Professional Documents
Culture Documents
• Volume 2, Number 1
OVERVIEW
PAGES 18-19
CONEXPO-CON/AGG
MARCH 15-19
LAS VEGAS
TABLE OF CONTENTS COMPANY CONTACT INFORMATION
3 The word is “modular” 2704 W. LeFevre Road
Sterling IL 61081
800-545-2125
815-626-6374
6 Road trips Fax: 815-626-6430
8 The new math: 1 = 3 E-mail: sales@astecmobilescreens.com
www.astecmobilescreens.com
10 Non-stop screening
12 Powering up for peak performance 35 Elgin Street 800-567-8267
14 Booming construction in Boca Chica Thornbury, Ontario, Canada
NOH 2PO
519-599-2015
“MODULAR”
is nothing more than an expression. But
one aggregate-producing company in New
Jersey found itself in a situation that made
that saying almost true—except instead
of gold, the producer’s plant was sitting
IS THE WORD
on high-quality trap-rock.
Tilcon New York, Inc., is a division of
Oldcastle Materials. It is a full-service
company that provides aggregate, hot-mix
asphalt, recycling, soil remediation, high-
Tilcon partnered with Telsmith to provide way construction, and paving services to
city, county, state, and private customers
a turnkey solution for a new crushing plant in New York City, Long Island, the lower
Hudson Valley, central and northern New
at its Millington quarry in New Jersey Jersey, and eastern Pennsylvania.
In 1999, Tilcon acquired a 100-year-old
quarry near Millington, New Jersey. A
crushing-and-screening facility that had
been pieced together in the 1980s was
already in place and provided satisfactory
production rates for the quarry’s new
operators. But in 2003, Tilcon was draw-
ing close to exhausting all of the quarry’s
reserves—all of them, that is, except for
the substantial reserves that lay beneath
the existing aggregate-production facility.
And that’s where the expression “sitting
on a goldmine” came in: If Tilcon could
gain access to those reserves, they would
have enough rock to continue production
for another five to seven years. But the old
plant’s presence on top of those reserves
presented a substantial problem: Moving
a 25-year-old plant was not feasible; it
would have to be torn down.
According to John Brownell, the New
Jersey-area manager for Tilcon, there was
not a lot of choice. “We only had three
options. We could get a subcontractor in
there to take the rest of the rock out. Or
we could leave the old plant there and
just close the quarry down when we felt
we had gotten all the rock we could get.
Or we could purchase our own new plant.
“We looked at it and considered all of the
options,” he said. “And we found that with
a deal we could make with Telsmith, we
would be able to put in our own plant and
still be ahead of the game.”
In order for the purchase of a new plant
to be an affordable option, the facility
would need to be designed to meet a few
tight specifications:
❏ First, it had to be designed, delivered,
and erected very quickly.
❏ Second, it would need to be efficient
and economical to operate, requiring only
a small number of people to keep it run-
ning in a productive manner.
The Tilcon facility in its Millington quarry has been described as “clean, simple, and safe.” Perhaps the
most interesting feature of the plant is its modular design: It was preassembled in modules at the Telsmith
factory and the modules were then fitted together at the jobsite. In these photos, you can see some of the
worker-friendly features of the plant: extra clearance under the plant for cleanup; large service platforms;
and extra-wide walkways in critical areas. There are even wrap-around catwalks at the head pulleys to
allow maintenance crews to service the bearings from both sides of the conveyor.
The automated plant controls were supplied by the Controls Division of Astec Industries. Not only can the
operator keep track of exactly what is happening at the plant by viewing the on-screen displays, but the
control system can be quickly and easily serviced by Telsmith. The control system is linked by telephone
to Telsmith in Milwaukee and to Astec’s Controls Division in Chattanooga. Because of this linkage, if there
is ever a problem, it can be serviced remotely—any time of the day or night. The plant can actually be run
from either of the two remote locations.
It is likely that you have heard of—or at The answer to their problem came in the would have to move,” said Hindman. “We
least seen—some of the products that are form of commercial crushing equipment. realized that if we could utilize just one
made by the Dallas, Texas-based Pavestone They discovered that the right crusher could power unit to move the entire unit, that
Company. That’s because Pavestone is a reduce the concrete blocks back to rubble so would make it much more accessible.”
leading manufacturer of segmental concrete they could be reused—or recycled—back
into the manufacturing process. Hindman said that they went back to KPI
products, including paving stones and
and told them how they wanted their recy-
retaining-wall blocks. These products are Bobby Hindman, the vice president of cling program to work: One crushing unit
utilized by a number of markets, ranging transportation with Pavestone, said the would be moved back and forth between
from contractors and commercial builders company began its recycling program by two or three different facilities, possibly as
to do-it-yourself weekend warriors. acquiring a portable crushing unit from often as once every three months.
Pavestone Company operates 18 regional Kolberg-Pioneer, Inc. (KPI) and setting it
up at its facility in Dallas, Texas. They soon “Our core business is not crushing,” said
manufacturing facilities across the United
realized that the concept was going to work Hindman. “This was a substantial capital
States. Several years ago, the company
well. They hoped to use one machine to investment for a company of our size. So
took a look at its manufacturing process
service several different facilities in differ- we needed to share that investment with a
and identified an area that they thought
they could improve. With every batch of ent locations, but the original crushing couple of different facilities.
paving stones or retaining-wall blocks that unit they purchased did not prove to be as “That’s when KPI went back to the drawing
portable as they preferred.
was produced, a few would come out with board to see if they could come up with a
defects that made them inadequate for “The first piece of equipment that we got piece of crushing equipment that was
sale. Pavestone wanted a way to be able to was mobile, but there was a disadvantage contained in one unit. They actually did it.
reuse these otherwise wasted products. in that there were several pieces that we And, so far, it’s worked out very well.”
Pavestone Company, a nationwide manufacturer and marketer of segmental manufacturing process for new product. The company plans to eventually
concrete products, is using several KPI CS4233CC closed-circuit mobile have six of these units operating. Each of them will rotate between two or
crushing plants to recycle material from rejected paving stones back into the three different recycling locations across the country.
Lancaster Quality Stone bought a Fold ‘n Go portable screening plant in May of 2004. They keep the unit working long days.
For example: At one point, they stacked up 22,000 tons (20,000 tonnes) of sand in only seven days of production.
HERE ARE
THE MAIN ATTRACTIONS
AT THE GROUP’S BOOTH
aInformation Center
Astec Aggregate and Mining Group
bAstec Controls
Plant Automation Demonstration
eKPI Vanguard ®
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The Kodiak Series cone crushers from JCI are available in a variety
of field installations, including portable crushing plants like the one
shown here. This is a Kodiak K400 cone crushing plant.
The Telsmith 44SBS portable crushing plant is the only plant on the market
that lets you fold the feed conveyor out of the way to provide easy access
to the crusher. The drawings to the right show the conveyor folds back to
the rear of the unit for crusher maintenance—and for transport.
The new PDF 2628VM mobile screen plant from Astec Mobile Screens, Inc. that allows material to be fed directly to the screen while oversize material is
features a modified 6 x 18-ft. (1.8 x 5.5-m) double-deck PEP Vari-Vibe® returned to the track crusher. This unit is track-mounted for ease of movement
high-frequency screen. This versatile plant incorporates a direct-feed system on the jobsite. It fits on a lowboy for convenient transport from site to site.
The recirculating conveyor on the PDF 2618VM in this photo is shown feeding This photo shows a PDF 2618VM processing reclaimed asphalt pavement
the track crusher while the fines conveyor transfers material to a radial- (RAP) with direct feed from the track crusher. A heavy-duty receiving hopper
stacking conveyor. A wrap-around catwalk—which is standard equipment— allows for direct feed from multiple angles when in tight operating areas. The
provides easy access to the screen. The plant offers hydraulic screen-angle high-power diesel engine powers all screen functions, as well as three on-
adjustment for various application needs. board transfer conveyors and three off-plant radial-stacking conveyors.
Now you can get a screening plant with a detachable feed bin
One of the newest product innovations away from the bin (shown in the bottom
offered by Astec Mobile Screens is to be photo). The hopper for the conveyor
found in the Fold ‘n Go 2512KDT track- swings easily into place. When it is in
mounted screening plant. For the first this configuration, you can feed the unit
time, you can have a portable screening with a conveyor from multiple angles
plant that can be fed by either conveyors for small footprints.
or by loaders and excavators.
The Fold ‘n Go 2512KDT is equipped
The 2512KDT can be equipped with a with a 60-sq.-ft. (5.5-m2) Kolberg screen.
detachable feed bin and a hopper for
conveyor feed. Here’s how it works: According to the manufacturer, all of the
Fold ‘n Go plants are driven by high-
❏ When using it in a stand-alone oper- power diesel engines and have hydraulic
ation, you attach the feed bin and feed operating controls. There are wrap-
the system with a loader or excavator around catwalks on the units for easy
(shown in the top photo). access during operation. Each plant has
❏ When you need it for in-line process- an innovative folding mechanism for the
ing with a crusher, you just detach the on-board stacking conveyors that allows
feed bin and track the body of the unit total set-up in under 15 minutes. •AMJ•