loads
need to be weighed and managed. Fulllength truck scales operate on a simple
mechanism, where the driver just has
to position the load on the weighing
platform.
They are available in several varieties choose the one that best suits your
requirements. They tend to be expensive
but they are quite popular owing to the
accuracy and ruggedness they offer.
42

PIT&QUARRY

August 2016

2) On-board truck scales: These scales

are designed to accurately measure large
loads to prevent overloading of the truck.
You can use on-board truck scales to track
the weight of a vehicle along with the load
it is carrying, and they can effectively
eliminate instances where drivers may
be subjected to overload fines.

Load scanners
minimize
uncertainties
presented by load
variations and
moisture content.
These scales are extremely durable,
easy to install and they help to monitor
and manage the weight compliance
accurately, allowing for maximum load
efficiency. The different types of on-board
truck scales you can incorporate include
load cells, air-suspension PSI gauges,
wireless on-board and analog on-board.
3) Truck-axle scales: Truck-axle scales
are known as the most adaptable, portable and economical for truck and

vehicle weighing purposes. They have

a low-profile design and offer higher
precision level, thus delivering better
performance as compared to most scales
in the market.
Available in a variety of configurations, lengths and capacities, truck-axle
scales can be incorporated with the
wheel-weigher system. This makes these
scales ideal for all those locations where
permanent scale installations are not
possible. They have a long life and are
extremely durable as they are built with
heavy-duty steel.
4) In-motion portable axle scales: In-motion portable axle scales act as a good
alternative to larger truck scales. These
scales allow the users to weigh the inputs
quickly and they can reduce overweight
load fines significantly. They are quite
robust, battery-operated and highly
portable, allowing for use in different
locations. These scales also come with an
integrated weight ticket printer, making
it possible to keep a log of printed weight
tickets for each vehicle.
5) Weighbridge truck scales: Weighbridge
truck scales incorporate a bridge-like
framework. They are comprised of scales
that can be used to measure enormous
pitandquarry.com

SCALES

amounts of raw materials and products.

They have heavy-duty designs and are
available in multiple sizes and shapes.
Customized design scales are also
available. All the designs offer incredible durability, sturdiness, accuracy and
reliability in their operations. The commonly used models include pit-mounted,
transportable, surface-mounted and
modular designs.
Shipping and logistics companies can
optimize weighing operations with the
help of these scales. Weighbridge scales
lead to faster throughput and also help
reduce the risks of overload fees.
6) Load scanners: Load scanners are not
an actual weighing scale but can track
loads by developing a 3D volume image,
which can be calculated into weight.

They incorporate scanner technology

that make them simple to weigh. Load
scanners are also accurate, fast and
extremely simple to install.
They offer affordable management
solutions as compared to portable axle
scales and heavy-duty weighbridges.
They minimize uncertainties presented
by load variations and moisture content.
They prove to be an affordable payload
management solution as installing them
costs 50 percent less than installing fixed
weighbridges.
Load scanners offer high throughput
and optimize efficiency. They can be
installed at the site and can be operated
on the same day. They require very little
maintenance and calibration as compared
to other systems. Moreover, it takes just
a few seconds to assess the payload data.

You can use advanced software solutions to access the data in real-time from
remote locations. There is no need to stop
the truck to take measurements and the
load data is generated and recorded as the
trucks pass seamlessly across the scanner.
Load scanners are ideal for operations
that require hundreds of truckloads to
be weighed on a daily basis.
All these scales rank high on accuracy,
reliability and sturdiness. Do thorough
research, study your requirements and
choose only those that best address your
needs. P&Q
Kevin Hill heads up the marketing
efforts and provides technical
expertise to the sales and service
teams at Quality Scales Unlimited in
Byron, Calif.

Design & Construction

of Fines Recovery Equipment

Doing What We Do Best

PLATE & FRAME PRESS

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Providing Solutions
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August 2016

DEWATERING SCREEN

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Learn More Call 866-616-9351

or Visit www.azfab.com

pitandquarry.com

MAKE SMART
SAND!
WITH HIGH TECH SAND YOU CAN SPEND
MORE TIME AT HOME AND LESS TIME CRUSHING
Modern producers can meet their sand demand with C33 grading and best
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A REMco SandMax will crush
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Talk to a REMco Representative to

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A WORLDWIDE PRODUCT OF REMco - AN AMERICAN COMPANY

DRONES

Do
it

yourself
A number of considerations must be made when evaluating
drone use and management at aggregates operations.

rones continue to captivate aggregate producers,

many of whom are currently exploring how to
incorporate the technology to better ascertain volumes and model topographies.
Michael Singer, co-founder of Drone
View Technologies, estimates that between 3 and 5 percent of producers have
adopted drones to date. But he expects
the industrys market adoption rate to
increase to between 60 and 70 percent
within three years.
Everybody is evaluating, Singer says.
Specifically, producers are evaluating
four factors related to drones, he says: the
accuracy of the data drones provide; the
timeliness of that data; whether or not the
technology is safe; and, of course, the cost.
From those factors [producers] then
ask what does it all mean from an operating
perspective, Singer says. Can this data
make us more efficient?
A number of producers are accustomed
to gathering inventory data on an annual
or semiannual basis, he adds, going about
the process with an ad hoc accounting
approach. But some producers whove
adopted drone technology are experiencing benefits they otherwise didnt
expect to gain.
Theyre seeing the benefit of being
46

PIT&QUARRY

August 2016

more timely in their assessments, Singer

says. Change with any big company
doesnt happen overnight. I think many
spent last year and some continue into
this year learning about the technologies
and capabilities. Theyre trying to figure
out if this is a core competency and if they
want to rely on a third party.
NOT THAT SIMPLE
According to Singer, some aggregate
producers have developed the idea that
they can purchase a drone on Amazon
and get a little training from an expert
before they can manage a drone on their
own. The process isnt that simple, though.
The reality is that the nuances of doing
it accurately, consistently, at scale and
safely are more challenging than many
realize, Singer says. [The technology]
works the vast majority of the time as
intended, and sometimes it doesnt.
Singer cites a fallen drone as an example
of something that can go wrong.
We had equipment fall out of sky from
about 200 ft. [one] week, he says. Fortunately, nobody was hurt. The equipment
was damaged beyond repair. It was a motor
failure, and that happens. People need to
realize that while the technology is cool,
safety is a real issue and were mindful of it.
We try to be as least destructive to the

operation as possible and stay away from

as many people as possible, Singer adds.
That means staying 500 ft. or more away
from people. We keep our operations to
FAA (Federal Aviation Administration)
standards and code.
These are all considerations aggregate
producers must make, as well.
Many large companies also have
their own engineering, surveying and
GIS (geographic information system)
capability, Singer says. They start off
thinking maybe they need to buy their
own drones and be their own resource.
Many have done that, but many have
also crashed the drones theyve acquired.
And, for a plethora of reasons, theyve
concluded maybe thats not their core
competency.
Insurance is another consideration
aggregate producers must make.
Regulations are something to be
mindful of, as is an additional insurance consideration related to aviation,
Singer says.
However aggregate producers decide
to go about drone management, Singer
is convinced more producers will soon
be managing drones.
[Drones] are going to be transformative to the mapping and survey world,
he says. P&Q
pitandquarry.com

ISTOCK.COM/CORR

BY K EV IN YANIK

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[ E VO L U T IO N

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years

Conveying
& Material
Handling
BY MEGAN SM A LLEY

Early on in the industrys history,

many producers designed and
built their own conveyors to save
money. With time, more conveyor
manufacturers emerged as the
industry faced stricter regulations on
equipment designs.
In more recent history, producers
have used material handling to
minimize the use of haul trucks. As
we glance through 100 years of Pit &
Quarry, we see the changes that have
been made in regard to conveying and
material handling technologies.

A number
of rubber
companies such as U.S. Rubber
Co., today known as Uniroyal, and
Quaker City Rubber Co. diversified
their businesses by also providing
aggregate producers with
conveyor belt material.

1919

Morris Machine Works

Co. manufactured
heavy-duty pumps in the early 1900s.
The company, founded in 1864, was
one of the first in the United States to
produce the centrifugal pump for the
aggregate industry.

1919

Each month in 2016, the Evolution Series

highlights industry advancements over the past
100 years, as seen in the pages of Pit & Quarry.

48

PIT&QUARRY

August 2016

pitandquarry.com

16 - 2 016
19

[ E VO L U T IO N

SE RIE S: C O N V E Y IN G

100
years

Novo developed a pumping outfit to handle

large volumes of water up to about 20,000
gallons of water per hour. According to Novo, the engine
proved to be a more successful design compared to others
developed in the 1920s.

1926

The Jeffrey Manufacturing

Co. designed belt idlers
for aggregate producers and other mining
operations throughout the first half of the
1900s. According to the company, its Reliance
belt idler provided conveyors with increased
strength and improved performance.

1933

50

PIT&QUARRY

August 2016

pitandquarry.com

Are you

for Mining?

Now more than ever, our industry needs to unite and voice the positive impact
that mining delivers throughout the world, and what better opportunity than at
MINExpo 2016?
Telsmith invites you to join us in Las Vegas and voice your support by saying that
you are ALL IN for Mining.
Please visit www.miningallin.com to learn about the unique experiences
Telsmith is providing at MINExpo and to reserve your opportunity to be
ALL IN for Mining.

TELSMITH

an Astec Industries Company

10910 N. INDUSTRIAL DR. MEQUON, WI 53092 USA 262.242.6600 FAX 262.242.5812 telsmith.com
2016 Telsmith, Inc.

[ E VO L U T IO N

Goodyear Tire
& Rubber Co.
installed the worlds longest
conveyor to date in April 1940. The
company installed the conveyor
at a gravel pit in Redding, Calif., to
send aggregate to the Shasta Dam
more than nine miles away. Material
traveled down the conveyor at a
speed of 550 ft. per minute.

SE RIE S: C O N V E Y IN G

1940

More conveyor and parts manufacturers emerged to service

the aggregate industry by the 1950s and 1960s, including
Barber-Greene, Cedarapids, Marco, Transall, Continental Gin Co., Rex,
Hewitt-Robins and Lippmann, to name a few.

1958

DIAMONDBACK
BELT WIPERS, SKIRTING AND
LINERS ARE RATTLESNAKE TOUGH!

BELT
WIPERS
BELT
SKIRTS

We offer a wide range of belt wiper solutions. The Diamondback GP Belt Wiper,
The USDA Wet, The Dual Duro, The Hi-Temp, The Tri-Layer, & The Ceramic Bead
Blade.
The Diamondback General Purpose wipers are available with beveled edges as
well. 20, 35, 45, & 90 degrees.
Diamondback sheet liners are available with a variety of durometers, colors,
and backings. Expanded Metal, Canvas, Plain and Ceramic Chip embedded. We
offer our proprietary Diamondback WedgieTM Bolts for your fastening solutions.

SHEET LINERS

Solutions...Not Problems

1-800-238-7638
Wedgie Bolt
Diamondback
Fasteners
TM

184 Gilbert Avenue

Memphis, Tennessee 38106
www.baileyparks.com
sales@baileyparks.com
Phone: 901-774-7930
Fax: 901-774-8444

52

PIT&QUARRY

August 2016

pitandquarry.com

FIELD TESTED & APPROVED.

904.356.6840 SALES@SCHURCOSLURRY.COM SCHURCOSLURRY.COM

Drop In Parts With OEM Equivalent Warranties

16 - 2 016
19

[ E VO L U T IO N

SE RIE S: C O N V E Y IN G

100
years

1966
Stephens-Adamson
Manufacturing
Co., today known
as Metso, served as
one of the biggest
conveyor belt
manufacturers in
the 1960s, along with
Dravo, Link-Belt and
Rexnord.

Conveyors vary in
construction and
design, as many manufacturers
engineer them differently and
some producers even custom-build
their own designs. Because of the
differences, Pit & Quarry supplied
some tips on basic conveyor
maintenance.

1973

AT HOME ON ANY RANGE

Wherever the job takes you, our variety of surface
crawlers will fit right in.
800-732-6762
www.atlascopco.us

54

PIT&QUARRY

August 2016

pitandquarry.com

What Difference
Does 6 Make?
In A Word ... TONS!
On a good day, you crank out a couple thousand tons of
crushed product. But what if the crusher jams? Shutting
down the entire operation to remove lodged material takes
at least an hour. Thats more than 10% of your output for
the day, each and every time.
Only Screen Machine Crushers offer our patented
Crusher Relief System. It lets you raise the crusher
lid and aprons up to 6 while the machine is in operation.
The result? Fewer jams, less downtime and improved
productivity. Its just another way Screen Machine
products help you Crush Every Job.

Patented Crusher Relief System

Continental
Conveyor &
Equipment Co. released a high-angle
conveyor model to help material
move through sites faster at rates
of about 3,000 tph for gravel and
crushed stone. The conveyor model
handled sand, gravel, iron ore,
pellets, copper ore and waste rock.

1985

4043T Crusher

Limited Tier III engines available!

5256T Crusher

CST Crusher

JHT Crusher

516T Spyder

514TS Spyder

107T Scalper

SCREEN MACHINE INDUSTRIES

American-Made Innovation Since 1966
800-837-3344

pitandquarry.com

740-927-3464

email@screenmachine.com

See how it works at www.screenmachine.com

August 2016

PIT&QUARRY

55

Ready to Monitor... in French

Now available in French, the Micromate has redeined

industry standards. Monitor vibration and noise or air
overpressure on one unit. Small enough to it in your hand,
Micromate provides a user friendly touch screen interface.
Support of USB 2.0 allows use of memory sticks, modem,
printers and GPS. Ruggedness and reliability are the
cornerstone attributes of Instantel products.

Contact an Instantel representative today!

(613) 592-4642 sales@instantel.com www.instantel.com

REMA TIP TOP/North America, Inc.

Industry Leader in Conveyor Belts, Service, & Wear Protection

Phone: 800.334.REMA (7362)

56

PIT&QUARRY

www.rematiptop.com

August 2016

Mt. Hope Rock Products, based

in Wharton, N.J., boosted its
production levels by adding a more efficient conveyor
design. The producer used high-quality conveyor
belts, solid-plate mechanical belt splices and
oversized conveyor pulleys to optimize operations.

1990

Automated telescoping radial

stackers such as the Superior
Industries TeleStacker conveyor were an important
advancement in material handling that developed in
the 1990s and early 2000s. Telescopic radial stackers
prevented stockpiles from segregating.

2002

pitandquarry.com

16 - 2 016
19

[ E VO L U T IO N

SE RIE S: C O N V E Y IN G

100
years

Aggregate producers
such as Youngquist
Brothers Inc. in Fort Myers, Fla., added
more conveyors to its operations to
achieve energy efficiency. The additional
8,000 ft. of conveyors moved material at a
rate of 2,500 tph.

2004

Overland conveyors work best for operations that need

to transport materials longer distances. This has been
important in recent years, as more producers are trying to reduce the need
for haul trucks. Geneva Rock Products added a long overland conveyor to
its operation in order to lower operational costs and increase the safety of
its workers.

2015

Simply
Reliable

Always Has Been, Always Will Be

Fine Material Screw Washers

Sand Classifying Tanks
Coarse Material Screw Washers
Log Washers
Portable Plants
Road Based Mixers

A McLanahan
Company

129 East Holcomb Avenue, Des Moines, IA 50313 USA

+1 (515) 243 1123 | eiwllc.com

pitandquarry.com

August 2016

PIT&QUARRY

57

MINEXPO INTERNATIONAL 2016

ON
MINEXPO
INTERNATIONAL
is scheduled for
Sept. 26-28 at the
Las Vegas Convention
Center, where a couple
thousand companies
plan to exhibit.

DECK
Another four years
have passed, putting
MINExpo once again
at center stage.
BY K EV IN YANIK

58

PIT&QUARRY

August 2016

from around the world, says Denise

Johnson, a group president at Caterpillar
who is MINExpo chairperson. MINExpo 2016 is showcasing real technologies,
advancements, innovations and solutions
that will impact the bottom line of mining
companies today and into the future.
In addition to the trade show, producers
are invited to attend an opening session
the morning of Sept. 26 that will explore
current mining industry issues and offer
perspectives on the industrys future.
Several education sessions are available
to attendees, as well. Sessions are available
Sept. 27 and 28, with topics including
automation, markets, mining projects,
processing, reclamation, research, safety
and water. Professional development
credits are available to producers who
attend these sessions, NMA says.
Luncheons are available as part of
the MINExpo experience, as well. The
Sentinels of Safety and NIOSH Awards
Luncheon takes place Sept. 27, and the U.S.
Department of Interior Awards Luncheon
takes place Sept. 28.
While MINExpo has a number of
opportunities at the convention center
to keep attendees busy there, NMA has
arranged several offsite tour options for
interested attendees. Museum visits and
tours of Las Vegas and Hoover Dam are

among the available options.

Learn more about MINExpo at
www.minexpo.com.

Cant make it
to MINExpo?
The Pit & Quarry staff will cover
the show and report live from the
Las Vegas Convention Center. Get
the very latest from Pit & Quarry
at MINExpo at www.pitandquarry.
com. In addition, connect with
us on Facebook (facebook.com/
PitandQuarry), Twitter (twitter.
com/PitandQuarry) and Instagram
(instagram.com/PitandQuarry)
for photos, videos and more from
the show floor. Readers can also
sign up for P&Q Weekly Report, an
e-newsletter that will be delivered
to your inbox each day of MINExpo,
for complete recaps of the days
events in Las Vegas.
pitandquarry.com

PHOTO COURTESY OF THE NATIONAL MINING ASSOCIATION

INExpo International returns next month, when

stone, sand and gravel producers from around the world
join other mining sectors at the quadrennial trade show in Las Vegas.
The show, scheduled for Sept. 26-28,
will span 831,000 sq. ft. across 12 indoor
and outdoor halls, according to the National Mining Association (NMA), which
serves as MINExpo sponsor. More than
1,800 companies are expected to exhibit,
showcasing their products, services and
technologies at the Las Vegas Convention
Center.
The 2016 event will cover about 2
percent more space than the 2012 show,
NMA reports. Exhibits will be housed in
the North, Central and South Halls, as well
as in the outdoor Silver Lot. Exhibits will
be open from 9 a.m. to 5 p.m. each day.
According to NMA, MINExpo is
applicable to individuals in a variety of
positions at mining companies, including
executive-level leaders; mine managers;
production, operations and maintenance
personnel; engineering managers and
engineers; geologists; and those who make
purchasing decisions.
I am honored and excited to chair
such an expansive showcase of mining
equipment, technology and expertise

Aggregate Drones

I was able to accurately measure the volumes of stockpiles at one of our quarries in just 10 minutes using the Kespry Drone
System. Previously, it took me about 2 days of strenuous GPS work to cross-section those piles. This is an amazing technology!
John P. Davenport, Construction Surveyor, Whitaker Contracting Corporation

Automatically measure aggregate stockpiles

Kespry drones are saving mining companies time and
money by automating the measurement of aggregate
stockpiles and construction materials.
Companies can fly their own sites and automatically
get the perimeter and volumes for all their
aggregate stockpiles as frequently as needed.
The Kespry 2D and 3D aerial models also assist
with mine surveying, planning and operations.
With Kespry, what used to take weeks now takes hours.

Aggregates | Construction | Insurance

www.kespry.com/aggregates

HILLHEAD 2016

EQUIPMENT

DEMOS
AND MORE

More than 18,000

withstood the
elements to attend
Englands quarry
equipment exposition.
STORY A ND PHO TOS
BY DARREN CONSTANTINO

ttendees to the Hillhead 2016

trade show near Buxton,
England, braved rain, wind
and chilly temperatures to
view nearly 500 exhibits, as well as live
equipment demonstrations. The threeday event, which took place at Tarmacs
Hillhead Quarry, attracted 18,655 visitors,
a 7 percent increase over the previous
show in 2014.
This years event included more working demonstrations than ever before,
creating some of the busiest live action
ever seen at Hillhead, including no fewer

Held once every

two years near
Buxton, England,
Hillhead is a trade
show specifically
for the aggregate
industry.

than 14 excavators in a new-look quarry

face area. Other demonstration areas
featured several portable plants at work.
Hillhead 2016 also recorded the shows
largest ever number of exhibitors (470) who
occupied the biggest area of exhibition
space to date.

Many of the 18,000+ visitors to Hillhead 2016 took advantage of the

demonstration areas to watch equipment in action.

60

PIT&QUARRY

August 2016

According to show organizers, the

newly extended area of the showground
worked extremely well and is already
oversubscribed for 2018, while the extended registration pavilion also proved
successful, prompting plans for a further
significant increase in size in 2018.

Here, a Volvo excavator loads a McCloskey portable

plant. Demos were sometimes halted by rain.

pitandquarry.com

Both a JCB excavator and Powerscreen portable plant were

featured in this equipment demonstration.

Portable crushing and screening plants, such as the

tracked models above from Sandvik Construction (top)
and Kleemann were on display, as well as working live
in the equipment demonstration areas. There were 470
exhibitors at this years event.
Excavators, wheel loaders and haul
trucks had their own demonstration
area at Hillhead 2016.

Terex Washing Systems debuted the

new FM UltraFines system, designed to
increase potentially sellable output.

pitandquarry.com

At Hillhead 2016, Terex companies showed off screening technologies that are
designed to prevent plugging and blinding. The wave-like screen at right is from
Spaleck, a German company, in a joint venture with Terex Finlay.

August 2016

PIT&QUARRY

61

UPDATE
NEW FEDERAL REQUIREMENTS
PROPOSED FOR MINING REGISTRANTS
he Securities and Exchange
Commission (SEC) proposed rules to modernize
the disclosure requirements
for mining properties by aligning them
with the current industry and global
regulatory practices and standards.
According to the SEC, the proposed
revisions would update disclosure requirements for mining registrants in Item 102 of
Regulation S-K under the Securities Act of
1933, the Securities Exchange Act of 1934
and related guidance in Industry Guide 7.
These proposed rules would modernize the commissions disclosure requirements by aligning them with global
standards and give investors more com-

prehensive information of a registrants

mining properties that they can use to
make informed investment decisions,
says SEC Chair Mary Jo White.
The SECs proposed rules would provide one standard requiring registrants
to disclose mining operations that are
material to the companys business or
financial condition. In addition, the rules
would require a registrant to disclose mineral resources and material exploration
results in addition to mineral reserves.
According to the SEC, a permit disclosure of mineral reserves would be based
on a preliminary feasibility study or a final
feasibility study. Updated definitions of
mineral reserves and mineral resources

would be required, as well.

The SEC would also require, in tabular format, a summary disclosure for a
registrants mining operations as a whole,
as well as more detailed disclosure for
material individual properties. In addition,
the SEC would require every disclosure
of mineral resources, mineral reserves
and material exploration results to be
reported in a registrants filed registration
statements and reports to be based on
and reflect information and supporting
documentation prepared by a qualified
person.
Yet another requirement is for registrants to obtain a technical report summary from the qualified person.

A G G R E G AT E S F O R E C A S T B y D a v i d C h e r e b

Are we currently at a demand peak for aggregate?

e are now
in the seventh year of
increases in
aggregates demand.
Gains in nonbuilding (186
million tons), residential
(182 million tons) and nonresidential (53 million tons)
have driven the 22 percent
increase in demand since
2009. Most of the gains have
occurred over the last two
years, as all three segments
supported higher levels. By
region, the Southeast and
West show continued gains
while energy regions lag.
With a lot happening
in the next year, including
a presidential election,

62

PIT&QUARRY

European Union disruptions,

negative interest rates and
ISIS activities, the outlook
for continued aggregates
demand increases becomes
less definite.
A slowdown in construction contracts that signals
a sharp decline has not yet
taken place. Still, this economy the world economy is

different than it once was.

People are more cautious
these days. Because of this,
we have projected a slowdown in aggregates demand
in 2017. A weaker housing
sector is the cause of most
of the slowdown. In addition,
we are underbuilding based
on normal demographic
demand models.

DCG Inc. U.S. Aggregates Forecast (billions of metric tons)

2011

2012

2013

2014

0.38
NON-RESIDENTIAL 0.69
NON-BUILDING
0.91
TOTAL
1.98
Yr/Yr/%Ch
-

0.43
0.68
0.91
2.02
+2.0

0.39
0.60
1.06
2.05
+1.5

0.48
0.65
1.06
2.19
+6.8

RESIDENTIAL

August 2016

2015est 2016est 2017est

0.53
0.70
1.05
2.28
+4.1

0.57
0.73
1.06
2.36
+3.5

0.51
0.70
1.04
2.25
-4.7

Dr. David Chereb has

many years of experience
forecasting construction
materials, and his webbased forecasting models
have captured every
major turning point in
materials demand for
more than 15 years. Chereb received his
Ph.D. in economics from the University of
Southern California. He can be reached at
david.chereb@sc-marketanalytics.com.

We are not operating in a

normal world. The demand
for higher home sales seems
nowhere to be found. We
may be at the cyclical peak
now, even though demand
remains historically low.
The strongest segment
for 2017 and 2018 will be
nonbuilding, as the highway
bill and improved state and
local budgets help to finance
more public works.
pitandquarry.com

CONGRESSIONAL BILL INCLUDES Short-term

extension of
WATERS OF THE US BLOCK
aviation bill
he Senate Appropriations Committee approved a bill that would
block the implementation of the
Waters of the United States (WOTUS) rule,
the National Stone, Sand & Gravel Association
(NSSGA) reports.
According to NSSGA, the 2017 Interior,
Environment & Related Agencies Appropriations Bill would cut $125 million from current
fiscal-2016 levels and is $1.1 billion less than
the White House originally sought.
NSSGA reports the House Appropriations
Committee marked up a bill that includes
a rider against WOTUS. The House bill is
funded at $32.1 billion and would cut $64

million from current spending levels.

The WOTUS rule is currently under a
judicial stay preventing implementation, according to NSSGA. Although the appropriate
venue for pending lawsuits against EPA to be
heard has not been finally determined, the 6th
U.S. Circuit Court of Appeals has published a
briefing schedule on the merits of the case that
will begin in the fall and extend into early 2017.
Earlier this summer, the U.S. Supreme Court
ruled that a landowner can appeal through a
federal court system a determination from the
Army Corps of Engineers that a water body
is subject to federal jurisdiction and permit
requirements under the Clean Water Act.

P&Q AGGREGATES INDUSTRY INDEX

350

300

August
335

250

SEPT
OCT
NOV
DEC
JAN 14
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
JAN 15
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEPT
OCT
NOV
DEC
JAN 16
FEB
MAR
APR
MAY
JUN
JUL
AUG

200

Source: Pit & Quarry

passes

ongress passed
another shortterm extension
of the Federal Aviation
Administrations (FAA)
policy and tax authority,
reports the National Stone,
Sand & Gravel Association
(NSSGA). The measure will
last until Sept. 30, 2017.
According to NSSGA,
the funding level of the
Airport Improvement
Program (AIP) will remain
at $3.35 billion in fiscal
2017, a level that has not
changed in six years.
It is important to keep
the FAA authorization stable, and this is a welcome
step from Congress, says
Michele Stanley, NSSGA
director of government
affairs. But jobs will not
be created and aggregates
producers will not increase
tonnage for much-needed airport and runway
improvements without
additional AIP funding.

The P&Q Aggregates Industry Index climbs for the fifth consecutive month.

STOCKS
|
As of July 13, 2016

12-MONTH
CHART

PRICE

Source: Yahoo! Finance

Cemex CX

52-WEEK RANGE
LOW

6.78

3.5

HIGH

9.7212

MARKET
CAP IN
BILLIONS
71.58

CRH (Oldcastle) CRH

29.78

23.33

31.55

24.50

Eagle Materials EXP

81.30

45.03

87.04

4.01

Granite Construction GVA

49.41

28.45

49.8

1.96

Heidelberg Cement HEI.DE

71.81

58.17

79.99

13.49

LafargeHolcim LHN.PA

39.89

30.33

70.27

23.71

Martin Marietta MLM

197.02

108.31

199.87

12.52

MDU Resources MDU

23.97

15.58

24.67

4.68

Summit Materials SUM

21.58

13.12

27.89

1.35

U.S. Concrete USCR

64.10

35.8

69.66

0.97

59.51

45.56

61.67

0.33

125.78

78.83

127.17

16.75

U.S. Lime & Minerals USLM

Vulcan Materials VMC

pitandquarry.com

NALC, Indian
Creek enter
agreement

ALC LLC entered

into an agreement
with the owners
of Indian Creek Quarries
(ICQ) LLC and Indian Creek
Trucking LLC to manage
all facets of the operations
of ICQ.
According to NALC,
ICQ owns a limestone and
dolomite surface mine near
Williams, Ind., as well as a
fleet of trucks that supports
the mines operations.

August 2016

PIT&QUARRY

63

COMMUNITY RELATIONS

WINNING

STRATEGIES
With ever-increasing public concerns about blasting,
a consultant shares tips on how to proactively
handle blasting complaints.

lasting tends to be one of the

biggest concerns homeowners
have with quarry operations.
Thats always been a given.
But Jeff Taylor, president of Sauls
Seismic, has noticed an increasing number
of damage claims lately against aggregate
producers and blasting companies.
Blasting seems to be the one thing people fear most about quarries, Taylor says.
So, how can aggregate producers put up
a stronger defense when blasting-related
complaints and lawsuits arise? Taylor
offers some recommendations that can
help producers avoid having to turn to
defensive tactics.
Perform pre-blast surveys with help
from a third-party company. Aggregate
producers should partner with an outside
company to perform pre-blast surveys to
protect themselves against blasting-related
lawsuits, Taylor says.
According to Taylor, performing a
pre-blast survey is one of the best defenses
against a blasting lawsuit. In a pre-blast
survey, a third-party company takes photographs of nearby homes prior to blasts
to check for any pre-existing damages on
structures. If homeowners are convinced
a blast cracked their house, a pre-blast
survey can test the claims validity.
This needs to be a standard practice,
Taylor says. If there are homes close to
where youre blasting, its wise to invest

64

PIT&QUARRY

August 2016

in this, like insurance. And its being a

good neighbor to the people.
Hiring an outside company to handle
this task is beneficial, Taylor adds, because
a third party tends to have more training
on this topic than a producer or a blasting
company.
Never ignore a complaint. As crazy as
some complaints might sound, aggregate
producers should take all complaints seriously. Although the aggregates industry
has made some improvements in this area,
Taylor says the industry could be better
at being proactive rather than reactively
handling complaints.
As a regulator, Ive been told by a lot
of citizens that they had to take an issue
to the state as a result of poor response
from the producer, he says. So take
their complaints seriously and respond
quickly. The worst thing you can do is
ignore it completely.
Taylor recommends producers have
a standard plan in place to address complaints. Producers should appoint one

person to handle any complaints, he says,

and that person should be a good listener.
Pick a person who can be talked to
meanly by a citizen, he says. A lot of
times, Ive found if you let a person vent
to you for a while, and then you calmly
tell them your concerns and the situation,
it tends to work best.
Set up community meetings. Not every
blast requires a community meeting, but
Taylor says it might be wise to host one
if a producer plans to change its blasting
locations or patterns. Use the meetings
as a way to educate the community on
blasting regulations and practices in
place that will protect their property
from damages.
Be transparent with the community,
he says. Thats all part of being a good
neighbor.
To inform people about a community
meeting, share news about it with the
local newspaper and post flyers in public
locations. Also, select someone to serve
as a moderator during the public conversation. This person can help to guide the
conversation if anyone goes on a tangent,
Taylor says.
Let them reel in the conversation, he
says. Youre always going to have some
people unhappy with a quarry blasting,
but if you can win the reasonable people to
your side in a meeting on what to expect,
you can get rid of potential issues. P&Q
pitandquarry.com

PHOTO BY TOM HINGST.

BY MEGAN SM A LLEY

Built like a brick...

Some things are built to stand the test of time.
Industrial gearing from SEW-EURODRIVE is
one of them. Old world quality and modern
engineering combine to produce units that wont
leave you sitting in the dark. Our industrial units
are designed for very demanding applications
with torque ratings to over 4,000,000 lb-in. The
best part...they are engineered and assembled in
South Carolina, USA.

seweurodrive.com / 864-439-7537

SAFETY

UPDATE

THEY
SAID IT

he U.S. Department of Labor

(DOL) announced two interim final rules to adjust its
civil penalties for inflation
based on the last time each
penalty was increased.
According to DOL, the first rule will
cover the majority of penalties, which
are assessed by the Mine Safety & Health
Administration, the Occupational Safety
& Health Administration, the Office of
Workers Compensation Programs, the
Employee Benefits Security Administration, and the Wage and Hour Division.
The second rule will be issued jointly with
the Department of Homeland Security to
adjust penalties associated with the H-2B
temporary guest-worker program.

Civil penalties should be a credible

deterrent that influences behavior far
and wide, says Thomas E. Perez, U.S.
secretary of labor. Adjusting our penalties
to keep pace with the cost of living can
lead to significant benefits for workers and
can level the playing field for responsible
employers who should not have to compete
with those who dont follow the law.
The new method will adjust penalties
for inflation, although the amount of the
increase is capped at 150 percent of the
existing penalty amount. The baseline is
the last increase other than for inflation.
The new civil penalty amounts are applicable only to civil penalties assessed after
Aug. 1, 2016, whose associated violations
occurred after Nov. 2, 2015.

Cellphone safety takes center stage

THE MINE SAFETY & HEALTH ADMINISTRATION (MSHA) and the Association of
Equipment Manufacturers (AEM) issued a mine safety alert regarding cellphones.
According to the U.S. Department of Transportation, cellphones are involved
in 6,000 auto fatalities each year.
Using a cellphone while operating
mobile equipment introduces the
hazard of distracting the equipment
operator and increases the chances
of being involved in an accident,
MSHA and AEM add.
Powered haulage is the leading
category of fatalities in metal and
nonmetal mining, says Joe Main,
assistant secretary of labor for
mine safety and health. Over the
past five years, there have been
29 fatalities in powered haulage.
Distractions caused by cellphone
MSHA and AEM report that using a cellphone use greatly increase the risk. No call
or text message is worth taking
while operating equipment is up to six times
that chance.
worse than operating while intoxicated.

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Joe Main, MSHA

STATES TO RECEIVE
MINE SAFETY
TRAINING FUNDS

orty-seven states will receive

more than $8.4 million in funds
to support safety and health
training courses and other
programs to reduce mining accidents,
injuries and illnesses, according to the
U.S. Department of Labors Mine Safety
& Health Administration (MSHA).
According to MSHA, grant recipients
will use the funds to provide miners with
federally mandated training. The money
will cover the training and retraining of
miners working at metal and nonmetal
mines, as well as surface and underground coal mines. This includes miners
employed at surface stone, sand and
gravel mining operations.
Some states will use the grants to
support their mine emergency response
efforts and other statutory functions,
MSHA reports.

HARD

NUMBERS

0
U.S. MINES that currently
meet the criteria for a Pattern
of Violations notice, according
to the Mine Safety & Health
Administration.

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NEW RULES TO ADJUST

CIVIL PENALTY AMOUNTS

WE HAVE SEEN a cultural

change in the mining industry
where high numbers of
serious violations at mines
are no longer tolerated.

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MSHA

&THE LAW

BY MICHAEL T. HEEN AN

NEGLIGENCE

PER SE
egligence per se is a legal
concept employed in lawsuits to cement a claim for
damages.
A motion for summary judgment will
contend there is no question of negligence
for a jury to decide. A defendants violation of a safety law caused the plaintiffs
injury, and that is negligence per se.
If parties to a suit are from different
states, the case may be removed to a
federal district court, which must then
apply the law of the state. In Kentucky, the
common law principle of negligence per
se is codified in a 1942 statute: A person
injured by the violation of any statute may
recover from offender such damages as
he sustained by reason of the violation.
Kentucky case law establishes conditions that must be satisfied: the statute
must have been intended to prevent the
type of occurrence that took place and
the violation must have been a substantial
factor in causing the result.

CASE AND RULINGS

Evansville Garage Door Co. was contracted for an installation in a building under construction at a Kentucky
mine facility operated by Covol Fuels.
During door tension adjustment,
David McCarty, one of the two Evansville employees, was knocked off a
ladder and suffered fatal injuries.
The Mine Safety & Health Administration (MSHA), having comprehensive jurisdiction on mine properties,
investigated and found manufacturer
installation instructions were not followed. Specifically, there was a failure
to block the door against unintended
motion. MSHA cited Evansville, writing
the following: The contractor employed
68

PIT&QUARRY

August 2016

by the operator had not securely blocked

the overhead rolling steel door being
installed in a newly constructed surface
structure on the site of Minuteman Plant
for Covol Fuels ... Contractor [Evansville]
employees were installing a 20-[ft.] x 14[ft.] door weighing 1,803 pounds when the
door began to descend. It contacted the
ladder from which one of the employees
fell, causing fatal injuries.
The decedents estate claimed the
mine operator was responsible for the
contractors violations of mine safety laws
and was negligent per se. (The estate had
already received workers compensation
from the employer, Evansville.)

mine site. However ... the only buildings

that fall within the definition of a mine
are those being used in connection with
the workings [of the mine]. The structure upon which McCarty was working
was an unfinished building under
construction and was not being used in
connection with the workings of Covols
mining operations.
With this, the Sixth Circuit affirmed:
The administrative regulations cited
by the Estate apply to mining operations,
mine workers and the traditional dangers
and risks ordinarily associated with coal
mining. We find nothing in the text of
these administrative regulations which
would indicate that McCarty
A contractor ID may avoid was within the class of persons
to be protected, or that his incitations to the mine
were within the type of
operator. It may also work juries
harms to be prevented by the
to head off misdirected
regulations.
Because Kentucky law differs
lawsuits.
from federal law, the result probA motion for summary judgment ably would not be different even if MSHA
asserted Covol was in violation of Ken- cited Covol. But MSHA clearly viewed
tucky mining laws. The only issue was Evansville as an independent operator.
monetary damages. The federal district
Thats one reason it is good for mine
court denied the motion.
operators to insist their contractors obtain
The case was appealed to the U.S. MSHA IDs. A contractor ID may avoid
Court of Appeals for the Sixth Circuit, citations to the mine operator. It may also
which referred the state law question work to head off misdirected lawsuits,
to the Kentucky Supreme Court. That notwithstanding there was no such effect
court advised there was no violation of in this Kentucky case. In other states, the
Kentuckys mining laws or regulations. mine laws might be more like MSHAs
Kentucky mine law jurisdiction at and might apply even if a contractor is
mines is narrower than MSHAs. The not doing mining work. P&Q
Kentucky court described the plaintiffs
Michael T. Heenan is with the national
problem: Central to the [estates] argu- labor, employment and safety law
ment is the assertion that McCartys fatal firm Ogletree Deakins. His book MSHA
injury occurred at a mine because the Compliance Essentials is available in
garage door installation was being per- English and Spanish (2016).
formed at a building situated on a coal michael.heenan@odnss.com
pitandquarry.com

GRADUATE MANAGEMENT PROGRAM AND

JUNIOR MANAGEMENT PROGRAM

ENROLLMENT IS NOW OPEN FOR FALL PROGRAMS!

NSSGA, in partnership with the Institute of Quarrying (IQ) is now

accepting applications for both the U.S. Graduate Management
Conversion, a two-year program, and the U.S. Junior Management
Program, which is a three-year program.
The Institute of Quarrying is an internationally recognized professional
body for quarrying, construction materials and related extractive and
processing industries. IQ is committed to helping the professionals that will
drive the industry forward by providing lifelong learning opportunities.
For more information or to apply, contact Catherine Whalen at

cwhalen@nssga.org

www.nssga.org

In partnership with

The Institute
of Quarrying

SAFETY

CRISIS

Management
Having a comprehensive management plan and
familiarizing your team with it is useful in the event of
a serious or fatal accident on mine property.
BY K EV IN YANIK

incident may not readily present itself to

mine operators. The best first step is one
operators can take long before an incident
occurs: develop a thorough and detailed
crisis management plan.
There are issues to consider when you
develop your crisis management plan,
says Karen L. Johnson, an attorney at Denver-based Jackson Kelly who delivered a

National Stone, Sand & Gravel Association

(NSSGA)-hosted webinar presentation focused on crisis management. You want to
think about eliminating legal liability. The
plan also needs to address how you work
with HR folks and the inner relationship
between HR people and the employees.
According to Johnson, a producers
response within the first 24 hours after an

ISTOCK.COM/KATIFCAM

o a serious or fatal incident has taken place

at your mine. A 911
phone call has been
made, and a mine
rescue team has been assembled.
Now what?
Because serious and fatal incidents are
rare, the best course of action for a specific

70

PIT&QUARRY

August 2016

pitandquarry.com

incident sets the tone for an investigation.

If you can maintain control of that
investigation right at the start, your response is going to be that much more
effective and smoother than an individual
or company that has no plan in place and
is kind of playing it by ear, Johnson says.
RESPONSIBILITIES
A good starting point to build an effective crisis management plan is to
assign certain tasks to individuals.
Roles should be defined, Johnson says,
but no template exists for all producers
to follow.
As an example, a plant manager can be
tasked with managing rescue and recovery efforts at one plant while somebody
in another role at another plant handles
those same efforts.
Its dependent on what works best for
you and your property, Johnson says.
Regardless of who handles what, operators should ensure responsibilities are
assigned for a number of incident-related
areas. Rescue and recovery is one such
area, and roles should be understood long
before an incident occurs.
Some mines have in their crisis management plan that one person will be
assigned to go to the front gate and guide
the ambulance in, Johnson says. Or, there
may be somebody who needs to man the
phone to communicate with MSHA (the
Mine Safety & Health Administration) or
first responders.
Another consideration is to determine
whos responsible for alerting MSHA about
the incident. Once a person at a mine site
with the authority to call MSHA has information to conclude that a serious incident
has occurred, a phone call must be placed
within 15 minutes of that moment. MSHA
will verbally issue a 103(j) order over the
phone, and operators will be tasked with
securing the accident scene.
You may have to designate whos
in charge of the scene, who is going
to guard the scene or make sure its
not accessed by anybody who is not
pitandquarry.com

authorized, Johnson says.

The Occupational Safety & Health
Administration (OSHA) also must be
notified, although operators are given
more time to alert OSHA about injuries
and fatalities, according to Johnson.

Because MSHA will be on site in the case

of a serious or fatal accident, operators
should assign someone to serve as the point
person for immediate agency requests.
This person doesnt have to be a company
employee, Johnson says, and they can be

mclanahan.com

August 2016

PIT&QUARRY

71

SAFETY

Aggregate producers are encouraged to develop a detailed crisis management plan.

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August 2016

by that document czar, Johnson says.

After all, any document that is turned
over to one agency is available to all
through a Freedom of Information Act
request.
Anyone can submit [a request] to a
federal agency, Johnson says. Under the
Sunshine Act, the federal government has
to respond to that request by producing
all documents that are responsive. They
will redact certain information but not
all of it.
FAMILY COMMUNICATIONS
Family member and survivor assistance is another area to incorporate
into your crisis management plan.
If you have not gone through a fatal
accident investigation, you would be
surprised by the amount of effort and
time dedicated to family and survivor
assistance, Johnson says.
She recommends tasking a top HR
representative with handling communications and interactions with families.
Often, we see family expecting or
requesting that the company pay for
a variety of expenses such as food or
bringing family in from other parts of
the country, Johnson says.
The people whom mine operators
pitandquarry.com

ISTOCK.COM/ENRICO FIANCHINI

a contact for OSHA and other agencies.

I have acted in this role myself in
a number of investigations, she says.
[This person] may be in-house counsel
that comes to the site for investigation.
It might be corporate safety. You have
to figure out who is the best person to
handle this.
Document control is another component of crisis management.
This is a big one in part because
documents start flying back and forth
in these serious investigations, Johnson
says. You may get multiple people from
an MSHA investigation party asking for
documents. You want one person to be
your document czar.
A document czar knows which documents have been requested, which have
been released to agencies and which have
been withheld.

should contact may not always be obvious.

For example, if an employee has children
from a previous marriage, additional
phone calls may be in order to notify
next of kin.
You dont want family members to
learn about it from the news, Johnson
says. You need to have personnel files
handy and make the calls to the appropriate designated people.
According to Johnson, communication
with family members is one of the most
difficult crisis components to manage.
Especially in this day of texting and
cell phone usage, she says. Often, theres
been a [report]. You try to manage it as
well as you can and make sure you have a
designated point person to communicate
with the affected family members.
Family members arent the only survivors mine operators should keep in mind,
she adds. A companys employees may have
a range of needs following an incident.
Summon a grief counselor and make
that person available to employees for
about a month after an incident, Johnson
suggests.
This sort of event has a significant
impact on your employees, she says.
Also, how will your company handle
the media if reporters have questions
following a serious or fatal incident?
When I think about media interface,
the main things that come to mind are
the camera shots we all saw of Anderson
Cooper standing outside the gates of the
Sago Mine, Johnson says. Typically,
were not going to see that sort of media
response unless we have a multiple fatality-type of situation.
But that doesnt mean a media response
wont be had. So whos going to be tasked
with handling the local newspaper, television stations or other media outlets
that want in? And what message is your
company prepared to deliver?
If the media is involved you have to
have an appropriate person to respond as
necessary, Johnson says. Oftentimes,
mine operators will hire an outside
pitandquarry.com

Your legal obligations

What if a serious or fatal incident
has taken place at your mine, and
contact with the MINE SAFETY &
HEALTH ADMINISTRATION (MSHA)
has been tried but not successfully
made? What are your legal obligations going forward?
According to Karen L. Johnson,
an attorney at Denver-based
Jackson Kelly, the Mine Act places
responsibility on mine operators
to preserve the accident scene
and ultimately allow MSHA to
investigate.
I would secure the scene and
guard it in anticipation of MSHA
showing up, Johnson says. I
wouldnt remove the equipment or
continue mining until you are abso-

lutely sure MSHA isnt going to come

out and investigate.
Johnson has not, however, experienced an instance in which MSHA
did not return a mine operators
phone call alerting the agency about
an incident.
Sometimes [a return call] takes
awhile depending on the day and
time of day, she says.
Generally, MSHA responds in
one of two ways, Johnson adds.
The agency will either immediately
issue a 103(j) order to secure the
scene or, depending on the initial
details of the incident, it will ask for
regular updates and make a decision to investigate the scene at a
later time.

August 2016

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73

SAFETY
company to act in that capacity. Theres
nothing wrong with doing that, because
youre going to have to determine what
your message [will] be. It may be delivered
by an employee, but [an outside company] can help you deliver your message.

to be cautious of both
Family members arent the
being on the property.
The local sheriff s
only survivors mine operators
office may also claim
should keep in mind following
jurisdiction, presentan accident. A companys
ing a sticky situation to
operators.
employees may have a range
WHO HAS AUTHORITY?
They may tell you
of needs, as well.
MSHA has jurisdiction over any serithey need to enter the
ous or fatal incident that occurs on a
scene and take a look
mine site, but mine operators may be
at things to perform their own invesThen you have to explain to MSHA
required to notify other agencies in
tigation, Johnson says. Your initial what happened, Johnson says. Say,
the wake of such an incident. If operresponse will be that MSHA has issued a Heres what the sheriff did and heres
ators arent aware of the agencies they
103(j) order. Youre stuck in the position how we handled it. Then let them fuss
must notify, they should familiarize
of, Do I let the sheriff go in and I maybe about who has the primary authority.
themselves with that information,
get in trouble with MSHA?
This early on can become one of the
Johnson says.
In such a situation, operators are most difficult parts of crisis management,
The state mine inspectors office will advised to inform the sheriff about she adds. But this typically goes away
also have jurisdiction, she says. There the mines obligations yet allow the fairly quickly once the local folks realize
are times when those two entities may local authority to enter the scene if the MSHA has the primary jurisdiction.
not necessarily get along, but youve got demand is made.
LIABILITY ASSESSMENT
Investigations, on the other hand,
generally arent quick processes. Who
an ounce of dirt
in your company will head an internal
investigation? Is this something a corpostopped 1000
rate safety representative should handle?
tons of rock?
Should safety representatives from other
company sites be sourced? Should a site
manager and a safety representative
manage the investigation together?
These questions should be answered
long before an incident occurs because a
mine operators investigation starts immediately following an accident, according
to Johnson.
The first thing you have to do right at
the outset is assess the types of injuries to
the employee, Johnson says. You have
to do this right off the bat for the MSHA
requirement of immediate notification.
Your folks on the ground need to be looking
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As an investigation progresses, operators
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may discover that an individual is at fault.
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If this discovery is made, operators may
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want to consider having a different attorney
74

PIT&QUARRY

August 2016

pitandquarry.com

represent that individual, Johnson says.

Products can also be at fault.
Think about the number of accidents
that involve pieces of equipment, Johnson
says. If that particular piece of equipment
was defective such that it provides a basis
for a product liability claim against the
manufacturer, thats something you as a
company need to evaluate.
Take a haul truck that has a brake
failure as an example.
You as an employer want to determine if [you] have a basis for a product
liability suit, and the manufacturer of
that haul suit will be interested in the
causation to determine whether they
have any potential liability, Johnson says.
A manufacturers requests can be
tough to handle. Mine employees may
have good working relationships with
manufacturer representatives, Johnson
says. But mine operators should put their
interests before the manufacturers.
Because of the potential for third-party liability against the equipment manufacturer, bringing that manufacturer
in to assist in your investigation may
not necessarily be the best thing, she

says. Their interest is in protecting

themselves, and they will certainly try to
deflect any instance of defective product
and push the liability onto the mine
operator and away from the equipment
manufacturer. P&Q

Information for this article was gathered from a presentation by attorney

Karen L. Johnson, which was part
of NSSGAs AGG1 Online Webinars
series. Learn more about the series at
www.nssga.org/education.

Should you
make the call?
The MINE SAFETY & HEALTH
ADMINISTRATION (MSHA) offers
a definition of mine accidents in
Title 30 of the Code of Federal
Regulations Section 50.2(h). The
severity of an incident sometimes
comes into question among mine
operators, but Karen L. Johnson, an
attorney at Denver-based Jackson
Kelly, says these incidents always
warrant a phone call to MSHA:
1. A death at a mine
2. An injury that has reasonable
potential to cause death
3. An unplanned inundation of a
mine by liquid or gas
4. An unplanned mine fire that is
not extinguished within 30 minutes

pitandquarry.com

www.elrus.com || info@elrus.com || 888-535-7877

August 2016

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Classifieds
F O R C L A S S I F I E D A D V E R T I S I N G:
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Payment must be received by the classifed closing date. Visa, MasterCard, American Express accepted.
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AUGUST AD INDEX
Advertiser

Page

Phone

Website

Am Cast Inc.

pg 72

888-993-2772

www.amcastonline.com

Atlas Copco

pg 54

800-732-6762

www.atlascopco.us

AZFAB

pg 44

866-616-9351

www.azfab.com

Bailey-Parks Urethane

pg 52

800-238-7638

www.baileyparks.com

Advertiser

Page

Phone

Website

Nordic Lights

pg 18

+358 20 1345
100

www.nordiclights.com

NSSGA

pg 69

703-525-8788

www.nssga.org

Orica

Back Cover

303-268-5000

www.orica.com

Philippi-Hagenbuch Inc.

pg 32

309-697-9200

www.philsystems.com

Baldor Electric Co.

pg 67

479-646-4711

www.baldor.com

Breaker Technology Inc.

pg 15

866-284-7278

www.rockbreaker.com

C.L. Dews & Sons

Foundry & Machinery

pg 36

877-339-7339

www.dewsfoundry.com

Rema Tip Top

pg 56

800-334-7362

www.rematiptop.com

pg 45

925-447-0805

www.remcovsi.com

pg 43

800-826-7625

www.construction.sandvik.com
www.scaniausa.com

Precision Pulley & Idler

pg 37

800-247-1228

www.ppipella.com

Regal Beloit Corp.

pg 74

800-626-2120

www.regalpts.com/aggregate

Cowin & Company Inc.

pg 73

205-945-1300

www.cowin-co.com

REMco

EIW LLC

pg 57

515-243-1123

www.eiwllc.com

Sandvik

Elrus Aggregate Systems

Inside Front
888-535-7877
Cover, 75

www.elrus.com

Haver & Boecker

pg 27

800-325-5993

www.havercanada.com

Hoyt Wire Cloth

pg 49

717-394-6871

www.hoytwirecloth.com

SEW Eurodrive

Instantel

pg 56

613-592-4642

www.instantel.com

Superior Industries

ISCO

pg 29

800-345-4726

www.isco-pipe.com

Italvibras USA

pg 40

815-872-1350

www.italvibrasusa.com

Syntron Material
Handling

Kespry

pg 59

650-434-5048

www.kespry.com/aggregates

KPI-JCI & Astec Mobile

Screens

pg 31

605-668-2524

www.kpijci.com

Liebherr

pg 33

757-245-5251

www.liebherr.us

Luff Industries Ltd.

Inside Back
Cover

888-349-5833

McLanahan Corp.

pg 71

Mellott Co.

pg 39

Scania USA Inc.

pg 41

210-403-0007

Schurco Slurry

pg 53

904-356-6840

www.schurcoslurry.com

Screen Machine

pg 55

740-927-3464

www.screenmachine.com

pg 65

864-439-7537

www.seweurodrive.com

pg 3

800-321-1558

www.superior-ind.com

pg 20

800-356-4898

www.syntronmh.com

Tandem Products Inc.

pg 34

800-533-0509

www.tandemproducts.com

Telsmith

pg 51

262-242-6600

www.telsmith.com

Terex Minerals
Processing Systems

pg 5

800-821-5600

www.terexmps.com

www.lufindustries.com

Uniied Screening
& Crushing

pg 35

866-968-3697

www.uniiedscreening.com

814-695-9807

www.mclanahan.com

Van der Graaf

Pg 17

888-326-1476

www.vandergraaf.com/
drummotor

717-504-9704

www.mellottcompany.com

Vermeer

pg 19

888-837-6337

www.vermeer.com

Volvo Construction
Equipment

pg 7

717-532-9181

www.volvoce.com

Mincon

pg 47

702-685-1167

www.mincon.com

Motion Industries

pg 25

800-526-9328

www.motionindustries.com

Nord-Lock Inc./
Superbolt Inc.

pg 50

412-279-1149

www.nord-lock.com

Wabash MPI

pg 28

260-563-1184

www.wabashmpi.com

Wirtgen America Inc.

pg 1, 21

615-501-0600

www.kleemann.info

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ADVERTISING INFORMATION

August 2016

PIT&QUARRY

79

A Look Back
P H O T O S F R O M P I T & Q UA R R Y S HI S T O R I C A L A R C H I V E

Fiat-Allis debuted its

FR15 front-end wheel loader
to the aggregates industry
during ConExpo 1981 in
Houston.

Contee Sand
& Gravel Co.,
based in Laurel, Md.,
used a washing and
classifying plant that
integrated an FLSmidth
Dorrco displacement
pump with a bowl
desiltor. The exact
date of the photo is
unknown.

Join the Historical Construction Equipment Association HCEA is a non-proit

organization dedicated to preserving the history of the construction, surface mining
and dredging equipment industries. U.S. and Canada memberships: $30.00 USD;
Others: $40.00 USD Contact: 419-352-5616, info@hcea.net

80

PIT&QUARRY

August 2016

pitandquarry.com