Aggregates Manager July 2016

July 2016 | www.AggMan.com

Y o u r g u i d e t o p r o f i t a b l e p r o d u c t i o n Y o u r g u i d e t o p r o f i t a b l e p r o d u c t i o n

Buying or selling? Know what that site is worth

OSHA’s crystalline silica rule may foreshadow MSHA’s

14Buying or selling? Know what that site is worth26OSHA’s crystalline silica rule may foreshadow MSHA’sOSHA’s crystalline silica rule may

26OSHA’s crystalline silica rule may foreshadow MSHA’sOSHA’s crystalline silica rule may 40

Roger Group’s Rutherford Quarry is rocking and rolling

Embrace new ways to engage your community

Cover_AGRM0716.indd 1 6/14/16 8:43 AM

For proof, visit JohnDeere.com/Big

THIS IS HOW

DEERE DOES BIG.

Your ideas carry lots of weight with us. You’ll see them in our expanded line of heavy equipment. And in the customized support you get that’s so critical to high-production operations. Together, we’re building big things.

37783-1AM_8x10.75.indd 1 1/14/16 4:14 PM

Untitled-36 1 1/20/16 2:26 PM

COLUMNS & DEPARTMENTSFEATURE ARTICLES

21Community Relations 101 Want to build better relationships with

your neighbors and community leaders? Learn from the pros — your peers.

OPERATIONS ILLUSTRATED

Design a conveying system to provide the necessary service and eliminate problems from the outset and it will lead to ease of operation throughout its lifetime.

Terex Minerals Processing System’s new portable impactor and screen plant is a quick set-up, standalone, closed-circuit plant that can produce up to three products at one time.

14 Keep on Rockin’ It, Baby Busy doesn’t even begin to describe a typical day at Ruth-erford Quarry in southeastern Tennessee.

26 Buying and Selling: A Primer Learn the best method for determining what your quarry is worth.

30 Smooth Moves Investing in the proper design of an overland conveyor system can pay off with low-maintenance operation.

35 Digging Deep Excavator upgrades target effi cient power use and faster cycle times.

3 EditorialCommunity relation efforts are a worthwhile investment.

5 Data MiningThe latest fi nancial analysis of issues impacting in the industry and Aggregates Manager’s exclusive aggregates industry outlook.

8 State and Province NewsA roundup of the latest news in North America.

11 RollOutsKomatsu’s new WA500-8 wheel loader, and other new equipment for the aggregate market.

40 Rock LawFor a preview of MSHA’s respirable crystalline silica rule, take a look at OSHA’s fi nal rule.

42 Advertiser Index See who’s who and where to fi nd their products.

43 Classifi ed AdsAggregate industry classifi eds.

44 Carved in Stone Speleotherms, such as stalactites and stalagmites, con-tinue to grow in the Kartchner Caverns.

PAGE 30

PAGE 11

On Our Cover: Runners in a 6k race pass through Wendling Quarries, Inc.’s Bowser Quarry as part of the community fundraiser.Cover photo courtesy of Daryl Schepanski, Anamosa Journal Eureka.

JULY 2016 | VOLUME 21, NUMBER 7 TABLE OF CONTENTS

TOC_AGRM0716.indd 1 6/14/16 9:20 AM

Aggregate Drones

www.kespry.com/aggregatesAggregates | Construction | Insurance

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.

“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

Untitled-1 1 5/5/16 9:39 AM

AGGREGATES MANAGER / July 2016 3

July 2016 Vol. 21, No. 7

aggman.com /AggregatesManager

@AggMan_editor

EditorialEditor-in-Chief: Therese Dunphy

Editorial Director: Marcia Gruver Doyle

Online Editor: Wayne Grayson

[email protected]

Design & ProductionArt Director: Sandy Turner, Jr.

Production Designer: Timothy Smith

Advertising Production Manager: Linda Hapner [email protected]

Construction MediaVice President, Construction Media: Joe Donald

[email protected]

3200 Rice Mine Rd NETuscaloosa, AL 35406800-633-5953 randallreilly.com

CorporateChairman: Mike Reilly

President and CEO: Brent Reilly

Chief Operations Officer: Shane Elmore

Chief Financial Officer: Russell McEwen

Senior Vice President, Sales: Scott Miller

Senior Vice President, Editorial and Research: Linda Longton

Vice President of Events: Stacy McCants

Vice President, Audience Development: Prescott Shibles

Vice President, Digital Services: Nick Reid

Vice President, Marketing: Julie Arsenault

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

Aggregates ManagerTM magazine (ISSN 1552-3071) is published monthly by Randall-Reilly, LLC copyright 2016. Executive and Administrative offices, 3200 Rice Mine Rd. N.E., Tuscaloosa, AL 35406. Subscription rates: $24 annually, Non-domestic $125 annually. Single copies: $7. We assume no responsibility for the validity of claims of manufacturers in any advertisement or editorial product information or literature offered by them. Publisher reserves the right to refuse non-qualified subscriptions. Periodical circulation postage paid at Tuscaloosa, Alabama and additional entries. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by an information storage retrieval system, without written permission of the copyright owner. POSTMASTER: Send all UAA to CFS. (See DMM 507.1.5.2); NON-POSTAL AND MILITARY FACILITIES: send address corrections to Aggregates Manager, 3200 Rice Mine Road N.E., Tuscaloosa, AL 35406.

Community relation efforts are a worthwhile investment

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

EDITORIAL

Community relations — or lack thereof — can have a profound effect on your ability to succeed in the aggregates industry. As one operator told me, involvement with members of your local community goes a long way toward dispelling some less-than-favorable myths about our industry.

In fact, I believe these programs are so vital to the health of not only your op-eration, but to the industry as a whole, that they are the theme of this year’s photo contest. Boy, did we have some fabulous entries. One even includes wedding pic-tures taken in an aggregates operation! Eight entries are featured in this month’s issue, including on the cover and in Operations Illustrated (page 21). All entries are featured in a photo gallery at www.aggman.com. Be sure to check it out and pick up an idea or two for a new initiative within your company.

If you don’t already have established community relation programs in place, get started with these tips from your peers.

• It doesn’t have to be complicated to have a big impact. Simple steps can go a long way. For example, Roger Group Inc.’s Rutherford Quarry (page 14) sweeps around the scalehouse, plant entrance, and main roads. “We sweep every day to keep the road clean for our neighbors,” explains Travis McGaffee, area pro-duction manager.

• Make sure you have support from the top. “Support from the top is critical,” says John L. Kulper, safety and environmental director for Wendling Quarries. He notes that the Manatt family, which owns the company, understands that community relations are a huge part of the success of the industry.

• Be receptive to new opportunities. When members of the community ap-proached Aggregate Industries about riding its barge along the Mississippi River, what Patty Christensen, land and environment manager for the North Central Region, refers to as its “shining star” began. Say yes to your next good opportunity.

• Play into your passion. Everyone has personal interests; figure out how to in-corporate yours into a community relation activity. “When it comes to pushing the flag issues, I’m the spearhead for this company,” says Tom Dupuis, man-ager of the environment and engineering departments at Dolese Bros. Co., and a military veteran. He brought a program for a military spirit medal to the company’s community relations committee for sponsorship.

Investment in simple activities shows the community your business is an asset to be appreciated and supported. Get out there and put your best foot forward!

Editorial_AGRM0716.indd 3 6/13/16 2:24 PM

THELARGESTMININGSHOW

ONAND UNDER

EARTH

September 26–28, 2016Las Vegas, Nevada USA www.minexpo.comS P O N S O R E D B Y

EXPLORETHE WORLD

OF INDUSTRIAL

MINERALSIN ONE PLACE

Dig into Everything Related to Industrial Minerals

Discover new state-of-the-art technology • Test innovative equipment and services • Learn about new trends • Build a powerful network

www.facebook.com/minexpo @minexpo2016

Get everything you need to meet the world’s demand for industrial minerals and other mined products. MINExpo® 2016 delivers solutions — state-of-the-art products and services, innovative technologies and expert-led educational sessions. With more than 1,700 companies exhibiting, you’ll find products and services to improve safety, reduce production costs, manage risk and increase productivity. MINExpo is also the place to network and discuss your current and future company needs in the Exhibit Halls and education sessions.

Owners, senior management, operations and purchasing personnel from small and large companies around the globe come to MINExpo for the opportunity to discover cutting-edge products and learn from industry experts. It’s all at one place — MINExpo INTERNATIONAL® 2016.

An event this big won’t come around again until 2020. Be there.

MINExpo® is a selected participant in the U.S. Department of Commerce’s International Buyer Program (IBP). Through the IBP, U.S. Embassies and Consulates around the world will promote and recruit buyer delegations to the event. If you are interested in joining a U.S. Embassy led delegation, please contact the location nearest you (http://www.export.gov/worldwide_us/index.asp).The CS logo is a registered trademark of the U.S. Department of Commerce, used with permission.

REGISTER NOWat MINExpo.com

NMA-462_AggregatesManager_Minerals_FNL.indd 1 2/1/16 9:02 AM

Untitled-1 1 3/8/16 1:23 PM

q

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

Cemex, S.A.B. de C.V. CX $6.27 p $9.40 $3.50CRH plc CRG $29.75 p $31.55 $23.33Eagle Materials Inc. EXP $79.71 p $87.04 $45.03Granite Construction Inc. GVA $43.83 p $48.59 $28.45Heidelberg Cement AG HEI $81.67 q $90.24 $65.62LafargeHolcim Ltd. ADR HCMLY $8.62 q $15.07 $6.92Martin Marietta Materials, Inc. MLM $185.54 q $193.87 $108.31MDU Resources Group, Inc. MDU $23.12 p $23.65 $15.58Summit Materials SUM $20.47 p $28.56 $13.12United States Lime & Minerals, Inc. USLM $57.91 p $63.59 $45.56U.S. Concrete USCR $64.57 q $69.66 $36.37Vulcan Materials Co. VMC $115.49 q $120.40 $78.83

6/6/16 One Week One Year

United States $2.407 +0.025 p -0.477 q

East Coast $2.436 +0.031 p -0.544 q

New England $2.471 +0.029 p -0.605 q

Central Atlantic $2.522 +0.017 p -0.600 q

Lower Atlantic $2.363 +0.041 p -0.490 q

Midwest $2.361 +0.019 p -0.413 q

Gulf Coast $2.278 +0.024 p -0.505 q

Rocky Mountain $2.390 +0.015 p -0.435 q

West Coast $2.681 +0.031 p -0.440 q

West Coast less California $2.600 +0.035 p -0.401 q

California $2.746 +0.028 p -0.471 q

Sources: Wall Street Journal Market Watch. Currency conversion calculated on date of close 6/10/16.

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

Stock Report

U.S. On-Highway Diesel Fuel Prices

q

DATAMINING


DataMining_AIO_AM0716.indd 5 6/14/16 9:43 AM

In June, the Aggregates Industry Outlook (AIO) bounced 1.68 percent from May, to an overall score of 128.15. With 100 as a neutral rating, respondents continue to be consistently positive. Results were up across four of the six questions. Respondents were slightly more optimistic about the outlook for their own businesses (3.95 on a 5-point rating scale) than the industry as a whole (3.90). The most positive outlook responses (4.05) were for demand during the upcoming quarter, with results falling slightly with longer projection terms of six months (3.89) and 12 months (3.62).

We have a very positive forecast across all product lines for the next 12 months. Fuel costs and interest rates, even with moderate increases, should not have a signifi cant dampening effect.

— Rick Gerroll, Sales Executive, County Materials Corp.

If the rain slows down, the next six months will be better than last year.

— O.F. “Russ” Patterson, III, Chief Geologist, Patterson Exploration Services

The aggregate industry, as far as I can tell as a consultant to the industry, is relatively upbeat. Most of my clients have a positive outlook for the remaining 2016 season. Even frac sand exploration activities have picked up in some parts of the United States.

— Mark J. Zdunczyk, Consulting Geologist, Mark J. Zdunczyk, LLC

We’re noting market stagnation in Illinois and western Kentucky for public works projects, likely attributed to state budget impasses. Coupled with the downturn in the coal industry, with their direct and indirect de-mand for aggregate, we’re even seeing some price erosion. Middle Tennessee demand remains robust.

— Robert L. Stone, Manager of Sales and Compliance, Hunter Sand & Gravel, LLC

July

2015

August

2015

September

2015

October

2015

November

2015

December

2015

January

2016

February

2016

May

2016

June

2016

July

2016

March

2016

100

110

120

130

140

150

Aggregates Industry Outlook

129.05

130.00

128.42130.99

125.60 127.51

128.61

131.68

128.99

126.03

128.15

122.49

Editor’s note: To join our panel, email Editor-in-Chief Therese Dunphy at [email protected].

Comments:

6 AGGREGATES MANAGER / July 2016

DataMining_AIO_AM0716.indd 6 6/14/16 9:43 AM

CUTTING DOWN ON EXPLOSIVES

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.

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.

More and more quarries are turning to surface excavation machines as a solution. They have numerous advantages over drilling and blasting: • 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 par-ticle 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

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.

It can be equipped with an optional GPS for pre-cision 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 fl itch plan, which can be uploaded to a computer on the machine. Mining companies are benefi tting from these features. There’s 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. Another customer had a million tons of mine-able 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 per-mitted, but if not for the surface excavation ma-chine, 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 option-al traditional water spray bar or an optional dust-collection system that uses vacuum tech-nology 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 fi 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 set-ting 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.

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, THEY’RE LIKELY TO SAY TRANSPORTING THEIR PRODUCT. IT’S EXPENSIVE AND LOGISTICALLY CHALLENGING.

Visit Vermeer at Booth #8401 at MINExpo.

Untitled-4 1 4/13/16 8:58 AM

by Therese Dunphy | [email protected]


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

STATE & PROVINCE

NEWS

KENTUCKYDefendants in a homicide at a Clark County quarry will be tried separately, The Winchester Sun reports. Ray Combs was shot to death at the site on May 12, 2015, while his cousin, Billy Combs, was shot but survived. Kirk Garrett is charged with murder and attempted murder in the case. Don Attaway, Kristi Mattingly, and Chris Coleman are charged with complicity. An attorney for the Commonwealth made the motion to sever the cases, saying it would be easier to try the cases one at a time.

MASSACHUSETTSAggregate Industries presented a Fill Management Plan for its Saugus facility, and it was accepted by the Aggregate Post Closure Committee. Wicked Local reports that the plan and an updated Land Reclamation Agreement must be approved by the Board of Selectmen before the operator can obtain an administrative consent order for its reclamation plan from the state Department of Environmental Protection. Aggregate Industries’ plan calls for nearly 5 million cubic yards of material to be taken in over three phases to fill the 31.3-acre quarry. Consultants for the town and operator exchanged viewpoints over issues such as how to handle suspect soil, protocols for sharing test results, hours of work, and storm water management. The committee unanimously approved the plan, subject to a review of final edits by its consultant.

OHIOA trip to the Flint Ridge State Memorial was highlighted in the Columbia Daily Tribune. The 525-acre site includes a museum built around a restored prehistoric quarry and trails past various quarries dug by Native Americans. A small museum, built in 1933, tells how they mined flint and traded it for copper, seashells, food, hides, and pottery. An archaeologist is on hand to demonstrate how to make a spearhead using a stone tool and antelope horn.

MAINEReclamation work at a Rockland quarry has drawn the wrath of neighbors who say that leveling about 20 acres and removing trees has exposed them to more noise and headlights from local traffic. Water is also being pumped from the site. According to the Bangor Daily News, a local code enforcement officer said that the work does not violate any land-use ordinances and needs no permits from the state or city. Water is being pumped from the site so the operator can put rip rap along two sides of the quarry to prevent erosion. The intended use is for the property to be rented out as a beach and swimming facility.

NEW JERSEY

ILLINOIS

CONNECTICUT

Tilcon donated $10,000 to the town of Riverdale to help with the purchase of a new digital sign in front of the mu-nicipal building. According to NorthJersey.com, municipal officials have been looking for a more efficient alternative to a public information sign that requires manual changing of the letters. A new digital sign could cost up to $25,000 due to requirements for new footings. Mayor Paul Carelli announced the donation at a council meeting, noting that he appreciated the funds and the good relationship be-tween the borough and the operator.

Racers recently completed the Quarry Crusher Atlanta Run, part of the Quarry Crusher Run Series, held at Vulcan Material Co.’s Norcross Quarry. According to the Gwinnett Daily Post, the event offered two different races: a 7.4-mile run and a 3.7-mile trek. Runners went more than 600 feet deep into the quarry, including running along haul roads with grades that exceeded 10 percent for more than a mile. Participants described it as the toughest race in the state. A portion of the net proceeds will go to the Gwinnett County Public Schools Foundation, as well as a cluster of schools that includes Louise Radloff Middle School. Radloff was at the race and greeted runners as they crossed the finish line. Elementary stu-dents handed out water bottles and race medals at the finish line.

The Westerly Town Council unanimously voted to consider hir-ing an appraiser to provide an estimated value of the 108-acre property where the Comolli family’s Westerly Granite Co. Inc. owns a quarry property. The Westerly Sun reports that Coun-cilor Louis Sposato Jr. first suggested that the town explore the possibility of purchasing the property “as a possible resolution to the millstone that has hung around this council’s neck for the last five years.” The company has a new agreement with Cherenzia Excavation to mine the property and to bring the property into compliance with state environmental regulations. Councilor Christopher Duhamel noted the appraisal would be needed to buy the property or take it through eminent domain. A principal in Westerly Granite said the family would consider selling the land to the town if a reasonable offer was made.

PENNSYLVANIASolebury supervisors announced that the Pennsylvania Envi-ronmental Hearing Board upheld a water-pumping limit im-posed by the state’s Department of Environmental Protection on New Hope Crushed Stone and Lime. According to The In-telligencer, the quarry had requested a temporary stay on the 500,000-gallon-per-day limit, but the request was denied by an Environmental Hearing Board judge, who said the agency had the discretion to impose the limits.

TENNESSEEA fire truck was sunk at the Gray Quarry, WJHL reports. A group of certified divers lowered the antique truck about 60 feet into the water, where it joins a school bus and several statues. The quarry owners let scuba divers train and ex-plore the water. They told the news outlet the truck adds a new dimension of excitement for recreational divers.

StateNews_AGRM0716.indd 8 6/14/16 10:17 AM

VERMONTAccording to the Burlington Free Press, granite used for a mock gravestone with Donald Trump’s name and the inscription, “Mak-ing America Hate Again,” comes from the Rock of Ages quarry in Barre. The 420-pound marker was featured in the New York Times and other media outlets when it turned up anonymously and un-announced in Central Park at the end of March.

WISCONSINDane County zoning officials have delayed a revocation hearing for a conditional use permit to give a quarry operator an opportunity to come into compliance, the Wisconsin State Journal reports. The action follows complaints about the quarry’s hours of operation made after trucks were seen entering and leaving the site one night in April. Upon inspection, the quarry was found to be in violation of eight of 18 permit conditions, including failure to im-plement proper erosion control, operating on 12 more acres than allowed in the permit, failing to install safety fences along the quarry perimeter, excavating in areas not identified on its reclama-tion plan, failing to provide blasting information for more than a year, and operating outside specified hours.

TEXAS

TENNESSEE

APAC Texas LLC’s request to increase annual production at its quarry near Marble Falls is being met with resistance from some area residents, DailyTrib.com reports. The plant currently produces 7.7 million tons per year and is seeking an amendment to its air quality permit to increase production to 12 million tons per year. Neighbors say they are concerned about the increase in particulate matter that would accompany higher tonnage levels. A group has banded together to form the Texas Hill Country Property Rights Coalition and has hired an environmental attorney to help them with their opposition to the expansion.

The Nashville International Airport is using an abandoned quarry to cut its cooling costs in half. According to WKRN, the airport is saving $430,000 per year. The geothermal lake cool-ing system pumps hot water from the terminal’s cooling plant to stainless-steel heat exchangers submerged in the reservoir. Water is cooled from 79 to about 63 degrees. The airport au-thority’s vice president of strategic planning and sustainability says the system is the largest of its kind in North America.


AIM FOR UPTIME The new RigScan audit program uses cutting edge tools to increase your safety and equipment availability. We’ll identify rig problems before they sideline production.

800-732-6762www.atlascopco.us

StateNews_AGRM0716.indd 9 6/15/16 8:24 AM

Get the the most current information with the2016 Aggregates Industry Atlas and the Atlas on CD.While the printed version of the Aggregates Manager 2016 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more.

� e Atlas on CD contains compete information on nearly 11,000 operations in the United States in a data � le as well as the entire 2016 Aggregates Industry Atlas in pdf format.

Order additional copies of the Aggregates Manager 2016 Aggregates Industry Atlas on CD or the printed version of the Atlas today!

To order, visit AggManAtlas.com or call 224-723-5372.

Purchase in Print

$50/1-5 copies$45/6-20 copies$35/21-49 copies

$20/50 copies or morePlus $4.50/Atlas shipping and $8

handling fee

Order on CD

$250 Plus shipping and handling: $8.70/CD

Download Online

$200(online download only)

June 2016 | www.AggMan.com


We review equipment trends by the numbers

USGS releases its list of top crushed stone producers

11We review equipment trends by the numbers19USGS releases its list of top crushed stone producers

191919191929

Are your equipment acquisitions keeping pace?

2016AGGREGATES

INDUSTRYATLAS

YOUR GUIDE TO AGGREGATESOPERATIONS, LOCATIONS & OWNERSHIP

20162016201620162016201620162016AGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATES

INDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYATLASATLASATLASATLASATLASATLASATLASATLAS

AGGREGATESINDUSTRYATLAS


2016201620162016201620162016AGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATES

INDUSTRYINDUSTRYINDUSTRYINDUSTRYATLASATLASATLASATLAS


2016201620162016201620162016AGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATES

INDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYATLASATLASATLASATLAS

Want to know what 10,885 U.S.

operations are up to?

AM2016_HouseAd_Atlas.indd 7 5/19/16 11:09 AM


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

ROLLOUTS Your complete guide to new and updated equipment and supplies in the aggregates industry.

Upgrades increase productivity of heritage crushersMetso launches a new generation of upgrades to increase the productivity of its old crusher models, while reducing maintenance costs and bringing equipment into line with enhanced safety practices. The upgrades include:

• Symons cone crushers — advanced bowl adjustment control, hydraulic motor bowl adjustment system, and hydraulic tramp release and clearing system.

• Nordberg HP800 and MP cone crushers — jack screw locking nut, top-mount clamp cylinder, heavy-duty head, MP1250 retrofit kit, and head maintenance stand.

• Superior gyratory crushers — super spider, arched spider, shimmed spider bushing, hydraulic shell separators, dual-balance cylinder.

Metso says users who implement the upgrades will see improved productivity through increased product rate capability, easier setting adjustments, better crusher reliability, and reduced bridging for over-sized material.Metso | www.metso.com

Tier 4 loader improves efficiency and productivityKomatsu America Corp. introduces the new WA500-8 Wheel Loader equipped with a 357-horsepower, Tier 4 Final engine. The standard bucket, with an increased capac-ity of 7.6 cubic yards, fills easier and retains material better, resulting in better efficiency and productivity gains of up to 10 percent. Komatsu’s SmartLoader Logic, combined with the lockup torque converter that activates in second, third, and fourth gear, provides opti-mal engine torque for improved acceleration, hill-climbing ability, a higher top speed, and fuel savings, while a new air-suspension, high-back heated seat softens machine vibration for operator comfort. The Komtrax telematics system provides key machine metrics, including KDPF status and diesel exhaust fluid (DEF)-level data, fuel consumption, and performance information collected and sorted by Operator ID.Komatsu America Corp. | www.komatsuamerica.com

New generation of bucket crusher attachments offers higher outputAtlas Copco Construction Equipment introduces its new genera-tion of bucket crusher attachments with higher output and greater reliability than previous models. The new bucket crushers — the BC 2500 and BC 3700 — are said to process about 80 percent more material due to their hydraulic drive system. The bucket crushers fit 49,000- to 85,200-pound carriers. The attachments feature components that allow carrier operators to crush up to 110 tons per hour of material; a drive system of two hydraulic motors and a timing belt that generates high torque needed to power the crushing jaw; and a reverse function that easily removes any blockage by pushing material back through the inlet.Atlas Copco Construction Co. | www.atlascopco.us

Rollouts_AGRM0716.indd 11 6/14/16 9:10 AM

ROLLOUTS


Three new scraper tires round out size offerings The Goodyear Tire & Rubber Co. rolls out three scraper tires for construction and mining/earthmover applications, the Goodyear RT-3A (E-3), RT-3A+ (E-3+), and RL-3J (E-3). The RT-3A (E-3) and RT-3A+ (E-3+) are designed to offer enhanced traction in all underfoot conditions. They feature cool-running, radial construction; an aggressive tread pattern; a unique, geometric lug pattern for long tread life, even pressure distribution and enhanced mobility; buttressed, self-cleaning lugs to help protect against sidewall cutting; and more. The RT-3A (E-3) is available in size 33.25R29, while the RT-3A+ (E-3+) is available in size 40.5/75R39. The RL-3J (E-3) is for high-speed use on moderate-to-severe underfoot conditions. It features a zig-zag, centerline groove to offer superior lateral traction in high-torque ap-plications; tapered, self-cleaning shoulder lugs for excellent forward traction; a high-tensile steel belt package for enhanced impact resistance; and more. The RL-3J (E-3) is available in size 37.25R35.Goodyear Tire & Rubber Co. | www. goodyear.com

New scrapers leverage automation for higher performanceCaterpillar says its new 630K Series wheel trac-tor-scrapers — 631K and 637K — were designed to replace the 630G Series. The redesign includes an Advanced Cushion Hitch that uses new soft-ware to dampen end-of-stroke movement of the load cylinder for a smoother ride, hydraulic-system refinement that simplifies the bowl quick-drop function, and draft-arm-overflow guards that divert material away from the sides of the bowl.

Plus, a new Auto-Stall system quickly brings the transmission to operating temperature for faster transitions from torque-converter drive. The open-bowl 631K and open-bowl twin-engine 637K offer a payload capacity of 34 cubic yards. The 637K features a Fuel Economy Mode that adjusts shift points and power distribution for optimum fuel economy. The 630K Series includes the following standard features: Engine over-speed protection, tire spin reduction, differential-lock-engagement protection, high-pressure steering, machine-speed limiter, ground-speed control, sequence assist, load assist, payload estimator, and Cat grade control.Caterpillar | www.cat.com

Standalone plant can produce three products Terex Minerals Processing Systems says its new CRH1313R portable impactor and screen plant offers versatility to handle rock crushing, concrete recycling, and asphalt recycling. The highly mobile plant is said to be a complete stand-alone, closed-circuit unit capable of producing three products. It features a high-production Cedarapids IP1313 impactor with a 3- or 4-bar 50-inch rotor powered by a Tier 4, 450-horsepower diesel en-

gine, direct drive to crusher, and 200-horsepower generator. A heavy-duty undercrusher pan feeder protects the conveyor belt from damage by absorbing the high-velocity discharge from the crusher. The 5-foot by 16-foot, patent-pending, dual-slope two-deck screen handles heavier loads for more capacity. Both screen deck products can be returned to the crusher for maximum production. A 48-inch by 16-foot high-stroke Cedarapids “Advantage” feeder with 60-inch grizzly bar or optional stepped-tine-style grizzly section feeds the impactor. The plant is said to be simple to operate, quick to set up, and easy to transportTerex Minerals Processing Systems | www.terexmps.com

Rollouts_AGRM0716.indd 12 6/14/16 9:14 AM

*Onsite registration is $10

Landstar Health & Wellness Pavilion

Being healthy is important to drivers. A clean bill of health can be the deciding factor in keeping jobs, maintaining a high quality of life and ensuring that your family has peace of mind. Landstar and GATS want to do their part to help the industry thrive and enjoy great health. After all, we’re family.

#GATS #TruckShow @TruckShow GreatAmericanTruckingShow

Thursday, August 25Friday, August 26

Saturday, August 272016

Kay Bailey Hutchison Convention Center Dallas

FREE ADMISSION ONLY WHEN YOU PRE-REGISTER!*Register at GATSonline.com or call 888-670-7549.

SP12790_GATS2016_HouseAd-July-STANDARD.indd 1 5/17/16 3:42 PMGATS_AGRM0716_PG.indd 1 6/10/16 9:49 AM

by Kerry Clines | Contributing Editor

PLANT PROFILE


Keep on Rockin’ It, Baby

Some of you may have at-tended AGG1 in Nashville a few months ago, and you may have made it out to

Rogers Group Inc.’s Rutherford Quarry for the NSSGA-sponsored tour of that operation. If you didn’t go on the tour, you really missed out. This quarry is large, extremely busy, and quite strikingly beautiful from the front

entrance to the bottom of the pit.“We try to keep things nice,” says

Travis McGaffee, area production man-ager for Rutherford Quarry and several other quarries in southeast Tennessee. “We keep things in good repair. When you drive into our operation, it looks clean and nice. I think we’ve got one of the nicest looking pits. I’m proud to show people this quarry.”

The limestone quarry was opened near Murfreesboro, Tenn., in 1985 by Stoneman, after which it passed through Lehigh Hanson’s hands and was eventually acquired by Rogers Group in 2000. Since then, it has become one of the top aggregate producers in the area, mainly because of all the growth going on in that part of the state.

Busy doesn’t even begin to describe a typical day at Rutherford Quarry in southeastern Tennessee.

PlantProfile_AGRM0716.indd 14 6/14/16 9:03 AM


“A lot of the area is farmland, but Murfreesboro is growing so much right now, the amount of residen-tial homes and multi-family homes being built is unreal,” McGaffee says. “We’ve taken off here because of all that growth. There hasn’t been a whole lot of roadwork going on be-cause of the lack of federal funding. If there was a whole lot of roadwork going on, it would be unbelievable how busy we would be.”

Daily operationsRutherford is a pretty typical aggre-gate operation in most ways — it makes big rocks into little rocks. That starts with drilling and blast-ing, which is contracted out. A local contractor does all the drilling, and Austin Powder comes in to design the shot, lay it out, load the shot, and shoot it.

Once the blasting is done, a pit loader loads the material into haul

trucks, which carry it to the primary plant located in the pit. After the rock goes through the primary crusher, it travels up a 300-foot conveyor to a service pile, or live storage surge pile, that can hold as much as 12,000 tons of material. A tunnel underneath the storage pile feeds material onto a conveyor that carries it to the second-ary plant with another crusher and an enclosed screen tower where three different products are pulled out.

Processing activity at Rogers Group Inc.’s Rutherford Quarry begins in the pit, which is quite beautiful.

Pho

to c

red

it: R

oger

s G

roup

, Inc

.



PLANT PROFILE

One of those three products is crusher run, which is conveyed to a stockpile. A tunnel running beneath that stockpile feeds material into the pug mill system, which is fully automated. The pug mill system includes a conveyor and a scale underneath two material bins — one for dry crusher run and one for pug, crusher run mixed with water. The truck driver simply pulls up to the sign with instruc-tions. He pushes a button to select the type of material he wants and the weight his truck can hold. Then, he pulls forward onto the scale under the bin holding the material he wants. The system loads the truck with material and automatical-ly cuts off when the truck reaches the proper weight. If the truck has an RFID tag, the driver doesn’t have to go to the scalehouse to get a ticket, he can pick it up from a kiosk as he exits the pug mill.

Material not pulled out at the second-ary plant is sent on to the tertiary plant where one dry product is taken out. The remaining material is sized, crushed, and sent to a wash plant where three differ-ent wash products are made for ready-mix concrete and asphalt customers.

The quarry operates two full-time scales at the scalehouse that are open from 6:30 a.m. to 5 p.m. Monday through Friday and from 6:30 a.m. to 3 p.m. on Saturday. Between the scales at the scalehouse and the scale at the pug mill, the operation is in constant motion with trucks coming and going.

Four months ago, the plant was fully automated so that one operator in the primary plant control tower in the pit can monitor and run the entire operation, including the two cone crushers in the secondary and tertiary plants, all the conveyors, and the surge pile. The opera-tor can tilt, pan, and zoom the cameras to see different locations in the plant. Two monitors located in the control tower al-low the operator to see the primary plant on one monitor and the secondary and tertiary plants on the other.

Part of the communityMany of the quarry employees live in Blackman, the small community where the quarry is located, so they care about

what their neighbors think of the op-eration. They work hard at keeping the quarry out of sight, but work just as hard at keeping it in the community’s mind, but in a positive way.

“I live in this community, in a neigh-borhood two miles down the hill, and my kids go to school here,” McGaffee says. “We defi nitely want to be a good neighbor. We’re involved in Blackman

and Stewart Creek schools and have built a good relationship with the school administrations. We do everything from teacher luncheons on teacher work days to working at fairs, such as book fairs at the schools or community fairs, to donat-ing to sports programs. We do a reading literacy program and donate books and computers to the schools. It gives us a face in the community.”

After material is crushed at the primary plant in the pit, it is carried via conveyor to a live storage surge pile on top. A guard was built beneath the conveyor where it crosses the quarry road to prevent material spillage from striking vehicles.

Material runs through an enclosed screen tower at the secondary plant, where it is separated into three different products.


CELEBRATING 20 YEARS OF

Aggregates Manager celebrates two decades of amplifying the successes of every strata of the aggregates industry from crushed stone, sand & gravel operators to equipment manufacturers and dealers, and providers of services and supplies. Aggregates Manager has provided knowledgable support to the aggregates industry through key editorial coverage, timely expert analysis, and fostering a constantly active online community. We, at Aggregates Manager, look forward to delivering the vital information that streamlines your operations in 2016 and beyond.

AggMan.com AggregatesManager @AggregatesMgr

KNOWLEDGE THAT RUNS DEEP

Untitled-32 1 2/17/16 1:33 PM


PLANT PROFILE

But McGaffee adds that it isn’t just about donating money or receiving awards, it’s about getting involved and having a positive impact on the people in the community.

A busy quarry means there’s a lot of truck traffi c through the neighborhood. Quarry personnel try to minimize the im-pact of that traffi c on the community by sweeping around the scalehouse and the plant entrance, as well as up and down the main road leading in both directions from the entrance to keep the road clear of any rock that might spill out of the

trucks leaving the plant.“We sweep every day to keep the

roads clean for our neighbors,” McGaf-fee explains. “We don’t want to be a nuisance. If the neighbors have any concerns, I want them to come to me and tell me what they are so I can address them and try to make things better rather than have them sit back and let it build until it becomes a big problem. Generally, when you address issues up front and people see that you’re being proactive and trying to remedy any problems they have, they’re much more receptive to you

as a company and as a person.”As they leave, customer trucks go

through a wheel wash, which cleans their tires and helps minimize the dust being tracked out of the quarry. A road-capable water truck not only reduc-es dust levels down in the plant, it can travel out onto the roads in the neighbor-hood to clean the roads when necessary.

One of the most popular events that the quarry hosts is its annual Barbecue in the Pit. Between 250 and 300 people, including the sheriff of Rutherford Coun-ty, school principals, local legislators, local public works people, and people from the neighborhood, are invited to attend the event. A large tent is set up in the bottom of the pit where everybody is served barbecue, and gifts and prizes are handed out. McGaffee says it’s a big, nice event, and people look forward to coming back every year.

The 5S programRogers Group has an internal award program called the 5S program, which includes Sustain, Standardize, Sort, Straighten, and Shine, but a sixth S has been added for Safety. To apply for the award, every operation can submit up to three different projects that they’ve done each year. Out of the submissions, the judges pick out the most creative projects and the projects that have had the most signifi cant impact.

“I’m very competitive and so are most of my guys,” McGaffee says. “The 5S program has really brought out our pride and competitive spirit, because every-body in the other areas competes with us. Rutherford won the fi rst two years of competition, so everybody wants to beat us. The competition is good, and it instills a sense of pride in the employees.”

One of the projects that won an award for Rutherford Quarry was the way it organized its shop. “We have conveyor, screen, and crusher V-belts hanging on the walls in the shop. We put signs above each of them that shows its size and what equipment it fi ts,” McGaffee explains. “There’s a labeled shelf for everything in the shop to keep it organized. So whether a guy has been here fi ve years or fi ve weeks, he can go to the shop and quickly

The pug mill system allows drivers to pull up, push a button to select the product and weight they want, pull under the correct bin, and push another button to begin loading. The scale beneath the bins automatically closes the bin when the desired weight is reached.


52


and easily fi nd what he needs. We do that to be more effi cient, but the key is not just to win the awards, it’s to maintain that organization going forward.”

One thing that was done recently pertains to hazard training for customers. At most sites, offi ce personnel go over a hazard recognition form with anyone who comes on site. Rutherford Quarry has implemented a kiosk, an area in the scalehouse with a computer, where those entering the site can watch site-specifi c hazard training videos and then print off a form with their signature showing they’ve completed the training.

“That was a 5S submittal when safety fi rst became a part of the program,” McGaffee notes. “That idea came out of Whites Creek Quarry. Brian Dillard came up with that, and after he did it, I did it. Now, kiosks are being put in at every site.”

Safety meetings take place every morning to get all the employees focused on safety before they go to work. A range of topics are discussed, includ-ing anything related to Rogers Group’s company-wide near-miss program. If an incident occurs that didn’t result in an injury, but could have, each site is responsible for writing up a near-miss report that says exactly what happened, what the contributing factors were, and what preventive measures going forward would help prevent it from happening.

“We don’t pattern our safety pro-gram after MSHA, we go above and beyond that,” McGaffee explains. “Our main goal is to not get people hurt. We have safety committees made up of hourly people who go to other sites to do inspections. They see things that people who are there every day might not see. They take pictures and do a write up at the end of the day, and then they present it to the plant manager. He goes over it with them and sets up dates to fi x anything that’s found. It’s just an extra thing we do internally to try to head off injuries and incidents. It’s a good thing.”

Looking to the futureThe primary, secondary, and pug mill were built new in 2007, but the tertiary plant has been in operation since the

plant was built in the 1980s. The tertiary plant was slated to be replaced in 2008, but the economy went south, so the proj-ect was tabled…until recently. In April, the project was being discussed and considered once again.

“Maybe by winter, we’ll have a set plan, and we can start requesting early capital for it next year,” McGaffee says. “It’ll probably be a six- to eight-month project. I fi gure we’ll probably be fi nished with the project by the fall of next year,

if it gets approved through corporate. I’ve got it laid out so we’ll be able to continue running the old plant while we’re build-ing the new one, and we won’t have to shut the old one down until we get ready to tie the new one in, which shouldn’t be more than a couple week process.

“That’s kind of what we see in the future. The market will support it, and the reserves are defi nitely here to support it. The reserves will be here long after we’re gone.” AM

At the tertiary plant, one dry product is taken out, then the rest of the material is sized, crushed, and sent to a wash plant to make wash products for ready-mix asphalt customers.

A tunnel running underneath the live storage surge pile feeds material onto a conveyor that carries it to the secondary plant, where it is processed through another crusher and an enclosed screen tower.


March 7–11, 2017 | Las Vegas Convention Center | Las Vegas, USA

IF IT’S NEW, IT’S HERE.Get the special $149 rate (and save up to $100)

by registering early at www.conexpoconagg.com.

Register today to get the ultimate view of where construction is going.

IMAGINE WHAT’S NEXT.Imagine less downtime. Imagine being more efficient. Imagine seeing what’s next from over 2,500 exhibitors spread out over 2,500,000 square feet.

Imagination becomes reality in Las Vegas on March 7–11, 2017—and if you make your reservation right now, you can ensure your spot at this huge event... and save!

Co-located with ®

Untitled-5 1 6/6/16 2:05 PM

School visits are a staple for many operators, including Walker Brothers Quarries.

Students, and their teachers and parents, gain an understanding and appreciation for the industry

Be sure to have visitors wear closed toed shoes, hard hats, and safety vests.

Simulators also provide a great activity for students — and may attract future employees.

Schedule a memorable experience, such as a blast.

Community Relations 101

PULL-OUT GUIDEBy Therese Dunphy, Editor-in-Chief

July 2016

OpsIllustrated_AGRM0716.indd 21 6/13/16 2:28 PM

Build better relationshipswith your neighbors and

community leaders

OPERATIONS ILLUSTRATED Community Relations 101

Logically, most operators understand the importance of having a good com-munity relations. In the

day-to-day environment of running a business, however, not all are willing to invest time into nurturing those relationships. Big mistake.

“A strong relationship with our neighbors and community leaders is such an integral component to the success of our business,” says Patty Christensen, land and environment manager for Aggregate Industries – North Central Region. Growing up, her father worked for an aggregates business that was later acquired by Aggregate Industries, and there was a very different atmosphere than the strong relationship she enjoys with neighbors today. “Things were always contentious between the residents and the mining company,” she recalls. But with some fairly simple initiatives to improve com-munication between operators and neighbors, she found a much better dynamic when she joined Aggregate Industries in 2000. “What a differ-ence,” she says. “I was amazed.”

Some community relations pro-grams can be quite elaborate, but small, simple outreach efforts can go a long way. When Tom Dupuis no-ticed the crowds that gathered near the Dolese Bros. Co.’s headquarters in Oklahoma City for a Pearl Harbor Day memorial, he suggested the company sponsor a hospitality tent with warm beverages and sweets. That simple task led to a series of

additional community relation initia-tives with local veterans, who greatly appreciate the support. “It’s been a good marriage for us,” Dupuis says.

While Wendling Quarries has a splashy community event with the 6k race that runs through its proper-ty, it continues smaller scale initia-tives such as school tours at its site. “We have folks whose yards back up to the quarry. For us to maintain a relationship, not only with our close neighbors, but the town itself, is very important to us,” says John L. Kulper, safety and environmental director for Wendling Quarries, Inc. “We just like the community involve-ment. It’s a chance for us to work with a close-knit, organized, and truly nice community.”

Establishing good relationships with the surrounding community is not only the right thing to do, it’s also the smart thing to do.

“We had a variance hearing in the city of Minneapolis in September 2015,” Christensen says. “One of the board members stated, ‘I just want the board to know that this company has been a great corporate citizen in our community. They have been involved with the National Park Service for years. They are a great example of how a business and the community can work together.’

“The value of hearing that state-ment from a regulatory offi cial says it all for us,” she adds. “It just brings home to us how important our community relations efforts are with these municipalities.”

AGGREGATES MANAGER

Aggregate Industries–North Central Region has a long-standing policy of actively participating in the communities in which it conducts business. It says the open-door policy has led to better communication, bet-ter understanding in both directions, and a signifi cant level of trust with neighbors and community leaders. Each year, every close neighbor and local offi cial from the communities in the greater Minneapolis-St. Paul Metropolitan Area are invited to attend its “Neighbor-hood Barge Ride.” Guests enjoy a unique cruise on the Mississippi River on a “working” barge and have the opportunity to meet employees and learn fi rsthand about the aggregates and ready-mix industries.

Lehigh Hanson’s Gainesville Quarry’s historic lake house and 9-acre man-made lake draw hundreds of visitors each year. The lake house was founded in1971 and has hosted hundreds of events involving thousands of community members over the years. Hanson shares the venue free of charge to ensure that fi nancial con-siderations will not restrict its use. Earlier this year, a wedding took place at the site. More than 150 people enjoyed the scenic setting of a tranquil lake at an op-erating quarry. The venue made for some dramatic and unique wedding photos.

Create a recreation area

Involve community leaders

1

4

2

5


OPERATIONS ILLUSTRATED OUREXPERTS

Community Relations 101

July 2016

John L. Kulper is the safety and environ-mental director for Wendling Quarries, Inc. He has served in that role for 12 years and oversees environmental training and compli-ance, as well as safety training and compli-ance. He previously served as an environ-mental consultant.

Tom Dupuis is the manager of the environ-mental and engineering departments at Dolese Bros. Co. Prior to joining the company in 1988, he spent 11 years in the U.S. Air Force. Dupuis is a passionate advocate for all issues regarding the U.S. military.

Patty Christensen is the land and envi-ronment manager for Aggregate Industries – North Central Region. She joined the company in 2000 and began in the accounting depart-ment before moving into the land and en-vironment department. She has an associate’s degree in paralegal.

Each year, Dufferin Aggregates, a division of CRH, plants trees at its Acton Quarry. Earlier this year, 2,600 were planted. Through the years, a total of 65,000 trees have been planted at the site. Volunteers from Scouts Canada North Halton District, neighbors, and Dufferin Aggregates and CRH Canada employees and family members make the initiative a successful one. As part of the day, the site organizes a complimentary barbecue lunch for all the volunteers. Feedback from key stakeholders is very positive.

Aggregate Industries US’ Littleton Quarry crew in the Northeast Region donated a day to clearing brush and grading observation areas to prepare the Rescue Dog site for two planned training events. Last year, three dogs were certifi ed for live fi nd by the International Rescue Dog Organization, which is affi liated with the United Nations and coordinates all rescue dog de-ployments to disasters such as the Nepal earthquake. This year, 13 dogs from nine states and Canada were trained to fi nd human remains. The participants were very excited to work in a new location and praised the site as one of the best in the country.

The goal of Rogers Group Inc.’s annual United Way em-ployee campaign is to encourage employees to fi nan-cially support the United Way of Metropolitan Nashville, but it does so in a way that shows the employees where their money goes and helps the local organization with current projects. Every year, corporate employees spend an average of 200 work-hours on various projects de-termined by that year’s campaign committee. Recent projects have included landscaping at a school, painting at a women’s shelter, and sorting donated items at a food bank. Each year, the amount donated by Rogers Group employees increases.

Dolese Bros. Co. helps to fund a program that recognizes the commitment made by young men and women who plan to enter the U.S. Armed Forces after high school graduation. Veteran Bob Lambert (left) is the founder and chairman of Oklahoma’s Military Spirit Medal. Students who apply to the program and write an essay are given the medal during senior recognition ceremonies at their high schools. Lambert says the medal is a way to “thank them from day one, rather than wait to see if they return home to be appreciated.”

Lehigh Hanson’s Gainesville Quarry’s historic lake house and 9-acre man-made lake draw hundreds of visitors each year. The lake house was founded in1971 and has hosted hundreds of events involving thousands of community members over the years. Hanson shares the venue free of charge to ensure that fi nancial con-siderations will not restrict its use. Earlier this year, a wedding took place at the site. More than 150 people enjoyed the scenic setting of a tranquil lake at an op-erating quarry. The venue made for some dramatic and unique wedding photos.

Create a recreation area

Involve community leaders

Support a well-known cause

Focus on sustainability efforts

Sponsor a patriotic program

Provide a unique service

2

5

3

6


AGGREGATES MANAGER

Voices of Experience John Kulper Tom Dupuis

Patty Christensen

W endling Quarries, Inc.’s Bowser Quarry, in Springville, Iowa, is gearing up for the

4th Annual Springville Extreme Quarry Run. “A lot of the towns in our area have their fun days where it’s a community get-together,” says John L. Kulper, safety and environmental director for Wendling Quarries. “Typically, it’s just a few carni-val rides and lots of fatty food.”

Four years ago, that changed when a group of event organizers who are avid runners approached Wendling Quar-ries Inc. about allowing a race to pass through the operation. The quarry has north and south locations that are split by Highway 151 — with a tunnel running between the two. “The tunnel at the Bowser Quarry draws a lot of interest,” he says.

Kulper and Marc Whitman, quarry development manager, met with the committee to discuss its involvement and determine if it was a good fit. Once their concerns were addressed, they were happy to participate in the event.

Each year, the race has drawn between 180 and 280 participants and has raised thousands of dollars for local charities such as the Springville Community Schools Backpack Program, which funds meals for kids in need, and the City of Springville’s Community Trails Project, which is building a walking and bike trail.

Its involvement does require some work at the quarry. “The runners like to see the equipment, so we set up the trail so they can get a good look at the quarry and its different features,” Kulper explains. Another important prepara-tion is to ensure that the roads are well groomed so there are no large rocks or divots in the roadway that could be haz-ards to the runners. Community volun-teers are spread throughout the course on race day to ensure runners participate in a safe manner, while enjoying the scenery in the unique venue.

“It’s been a really good collaboration between us,” Kulper says.

T om Dupuis, manager of the environmental and engineering departments at Dolese Bros. Co., says his heart is with the military. “I am from a big military family,” he explains, noting numerous family members have served. “I was in a

combat construction outfit overseas. When I started working for Dolese in August 1988, it didn’t take long to realize the company was a good fit for me.”

His community relation efforts reflect that bond. For example, the company sponsored a hospitality tent for those who attend a Pearl Harbor Day ceremony. The tribute is held near Dolese’s Oklahoma City headquarters where the anchor from the USS Oklahoma, a battleship sunk during the attack on Pearl Harbor, is on display.

There, he met Bob Lambert, founder and chairman of Oklahoma’s Military Spirit Medal. The medals are awarded to young people who have committed to military service after graduation. To receive the medal, the recipient must have completed high school, enlist-ed in any branch of the U.S. Armed Forces, submitted an application, written a 100-word essay entitled, “I choose to serve in the U.S. military because…,” and plan to attend the school’s senior awards ceremony where the medal is presented. The program has grown from two medals being awarded in 2010 to 122 medals in 2015.

Since funding is a challenge, Dupuis took the program to Dolese’s community relations committee, which contributed $1,000. While the program is currently involved with 30 high schools in the greater Oklahoma City area, the group would like to grow it across the state and, eventually, the nation.

“I like the whole concept of recognizing them from day one for having the ‘Spirit’ to commit to military service,” Dupuis says. “One of Mr. Dolese’s mottos was ‘Fly the flag. He was a true American, and there is nothing better than working for a company that has the same beliefs and values.”

W hen a group at the Weisman Art Museum at the University of Minnesota spot-ted a group of people on a tugboat and barge, one of Aggregate Industries – North Central Region’s most popular community relation events was born.

According to Patty Christensen, land and environment manager for the region, the group’s inquiry sparked what is now an annual event. Close neighbors, as well as ap-pointed and elected officials are invited. “It’s as popular now as when it commenced in 2000,” she says.

Preparations for the barge ride run like clockwork, despite having 200 to 225 guests. Several days prior to the event, the barge is prepped, and welders install anchors for the tents that are put on the barge. Tables, chairs, and portable restrooms are brought in to ensure a comfortable trip, while life jackets and a first aid kit are on hand in case of any emergency.

“It’s become a very finely-tuned event, and it could not happen without our operations staff,” Christensen says. “They put a lot of work into this event to get the barge ready and to ensure that the river travel will be smooth and memorable.”

A mix of volunteers from the office and operations serve as hosts for the ride and an-swer guests’ questions about construction materials. For a number of years, the ride was extended to participants of the Mississippi River Recreation Area Junior Ranger Program. National Park Rangers on board the ship would answer questions about the river corridor and explain the river’s significance to the community.

“This barge ride combines two of the key components of Aggregate Industries’ value system: commitment to community and sustainability,” Christensen explains. “Guests walk away from the barge with a better understanding of the importance of the aggre-gates industry and how the river plays into their day-to-day lives.”


When you join NSSGA you can be sure your voice is heard. As we work together to ensure adequate transportation funding, eliminate needless regulation and rebuild our infrastructure to world-class status.

Join us today in leading the way to an even stronger tomorrow. To be a part of it, visit us at www.nssga.org or email [email protected]. www.nssga.org

WE’RE REBUILDING AMERICA’S INFRASTRUCTURE. BE A PART OF IT.

NSG3726 New Member AD-AggMan-Full.indd 1 5/5/16 11:41 AM

Untitled-12 1 5/6/16 8:47 AM

MINE MANAGEMENT


Learn the best method for determining what your quarry is worth.

by Mike Nowobilski

Buying and Selling: A Primer

MineMgmt_AGRM0716.indd 26 6/14/16 8:56 AM


If you are in the market to expand your company via an acquisition, you may wonder whether the property advertised in the illustration at left is a good buy. Should you call and inquire? Is the indicated sales price too high?

How would you react to this ad? Perhaps you are a loan officer at a bank and a quarry owner

asks for a $5 million loan based upon the fact that a similar-ly sized quarry producing 1 million tons sold for $25 million. Should the loan officer react favorably? After all, the collateral is apparently worth five times the requested amount of the loan?

I assume your reaction to these questions, is “I do not know.” Based upon discussions with many owners over the years, my observation is that most owners formulate their opinion regarding fair market value based upon what they hear with respect to the sales price a competitor received. This practice may stem from the use of comps in real estate where it seems to work fairly reliably. However, using comps to estimate the fair market value of a quarry or mine based upon its annual sales volume is not a reliable method, even in those instances where a similar mineral is being mined and sold.

Perhaps you are skeptical. Would you not expect the pur-chase prices (aka fair market value) of three limestone quarries each producing and selling approximately one million tons of construction aggregates to be similar? The actual results may surprise you. The individual quarry values shown in Figure 1 ranged from a high of $24.89 per ton sold to a low of $7.82 per ton sold.

Figure 1: Fair Market Value Comparison of 1 Million Ton Quarries

Just in case you are still skeptical, let’s look at the actual results of three quarries producing and selling approximately 600,000 tons annually. As Figure 2 illustrates, the range was from a high of $20.32 per ton sold to a low of $13.26 per ton sold. Again, these examples are based upon actual results.

Figure 2: Fair Market Value Comparison of 600,000 Ton Quarries

So, how is the fair market value of a quarry or mine de-

termined? The remainder of this article will provide guidance beginning with the definition of fair market value.

What is fair market value?Fair market value is defined as “the most probable price that a property (quarry) should bring in a competitive and open market under all conditions requisite to a fair sale, the buyer and seller each acting prudently and knowledgeably, and the price is not affected by undue stimulus.” The last part of the definition states: “The price represents the normal consideration for the property sold, unaffected by special or creative financing or sales conces-sions granted to anyone associated with the sale.”

How is fair market value determined?There are three primary methods used to determine a mine’s fair market value. They are the asset-based approach, market-based approach, and the income approach. Each will be briefly described, but, in its mergers and acquisitions practice (M&A), Mid-America typically finds that the fair market value estimate determined by means of the income approach has the best cor-relation to a quarry’s actual sales price.

Asset-based approach: The basis for this methodology is that a business is a bundle of assets. Accordingly, the value of the business is the sum of the current fair market value of the mobile equipment fleet, plant, real estate (typically any owned surface or mineral), stockpiled materials, and good-will. The structure of the transaction, whether an asset sale or stock transaction, determines how working capital (payables, receivables, cash, etc.) and long-term debt is considered in the calculations. We find that using the asset-based approach to estimate fair market value results in a materially lower value

Learn the best method for determining what your quarry is worth.

Buying and Selling: A Primer $0.00

$6.50

$13.00

$19.50

$26.00

$32.50

Quarry A Quarry B Quarry C

Fair Market Value Per Ton of Annual Sales

$0.00

$5.25

$10.50

$15.75

$21.00

$26.25

Quarry D Quarry E Quarry F


$0.00

$6.50

$13.00

$19.50

$26.00

$32.50



$0.00

$5.25

$10.50

$15.75

$21.00

$26.25





MINE MANAGEMENT

than the other two methods, except in those cases where the quarry is not profitable. For smaller family-owned quarries and mines, it seems this is partly due to the fact that the plant and equipment fleet are relatively old and, therefore, have low fair market values.

Market-based approach: This approach is based upon the use of comps to establish fair market value. It is imperative that the selected metric of comparison be appropriate. For example, as illustrated above, using annual sales volume to determine price is not a reliable metric. This is because the use of annual sales volumes does not take into consideration profit margins. Accordingly, a much more reliable metric considers profits such as Earnings Before Interest, Taxes, Depreciation & Amortization (EBITDA).

There are potential inherent problems with the use of this approach. One drawback is that the selected metric is typically applied to historical performance. Obviously, the quarry’s future performance could be similar, better, or worse. Another draw-back is the fact that it is based upon the application of multiples derived from other markets which may, or may not be, more dynamic or less competitive. However, we typically find the use of this methodology yields more reliable results than the asset-based approach.

Income approach: It has been our experience that the in-come-based approach yields the most reliable estimate of fair market value. Most of the larger companies rely most heavily on this methodology.

This approach is based upon a multi-year projection of future sales and financial performance. Historical performance forms the basis of the financial model in that historical sales volumes, sales prices, costs, and profits are considered. Factors that are evaluated include the following:

• Sales performance – adjust historical sales volumes and sales prices in light of expected changes in market demand or the competitive environment.

• Reserve characteristics – projected mine life, change in over-burden thickness, or rock quality.

• Mine costs – adjust historical mine costs in light of projected changes in labor costs, geologic conditions, or equipment changes.

• Capital requirements – consider replacement of worn equip-ment or potential increase to annual capacity.

Once the multi-year sales and financial forecast is complet-ed, the resultant cash flow forecast is adjusted by a discount rate. Selection of the appropriate discount rate is a key success factor when employing this approach to valuation.

Perhaps too simplistically, the income approach yields the most reliable fair market value estimate because it is based

upon a forecast of future cash flows. Future cash flow is ulti-mately what a prospective purchaser is buying. You may have heard the saying “cash is king.”

How can fair market value be so different?The dissimilarities in fair market values result from material variances in one or more of the factors described previously. First, let’s apply these principles towards reconciling the dissimilarities in fair market values between the three 1-million-ton quarries. Figure 3 illustrates there is a $1.40 per ton difference in cash op-erating margin between the highest valued (Quarry A) and lowest valued quarry (Quarry C). Further inspection indicates that $1 per ton can be attributed to a higher average sales price. Quarry A’s greater profits account for a little more than 50 percent of the difference in fair market value.

Figure 3: Financial Performance Overview of 1-Million-Ton Quarries

The remainder of the difference is attributed to the fact that future annual sales and profits will be significantly higher than historical levels. The quarry had just landed a new likely long-term customer who would increase annual sales volumes by nearly 25 percent without an increase in overhead expenses. Also, a three-year road project not only was going to increase annual sales volumes, but permit the sale of previously spoiled cap rock. By contrast, the trend of Quarry C’s annual sales vol-umes was negative. As a matter of fact, they decreased nearly 20 percent over the subsequent two years.

Similarly, analyzing the dissimilarities in fair market values between the three quarries operating at 600,000 annual tons also illustrates the importance of considering non-financial factors. Considering only the financial performance of Quarry D versus Quarry E one would expect that Quarry E’s fair market value to be twice that of Quarry D as its profit margin is nearly twice that of the other quarry, $3.48 per ton versus $1.78 per

$0.00

$1.50

$3.00

$4.50

$6.00


Financial Performance ($/Ton)

0.

4.

8.

12.

16.



Avg. Sales Price Cash Ops Costs Cash Margin EBITDA




ton. Figure 4 also illustrates Quarry E has an average sales price that is twice that of the other two quarries, but much of this ad-vantage is offset due to significantly greater mining costs. Why? Because this quarry produces a high-value product that is both capital and labor intensive.

Figure 4: Financial Performance Overview of 600,000-Ton Quarries

The reason why Quarry E is not valued at twice that of Quarry D is two-fold. Most significantly, Quarry E’s reserves will be depleted in approximately 10 years. A second contrib-uting factor is the fact that there is a new competitor capa-ble of producing the high-value product that will negatively impact the ability to maintain current sales volumes and raise sales prices to meet inflation.

ConclusionsThe fair market value of a profitable quarry or mine is deter-mined by future cash flow. To the extent that forecast future cash flow is greater, the quarry’s fair market value should be higher. What should be evident is using comps to estimate the fair market value of a quarry or mine based upon their annual sales volume is not a reliable method. Rather, there are numer-ous factors that need to be considered in developing an esti-mate of fair market value because value is about the amount of future cash flows. And, always remember, cash is king. AM

Mike Nowobilski is president of O’Fallon, Ill.-based Mid-American Energy and Mining Services, a company specializing in mergers and acquisitions.

$0.00

$1.50

$3.00

$4.50

$6.00



0.

4.

8.

12.

16.





LaPlant-Choate:

No Job Too Tough!

AEM Inducts 2014 Class

into Hall of Fame

Insley Manufacturing

Corporation

An Unsung Hero:

The Dry Batch Paver

Double Dude…Out Front Again!

SPrINg 2015 • ISSUE #116READ ALL ABOUT IT!

It’s only $35 US in the USA and Canada, $45 US all others. To join, call us at 419-352-5616, or mail a check or money order to HCEA, 16623 Liberty Hi Road, Bowling Green, Ohio 43402.

Join online and learn more about us at www.hcea.net.Thank you for your interest and support!

That’s not all we do! We also feature:International Convention & Old Equipment Exposition

Held annually and featuring working demonstrations and static displays. National Construction Equipment Museum and

ArchivesA world-renowned collection, open to the

public, of everything from fully restored antique machinery to 1800s literature and photographs.

Join the Historical Construction Equipment Association (a non-profit organization) and

receive its quarterly magazine, Equipment Echoes. Read fascinating articles about all types of old construction equipment, illustrated by beautiful historic photos.

ABOUT IT!

That’s not all we do! We also feature:International Convention & Old Equipment Exposition

Held annually and featuring working demonstrations and static displays. National Construction Equipment Museum and

ArchivesA world-renowned collection, open to the

public, of everything from fully restored antique machinery to 1800s literature and photographs.

Join the Historical Construction Equipment Association (a non-profit organization) and

receive its quarterly magazine, Read fascinating articles about all types of old construction equipment, illustrated by beautiful historic photos.

JOIN HCEATODAY! READ ALL

ABOUT IT!

Untitled-38 1 10/22/15 1:27 PM


EQUIPMENT MANAGEMENT


Investing in the proper design of an overland conveyor system can pay off with low-maintenance operation.

EquipmentManagement_AGRM0716.indd 30 6/14/16 8:48 AM


Aggregate producers spend millions of dollars every year maintaining conveyor systems. Oftentimes, conveyor design

does not provide the means for ease of maintenance, and, as a result, maintenance may not be performed correctly, on time, or at all. This eventually leads to a greater risk of component failure and a resulting loss of production. Designing a conveyor to be mainte-nance friendly means providing adequate provisions for necessary service from the onset. It also means eliminating problems such as inadequate component spacing, inaccessible positions, and other non-re-pairable confi gurations.

Material characteristicsWhen designing a conveyor, the type of material to be conveyed is the fi rst item to be taken into consideration. The fl owability of a material affects the size of the cross section of material load that can be carried on a given belt width. Flowability is affect-ed by material characteristics such as: size and shape of the fi ne particles and lumps, roughness, or smoothness of the material particle surface; the proportion of fi nes and lumps present; and material moisture con-tent. Considerations should also be given to the weight per cubic foot of material, abrasiveness, and temperature.

Belt width, speed, and capacityFor a given speed and material density, the wider the conveyor belt, the higher the ca-pacity of the conveyor. A belt must be wide enough so that the combination of fi nes and lumps do not push the lumps too close to the edge of the belt.

Conveyor belt speeds depend upon the material characteristics, the capacity desired, and belt tensions. Heavy material with sharp edges should be conveyed at moderate speeds. The sharp edges will cause wear to the belt, particularly if the loading velocity of the material in the direction of belt travel is lower than the belt speed. Light, powdery materials must also be conveyed at lower speeds to reduce dust particles, especially at loading and discharge points on the conveyor. Frag-

Proper system design reduces operating costs and improves an operator’s ability to properly perform maintenance.



EQUIPMENT MANAGEMENT

ile materials may degrade at loading and discharge points, as well as when moved over idlers. Therefore, these types of materials should also be con-veyed at lower speeds.

As stated previously, belt capaci-

ty increases with the increase of belt width. It is important to know the tons per hour of material an end user ex-pects to move with a conveyor. If there is uniform feed to the conveyor, a cross section of the material loaded on the

belt is used in calculating the capac-ity of a conveyor. The cross section of material must meet the following two conditions:- The material does not extend beyond

the belt edge or the distance recom-mended by the Conveyor Equipment Manufacturers Association, and

- The top of the load does not exceed the surcharge angle of loading.

Idler selectionAll belt conveyor idlers have the same purpose. They provide shape and support for the belt and minimize the power needed to transport material. Idler spacing affects both the shape and support of the conveyor belt. Idlers placed too far apart will not properly support the belt or enable it to maintain the desired profi le.

Idlers that are placed too close together will provide the necessary support and profi le, but may add a prodigal expense to the conveyor. The main infl uences in idler selection are belt weight, material weight, idler load rating, belt sag, idler life, belt rating, and belt tension.

Proper idler roll diameter and size of bearing and shaft selection is based on load carried, belt speed, and operating conditions.

Pulley and shaft selectionThe standardization of pulleys lends itself to the ease of choosing the correct pulley for a given application. The most commonly used pulley is the standard steel pulley. Plain steel drum pulleys are best used in dry clean environments where traction is not critical and when no foreign material is present on the return belt.

Conveyor pulleys may also be covered with rubber, fabric, or other material. This is referred to as lagging. Lagging on a drive pulley provides an increase in the friction between the belt and the pulley. Lagging is also used to reduce abrasive wear to the face of the pulley and to create a self-cleaning

The pile under this conveyor was partially caused by carryback, which stuck to the bottom side of the conveyor belt.

A combination of primary and secondary belt cleaners is used to ensure carryback ejects at the conveyor’s discharge point.



action on the surface of the pulley.Wing pulleys are typically used in tail

pulley applications to reduce the build up of material between the belt and pulley. Trapped materials fall through the paddle-like formations of the pulley. Lagged winged pulleys are used in ap-plications with abrasive material present on the return side of the belt. It is natu-ral, under these conditions, for the wing tips to wear prematurely. The rubber lagging will add life to the pulley.

Shafting is commonly considered to be a part of the pulley assembly since the strength and rigidity of the assem-bly depends on both of these compo-nents. When choosing shaft diameter, it is important to consider both the shaft diameter required for strength and shaft diameter required for defl ection. Depending on the pulley assembly, either strength or defl ection may be the deciding factor of shaft diameter.

Belt cleanersCarryback is the fugitive material that sticks to the belt after the belt passes over the head pulley and, subsequent-ly, creates fugitive material piles along the underside of the conveyor. Fugitive material is a costly problem, considering that many maintenance hours are spent

cleaning fugitive material piles. In order to correct carryback, a belt cleaner is used. This is usually a form of wiper or scraper device mounted near the discharge (head) pulley.

A common type of belt cleaner is the pre-cleaner. This is often referred to as the primary cleaner and functions by scraping off most of the carryback leaving only a thin layer of fi nes on the belt. The pre-cleaner is mounted on the face of the head pulley just below the discharge trajectory. This allows the material scraped from the belt to fall with the discharge materials.

Multiple cleaner systems are the preferred method for eliminating carry-back. The multiple systems consist of a pre-cleaner and one or more secondary cleaners. In addition to the improvement in belt cleaning, multiple belt clean-er systems increase the time interval between scheduled maintenance times. Belt cleaners should be positioned as close to the head end as possible.

Secondary cleaners are designed to remove the thin layer of fi nes left by the pre-cleaner. It’s best to place the sec-ondary cleaner in contact with the belt while it is still against the head pulley. This enables the cleaner to scrape against a fi rm surface.

There are several types of belt cleaners available to eliminate carry back. The brush type can be driven by the pulley motion or motorized. This type is effective on dry materials, as the bristles of the brush sweep the belt clean. The disadvantage to brush type cleaners is the potential for build up on the brush’s bristles.

Pneumatic type belt cleaners send a stream of air across the face of the pul-ley to blow off the carryback materials. They are best utilized when moving dry materials. The disadvantages of the pneumatic cleaners are the expense of the continual air stream, and the cre-ation of airborne dust, as the carryback is not deposited in the discharge pile.

There are two styles of wash-type cleaners that use water to clean the belt. The fi rst is a system that sprays a misting of water on the belt in order to make the scraping process easier. The second type uses a high-pressure wash to completely remove carryback.

Problems occur with these types of cleaning systems with the removal of the sludge that is created. However, in some cases, the water-material mixture can be returned to the material load. These sys-tems also have the potential for trouble under cold operating conditions.

Return belt cleaner systems, also known as v-plows, are used to prevent large objects and tramp iron on top of the return belt from damaging conveyor components. A low-pressure mechanical scraping is used to remove the material from the belt.

Maintenance is an important part of the life span of any piece of equip-ment. The harsh operating conditions experienced by aggregate conveyor systems not only increase the need for proper maintenance, but also create a need for design considerations that facilitate proper maintenance. In many cases, proper design considerations may reduce the cost and time involved with conveyor maintenance. AM

The ideal transfer point is designed to load the belt in the center and at a uniform rate.

Article courtesy of Superior Industries.


Get the the most current information with the2016 Aggregates Industry Atlas and the Atlas on CD.While the printed version of the Aggregates Manager 2016 Aggregates Industry Atlas will become an integral part of doing your job, don’t forget to order your copy of the Atlas on CD to see additional information about companies’ mine locations, types of rock mined, GPS coordinates, pertinent facts about companies listed in the atlas, and more.

� e Atlas on CD contains compete information on nearly 11,000 operations in the United States in a data � le as well as the entire 2016 Aggregates Industry Atlas in pdf format.

Order additional copies of the Aggregates Manager 2016 Aggregates Industry Atlas on CD or the printed version of the Atlas today!

To order, visit AggManAtlas.com or call 224-723-5372.

Purchase in Print

$50/1-5 copies$45/6-20 copies$35/21-49 copies

$20/50 copies or morePlus $4.50/Atlas shipping and $8

handling fee

Order on CD

$250 Plus shipping and handling: $8.70/CD

Download Online

$200(online download only)

June 2016 | www.AggMan.com


We review equipment trends by the numbers

USGS releases its list of top crushed stone producers

11We review equipment trends by the numbers19USGS releases its list of top crushed stone producers

191919191929

Are your equipment acquisitions keeping pace?

2016AGGREGATES

INDUSTRYATLAS


20162016201620162016201620162016AGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATES

INDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYATLASATLASATLASATLASATLASATLASATLASATLAS

AGGREGATESINDUSTRYATLAS


2016201620162016201620162016AGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATES

INDUSTRYINDUSTRYINDUSTRYINDUSTRYATLASATLASATLASATLAS


2016201620162016201620162016AGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATESAGGREGATES

INDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYINDUSTRYATLASATLASATLASATLAS

AM2016_HouseAd_Atlas.indd 1 5/18/16 4:42 PM

35AGGREGATES MANAGER / July 2016

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

SUPPLYLINESDigging DeepExcavator upgrades target efficient power use and faster cycle times.

The new Cat 6015B Hydraulic Shovel is said to deliver a productivity advantage over other excavators in its size class thanks to the most powerful engine in its class, a large standard bucket, and payload capacity of 16.0 tons. The design translates to fast cycles and a pass match advantage over leading standard-equipped shovels in its class when loading trucks of 60-, 70-, and 100-ton capacities. The 6015B is equipped with a Cat C27 Acert engine that pro-vides 813 horsepower. The 10.6-cubic-yard standard bucket further boosts production capability. Caterpillar | www.cat.com

Doosan says the 373-net-horsepower DX490LC-5 Tier 4-compliant crawler excavator has unmatched reliability and durability, making it perfect for quarry applications. With a bucket breakout force of 67,902 foot-pounds, the excavator is said to ensure precise digging capabilities even in the toughest digging conditions. Features include larger bushing in track rollers, thicker sprocket teeth, added reinforcement plates, and increased plate thickness to the excavator’s boom and arm. Four power modes allow the excavator to better balance fuel consumption and ma-chine power to the working conditions, while four work modes maximize efficiency and fuel economy in specific applications.Doosan | www.doosanequipment.com

Said to have most powerful engine in class

Precise digging capabilities in tough conditions

NEW

NEW

The Case CX350D weighs 82,483 pounds, is powered by a 268-horsepower engine, and offers a bucket dig-ging force of 51,638 pounds, maximum dig depth of 24 feet, and drawbar pull of 61,373 pounds. It is designed to provide improved performance and productivity over its predecessors, including faster cycle times (up to 8 percent faster), increased breakout forces, improved re-sponsiveness and multifunctional control, and greater fuel efficiency (up to 12 percent better). The CX350D comes standard with Case ProCare, which includes a three-year Advanced Case SiteWatch telematics sub-scription, a three-year/3,000-hour full-machine factory warranty, and a three-year/3,000-hour planned main-tenance contract. Case Construction Equipment | www.casece.com

Offers faster cycle times and more fuel efficiency

SupplyLines_AGRM0716.indd 35 6/14/16 9:16 AM

SUPPLYLINES

AGGREGATES MANAGER / July 201636

The exclusive All-Around Viewing Monitor system for 360-degree-surround virtual oper-ating view displays on an 8-inch cluster-monitor in the operator’s cab of Hyundai’s HX series, including the mid-sized, 173-horsepower HX220L. The Intelligent Moving Object Detection system warns the operator when objects come within 16.5 feet of the machine. Hydraulic system improvements include Boom Float mode for grading control, Fine Swing mode for load control, faster cycle times, Intelligent Power Control, and Eco Breaker mode. The Tier 4 final unit weighs 49,960 pounds and has a max dig depth of 22 feet, 1 inch and bucket-digging force of 32,550 pounds.Hyundai | www.hceamericas.com

Equipped with a rugged Final Tier 4 diesel engine, the 870G LC boasts 512 horsepower and a maximum digging depth of 31 feet, 5 inches. The 96-ton machine comes equipped with the exclusive John Deere Powerwise III engine management system. It features more hydraulic flow for faster work cycles and greater productivity, as well as a comfortable and spacious cab for improved operator comfort. The production class excavator is said to be easy to service with cab-level machine access and points of contact all around the machine. A five-year subscription of JDLink Ultimate telematics gives 870G owners real-time utilization data and alerts to help maximize productivity and efficiency while minimizing downtime.John Deere | www.deere.com

Kobelco’s 49,400-pound, Generation 10 SK210 is powered by a 160-horsepower Tier IV Final HINO engine, enabling it to remain fuel ef-ficient while easily tackling heavy-duty applications. The new unit delivers a dynamic digging force of 29,330-foot-pounds to achieve what is said to be leading-class work volume. It boasts a 7-percent increase in work volume per hour, while providing up to a 10-percent increase in fuel econ-omy in S-mode and a further 6-percent increase in ECO-mode. This boost in efficiency comes from a new hydraulic regeneration system, which aids the arm by reusing force generated by the boom, further minimizing en-ergy loss and ensuring outstanding performance.Kobelco | www.kobelco-usa.com

With an operating weight range of 105,670 to 110,220 pounds, Komatsu America’s PC490LC-11 is said to be an ideal option when there’s a need to move mass quantities of material in short order. It’s a large and versatile performance-oriented excavator equally at home excavating quarry rock or running a breaker. With rated bucket capacities up to 4.15 cubic yards, the PC490LC-11 is a good match to the Komatsu HM300 and HM400 articu-lated trucks.Komatsu America | www.komatsuna.com

360-degree operating view display

Faster work cycles and greater productivity

Boasts intelligent machine controls

New hydraulic regeneration system increases efficiencyNEW


Test it out for yourself and subscribe at AggMan.com.

Ready whenever and wherever you are.Aggregates Manager Magazine makes it easy to

keep up-to-date while you are on the go. Get the latest

news in the aggregates industry, along with insight from

our award-winning editorial team, through our mobile

version of AggMan.com.

SP12825_AggMan2015_MobileWebsiteAd.indd 1 5/20/15 9:51 AM

Untitled-34 1 5/21/15 11:39 AM

“The Story of Cubee the Aggregate”helps teach children at the youngest ages about the important role aggregate playsin their daily lives. Geared for students in grades K-3, Cubee and his aggregatefriends will take children on a magical journey from Cubee’s birthplace in theneighborhood quarry to his new home in the schools, roads and other structuresthat enrich our communities and our lives.

The “You’re on Rock” Workbookpresents basic earth science information while emphasizing the vital role of theindustry in our world. An aggregate activity book for junior geologists, miningengineers and earth scientists. Geared for students in grades 4-6.

Cubee the AggMan T-Shirts are available.

To learn more about these great tools for community outreach, adopt-a-school programs, andreceive sample copies of the coloring/workbooks,

Call 800-430-4540 e-mail: [email protected] or visit www.AggMan.com

helping educatechildren about the

importance ofaggregate

since 1998

Cubee the AggManCubee the AggManCubee the AggMan

Cubee_AGRM0612pg145.indd 1 5/15/12 8:53 AM

SUPPLYLINES

39AGGREGATES MANAGER / July 2016

Liebherr’s R936 excavators are equipped with integrated, perfor-mance-enhancing technology, based on the Positive Control hydrau-lic system with sensors attached at strategic points on the excavator. When the operator moves the machine, the intelligent control for the engine and hydraulic system optimizes each movement, facilitating fast, fluid, and precise working movements. The pump circuits can work independently or together, making optimal energy utiliza-tion possible. Its operating weight is between 30 and 38 tons, and the engine power is 231 horsepower. The R 936 is said to achieve maximum digging and breakout forces for a significant increase in productivity of up to 13 percent over the previous model. Liebherr | www.liebherr.com

LiuGong introduces the 925E Series Excavator. The 65,612-pound machine is powered by a Cummins engine and meets Tier 4 Final requirements. The unit has a maximum digging depth of 22 feet, 7 inches. Standard features include six selectable working modes and a multi-functional LCD display with maintenance information that is available in seven languages. Audible alarms provide alerts while safety is also enhanced by a built-in, rear-view camera.LiuGong | www.liugongna.com

The 22-ton Volvo EC220E is powered by a Tier 4 Final Volvo D6 engine. The fully optimized hydraulic system and ECO mode deliver the power required to complete a task, while auto engine shutdown helps reduce fuel consumption and emissions. The increased pump power enables responsive operation for greater productivity and cycle times — and with the boom float function, the pump power normally used for boom lowering can be saved or used for other functions, also reducing cycle times. The new valve controls the boom opera-tion proportionally according to the arm operation while grading. This system also improves lifting controllability while traveling simultaneously.Volvo Construction Equipment | www.volvoce.com

The TB1140 Series 2 excavator, from Takeuchi, features a pivot boom and standard backfill blade, giving it the functionality of a compact excavator. The hydraulic system, dual auxiliary hydraulic circuits, and proportional auxiliary hydraulic controls are said to make it suitable for a range of hydraulically controlled attachments. With an operating weight of 34,116 pounds, it has a maximum digging depth of 18 feet, dump height of just over 20 feet, and maxi-mum reach of nearly 29 feet. The excavator has a bucket breakout force of over 22,000 foot-pounds. Powered by an Isuzu engine, the 103.3-horsepower unit can travel up to 3.3 miles per hour. Takeuchi | hwww.takeuchi-us.com

Performance-enhancing technology boosts productivity

Features six working modes

Responsive operation for greater productivity and cycle times

Suitable for a range of hydraulically controlled attachments

NEW



For a preview of MSHA’s respirable crystalline silica rule, look at OSHA’s final rule.

Peter S. Almaas is an associate in the Denver office, practicing in the Occupational Safety and Health Practice Group. He can be reached at 303-390-0178 or [email protected].

Clarity on Crystalline Silica

Dust control can be a major concern on industrial worksites and is par-ticularly relevant to the production of aggregate materials. Airborne

dust particles present difficulties that are rel-evant to equipment maintenance, employee comfort, and, most importantly, employee health. Exposure to crystalline silica is of par-ticular importance. In an effort to reduce em-ployee exposure to silicosis, lung cancer, and other diseases, both the Occupational Safety and Health Administration (OSHA) and the Mine Safety and Health Administration (MSHA) have taken steps to limit employee exposure to crystalline silica. On March 24, 2016, OSHA announced a final rule that revises downward the permissible exposure limit (PEL) for expo-sure to crystalline silica in the workplace. The expectation is that MSHA’s version to lower exposure limits may soon follow.

MSHA is currently in the process of de-veloping a respirable crystalline silica rule of its own that will establish a new PEL for work activities subject to MSHA regulation. At the outset of rulemaking, MSHA intended to publish a final rule by October 2015. The timeline for publishing the new rule has suffered significant delays. At an MSHA Stakeholder Meeting held on May 12, 2016, MSHA was reticent to discuss the specifics of its proposed crystalline silica rule. When asked about the rule, MSHA representatives responded that the process to create the rule was underway, but that they could not com-ment at this time.

Although MSHA would not offer specifics, MSHA did mention that it had “looked at the OSHA Rule.” The National Institute for Oc-cupational Safety and Health (NIOSH) recom-mends exposure limits of 50 µg/m3 averaged over an eight-hour shift, as selected by OSHA. Factors that indicate that MSHA may tack closely to the new OSHA rule include NIOSH’s endorsement of the new OSHA PEL and that the issues faced by MSHA in seeking to limit employee exposure to respirable crystalline silica are very similar to those faced by OSHA.

The newly issued OSHA crystalline silica rule reduces the PEL for respirable crystalline silica to 50 micrograms per cubic meter of air (µg/m3), averaged over an eight-hour shift. Under the rule, the limit of an employee’s exposure to crystalline silica varies according to the duration of exposure. Employees may be exposed to concentrations of respirable crystalline silica of 200 µg/m3 for a maximum two hours, 100 µg/m3 for a maximum of four hours, and 50 µg/m3 for a maximum of eight hours. This represents a significant reduction from the previous PEL for respirable crystal-line silica of 100 µg/m3 averaged over an eight-hour shift for general industry and 250 µg/m3 averaged over an eight-hour shift for construction and shipyards.

To implement the reduced PEL for expo-sure to respirable crystalline silica, OSHA’s rule establishes several requirements that must be met by employers. Employers must employ engineering controls to limit or elimi-nate employee exposure to respirable crystal-

by Peter s. Almaas

ROCKLAW

RockLaw_AGRM0716.indd 40 6/15/16 8:42 AM


line silica. OSHA has identified four categories of engineering controls to limit exposure: substitution, isolation, ventilation, and dust suppression. These controls can take the form of the use of water to reduce dust propagation and increased venti-lation to clear areas of airborne dust, amongst others.

Employers are required to provide employees with respira-tors in situations where engineering controls are not sufficient to adequately limit exposure. Employers must take steps to limit employee access to areas that have, or have the poten-tial to have, high concentrations of respirable crystalline silica. Employers must also develop and implement a written expo-sure control plan that describes the tasks in the workplace that involve exposure to respirable crystalline silica.

The plan must take steps to ensure that the proper engi-neering controls are identified and implemented, procedures are developed to restrict employee access to high exposure areas, proper personal protective devices are identified and obtained for use in situations where engineering controls are inadequate, and employee training on work operations that result in high respirable crystalline silica exposure is performed and documented. The plan must also describe the housekeep-ing measures to be used to limit employee exposure.

OSHA’s new crystalline silica rule implements require-ments for employers to provide medical exams and moni-toring for employees who are exposed to concentrations of respirable crystalline silica in excess of the PEL for 30 or more days per year. Employers must provide a medical exam to employees within 30 days of initial assignment to a task that exposes them to crystalline silica. The exam must be repeated at least every three years.

The OSHA rule takes effect on June 23, 2016, triggering a five-year window during which employers must achieve compliance with the new standard. Construction employ-ers must comply with the new rule by June 23, 2017, one year from the effective date. General industry and maritime employers must comply by June 23, 2018. Employers in-volved in the hydraulic fracturing industry must comply with all provisions except those related to engineering controls by June 23, 2018. The hydraulic fracturing engineering controls contemplated by the standard must be implemented by June 23, 2021.

We will continue to monitor MSHA’s regulatory activity and provide updates on any crystalline silica exposure rule-making from MSHA. AM

ROCKLAW

Be a cool operatorBe a cool operator

1-800-267-2665 • [email protected] • www.hammondac.com

When you work hard in small spaces, you need AC big time! With over 1200 different kits engineered and developed, count on Arctic Wolf™ for factory-style integrated air conditioning systems in ready-to-fit kits. Loaders. Dozers. Excavators. Graders. Tractors. If your equipment has an engine and a cab on it, we can put cool air into it.

Call today. 1-800-2 MR COOL or go online at www.hammondac.com and order your system and parts today.

081-178 Equip World 4.5x4.5.indd 1 2016-06-01 2:18 PM

Untitled-7 1 6/6/16 2:14 PM

RockLaw_AGRM0716.indd 41 6/15/16 9:16 AM

ADINDEX


July 2016

Advertiser Web Page

Aggregates Manager Atlas Data/CD Products www.aggmanatlas.com 10

Aggregates Manager Community Outreach www.aggman.com/community-outreach 38

Atlas Copco Construction Mining Technology www.atlascopco.us 9

Bill Langer - Research Geologist www.researchgeologist.com 43

C.L. Dews & Sons Foundry www.dewsfoundry.com 43

Conexpo-Con/Agg 2017 www.conexpoconagg.com 20

Elrus Aggregate System www.elrus.com IBC

Great American Truck Show www.gatsonline.com 13

Hammond Air Conditioning, Ltd www.hammondac.com 41

HCEA www.hcea.net 29

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

Kespry, Inc. www.kespry.com/aggregates 2

Kruse Integration www.kruseintegration.com 41

Minexpo 2016 International www.minexpo.com 4

NSSGA Legislative www.nssga.org 25

Pugmill Systems, Inc. www.pugmillsystems.com 43

Stedman Machine Co. www.stedman-machine.com/save 43

Sweet Manufacturing www.sweetmfg.com 43

Vermeer www.vermeer.com 7

Volvo Construction Equipment www.volvoce.com/exfactor BC This index is provided as a service. The publisher does not assume any liability for errors or omissions.

AdIndex_AGRM0716.indd 42 6/15/16 9:17 AM


MARKETPLACE

New 300 tph

WEAR PARTSCALL 1.877.339.7339

WWW.DEWSFOUNDRY.COM

CL Dews_AGRM0113_PG.indd 1 12/12/12 3:43 PM

To advertise here call

Pete Austin (205)248-1258

Bulk Material Handling & Conveying Equip.www.sweetmfg.com

Conveyors & Support SystemsBucket Elevators

Bin Gates • Grating

937-325-1511 • FAX [email protected]

SPRINGFIELD, OHIOMANUFACTURING CO.

Sweet_AGRM0910.indd 1 8/19/10 2:24 PMYIPPIE!STICHWEH

DEWATERING BUCKET WHEELS RECOVERS SAND

TO 200 #POWERED BY STICHWEH LLC.

LARGEST RANGE OF BUCKET WHEELS IN THE WORLDWWW.BUCKETWHEEL.COM

WORK LIKE A STICHWEH! SNOBY SEPARATION SYSTEMS LLC

216 Chastatee Industrial Drive • Dahlonega, GA 30533 • USACall: 855-766-9233

[email protected] • www.snobyllc.com

WITH LOW MOISTURE

WORK LIKE A STICHWEH! WORK LIKE A STICHWEH!

WWW.BUCKETWHEEL.COMWWW.BUCKETWHEEL.COMWWW.BUCKETWHEEL.COMWWW.BUCKETWHEEL.COM

snoby_114hx88,9w_AM_020715_RZ.indd 1 02.07.15 21:04Untitled-3 1 5/5/16 9:46 AM

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

Services Offered: Applied geology and geological research for construction rocks

and minerals, with an emphasis on aggregates.

Contact me at: [email protected]

www.researchgeologist.com

• Resource evaluation• Expert testimony

• Technical writing and review• Lecturer

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

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

Marketpl_0716.indd 43 6/15/16 10:33 AM

Bill Langer is a consulting research geologist who spent 41 years with the U.S. Geological Survey before starting his own business. He can be reached at [email protected]

CARVED IN STONE


My wife, Pam; grandkids, Donovan and Delaney; and I spent spring break camping in southern Arizona around Tucson. The highlight of the trip was our visit to a world-class geologic wonder Kartchner Caverns State Park.

The obvious draw to the park is Kartchner Caverns and its intricate formations, called “speleothems.” Kartchner Caverns is considered a “living cave” because its speleotherms are still growing, and new speleotherms continue to be formed. Rainwater, combined with carbon dioxide from the atmosphere and decaying veg-etation, forms carbonic acid that percolates through fractures in the surrounding limestone. The acid dissolves rock, creating openings. Over geologic time, these openings enlarged, forming Kartchner Caverns with its ceilings and floors orna-mented with speleotherms, such as stalactites hanging from the ceiling (where they hang on tight) and stalagmites on the floor (where you might trip on them).

There are two 90-minute guided tours through the caverns. The Throne-Ro-tunda tour has grand vistas overlooking the cave formations. The tour through the Big Room offers visitors an up-close look at the formations. We went on both tours; both were fantastic.

We saw one the world’s largest soda straws (in the Throne Room), bacon, ‘tur-nip’ shields (Big Room), totems, waterfalls, columns, helictites, fried eggs, cave coral, popcorn, draperies, ‘birds nest’ needle quartz formations (Big Room), straw-berry flowstone, and the world’s most extensive formation of brushite moonmilk (Big Room).

The shape of a speleotherm depends on whether the water is seeping, drip-ping, or flowing and whether the water is under pressure or not. Seeping water forms shields. Fast dripping water forms stalagmites. Slowly dripping water forms stalactites and soda straws. Water flowing along fractures forms waterfalls or flowstones. Water under pressure forms helictites, which are stalactities that defy gravity by branching out in various directions.

Calcite that forms speleotherms is naturally white. However, it can be colored by other minerals in the water – red from iron oxide (rust), blue or black from manganese, and brown or tan from organic matter.

The speleotherms were formed over the past 200,000 years; many have been continuously growing for tens of thousands of years. A soda straw, for example, grows just 1/64th of an inch in a year, and a cubic inch of calcite takes a century to form.

In addition to a place of beauty, the Big Room is a cave bat maternity ward. There is black grime on the ceiling where the bats hang and piles of guano line the floor. There even is a bat’s body entombed in one of the cave’s formations.

Bats do not occupy the Throne Room. When the guide asked if anyone knew why, Delaney (11 years old) popped up, “Be-cause they don’t have food.”

“Right!” a somewhat surprised guide replied.When I asked Delaney how she knew the answer she said, “It’s common knowledge. You need food, water, and shelter to live.

There is plenty of water, and the cave provides shelter, so the only thing missing is food.”Common knowledge, indeed. Kartchner Caverns is one of the top 10 living caves in the world and was voted the best cave in America (2016 USA Today 10

Best Readers’ Choice Awards). But the geology is only half the story. How the caverns were discovered and developed is a story in itself. More about that next month.

Speleotherms, such as stalactites and stalagmites, continue to grow in this living cave.

Kartchner Caverns: A World-Class Geologic Wonder

Kubla Kahn is a 58-foot tall column. Notice person for scale.

Pho

to c

opyr

ight

Ariz

ona

Sta

te P

arks

.

Carved_AGRM0716.indd 44 6/13/16 2:22 PM

To learn more visit: www.elrus.com, email: [email protected] or call 888-535-7877

•

• • •

TM

Untitled-26 1 3/15/16 8:31 AM

There are multiple reasons Michael Knight says the last three years of excavator purchases have gone to Volvo — fuel efficiency and operator comfort among them. But it’s the minimal maintenance they appreciate most, keeping their excavators,

and production, up. On top of that, it’s peace of mind. “These excavators take a beating — knowing we’re backed by a Lifetime Frame and Structure Warranty is a nice add.”

Find tips to get the most from your excavator at volvoce.com/ExFactor.

We used to spend time welding booms and sticks, but with Volvo, we get to spend our time differently — up and running.

That’s our Ex Factor.– Michael Knight, vice president, Good Hope Contracting Co., Inc.

Untitled-4 1 6/9/16 10:33 AM

Documents

Aggregates Manager July 2016