THE AUTHORIT Y ON EQUIPMENT & TECHNOLOGY

How one of Denver’s

LAST
OF ITS
remaining independents
effectively serves
a market amid giants.

KIND
ALBERT FREI & SONS’
Walstrum Quarry

MODERNIZE YOUR
MOTOR MAINTENANCE
WHAT’S NEXT WITH
SILICA REGULATION?
INSIGHTS FROM
INTERDRONE

|
OCTOBER 2017 PitandQuarry.com
V OL . 1 1 0 NO . 4
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deistermachine.com
CONTENTS VOL UME 1 1 0 OC T OBER 2017 NO. 4

36 Types of bearing damage

Knowing what to look for is a first
step in determining the type of
damage bearings have sustained.
EDITED BY KEVIN YANIK

46 Power transmission
components
Bearing pedestals, power
transmission belts, lubrication
systems and more

48 SAFETY &
ENVIRONMENTAL
Safety and environmental products,
including handrails, wireless
monitors, stop switches and dust
control equipment

ELEVATING DUST CONTROL

With OSHA’s rule on silica being enforced, the aggregate industry
anticipates the development of an MSHA rule on silica. PAGE 22

UP FRONT
4 AN INSIDE LOOK 22 DUST CONTROL
MSHA moving forward Clearing the air
BY KEVIN YANIK What are the ramifications for
aggregate operations now that
8 UP TO SPEED OSHA is enforcing a new silica
The latest industry happenings standard for construction?
BY KEVIN YANIK

P&Q TECH 32 MOTORS, DRIVES &

10 CUTTING EDGE
The latest in equipment and
technology for the industry
12 OPERATIONS
The evolution of Albert Frei & Sons
How a space-strapped operation on
the outskirts of Denver effectively
serves the market.
BY KEVIN YANIK
BEARINGS
Motor maintenance in an IIoT world
Enhance your approach by blending
emerging Industrial Internet of
Things (IIoT) technologies with
traditional methods.
BY DAN PHILLIPS, THERESA SMIGURA
AND RICK MUNZ
Cover photo by Kevin Yanik
INSIDE
CONVEYING & MATERIAL
HANDLING SUPPLEMENT
Pit & Quarry’s 24-page pullout,
which starts after page 52, is
dedicated to conveying and
material handling. It includes
company features, the latest
equipment details and more.

pitandquarry.com October 2017 PIT&QUARRY 1

CONTENTS VOL UME 1 1 0 OC T OBER 2017 NO. 4

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

KEEPING TABS ON
THE UAV SCENE
Who deserves more pay: Drone
pilots or commercial truck drivers?

PHOTOS COURTESY OF LUCK STONE (TOP LEFT; BOTTOM RIGHT) AND DRONEVIEW TECHNOLOGIES (TOP RIGHT)
The UAV industry is on the brink of
a massive transformation that is
going to change
the pay scale, and
that is good for
vendors serving
the market and the
INSIGHTS FROM INTERDRONE businesses utiliz-
Pit & Quarry explored the UAV conference and expo in Las Vegas, walking away with
ing drones, says
URC Ventures’
several takeaways to share with aggregate producers. PAGE 53 David Boardman.
This leads Boardman to ask: Should
drone pilots or truck drivers be paid
51 WASHING/CLASSIFYING 62 MSHA & THE LAW more? Learn more at pitandquarry
Wash plant upgrade in Washington MSHA change coming gradually .com/who-deserves-more-pay
A sand and gravel producer shares BY BILL DORAN AND MARGO LOPEZ
Drones a growing
insights from a recent investment. tool for aggregate
EDITED BY KEVIN YANIK IN BACK industry
Drones are becom-
66 P&Q PROFILE ing more and more
53 MAPPING RESERVES & Doug Lambert
INVENTORY ANALYSIS common at aggre-
A conversation with the sales and gate operations,
7 Takeaways from InterDrone applications engineer at Superior from measuring
Observations from the UAV show. Industries stockpiles to documenting project
BY KEVIN YANIK progress. Find out how some com-
68 A LOOK BACK panies are using drones to enhance
P&Q BUSINESS Photos from Pit & Quarry’s historical their operations at www
archive .pitandquarry.com/tag/drone.
58 BUSINESS UPDATE
Aggregate industry forecasts,
stocks, economic news and more CL ASSIFIEDS & CONNECT
AD INDEX facebook.com/PitandQuarry
SAFET Y 63 CLASSIFIED ADS twitter.com/PitandQuarry
60 SAFETY UPDATE pitandquarry.com/linkedin
Safety and environmental news, 67 ADVERTISER INDEX
youtube.com/PQTV3
including the latest from MSHA
instagram.com/PitandQuarry

2 PIT&QUARRY October 2017 pitandquarry.com

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

Phone: 216-706-3700

MSHA MOVING FORWARD Fax: 216-706-3711

EDITOR-IN-CHIEF Kevin Yanik
216-706-3724 | kyanik@northcoastmedia.net

T
he forthcoming nomination of a former coal executive for the top
position at the Mine Safety & Health Administration (MSHA)
comes as a bit of a disappointment for the aggregate industry.
Between coal and metal/nonmetal mining, the metal/nonmetal
sector that’s comprised of aggregate producers and others is by far and away the
one that makes up the majority of the mining industry MSHA regulates.
In fact, more than 90 percent of the 13,089 mines MSHA oversaw in 2016
are in the metal/nonmetal sector. Additionally, nearly 75 percent of the 318,723
miners in the industry serve the metal/nonmetal sector, according to MSHA.
Yet, a representative from the coal sector will again be leading the agency.
On the bright side for aggregate operations, David Zatezalo, President Don-
ald Trump’s nominee for the MSHA post, has a producer’s
background, albeit in coal. So Zatezalo at least has an un-
derstanding from a producing company’s standpoint of
the working relationship between MSHA and the mining
industry. That’s one potential plus.
Consider too that Joe Main, the agency’s last assistant
secretary of labor, arrived at MSHA after a long career rep-
EDITOR Darren Constantino
330-533-6804 | dconstantino@northcoastmedia.net
ASSOCIATE EDITOR Joe McCarthy
216-363-7930 | jmccarthy@northcoastmedia.net
DIGITAL MEDIA CONTENT EDITOR Allison Barwacz
216-706-3796 | abarwacz@northcoastmedia.net
MSHA & THE LAW COLUMNISTS
Bill Doran | william.doran@ogletree.com
Margo Lopez | margaret.lopez@ogletree.com
AGGREGATE FORECAST COLUMNIST
David Chereb | david.chereb@sc-marketanalytics.com
MARKET INSIGHTS COLUMNISTS
George Reddin | greddin@fminet.com
Scott Duncan | sduncan@fminet.com
WESTERN U.S. CORRESPONDENT Loretta Sorensen
GROUP PUBLISHER Rob Fulop
216-706-3741 | rfulop@northcoastmedia.net
ASSOCIATE PUBLISHER Dino Vitanza
216-706-3744 | dvitanza@northcoastmedia.net
PRESIDENT & CEO Kevin Stoltman
216-706-3740 | kstoltman@northcoastmedia.net

resenting the United Mine Workers of America.
The relationship between Main’s MSHA and
mine owners and operators could be described
as contentious, among other things. While
mining fatalities have been trending down-
ward, the feeling among a number of aggre-
Kevin Yanik
gate producers is that the agency has been
EDITOR-IN-CHIEF more like an adversary in recent times than
the safety partner they’d like MSHA to be.
Perhaps the nomination of Zatezalo will
improve the tone of the agency-industry relationship. The National Stone, Sand
V.P. FINANCE & OPERATIONS Steve Galperin
216-706-3705 | sgalperin@northcoastmedia.net
V.P. GRAPHIC DESIGN & PRODUCTION Pete Seltzer
216-706-3737 | pseltzer@northcoastmedia.net
ART DIRECTOR Kim Traum
216-706-3779 | ktraum@northcoastmedia.net
GRAPHIC DESIGNER Courtney Townsend
216-363-7931 | ctownsend@northcoastmedia.net
PRODUCTION SERVICES MANAGER Terri Johnstone
216-978-9622 | tjohnstone@northcoastmedia.net
SR. AUDIENCE DEVELOPMENT MANAGER
Antoinette Sanchez-Perkins
216-706-3750 | asanchez-perkins@northcoastmedia.net

& Gravel Association (NSSGA), for one, is eager to find additional ways to part- SR. MARKETING & EVENT MANAGER Michelle Mitchell
216-363-7922 | mmitchell@northcoastmedia.net
ner with MSHA moving forward.
MARKETING & EVENT MANAGER Angela Gibian
“Our industry has a demonstrated commitment to safety and a track record 216-363-7936 | agibian@northcoastmedia.net
of positively working with MSHA,” says Laura O’Neill-Kaumo, NSSGA senior MARKETING & SALES MANAGER, BUYERS’ GUIDE INQUIRIES
vice president of government and regulatory affairs. “We look forward to work- Chloe Scoular
216-363-7929 | cscoular@northcoastmedia.net
ing with the new administrator, once confirmed.”
Although Zatezalo is expected to be at the top of the nation’s mine safety and DIRECTOR OF AUDIENCE ENGAGEMENT Bethany Chambers
216-706-3771 | bchambers@northcoastmedia.net
health agency, the MSHA chief will eventually build a team of high-ranking lead-
WEB DEVELOPER Jesse Malcmacher
ers upon whom he can lean. The placement of a crushed stone, sand and gravel 216-363-7925 | jmalcmacher@northcoastmedia.net
stakeholder on that team would be a positive takeaway for the aggregate industry. LIST RENTAL, THE INFORMATION REFINERY, INC
Brahm Schenkman
800-529-9020 | bschenkman@inforefinery.com
The beat goes on
REPRINTS Brett Petillo, Wright’s Media
One takeaway for readers of this particular edition of Pit & Quarry is that 877-652-5295 | bpetillo@wrightsmedia.com
the publication’s parent company, North Coast Media (NCM), is donating a CLASSIFIED ADVERTISING
portion of its October revenues to cancer research. NCM launched the cancer 216-363-7929 | cscoular@northcoastmedia.net
research initiative in 2014 as a means to help researchers pursue cancer causes SUBSCRIPTIONS / CUSTOMER SERVICE
and cures. Although October is Breast Cancer Awareness Month, NCM’s do- 847-513-6030 | pitandquarry@omeda.com
Fax: 847-763-9694
nation will help researchers find causes and cures for all types of cancer. P&Q Web: www.pitandquarry.com/subscribe

4 PIT&QUARRY October 2017

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FOR QUALITY SHAPED PRODUCTS, ESPECIALLY IN HARD ROCK. MOBICONE mobile cone crushers
are used in medium-hard to hard applications as well in abrasive natural stone operations. They cover a
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all the way through to large quantities in tough quarrying operations. The MOBICONE crushers are the
perfect match for mobile KLEEMANN jaw crushers and/or screening plants. MOBICONE mobile cone
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UPtoSPEED
ICYMI
PRODUCERS

NSSGA names award I N C A S E Y O U M I S S E D I T

winners, scholarship recipient R E G U L AT I O N S

AGGREGATE PRODUCER

T
he National Stone, Sand &
Gravel (NSSGA) Association
revealed the recipients of its
2017 Grassroots Awards. The awards
are presented to individuals who edu-
cate policymakers on the value of the
aggregate industry and ex-
plain how certain policies
benefit or harm operations
around the United States.
McLana han Corp.’s
George Sidney will re-
ceive the Grassroots CEO of the Year
award. McLanahan Corp. invited
presidential candidates to tour the
company’s facility in Hollidaysburg,
Pennsylvania.
Gernatt Asphalt Products Inc.’s Bill
Schmitz will receive the Grassroots Co-
ordinator of the Year award. He estab-
lished relationships between his com-
pany, NSSGA and three congressmen
by setting up facility visits and partic-
ipating in fundraising events.
Also, Bluegrass Materials’ Brian
McNamara will receive the Grassroots
EVENTS
HARVEY SITUATION RAISES QUESTIONS
ABOUT AGG1 2018
Advocate of the Year award for testify-
ing before the White House Office of
Management & Budget on the harmful
effects of the Mine Safety & Health Ad-
ministration’s Examination of Working
Places rule.
In addition, NSSGA’s
Manufacturers & Services
(M&S) Division selected
Gregory Meyer, a senior
at Virginia Tech, as the re-
cipient of its 2017 Barry K.
Wendt Memorial Scholarship.
Meyer, who is pursuing a bachelor
of science in mining and minerals en-
gineering, was chosen for his academic
achievements and intent to pursue a ca-
reer in the aggregate industry.
Through his internships, Meyer
learned about the daily operations of
an aggregate quarry, including operat-
ing mobile equipment and performing
plant equipment maintenance. He also
helped coordinate quarry tours with
local boy scout and cub scout troops,
NSSGA says.
ASKS CONGRESS TO
ADJUST REGULATIONS
Louis Griesemer of Missouri-based
Springfield Underground called
on the House Small Business
Committee to take action on regu-
lations that cause delays and harm
small operations, the National Stone,
Sand & Gravel Association (NSSGA)
reports.
According to NSSGA, Griesemer
told the committee that many feder-
al permit requirements work at cross
purposes. For example, federal air
permits require the use of water for
dust mitigation. However, the Federal
Aviation Administration doesn’t want
Springfield Underground to store
water in ponds because the quarry
is close to an airport and migratory
birds could impact air traffic.
Griesemer serves as the co-chair of
the MSHA-NSSGA Alliance.
INFRASTRUCTURE
TRUMP NIXES
INFRASTRUCTURE
ADVISORY COUNCIL
President Donald Trump put a halt to
his still-developing Advisory Council
on Infrastructure.
According to Bloomberg, real
PHOTO BY KATIE HAUGLAND BOWEN VIA FLICKR.COM

estate developers Richard LeFrak

Thousands of flood victims were and Steven Roth were expected to
being housed at Houston’s George lead the group, which was estab-
R. Brown Convention Center, which lished by executive order this sum-
is slated to serve as the home of mer. The council was designed to vet
AGG1 Aggregates Academy & Expo transportation projects, help guide
next March. AGG1 is scheduled to be Trump’s infrastructure plan and
AGG1 Aggregates Academy & Expo is
co-located with the World of Asphalt. scheduled for March 6-8, 2018, in Houston. advise the president on infrastruc-
Houston is also expected to ture spending.
host the National Stone, Sand & Gravel Association’s (NSSGA) 2018 Annual The end of the Advisory Council on
Convention next March at the city’s Marriott Marquis. When approached short- Infrastructure comes after two other
ly after Hurricane Harvey, NSSGA noted that it is monitoring the situation in advisory councils to the president
Houston to determine any impact to AGG1 and the Annual Convention. were disbanded.

8 PIT&QUARRY October 2017 pitandquarry.com

 UPtoSPEED
MANUFAC TURERS

Michelin, TIA offer training course for

earthmover tire service Left to right:
Charles Cutlip,

M
ichelin Earthmover announced it has launched a new OTR tire techni-
300-level training and certification course with the cian, McCarthy
Tire Service;
Tire Industry Association (TIA) to certify dealer and the Michelin
industry service technicians who specialize in fitting earth- Man; and Mark
mover tires. Shimko, OTR
and commer-
“We are excited to work with TIA to offer this new cer- cial corporate
tified technician course,” says Richard Ameris, earthmover safety trainer
training manager, Michelin North America Inc. “In addition technician,
McCarthy Tire
to demonstrating the skills learned in the basic TIA program Service.
(200-level) and Michelin’s earthmover service technician sem-
inar, participants will be able to reinforce the culture of safety technician seminar are required before registering for the
needed for servicing mine, quarry and construction/industrial new course. The multi-day technician certification class is
tires to reduce injury.” designed for technicians with at least three years of active,
Completion of both TIA’s basic Earthmover Tire Ser- hands-on OTR experience to demonstrate safe application of
vice (ETS) program and Michelin’s earthmover tire service industry-accepted procedures and skills.

According to the company, the

GOVERNMENT
clients who attended the day-long
COMPANIES SELECTED forum learned about Cemex’s safety
TO BUILD BORDER-WALL practices, as well as how to improve
PROTOTYPES safety culture and trends in the con-
Although the U.S. Congress has struction industry. They also gained
not approved funding for a border insight into upcoming changes in the
wall between the United States and construction industry.
Mexico, the Trump administration has During the forum, Cemex experts
selected four companies to build con- from across the west region present-
crete prototypes. ed insights about labor shortages
PHOTOS BY MICHELIN (TOP); MITCHELL HAINDFIELD VIA FOTER.COM (BOTTOM)

The Washington Post reports in the industry, forecast growth in

that the prototypes will be built in
San Diego, and the four companies
chosen to do the work are Caddell
Construction of Montgomery,
Alabama; Texas Sterling Construction
of Houston; W.G. Yates & Sons
Construction of Philadelphia,
Mississippi; and aggregate producer
Fisher Sand & Gravel (DBA Fisher
Industries of Tempe, Arizona).
Each of the four contracts is worth
between $400,000 and $500,000,
and according to Ronald Vitiello,
acting deputy commissioner of U.S.
Customs and Border Protection, four
more contracts for non-concrete pro-
totypes will be announced soon.
The Washington Post reports the
Four companies are building concrete
border-wall prototypes.
concrete prototypes will be 30 ft. long
and up to 30 ft. high, and should be
complete this month. Officials will
then use small hand tools to test the
prototypes’ resistance to tampering
and penetration.
PRODUCERS
CEMEX HOSTS FIRST
BUILDING MATERIALS
FORUM
Cemex hosted nearly 70 customers
at its first building materials forum in
Scottsdale, Arizona.
Arizona
and how
chang-
es can
affect
business planning. Daniel Bachman,
senior economist for Deloitte, deliv-
ered the keynote address for the
event. During his presentation, he
covered U.S. and regional economic
trends.
The event concluded with a panel
discussion, where construction
industry experts shared the latest
developments in the Arizona market,
including changes in construction
standards and how to tackle them,
Cemex adds.

pitandquarry.com October 2017 PIT&QUARRY 9

 CUTTING EDGE
PRODUCE PRECISE 3-D MODELS
ASGCO’S point cloud laser scanner is a powerful high-speed
Focus3D X 130 HDR 3-D scanner, delivering realistic and
true-to-detail scan results. The laser technology looks at
thousands of points along the clearance plane, not just a few
sample points. The portable point cloud laser scanner ena-
bles accurate measurements of facades, complex structures,
production and supply facilities, accident sites and large-vol-
ume components. ASGCO’s point cloud laser scanner delivers
color overlays for scanned point clouds, which improves the
visualization of important details on site. The system can
capture more than 1 million points per second and can scan
through 360 degrees horizontally and vertically. Once the
chute and conveyor are modeled, the image is overlaid into
KEEPING IT CLEAN the cloud point scan to ensure there are no interferences and
that all modeled equipment fits properly. 
MADISON CHEMICAL’S AquaBlue is an alkaline detergent www.asgco.com
that removes dirt, oil, grease, sulphurized cutting oils,
metalworking fluids and more from a variety of surfaces.
With penetrating and wetting properties, it is a water-
based cleaner and degreaser suited for general-purpose
cleaning, as well as challenging degreasing applications.
AquaBlue has numerous applications, including the clean-
ing of components during maintenance and repairs, floors,
machinery, equipment, engines and more. It can be used
as a spray, in foaming or gelling applications, as a soak, in
ultrasonic tanks and with pressure washers. It’s safe on fer-
rous, stainless, aluminum and zinc alloys. AquaBlue is also
acceptable for use in food and beverage plants as an A1
general cleaning agent on all surfaces or for use with steam
or mechanical cleaning devices in all departments
www.madchem.com

ADDING OPTIONS FOR UNLOADING MATERIALS

ROCKLAND’S new SDB side dump bucket features a removable
dump plate that allows operators to transform the side dump
bucket into a general-purpose bucket. It allows operators to safely
unload material either conventionally or laterally at a 45-degree
angle. The SDB’s dump plate can be removed anywhere and also
functions as an easy-to-replace wear part, reducing the need for
re-builds and increasing the total life of the side dump bucket. All
Rockland SDB side dump buckets are powered by a heavy-duty,
dual-cushioned cylinder. The entire side dump bucket body and
dump plate is crafted from high-strength alloy plate, making it wear
and abrasion-resistant even with frequent contact with asphalt and
other hard surfaces.
www.rocklandmfg.com

10 PIT&QUARRY October 2017 pitandquarry.com

CAPTURE 3-D FACE PROFILES
The BlastMetriX UAV program from 3GSM GMBH allows quarries and mining
operations to take advantage of UAV technology to capture 3-D face profiles for
enhanced visualization of the blast area. The system can be used as a tool for sur-
veying large blast
sites and does not
require the use of
propriety UAVs. The
system requires only
the use of aerial
targets or the stand-
ard BlastMetriX 3-D
targets as reference
points. The low-fly-
ing UAV captures
multiple data-rich
overlapping images
to generate hun- ADJUST
dreds of thousands
of datapoints for accurately characterizing typography of the surveyed area and PARAMETERS
creating a 3-D profile of the face to ensure blast safety and performance. The scal-
able BlastMetriX UAV software allows companies to integrate as much or as little WHEN WELDING
technology as required.
MILLER ELECTRIC MFG. CO.
www.ramets.com
enhanced its ArcReach technol-
ogy with two new capabilities:
cable length compensation (CLC)
and adjust while welding (AWW)
KEEP CONVEYOR ON TRACK technology. CLC technology
automatically compensates for
A new powered conveyor belt tracker from MARTIN ENGINEERING delivers con- voltage drops in the weld cable,
tinuous precision adjustments of hard-to-track reversing conveyors, helping oper- and AWW technology allows for
ators reduce spillage and extend the life of belts and other system components. precise adjustments and parame-
The belt tracker has the ability to center the belt regardless of the travel direction. ter changes at the wire feeder or
The powered conveyor belt tracker can run on 110V/220V power or a plant’s exist- remote without stopping the arc.
ing compressed air – and it can also create its own mini power station for locations So, operators can make changes
without electricity or plant air. The belt tracker can be specified with either a pneu- during welding to compensate
matic or electric actuator. A direct sensor determines which side of the unit should for heat buildup, changes in weld
be actively tracking the belt. position or variations in part fit-up.
www.martin-eng.com These expanded ArcReach capa-
bilities are available by pairing
enhanced ArcReach accessories
with the new XMT 350 FieldPro
from Miller. The XMT 350 FieldPro
lineup includes a polarity revers-
ing model that joins the larger
ArcReach portfolio. The XMT 350
FieldPro power sources are com-
patible with all ArcReach accesso-
ries, which include multiple feeder
and remote options.
www.millerwelds.com

pitandquarry.com October 2017 PIT&QUARRY 11

 OPERATIONS

THE EVOLUTION OF
ALBERT FREI
& SONS
How a space-strapped, independent
operation on Denver’s outskirts
effectively serves the market.
BY K EV IN YANIK

T
he single stockpile of washed concrete aggregate – 67s

PHOTOS BY KEVIN YANIK

to be precise – is an anomaly at Albert Frei & Sons’
Walstrum Quarry.
Call the small pile a luxury, even, for this operation
nestled along U.S. Route 6 and Interstate 70 in the Rocky Mountains,
about 30 miles west of the heart of Denver.

Overhead and
ground views of the
Walstrum Quarry’s
loadout system,
which can handle
as many as 500
customers per day.

12 PIT&QUARRY October 2017 pitandquarry.com

FROM INCREASING
OIL LIFE TO
EXTENDING
HIGHWAYS
TOGETHER IT’S POSSIBLE
To discover how we can help keep your
business running, go to shell.us/lubricants

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 OPERATIONS
Pressed for space since 1982,
when Albert Frei Sr. permitted
and started production at this
crushed-stone site, loadout is
very much a just-in-time function
driven by specialized systems
of bins and silos that directly
load customer trucks, as well as
other components that propel
efficiencies.
“We’ll maximize your load
every time right in the center of
your truck, and you’re going to
be ticketed and out in five minutes,” says
Albert Frei Jr., company president.
One of the most unique components
of Albert Frei & Sons’ loadout is a wash
system that was originally put in for a
former customer who produced concrete
railroad ties. For Albert Frei & Sons, whose
top-selling product is its washed 67s, the
system eliminates any rehandling the
operation would otherwise take on if it
wasn’t directly loading trucks via the silos.
“If you rehandle the quarry rock three
14 PIT&QUARRY October 2017
or four times, you subject yourself to the
mercy of a loader operator and contam-
ination,” says Albert Jr., adding that the
wash system is composed of a 6-ft. x 20-
ft. double-deck screen and four 250-ton
silos. “When we rinse it, it goes into the
silos and directly into the truck. It never
touches the ground.”
Concepts like the loadout wash system
are ones the late Albert Sr. pioneered at the
Walstrum Quarry, the last quarry of its
kind to be permitted on Colorado’s Front
The construction of the
secondary/tertiary plant within the
green facility pictured above was a
bit of a risk just ahead of the Great
Recession. But time has proven the
investment in equipment – such
as Metso’s HP500 cone crushers,
pictured at left, and four-deck
Deister screens – to be worthy.
Says Albert Frei Jr.: “Plant mangers
dream of building this kind of plant,
but logistically there are few who
have gotten to it because of the
financial responsibilities that come
with the big companies.”
Range, according to Albert Frei & Sons.
“My dad knew his quarry was farther
away from the market,” Albert Jr. says.
“He knew his freight rates would be more
expensive than his competition. So how
do you get the best freight rate per mile?”
Well, by quickly getting customers
back on the road.
“Elsewhere, maybe you get four loads
per day,” Albert Jr. says. “Here, they can
get five. That has helped to separate us
with customers.”
pitandquarry.com

MOBILE EQUIPMENT
RUNDOWN:
ALBERT FREI & SONS
2 – WA900 base loaders (Komatsu)
4 – WA600 loaders (Komatsu)
2 – PC490 excavators (Komatsu)
5 – 605 haul trucks (Komatsu)
2 – 775 haul trucks (Caterpillar)
Precisely weighing material in hoppers
before it’s distributed to customers is
another approach that gets customers
at Albert Frei & Sons back on the road
quickly.
Still, keeping all of those bins and
silos full is a science the operation has
mastered over a number of years. Albert
Frei & Sons’ success stems from a number
of areas – from a large investment a de-
cade ago in its secondary/tertiary plant,
to the 40 employees ranging from new
hires to 30-year veterans who currently
work on site.
“The real credit of success goes to the
boots on the ground,” Albert Jr. says. “Our
people are the greatest asset within the
business. If we don’t have good people,
we have nothing.”
The goal at the end of the day, of
course, is to send those employees home
safely. In terms of production, the op-
eration’s goal is to continuously keep
those bins and silos full. And that means
providing employees with a plant that
can essentially produce 3.3 million tpy
in just-in-time inventory.
“We fill the bins up every night and
it’s a wild ride,” Albert Jr. says.
IT STARTS WITH A VISION
But getting a sense of why Albert Frei &
Sons operates as it does – and why it’s made
some of the investments in equipment
and technology that it has – requires an
understanding of the Walstrum Quarry’s
origins.
“The Denver metro area was pretty
flush with sand and gravel,” Albert Jr.
says. “The gravel pits in that area pros-
pitandquarry.com
pered pretty well, but they eventually all
got depleted.”
As the availability of more metro-area
alluvial pits dried up, five producers looked
to the Front Range for opportunities in
the 1970s and 1980s, Albert Jr. says. The
producers targeted Boulder County to
the northwest of Denver and Jefferson
County to the west and southwest. But
all five producers came up empty in
their attempts to permit a crushed stone
site, he says.
“Jefferson and Boulder Counties like
their Front Range-scenic views,” Albert
Jr. says.
Albert Jr.’s father, however, had the
foresight to go one more county to the
west – to Clear Creek County. Albert
Sr. ultimately got his permit, and the
Walstrum Quarry opened alongside the
highway.
“Everybody kind of thought my dad
was crazy because we’re so far away from
the market,” Albert Jr. says. “We’re about
22 miles farther away than our competi-
tion. They all kind of thought he was a little
delusional that this would really work.”
The setup has worked, though. The
first 10 years in business were difficult,
according to Albert Jr. But his dad bided
his time and watched more ideally situated
alluvial gravel sites fade away. And now,
with an estimated 40 to 50 million tons
remaining in the operation’s permit, the
Walstrum Quarry is considered a go-to
site for the Denver area despite its more
remote location.
“We’re really the last independent
aggregate supplier in the Denver market,”
Albert Jr. says.
OPTIMIZING THE PLANTS
Based on its location, Albert Frei & Sons
must enhance any efficiency it can to di-
minish the rewards its nearest competitor
reaps being 22 miles closer to the market.
The secondary/tertiary plant the operation
built 10 years ago is a classic example of an
investment that’s enhanced the operation’s
efficiency, as well as its production. www.kpijci.com
“This is a really unique plant,” says
October 2017 PIT&QUARRY 15
 OPERATIONS
Little touches like the conveyor speed
wheels that enhance production are often
the result of partnerships with engineers,
equipment suppliers and industry
consultants, says Albert Frei Jr.
Albert Jr., who erected the enclosed plant
over a two-year period with the help of
design and engineering firm M.A. Bielski
& Associates, his brother Tommy, and
skilled labor from existing production
and maintenance crews. “In theory there
are three separate plants in there. They
are identical, but they are isolated so
they each can run independently. The
purpose of that is if one line goes down
or if one crusher goes down, the other
two are running just fine. They’re not
restricted by anything else. That’s part
of the redundancy we planned into this.”
Three separate conveyor lines feed into
the secondary/tertiary plant from a surge
pile the primary produces.
“The surge pile is a combination of
everything that meters into [the second-
ary],” Albert Jr. says. “We separate the
three products from the surge pile. We
have natural fines, and all of the coarse,
surge rock comes into [the secondary].”
In other aggregate operations, a
downed secondary plant puts a halt to
any activity at a tertiary. Albert Frei &
Sons does not, however, have that worry.
“The really unique thing about this
plant is that there are eight FMC feeders
moderating and feeding the different rates
of product,” Albert Jr. says. “There are
three HP500 Metso cone crushers inside
and three 8-ft. x 24-ft. four-deck Deister
[screens]. The three bottom decks are your
traditional screens, and that fourth deck
pitandquarry.com
gives us flexibility.”
The design gives Albert Frei & Sons
the ability to make three “core” products
plus three secondary products at a time.
According to Albert Jr., that fourth screen
deck essentially serves as the operation’s
“secondary” plant.
It’s a unique setup to say the least.
“[One day] we’re making ballast, which
is a 2.5-in.-minus,” he says. “So we can run
one line making 2.5-in. and other ones are
making 1 in. The next day, we shut down
that 2.5-in., close up that line, at the touch
of a button open the other one and make
a #4, which is like a 2-in.-minus.
“We consolidated everything in, went
vertical, and made a secondary out of an
extra deck on a screen,” Albert Jr. adds.
“We had to get real creative because we
don’t have a lot of real estate like these
big, massive quarries.”
KEEPING PLANTS IN CHECK
Plant automation makes the experience at
both the secondary/tertiary plant and the
BY THE NUMBERS:
THE WALSTRUM
QUARRY
2
Daily shifts at the quarry.
22
Miles between the quarry and
its nearest competitor, which is
significantly closer to the
Denver market.
300
Acres in the Walstrum Quarry’s
permitted boundary. The property
spans a total of 2,000 acres.
3.3 million
The quarry’s annual
production tonnage.
40 million
The approximate number of tons
www.kpijci.com
mined at the Walstrum Quarry
over 35 years.
October 2017 PIT&QUARRY 17
HEARD AT THE PLANT LATE ONE AFTERNOON…
Dad: Son, I really need to reire, and I know you don’t want to
run this company without me. Business is the best it has
been in years, and we’re as profitable as ever. And I keep
geing calls from the big boys asking if I want to sell - but
I just don’t know how to go about it.

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and now that ime is back. We can provide the best markeing effort and
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 OPERATIONS
Three conveyors angle upward into the Walstrum Quarry’s secondary/tertiary plant,
which was designed vertically owing to space constraints.
primary a more pleasant one. Both plants
are fitted with programmable logic con-
trollers (PLCs) that increase their uptime,
although the design of the secondary/
tertiary is a bit more sophisticated.
“For us, the automation isn’t to reduce
the size of our labor force but to enable
it,” says Kent Brown, senior electrician at
Albert Frei & Sons. “You see companies try
to implement a lot of automation to reduce
their labor force, but that’s not our goal.”
On the secondary/tertiary plant, for
example, the operator consumes data
related to motor amperages, materi-
al volumes and more. The operation’s
touch-of-a-mouse system empowers the
operator with an assortment of data in
an easy-to-read form.
“He can take information – averages,
feed rates and plant production data – to
make decisions that allow the plant to run
more efficiently,” Brown says.
The same applies at Albert Frei & Sons’
primary, except the operator there reacts
with the push of buttons.
“The wiring behind the controls goes
to a PLC, and the PLC makes the decisions
on the output of the plant,” Brown says.
“It lets you monitor for safety and other
issues. If you have a conveyor shut down,
for example, it will shut down everything
behind it that feeds that conveyor so you
don’t have big messes.”
In the rare event that a PLC fails,
Albert Frei & Sons has a second check
pitandquarry.com
in place to avoid plant issues.
“Each conveyor has a speed wheel,”
Albert Jr. says. “The speed wheel measures
motion. Most of the drives here are V-belt
driven – it’s a motor, belt and gearbox.
Say the V-belts break – the motor’s still
running but the conveyor stops moving.
The computer thinks the starter is still
engaged but the belt is not operating.
“Well, now you have that second
check. If the belt is not moving, the
speed wheel senses it, alerts you and
shuts everything else down behind it.”
Before, belts could continue to stall
and create spillages.
“Then you’re spending an hour or
two cleaning it up, and you’re pushing
your conveyors later to try to catch up,”
Albert Jr. says.
It’s little things like speed wheels and
big things like the company’s willingness
to strategically invest in equipment,
technology and skilled labor that make
Albert Frei & Sons a competitive outfit
despite its home in the mountains.
“I want to get our guys whatever
tools they need to keep those bins full,”
Albert Jr. says. P&Q
MORE TO COME
Look for additional coverage based
www.kpijci.com
on Pit & Quarry’s 2017 visit to Albert
Frei & Sons in an upcoming edition.
October 2017 PIT&QUARRY 19
From individual components to complete turnkey solutions
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 DUST CONTROL

CLEARING
THE
AIR

22 PIT&QUARRY October 2017

 E
ven though the Occupational Safety & Health Administration’s (OSHA)
rule on respirable crystalline silica is now being enforced, a number of
businesses undoubtedly have lingering questions about the rule’s impact
on them.
BossTek’s Mike Lewis, for one, can attest to some of the confusion
that exists in the marketplace.
“There’s been a huge uptick in calls related to the silica standard,” says Lewis,
sales manager at BossTek, in an early summer conversation. “I feel like 50 percent
PHOTO BY KEVIN YANIK

of the calls lately all reference that silica rule.”

pitandquarry.com October
June 2017 PIT&QUARRY 23
 DUST CONTROL

Among the questions Lewis’ customers

are asking: Does OSHA’s rule apply to us?
What measures should be taken to be in
compliance with the rule? And what are
the consequences of non-compliance?

THE RULE’S APPLICABILITY

According to Adele Abrams, an attorney
whose practice is focused on occupational
and mine safety and health, operations
that fall under the regulatory purview of
the Mine Safety & Health Administration
(MSHA) are not obligated to meet OSHA’s
silica standard. MSHA has tabled imple-
mentation of its own silica rule for the
moment, she says, but the topic remains
on the agency’s regulatory agenda.
When developed, though, MSHA’s rule
will likely mirror OSHA’s rule, according
to Abrams.
“MSHA has had this on their regulatory
OSHA’s new silica rule is prompting
employers in construction to turn to
solutions such as vacuum dust-collection
systems for tasks like tuckpointing. What
sorts of dust-collecting solutions might
aggregate operations turn to should a new
MSHA silica rule come to life?

agenda as long as OSHA has been work-

ing on this rule,” Abrams says. “MSHA
just came out with a new semi-annual
regulatory agenda – the first under the
Trump administration. They nuked about
90 percent of what was left on the Obama
administration’s regulatory agenda.”
Yet silica remains on the agenda, she
says.
“It’s to be determined,” Abrams says.
“We’re very emphatic that what they do is
going to parallel the OSHA rule.”
For construction, compliance with
OSHA’s rule means providing a work
PHOTO COURTESY OF TECH IMAGE

environment that reduces the permissible

exposure limit (PEL) of crystalline silica
to 50 micrograms per cubic meter (µg/m3)
averaged over an eight-hour shift, with
an action level of 25 µg/m 3. A number
of industries have argued over the last
year and a half that the previous limit
(100 µg/m3) was protective when reliably

24 PIT&QUARRY October 2017 pitandquarry.com

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 DUST CONTROL

enforced and complied with, adding that silica-related disease

has dropped dramatically over the course of four decades since
a PEL was put in place.
Enforcement of the OSHA standard was slated to come on-
line early this summer, but the agency delayed enforcement to
conduct additional outreach and provide educational materials
and guidance for employers. At press time, the standard was
still slated to be enforced Sept. 23 for the construction sector,
with enforcement for general industry commencing June 23,
2018. Some OSHA “state plan states,” including Virginia, began
enforcement in construction on June 23 of this year.

MEASURES TO TAKE
Mine operators are already required to provide training on
potential silica hazards as part of MSHA’s mandated hazard
communication training, but those who operate a pit or quarry
would be wise to familiarize themselves with OSHA’s standard
so they’re best prepared when an applicable rule arrives.
For example, construction employers are required under
OSHA to establish and implement a written exposure control
plan that identifies tasks that involve exposure and methods used
A variety of sources produce dust in an
aggregate operation, including crushing
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Employers are required to offer medical
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 DUST CONTROL
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Dust control is already a fundamental part
of aggregate operations through the use of
equipment such as water trucks.
THE COSTS INVOLVED
Of course, all of these measures come with
tangible costs to businesses. OSHA estimates
the requirements in the new standard will
cost employers $1.03 billion each year, with
nearly two-thirds of the annual expenditure
($661.5 million) dedicated to engineering
controls that mitigate silica.
Respirators ($32.9 million) are another
cost tied to compliance.
“Employers are required to use ‘engineer-
ing controls’ such as vacuum dust-collection
systems and water-delivery systems to
limit worker exposure to respirable silica
dust and use respirators as required,” says
Joe Nasvik, who has more than 40 years of
experience in the concrete and decorative
concrete industries.
OSHA has even assigned engineering and
work practice control methods to specific
PHOTO BY KEVIN YANIK
equipment and tasks. For example, when
using vehicle-mounted drilling rigs for rock
and concrete, employers can be in compli-
ance in one of two ways: Use a dust-collection
system with a close-capture hood or shroud
pitandquarry.com
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 DUST CONTROL
around the drill bit, with a low-flow water
spray to wet the dust at the discharge point
from the dust collector; or have employees
operate from within an enclosed cab and
use water for dust suppression on a drill bit.
No respiratory protection is required for
30 PIT&QUARRY October 2017
employees in the vehicle-mounted drilling
rig for rock and concrete example, but
OSHA does specify which equipment and
tasks require use of respiratory protection.
“This entire effort ties back to keeping
people safe,” Nasvik says. “There is no cure
for silicosis or other silica-related diseases,
so worker health depends on limiting ex-
posure. Although regulation is sometimes
viewed as limiting productivity, in this
instance it can actually be enhanced. The
respirable silica dust regulations require
use of already accepted control methods
that make implementation easier.”
In addition to engineering controls and
respirators, medical surveillance ($96.4 mil-
lion), exposure assessments ($96.2 million),
familiarization and training ($95.9 million)
and written exposure plans ($44.3 million)
are among the other big expenditures tied
to compliance. But OSHA estimates that
nearly $8.7 billion in annualized benefits
will be realized as a result of the costs em-
ployers take on.
Non-compliance with OSHA’s standard
comes with a cost, as well. One serious
violation could cost an employer up to
$12,675, while a willful violation can be
assessed at up to $126,749 per affected
worker, Abrams notes.
SO WHAT’S NEXT?
Although an MSHA rule on silica isn’t
immediately coming down the pike, it’s
likely only a matter of time before one does.
“In construction and demolition, they’re
often in close proximity to neighbors,” Lewis
says. “Aggregate operations are sometimes
in the middle of nowhere – some of them
are in close proximity to neighbors – but
they’re not noticed as much.
“With this coming into effect, I’m sure
[aggregate producers] are going to have
a little bit of a rude awakening,” he adds.
“They’re going to have to act fast.”
Consider some key sources of dust at
aggregate operations. Dust is produced at
primary crushers, at conveyor belt transfer
points and at load-out areas. Could these
be among the areas targeted for future
enforcement?
“Silica is affecting a lot of different in-
dustries,” Lewis says. “If you’re demolishing,
there’s concrete in there. If you’re crushing
stone, that’s silica. So this is transcending a
lot of industries.” P&Q
pitandquarry.com
 MOTORS, DRIVES & BEARINGS

Motor maintenance
in an IIoT world
Knowing what to look for is a first step in determining
the type of damage bearings have sustained.
BY DAN PHILLIPS, THERESA SMIGUR A AND RICK MUNZ

I
n an industry driven toward higher
levels of productivity, with the ulti-
mate goal being minimal downtime,
proper maintenance of rotating
equipment such as electric motors
is essential.
Establishing a healthy blend of tra-
ditional best practices and emerging
Industrial Internet of Things (IIoT)-en-
abled technology is key in developing the
most cost-effective motor maintenance
program.
The content in this article provides
an overview of emerging technologies
within the IIoT, which work in tandem
with traditional best practices to ensure Imagine the efficiencies that can be achieved by transforming a personal computer or
mobile device into an operation command center.
your operation is always performing at its
optimum level of productivity and pro- anced rotor, as well as by utilizing best cation checklist to help ensure you don’t
viding the highest possible return on the practices during installation, such as laser miss any critical nuances, such as specifi-
investment you’ve made in a pit or quarry. alignment techniques. A special insulation cation of roller bearings for certain belted
system and/or shaft grounding may be loads. Also, beware of “motor creep,” the
START WITH THE BASICS required if your motor is being powered phenomenon that results from replacing
The best place to begin a motor manage- by a variable frequency drive. original motors with an available stock of
ment program is before you buy it. One other consideration is whether incorrect power ratings.
The performance of any asset is depen- the motor will be stored for an extended Maintenance strategies are best de-
dent upon its inherent reliability, operating time prior to, or between uses, as this veloped using reliability-centered main-
conditions and maintenance strategy. No may require specifying space heaters and tenance practices. This begins with iden-
PHOTO COURTESY OF REGAL BELOIT AMERICA INC.

amount or manner of maintenance is
going to improve the reliability of a poorly
designed or manufactured motor. Select
a motor from a reputable manufacturer
who stands behind their product.
Because one of the common failure
modes is bearing contamination, select a
motor with adequate ingress protection.
Bearing failures due to misalignment or
excessive vibration can be reduced by
specifying a motor with a precision-bal-
other precautionary intervention such
as manual rotation of the shaft every 30
days to redistribute the grease and prevent
damage to the bearings.
“Right-sizing” a motor for its intended
application means understanding what
will be expected of it. Make sure it’s of a
sufficient but not excessive horsepower
rating; operation at reduced loading tends
to result in lower efficiency.
Most manufacturers have an appli-
tifying critical equipment in the facility,
determining applicable failure modes,
and employing various methods to mit-
igate or eliminate those failure modes.
Mission-critical motors deserve special
attention; establish a spares inventory
from which maintenance personnel can
draw upon in an emergency.
Obtaining baseline performance data
on new or rebuilt motors will provide use-
ful information, which can be incorporated

32 PIT&QUARRY October 2017 pitandquarry.com

 AGGREGATE SYSTEMS

To learn more visit: www.elrus.com, email: info@elrus.com or call 888-535-7877

 MOTORS, DRIVES & BEARINGS
into the various predictive maintenance
options offered in a traditional venue or
via IIoT-enabled technologies that pro-
vide local and remote monitoring with
advanced analytics.
Traditionally, time- or cycle-based
maintenance strategies have been utilized
to prevent failures. This typically incor-
porates periodic physical inspection using
your senses to safely see, hear, touch and
smell the many clues your motor is giving
you to alert you to abnormalities – we
recommend you avoid tasting your motor.
Unfortunately, human senses are not
acute enough to detect failures early in
their progression, requiring an extensive
inventory of spare parts (and their associ-
ated carrying costs) to be available when
equipment fails.
According to a frequently cited Electric
Power Research Institute (EPRI) study, the
34 PIT&QUARRY October 2017
relative cost of a proactive maintenance
program is 77 percent less than a reactive
program. Since downtime on a rock
crusher in a typical quarry can be many
thousands of dollars per hour, the benefit
in establishing and maintaining a proac-
tive maintenance program is obvious. In
an ideal world, elimination of downtime
through predictive techniques would
save the average pit or quarry millions of
dollars each year while improving worker
productivity and safety.
Sophisticated, yet simple to deploy,
IIoT-enabled systems gather and report
operation conditions, identify fault pro-
gression through pattern recognition and
trending, and calculate duty cycles via a
cloud-based network.
As IIoT-based systems become more
common, their smaller sensors and lower
costs will make them more attractive to
your operation. Imagine gathering and
reporting operational conditions, duty
cycles and trending of your valuable
equipment’s lifecycle via a local or cloud-
based network.
OPERATING PARAMETERS
Fundamentally, an electric motor con-
verts electrical energy into mechanical
energy, exchanging current for torque.
In the process, many critical electromag-
netic and mechanical forces come into
play. Each element tells a story about the
motor’s overall health. Effective motor
maintenance programs should detect the
following faults and conditions:
◾ Rotor circuit porosity or rotor faults
◾ Motor misalignment
◾ Rotor eccentricity
◾ Power quality issues
◾ Overload conditions
pitandquarry.com
◾ Load imbalance and/or disturbances
◾ Foundation looseness
◾ Bearing faults
Whether traditional or more innovative
methods are employed, the same operating
parameters must be captured to provide
useful signals to maintenance personnel.
These include:
Operating temperature. What is the
baseline versus manufacturer/rebuilder
specifications? Is there a trend? Are ap-
plication demands changing, impacting
operating temperature? Has the motor
been relocated to an application different
from that which it was originally selected?
Simplistic measurements of the mo-
tor’s temperature, such as the infamous
“calibrated hand,” should be avoided – for
obvious reasons. Not only is this practice
unsafe, but it’s terribly inaccurate. Tem-
perature of the windings and bearings is
the No. 1 clue as to a motor’s health, as
most other anomalies manifest themselves
as motor heating.
Vibration. Vibration levels outside
specification can provide useful clues
as to irregularities within and external
to a motor, from defects in material or
workmanship to misalignment or an
inappropriate mounting arrangement
with inadequate support structure.
Vibration is also used to detect bearing
faults long before bearings actually fail.
By tracking vibration over time, many
mechanical faults can be detected well in
advance before they become catastrophic
failures.
Sound level. Excessive sound levels can
be traced to electrical or mechanical issues.
Mechanically induced sound is most often
another symptom of vibration levels, while
electrical noise can be attributed to issues
within the motor or power supply. Good
systems can discern the difference.
Voltage. Measurement of motor voltage
– and equally important, the balance of
voltage between each of the three phases –
is a critical piece of data used to determine
motor health.
Current. Because the motor’s output
pitandquarry.com
torque is directly related to input current,
measuring this important parameter
helps you understand whether the motor
is operating within its specified limits.
Measuring and plotting this data over
time provides useful clues as to whether
anything in the motor’s operation or
within the application has changed, which
could signal imminent failure.
With the use of motor current signature
analysis, even more detailed data, such as
failed windings or a broken rotor bar, can
be gleaned from just the motor’s current.
TEXT ALERTS
Today, more than ever, data from nu-
merous sources is available. This can aid
in improving operations, performance
and reliability. These continuous data
streams exceed human capability to
effectively analyze, interpret and act on
this information.
Available IIoT-based systems run the
spectrum from relatively simple motor
sensors, which monitor vibration, tempera-
ture, current and voltage, to GPS-based
remote monitoring equipment capable
of transmitting operating conditions
and trends anywhere in the world. More
sophisticated systems offer predictive
and adaptive functionality to sense trou-
ble and command the system to reduce
loading while maintenance personnel are
dispatched to investigate the situation.
Imagine the downtime you can prevent
when your monitoring system automati-
cally sends you an email or text message
alerting you to an equipment failure
before it actually fails. Imagine no more,
because the days when you can do all that
are here. P&Q
Dan Phillips is the director of PTS lifecycle
services at Regal Beloit America Inc.;
Theresa Smigura is innovative devel-
opment engineer in R&D and IIoT at the AGGREGATE SYSTEMS
company; and Rick Munz is Regal Beloit’s
product/marketing manager of general
industries, commercial and industrial
systems. www.regalbeloit.com
October 2017 PIT&QUARRY 35
 MOTORS, DRIVES & BEARINGS

TYPES OF
BEARING
DAMAGE
Knowing what to look for is a first step in determining
the type of damage bearings have sustained.
EDI T ED BY K EV IN YANIK

A
n important part of bearing repair is properly
diagnosing the root of the problem.
This story explores the most commonly iden-
tified causes of damage for anti-friction bearings,
including cylindrical, spherical, tapered and ball
designs, taking you a step closer to solving your bearing
maintenance issues.

WEAR, ABRASIVE CONTAMINATION

Foreign material (i.e., sand, fine metal) in the bearing can cause
excessive abrasive wear. In tapered bearings, the roller ends
and cone rib will wear to a greater degree than the races. This
wear causes increased end play or internal clearance, which
can reduce fatigue life and create misalignment in the bearing.
WEAR, PITTING AND BRUISING
Hard particles (i.e., metal chips, dirt) rolling through the bear-
ing may cause pitting and bruising of the rolling elements and
races. These particles can travel within the lubricant, through
the bearing and eventually bruise (dent) the surfaces. Raised
metal around the dents acts as surface-stress risers to cause
Excessive heat generation caused complete seizure of this bearing.
in through damaged, worn or inadequate seals. Improperly
washing and drying bearings can also cause considerable
damage.
When preparing bearings for storage, wash and dry the
bearings, then coat them with oil or another preservative and
wrap them in protective paper. Always store bearings, new or
used, in a dry area, and keep them in their original packaging
to reduce the risk of static corrosion.
PHOTOS COURTESY OF THE TIMKEN CO.

premature spalling and reduce bearing life. INADEQUATE LUBRICATION

ETCHING
Etching, or corrosion, is among the most serious problems
anti-friction bearings encounter. The high degree of surface
finish on races and rolling elements makes them more sus-
ceptible to corrosion damage from moisture and water.
Etching often results from condensate collecting in the
bearing housing from temperature changes. Moisture can get
It’s important that the right lubricant amount, type, grade,
supply system, viscosity and additives be properly engineered
for each bearing system. Selection should be based on histo-
ry, loading, speeds, sealing systems, service conditions and
expected life. Without proper consideration of these factors,
bearing and application performance may be underwhelming.
The following section outlines the progressive levels of
bearing damage caused by inadequate lubrication:

36 PIT&QUARRY October 2017 pitandquarry.com

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 MOTORS, DRIVES & BEARINGS
Careless handling and using improper tools
during installation may cause cage or retainer
damage. These are usually made of mild steel,
bronze or brass, and can be easily damaged.
38 PIT&QUARRY October 2017
Level 1: Discoloration
◾ Metal-to-metal contact results in ex-
cessive bearing temperature.
◾ High temperatures result in discolor-
ation of the races and roller.
◾ In mild cases, the discoloration is
from the lubricant staining the bearing
surfaces. In severe cases, the metal is
discolored from high heat.
Level 2: Scoring and peeling
◾ Insufficient or complete lack of
lubricant.
◾ Selecting the wrong lubricant or
lubrication type.
◾ Temperature changes.
◾ Sudden changes in running conditions.
Level 3: Excessive roller end heat
◾ Inadequate lubricant film results in
localized high temperatures and scor-
ing at the large ends of the rollers.
Level 4: Total bearing lockup
◾ High-localized heat produces metal
flow in bearings, altering the original
geometry and the bearings’ material.
This results in skewing of the rollers,
destruction of the cage, metal transfer
and complete seizure of the bearing.
FATIGUE SPALLING
Spalling is the pitting or flaking away
of bearing material. This primarily oc-
curs on the races and rolling elements.
The many types of primary damage
referenced throughout this guide may
eventually deteriorate into a secondary
spalling damage mode. Three distinct
modes are classified:
1. Geometric stress concentration
(GSC) spalling. The causes include
misalignment, deflection or edge load-
ing that initiates high stress at localized
regions of the bearing. GSC occurs at the
extreme edges of the race/roller paths,
or it can also be the result of shaft or
housing machining errors.
pitandquarry.com
 MOTORS, DRIVES & BEARINGS

2. Point surface origin (PSO) spall-
ing. Very high and localized stress gen-
erates this type of damage. The spalling
is typically from nicks, dents, debris,
etching and hard-particle contamination
in the bearing. It’s the most common type
Large particle contamination wedged
in the soft cage material can result in
grooving.
of spalling damage and often appears as
arrowhead-shaped spalls, propagating in
the direction of rotation.
3. Inclusion origin spalling. This
damage, in the form of elliptically shaped
spalls, occurs when there’s bearing
material fatigue at localized areas of
sub-surface, non-metallic inclusions
following millions of load cycles.
Due to improvements in bearing
steel cleanliness in recent decades,
encountering this type of spalling
is unlikely.
EXCESSIVE PRELOAD
OR OVERLOAD
Excessive preload can generate a
large amount of heat and cause damage
similar in appearance to inadequate
lubrication. Often, the two causes may
be confused. So it is important to check
the bearing thoroughly to determine the
root problem.
A lubricant that’s suitable for normal
operation may be unsuitable for a heavily
preloaded bearing, as it may not have the
film strength to carry the higher loads.
EXCESSIVE END PLAY
Excessive end play results in a very small
load zone and excessive looseness between
the rollers and races outside the load
zone. This causes the rollers to unseat,
leading to skidding and skewing as the
rollers move into and out of the load zone.
This movement creates scalloping in the
cup race and can also cause cage wear.
MISALIGNMENT
Misalignment will shorten bearing life
depending on the degree of misalign-

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 The Original and Still
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When Dodge® created the Type E bearing in 1943,
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 MOTORS, DRIVES & BEARINGS

This cylindrical bearing inner ring over these surfaces, creating premature,
shows etching and corrosion. localized spalling.

Typical causes of misalign- DAMAGED BEARING

ment. To achieve longer life, the seats
and shoulders supporting the bearing
must be within the specified limits set by
the manufacturer. If the misalignment
exceeds those limits, the load on the
bearing won’t be distributed along the
rolling elements and races as intended.
THE 812 GEO™ HSI
INTELLIGENCE
ment include:
◾ Inaccurate machining or wear
of housings or shafts.
◾ Deflection from high loads.
◾ Out-of-square backing shoul-
ders on shafts or housings.
HANDLING AND
INSTALLATION DAMAGE
Care must be taken when han-
dling and assembling bearings so the
rolling elements, race surfaces and edges
aren’t damaged. Deep gouges in the
race surface or battered and distorted
rolling elements will make metal rise
around damaged areas. High stresses
will occur as the rolling elements go
CAGES OR RETAINERS
Careless handling and using improper
tools during installation may cause cage
or retainer damage. Cages and retainers
are usually made of mild steel, bronze
or brass and can be easily damaged. In
some applications, environmental and
operating conditions can cause fractured
cages or retainers. If this occurs, contact
a service engineer.
HIGH SPOTS AND
FITTING PRACTICES
Careless handling or damage caused
when driving outer races out of housings
or wheel hubs can create burrs or high
spots in the outer race seats.
If a tool gouges the housing seat sur-
face, it will leave raised areas around the
gouge. If these high spots are not scraped
or ground down before reinstalling the
outer race, they will transfer through the
outer race and cause corresponding high
spots in the outer race’s inside diame-
ter. Stresses increase when the rolling
elements contact this high area, which
can shorten service life.

ON TRACKS. IMPROPER FIT IN

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HOUSINGS OR SHAFTS
Always follow the manufacturer’s recom-
mended bearing fit to ensure bearings
perform properly. Generally, the bearing
race – where the rotating load exists –
is applied with a press or tight fit. An
example is a wheel hub, where the outer
race should be applied with a press fit.
The races on a stationary axle would
normally be applied with a light or loose
fit. Where the shaft rotates, the inner
race should normally be applied with
a press fit, and the outer race may be
applied with a split fit or even a loose fit.
BRINELL AND IMPACT DAMAGE
Brinelling from improper bearing as-

42 PIT&QUARRY October 2017 pitandquarry.com


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 MOTORS, DRIVES & BEARINGS
sembly and disassembly happens when
a force is applied against the unmounted
race. When mounting a bearing on a
shaft with a tight fit, pushing the outer
race will exert an excessive thrust load
and bring the rolling elements into sharp
contact with the race, causing brinelling.
Extremely heavy impact loads can
also result in brinelling of the bearing
races, or even fracture the races and
rolling elements.
FALSE BRINELLING
False brinelling is fretting wear caused by
slight axial rolling-element movements
while the bearing is stationary. Vibration
can make the rolling element slide back
and forth across the race, wearing a
groove into it.
Roller bearings also exhibit false
brinelling when used in positions that
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44 PIT&QUARRY October 2017
encounter very small reversing angular
oscillation – less than one complete
rotation of the rolling element.
To distinguish false brinelling from
true, examine the depression or wear
area. False brinelling will wear away
the surface texture, whereas the original
texture will remain in the depression of
a true brinell.
BURNS FROM
ELECTRIC CURRENT
Arcing occurs when an electric current
that passes through a bearing is broken
at the contact surfaces between the races
14 steps for bearing analysis success
Consider following these steps when
investigating any bearing damage:
1. Gather operating data from
bearing monitoring devices; analyze
service and maintenance records,
as well as charts; and secure appli-
cation diagrams, graphics and engi-
neering drawings.
2. Prepare an inspection sheet to
capture observations, and take pho-
tographs throughout to document or
describe damaged components.
3. Extract any used lubricant
samples from bearings, housing and
seal areas to determine lubricant
conditions. Package these separate-
ly, and label them properly.
4. Secure a sample of a new,
unused lubricant. Record any speci-
fication/batch information from the
container, and obtain the technical
specifications and any related mate-
rial safety data (i.e., handling, dis-
posal, toxicological) documentation
to accompany lubricant shipments.
5. Check the bearing environment
for external influences, like other
equipment problems, that preceded
or occurred at the same time bear-
ing damage was reported.
6. Disassemble the equipment
and rolling elements. Each time the
current is broken while passing between
the ball or roller and race, it produces
a pit on both parts. Eventually, fluting
develops.
Causes of arcing include static elec-
tricity from charged belts or processes
that use calender rolls, faulty wiring,
improper grounding, welding, inade-
quate or defective insulation, loose rotor
windings on an electric motor and short
circuits. P&Q
Information for this article provided by
The Timken Co. www.timken.com
and record an assessment of the
mounted bearing condition.
7. Inspect other machine ele-
ments, including locknuts, adapters,
seals and seal wear rings.
8. Mark and record the mounted
position of the bearings and compo-
nents prior to removal.
9. Measure and verify shaft and
housing size, roundness and taper
using certified gauges.
10. Following removal, but before
cleaning, record observations of
lubricant distribution and condition.
11. Clean parts and record the
manufacturer’s information from
markings on the bearing rings (i.e.,
part number, serial number, date
code).
12. Analyze the condition of the
internal rolling contact surfaces,
load zones and the corresponding
external surfaces.
13. Apply preservative oil and
repackage the bearings to avoid
corrosion.
14. Compile a summary report of
all data for discussion with a trusted
sales or service engineer.
pitandquarry.com
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 MOTORS, DRIVES
& BEARINGS
Hit the brakes for maintenance
FORCE CONTROL INDUSTRIES introduced its maintenance- and
adjustment-free curing press brake (CPB). The Posistop CPB is a direct
fit-in replacement to the currently used dry friction brakes mounted
on the back of a motor, which are used to open and close the
NRM/McNeil mechanical curing
press for tire manufacturing
and retreading operations.
Totally enclosed and sealed,
the Posistop CPB features
oil shear technology. Oil Split halves assemble
shear technology includes around shaft
a layer of transmission fluid
between the brake disc and New SAFQ inch-series COOPER Quick-Change
the drive plate. During engage- angled bearing pedestals have a unique design
ment, the transmission fluid that consists of two split halves that enable
transmits torque and sep- assembly around a fixed shaft. In addition, the
arates the friction discs and pedestal’s innovative angled bottom-half slides
drive plates. The Posistop’s air-actu- under a shaft without requiring a jack or hoist.
ated piston system is designed to seal Typical applications include fans and similar
the piston for maintenance-free service rotating machinery in the mining, marine, steel
life. In addition to the O-rings used to seal the piston, Teflon liners are and power generation industries. The SAFQ
installed over the O-rings to keep them from rolling up and breaking. Series pedestals are available for shafts with
www.forcecontrol.com diameters from 2 3/16 in. to 5 5/16 in. All inte-
grate standard Cooper 01, 01E, 02 or 02E split-
to-the-shaft bearings and are interchangeable
with other Cooper split roller bearing pedestals.
Lubricate multiple rotating points The split-to-the-shaft roller bearings simplify
The new SKF multipoint automatic lubricator TLMP series introduced disassembly and reduce time needed for instal-
a centralized and ready-to-use lubrication system. It automatically lation, changeover and inspection.
lubricates multiple bearing lubrication points in rotating equipment www.cooperbearings.com
applications across a variety of industries. This system has pluggable
outlets and is packaged as a complete kit, designed for installation
and programming via a keypad with an LED display. The TLMP system
can supply from one to 18 lubrication points on a controlled and timely Reduce installation time
basis to deliver the proper lubrication PowerTwist Drive, a new power transmission
amount at the required frequen- belt from FENNER DRIVES, does not require
cy. The system features a metal retensioning after installation. PowerTwist Drive
housing, 1-liter reservoir capacity, is made of high-performance polyurethane/
stirring paddle to prevent grease polyester composite material. It is resistant to
separation and cycle control heat, cold, oil, grease, water and many com-
sensor to govern ideal mon industrial and agricultural chemicals.
delivery of lubricant. PowerTwist Drive is installed in basically the
The TLMP system same way as the original PowerTwist link belt-
features low-level ing, however, belt length measurements may
and malfunction differ somewhat. Force deflection data charts
alarms, alerting are included in the installation instructions to
when the reservoir ensure proper tension. Like all PowerTwist prod-
is empty or when an ucts, PowerTwist Drive drops right in to existing
outlet is blocked. pulley setups.
www.skfusa.com www.fennerdrives.com

46 PIT&QUARRY October 2017 pitandquarry.com

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 SAFETY &
ENVIRONMENTAL
Remove dust from clothing
AIR CONTROL INDUSTRIES’ (ACI) per-
sonnel cleaning booth provides a safe
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dust and other contaminants from workers’
clothing. The booth uses low-pressure, high-vol-
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free-standing unit that incorporates ACI’s blow-
Advancements from BOSSTEK allow
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tions in customizable shapes and
points of critical areas of a plant. Any dust removed can be
sizes. Bosstek is complementing its
collected into bags via a standalone extraction and filtration unit or alternatively
existing line of stationary dust sup-
ducted into an existing extraction system. www.aircontrolindustries.com
pression rings with the ability to pro-
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Reduce risks configurations, customized to the
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with stop switch  design is specially engineered for
The new A02ES-H is APEM’S lat- the application and equipment of the
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The A02ES-H includes an automatic a virtually unlimited array of shapes
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released a new conveyor compo-
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Universally mounting to all idler CURRY SUPPLY’S line of water
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rail helps prevent entanglement in of updates as a result of con-
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safety handrail in place of an e-stop made improvements to its water
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order. Extra pipe endcaps and extra fied company that manufactures
brackets are available to order. commercial service vehicles.
www.superior-ind.com www.currysupply.com

48 PIT&QUARRY October 2017 pitandquarry.com

 Built rock solid.
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 SAFETY & ENVIRONMENTAL

Wireless monitor senses hazards,

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Safety in fuel or solvent storage areas

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T: 604-813-9577 Houston, Texas 77084
E: info@b3solutions.ca T: 281-859-5999 M: 713-299-5359
www.b3solutions.ca E: sales@ce-grp.com
www.ce-grp.com Bat Booth
50 PIT&QUARRY October 2017 pitandquarry.com

Wash plant upgrade
in Washington state
Blake Sand & Gravel
was founded in 1953 in
Sequim, Washington,
selling sand, gravel and
ready-mix concrete.
A sand and gravel producer shares observations
and insights from a recent investment.
B
lake Sand & Gravel
Inc. has been provid-
ing sand and gravel
products in the state
of Washington since
PHOTOS COURTESY OF TEREX WASHING SYSTEMS
1953, producing aggregate for ready-mix
concrete, as well as sand and washed rock.
Recently, operation leaders sought to
replace an existing wash plant to achieve
a higher production capacity due to in-
creased demand. The operation’s previous
plant produced 75 tph and required inten-
sive labor for cleaning ponds, according to
Owner Dave Blake. And the costs to run
it were rather high, Blake adds.
So, the company made the decision to
pitandquarry.com
WASHING & CLASSIFYING
EDI T ED BY K EV IN YANIK
invest in a new solution that could achieve
a higher efficiency to maximize its yield.
Ultimately, Blake Sand & Gravel in-
vested in an AggreSand 165, a three-deck,
two-sand processing plant.
The new plant and its 16-ft. x 5-ft.
screen are currently producing five clean
products, including 7/8 in. to 1 1/2 in.;
7/16 in. to 7/8 in.; 7/32 in. to 7/16 in.; and
a couple of sand fractions.
“We are using 20 percent less electricity,
substantially reducing our running costs,”
Blake says. “We have increased our feed
by 50 percent, enabling us to supply to
demand, and the added benefits from
the AggreSand give us the ability to blend
materials for specific grades.”
In addition, the operation has achieved
a more effective fine sand recovery, halving
the frequency of pond clear outs, accord-
ing to the company. This further reduces
Blake Sand & Gravel’s running costs and
increases yield by reducing the losses of
material to ponds, Blake says.
“The plant has been producing effec-
tively since it was installed,” he says. “The
ability and ease of obtaining live data in
terms of water pressures, flows, cyclone
feed pressures, as well as motor amp
reading, was very impressive.”
The AggreSand 165 is processing nat-
ural sand and gravel to produce a coarse
October 2017 PIT&QUARRY 51
 WASHING & CLASSIFYING

The operation has

achieved a more
effective fine sand
recovery, halving the Says Dave Blake of the wash plant: “The AggreSand is extremely quiet running, [has] no
spillages and the belts run very smoothly, with no rollback that can be a typical problem
frequency of pond with some plants. The access and serviceability features of the machines, along with the
clear outs. rollout centrifugal pumps and rollout chute work, were especially valuable features.”

concrete aggregate and fine con-
crete sand (C33 spec). The sand
is also being sold for septic sand
and equestrian sand.
“When we were considering
purchasing a wash plant, we were
keen to find a solution that would
achieve efficiencies, as well as a
seamless easy setup – something
with a reduced footprint and
the capability of producing two
grades of sand,” Blake says.
According to Blake, the plant
arrived at his site on a Monday,
and the operation was making
product on the ground by that
Friday.
The operation’s new
wash plant produces Powerscreen Washington, the
five clean products. Terex Washing Systems (TWS)
distributor within the state of
Washington, assisted Blake Sand & Gravel
throughout the process, as did TWS’
applications and engineering teams. P&Q
ABOUT
BLAKE SAND & GRAVEL
Charles and Margaret Blake founded
Blake Sand & Gravel In 1953 in
Sequim, Washington, selling ready-
mix concrete, sand and gravel.
Their son Dave became president
in 1980. In 2002, the Blakes sold the
concrete portion of their business,
but they continue to operate the
gravel pit located on Cays Rd., pro-
viding customers with a variety of
materials. Dave’s daughter, Casey,
has since become a third-generation
Blake to lead the business.

52 PIT&QUARRY October 2017 pitandquarry.com

 MAPPING RESERVES
& INVENTORY ANALYSIS

7 Takeaways Insights and

observations
for aggregate
from producers from

InterDrone the UAV show.

BY K EV IN YANIK

A
bout 4,000 attendees one or two – if that.
and 65 exhibiting com- Based on conversations had,
panies participated some vendors are still developing a
in InterDrone 2017, a sense of where their opportunities
three-day UAV conference and expo lie. Their opportunities could be in
held in September in Las Vegas. the commercial market or in the
The show was a first for Pit & consumer arena – or both – but the
Quarry, which has kept close tabs sense is that a number of vendors
on the drone evolution through- are still feeling out opportunities
out 2017. InterDrone brought a and how they can fit into the rather
number of representatives from crowded field.
aggregate-producing companies to Keep in mind, of course, that the
Las Vegas to explore the viability of UAV industry is very much in its
drone technologies for their busi- Attendance at InterDrone 2017 was up over the previous
year, a show organizer says.
infancy. A handful of vendors will
nesses. These producers sought to likely be validated as top providers
familiarize themselves with the vendors many vendors dedicated to the same craft to the aggregate industry in the years to
in this space and learn the latest on the can be a little overwhelming. So where is come, while others focus their attention
drones research-and-development front. a newbie to start? on opportunities elsewhere. Some of
At Interdrone, an educational track “My advice would be to get a trusted ref- these vendors could also potentially fade
focused on mining and aggregate provided erence,” says Lewis Graham, the president completely from the U.S. market.
our industry’s producers with opportuni- and chief technical officer of GeoCue Group
ties to hear from experts in the UAV in- Inc. “It’s so easy to get into this business
dustry. These experts shared best practices because you can get a [drone] at Best Buy.
for flying drones, collecting data, staying It’s easy in this business to get bad data.”
2 The drone industry continues
to develop at an extremely
rapid pace.
in compliance with Federal Aviation The fact that two trade shows – Inter- Adam Rice, business development direc-
Administration regulations, and more. Drone and Commercial UAV Expo, which tor at Kespry, points to 2014 as the year
Pit & Quarry departed InterDrone with takes place in October in Las Vegas – are commercial drones truly hit the market.
a number of things to chew on. Here are dedicated to the UAV industry speaks to And a lot has changed in the market since
seven for aggregate producers to consider: the sheer volume of vendors who have that time, he says.
targeted the U.S. market. Also, anyone “We’ve seen mission planning apps

1 There are a slew of potential

vendor partners to choose
from.
who walked InterDrone and spoke with at being built; we’re seeing accuracy improve-
least a handful of vendors quickly realized ments; and the introduction of PPK (post
a number of companies in this space have processed kinematics),” Rice says. “We’re
If you’re an aggregate producer who has international roots. seeing technology that’s safer; laser sensors
PHOTO BY KEVIN YANIK

yet to explore the use of a drone for your In addition, not every vendor is focused on drones to create a more autonomous
operation and you attended InterDrone on specifically serving the aggregate experience; and vertical integration. We’re
for the first time, you certainly went to industry. While some vendors currently seeing drone companies focus on specific
the right place. serve tens or hundreds of aggregate sites industries. They’re starting to develop
At the same time, sifting through so at this juncture, others may only serve solutions for industries.”

pitandquarry.com October 2017 PIT&QUARRY 53

 MAPPING RESERVES
& INVENTORY ANALYSIS
The rapid development of the market has been a sight for
Graham to see, as well.
“We would have laughed four years ago about mapping with
a camera on a DJI [drone],” Lewis Graham says. “Today, that’s
serious technology.”
3 ‘Drone budgets’ are a real thing.
Rice discussed this development, which is an indicator of
our industry’s progression with drones, during an educational
session at the show.
“When we used to go to companies, they’d say they have
an exploratory budget to look at new technologies,” Rice says.
“They just wanted the capability to test equipment out. Then,
people started getting ‘drone budgets.’ Now, the drone is falling
into an operational budget.”
4 Most aggregate producers are flying drones
themselves these days.
According to Tony Jacobson, vice president of product at Stock-
pile Reports, 85 percent of his company’s customers are flying
drones on their own.
“Fifteen percent of it is happening with the networked
54 PIT&QUARRY October 2017
Aggregate producers were more open to using drones once the
Federal Aviation Administration simplified its rules in August
2016, UAV industry experts say.
drone services,” says Jacobson, referring to the aggregate and
construction market specifically.
Generally, the expectation among UAV industry leaders is
that more end users will ultimately take on flight responsibilities
themselves.
“I can’t see the industry scaling if [users] are not flying their
own drones,” Graham says. “It’s probably not cost-effective.
Companies now are flying their own drones that two years
ago said they wouldn’t. They can’t see how to do it themselves
without internalizing at least part of it.”
Mike Winn, CEO and cofounder of DroneDeploy, agrees
more end users will be taking on this added responsibility.
“When a lot of companies first use a drone, they will contract
someone to do it,” he says. “But when they realize how easy it is,
there are reasons to bring it in house. Typically the trend is toward
more in-house [management], scaling it out. Service providers
are going to be doing other important things in the long term.”
5 Developing an internal drone training
and maintenance program isn’t a bad idea.
Two representatives at Rio Tinto, a company focused on mining,
made a strong case for formalizing drone training and mainte-
nance at InterDrone. While Rio Tinto isn’t an aggregate-focused
company, the company’s use of drones is very similar to the
drone use of aggregate producers.
“We have never crashed a drone,” says Andrew Carey, Rio
Tinto’s senior engineer and director of drone operations who is
PHOTO COURTESY OF KESPRY
Who deserves more pay?
URC Ventures’ David Boardman explores whether a
drone pilot should be compensated better or worse
than a commercial truck driver in an article at www.
pitandquarry.com/who-deserves-more-pay
pitandquarry.com
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 MAPPING RESERVES
& INVENTORY ANALYSIS
responsible for building and developing cause issues. So [chief drone pilot] Matt
Kennecott Utah Copper’s drone proce- [Key] is the only one who does firmware
dures and policies. “We have over 1,000 updates and updates to the app.”
flights this year alone. We have a robust
maintenance program and a robust train-
ing program for pilots to go through.”
Avoiding drone crashes is really de-
6 A drone flying out of the sky
is a real possibility.
Michael Singer, the founder and CEO of
pendent on a maintenance program, DroneView Technologies, has experienced
Carey says. this. He experienced one dropping out of
“After so many hours we do mainte- the sky from about 200 ft., he says.
nance on it, including different checks,” “It was a motor failure – it crashed and
Industry experts say more aggregate
he adds. “We do scheduled maintenance. producers are internalizing drone flights. burned,” he says. “The battery exploded.
Drones come in, whether they went out or We [also] had another fixed-wing not

PHOTO COURTESY OF LUCK STONE

not. We prep them for the day’s mission; into commission. come back to home.”
get them into an area for the geotechs, “That’s a really practical thing,” Carey So be mindful that drones have single
surveyors and get the drones back out. says. “It takes a little bit of effort, but I points of failure, Singer says.
We have a really good system for feedback, think it pays off in the long run.” “Our goal is a zero-failure rate in the
as [those individuals] will tell us what the Carey also advises drone users to be field in operations but we don’t always
drones were doing.” wary of service updates. control all of those variables,” he says.
Rio Tinto even tests drones in an “We’ve seen some issues arise from Consider, too, that drone pilots might
isolated area before putting them back those,” he says. “There are bugs that can have to abruptly end an ongoing flight

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56 PIT&QUARRY October 2017 pitandquarry.com

for a variety of reasons.
“We’ve taken equipment down for
birds, for helicopters coming out of no-
where and for flight training,” Singer says.
Problem.
“All of a sudden, a small, unannounced
plane is flying where we are.”

7 Drone technology should

continue to improve.
According to Winn, the biggest change
to come is going to be how deep users can
go with data.
“In the not-too-distant future, there
is not going to be one drone flying but
multiple [per site],” he says. “The scale of Solution.
the drone operation and the data collected
is going to completely change.”
Rice has a similar outlook for the future.
“It is about the true marriage of the
digital and physical space,” he says. “There
are going to be multiple drones on the
jobsite. The industry is looking at the
integration of multiple sensors to provide
insights about the jobsite.
“What we’re doing is taking very
high-resolution pictures. So there’s this
incredible dataset we can use to track
machinery and vehicles – how they’re
moving across the site. We can have
that integrated with other sensors on Results.
the site.” P&Q

More drones
coverage
Pit & Quarry
published a
A SUPPLE MENT
TO
CRUSH
EVERY JOB
TM
a 16-page
ANGER
supplement THE GAME CH

in its August D R O N ES
2017 edition
completely
dedicated to KPIL E
LUTIONIZE STOC
AS UAVS REVO AND MINE PLANNING,
drones. The MAN AGEMENT
THE SKY IS
THE LIMIT FOR
WHAT’S TO
COME .

supplement ®
features application-specific
content, producer profiles and
more. Access your print copy for AMERICAN-MADE INNOVATION SINCE 1966
this coverage, or check the content
out at www.pitandquarry.com, 740-927-3464 800-837-3344 www.screenmachine.com
where you can search for “drone”.

pitandquarry.com October 2017 PIT&QUARRY 57

 UPDATE
VULCAN MATERIALS TO ACQUIRE POLARIS
ulcan Materials Co. has reached “We are very pleased to have reached enhance our logistics capabilities with

V a definitive agreement to acquire

Polaris Materials Corp., an ag-
gregate and logistics company that serves
California markets from operations in
British Columbia.
The Polaris business includes a high-ca-
pacity aggregate processing plant and
deepwater port on Vancouver Island,
along with associated long-term aggregate
reserves and five distribution outlets in
the San Francisco Bay area and in Long
Beach, California.
agreement to acquire Polaris Materials,
which is expected to further enhance our
ability to serve major California markets,”
says Vulcan Materials Chairman and
CEO Tom Hill. “Polaris has assembled
high-quality aggregate reserves that will
further expand our product offerings,
particularly for certain concrete applica-
tions, as well as our geographic coverage
in markets in the San Francisco and Los
Angeles metro areas.”
Hill continues, “This acquisition will
the ship delivery of aggregate products
and provide Vulcan with a platform for
future distribution outlet opportunities
along the Pacific Coast. The acquisition
is especially timely,” he says, “given Cali-
fornia’s recent passage of SB1, which will
provide $52 billion for key transportation
infrastructure projects over the next 10
years, in addition to passage of local ballot
measures that add more than $1 billion
annually for infrastructure projects in key
growth markets that we serve.”

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

many years of experience
forecasting construction
The effects of Hurricanes Harvey and Irma materials, and his web-
based forecasting models
have captured every
demand leveling off and reason for a slowdown in

W
eather impacts major turning point in
materials demand for
have extended slightly declining for 2018 housing is high prices. We more than 15 years. Chereb received his
themselves into and into 2019. The basic think prices have outrun Ph.D. in economics from the University of
Southern California. He can be reached at
fall – not confined to early david.chereb@sc-marketanalytics.com.
spring as in most years. U.S. Aggregate by Segment (billions of metric tons)
Hurricanes Harvey and Irma, buyers’ ability to qualify and
combined with some unusu- 1.30 pay the higher mortgage
ally wet areas in late spring, 1.20 payments.
1.10
mean seasonal patterns will 1.00 With rents also increas-
.90 ing rapidly, we will be caught
be disturbed throughout .80
2017. The impact on overall .70 in this plateau for years
.60 to come. Nonresidential
aggregate consumption is .50
small but negative for 2017. .40 demand will begin a slow
.30 multi-year decline in 2018
A large infrastructure .20
program is less certain 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 as structural changes in
because now billions of RES NRES NBLD retail shopping and slower
dollars will be concentrat- Source: USGS, SCMA
employment growth (we
ed into Texas and Florida. are at full employment) take
This may dampen enthu- their combined toll on new
DCG Inc. U.S. Aggregate Forecast (billions of metric tons) higher demand.
siasm for billions more for
a new infrastructure boost 2013 2014 2015 2016est 2017est 2018est 2019est Even with these head-
over the next few years. In RESIDENTIAL 0.39 0.48 0.52 0.58 0.59 0.51 0.55 winds, total aggregate
our opinion, it delays but demand will remain high.
NONRESIDENTIAL 0.60 0.65 0.69 0.72 0.75 0.73 0.71
does not eliminate a big Regionally, 2018 will be very
NONBUILDING 1.06 1.06 1.05 1.04 1.05 1.13 1.20 diverse: Illinois, Louisiana,
program.
In the meantime, many TOTAL 2.05 2.19 2.26 2.34 2.39 2.37 2.46 Delaware and Minnesota are
states will boost infrastruc- Yr./Yr. %Ch. +1.5% +6.8% +3.2% +3.5% +2.1% -0.9% +3.8% doing well, while Wisconsin,
ture spending on their own, Note: There is a small difference between our estimates of consumption and Florida, South Carolina,
helping 2018-19 public the USGS because of our own estimates in states where USGS does not South Dakota and Nebraska
works. We show private report values owing to competitive concerns. are not doing well.

58 PIT&QUARRY October 2017 pitandquarry.com

 PB MATERIALS ACQUIRES Manufacturer
AGGREGATE, READY-MIX ASSETS Briefs
◾ Toromont Industries

P
B Materials Holdings Inc. (PBM), a company’s current operations by providing buys Hewitt Equipment:
regional producer of aggregate and more vertical integration throughout PBM’s Toromont Industries Ltd.,
ready-mix concrete in the Permian footprint in West Texas and eastern New Mex- a diversified industrials
Basin, completed the acquisitions of nearly ico, as well as expand the company’s existing company providing special-
all of the assets of ARM Trucking Ltd. Co. aggregate and ready-mix concrete operations ized capital equipment and
(ARM Concrete), Kermit Concrete Co. LLC in its core markets. ongoing support to cus-
and WUUD Aggregate LLC. “We are excited to add this group of assets tomers in various sectors,
ARM Concrete and Kermit Concrete are and welcome the employees of the three busi- has entered into a definitive
providers of ready-mix concrete in Lubbock nesses to the PBM team,” says Christopher agreement to acquire the
and Kermit, Texas, as well as surrounding businesses and net oper-
Crouch, CEO of PBM. “The operations are
ating assets of the Hewitt
markets. WUUD Aggregate provides sand a sound fit with our existing strategic asset
Group of companies for
and gravel in the Permian Basin and re- base in the Permian Basin and further allow approximately CA$1 billion.
portedly has a significant reserve position PB Materials to provide high-quality service Hewitt Equipment Ltd. is the
in the region. and construction materials to our customers authorized Caterpillar dealer
The assets PBM acquired will add to the in the region.” for the province of Québec,
Western Labrador and the
Maritimes, as well as the
P&Q AGGREGATE INDUSTRY INDEX Caterpillar lift truck dealer
400
for most of Ontario. Hewitt
is also the MaK dealer for
Québec, the Maritimes and
350
the Eastern U.S.
◾ Supplier of custom
October dredges opens in
California: Aggregate
300 375 Dredge Solutions is a new
company that specializes
250 in custom-built mechanical
dredges for the aggregate
NOV
DEC
JAN 15
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEPT
OCT
NOV
DEC
JAN 16
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT
NOV
DEC
JAN 17
FEB
MAR
APR
MAY
JUN
JUL
AUG
SEP
OCT

industry. Services include

Source: Pit & Quarry consulting, design and
engineering, as well as
The P&Q Aggregate Industry Index continues its plateau in the second half of 2017 after
installation support. While
a mostly steady climb for more than a year. The index currently stands at 375. specializing
in complete
MARKET
STOCKS
|
As of Sept. 7, 2017 Source: Yahoo! Finance
12-MONTH
CHART
PRICE 52-WEEK RANGE
LOW HIGH
CAP IN
BILLIONS
customized
dredge and
Cemex – CX 9.18 6.91 10.37 13.59 conveyor
systems,
CRH (Oldcastle) – CRH 34.93 31.55 38.04 28.97
Aggregate
PHOTO COURTESY OF AGGREGATE DREDGE SOLUTIONS

Eagle Materials – EXP 100.82 73.27 110.64 4.89 Dredge

Granite Construction – GVA 55.37 42.59 62.18 2.21 Solutions also offers com-
ponents and spare parts for
Heidelberg Cement – HEI 81.53 76.94 94.59 16.18
existing mechanical dredg-
LafargeHolcim – LHN 49.03 44.745 57.09 29.53 es. The new business ven-
Martin Marietta – MLM 207.38 167.06 244.32 13.03 ture was started by Jochen
Rohr, whose family has been
MDU Resources – MDU 27.22 23.06 29.92 5.32
in the aggregate business
Summit Materials – SUM 29.97 17.48 30.60 3.35
since the 1930s, operating
U.S. Concrete – USCR 78.00 42.82 83.85 1.24 four sand-and-gravel sites
U.S. Lime & Minerals – USLM 80.25 62.32 83.00 0.45 in Germany. Rohr was the
founder of the Rohr Corp.,
Vulcan Materials – VMC 119.23 105.71 138.18 15.77
which was sold in 2011.

pitandquarry.com October 2017 PIT&QUARRY 59

SAFETY NSSGA NAMES SAFETY
AWARD RECIPIENTS
UPDATE
T
he National Stone, Sand & Gravel Association
(NSSGA) selected Mark Rock, senior vice pres-
ident of risk management for CalPortland, to
receive its 2017 James M. Christie Safety &
Health Professional of the Year Award.

FORMER COAL EXEC The award recognizes an individual for substantial

commitment and contributions to safe and healthy

TO BE NOMINATED practices within his or her company and the industry.

Rock earned the award for established a program for

AS MSHA CHIEF managing compliance and worker safety and health at

CalPortland. He also collaborated with senior manage-
ment, insurance companies, safety business partners and

P
resident Donald Trump announced his intent to
nominate David Zatezalo, a former coal executive, to
be the assistant secretary of labor at the Mine Safety
& Health Administration (MSHA).
The announcement is a disappointing development for some
in the aggregate industry, which was lobbying for a representative
from its sector to be nominated for the MSHA post.
According to the White House, Zatezalo served as chairman of
Rhino Resources until his retirement in 2014. He had previously
served as the company’s president and CEO and was previously
COO of Rhino, as well as president of Hopedale Mining LLC.
Zatezalo began his mining career in 1974 with Consolidation
Coal Co. as a United Mine Workers of America laborer. He became
a foreman and subsequently general
superintendent for Southern Ohio
Coal Co. and general manager of
employees to advance the culture of safety and health,
NSSGA says. In addition, he pushed for the company to
put a more thorough effort toward avoiding accidents.
In addition, NSSGA named recipients of its 2017
Safety Excellence and Sterling Safety Awards.
Winners of NSSGA’s Safety Excellence Gold Awards
include Oldcastle Inc.’s Tilcon Connecticut Southington
Sand & Pit in New Britain, Connecticut; Rogers Group’s
Princeton Quarry in Princeton, Kentucky; and Vulcan
Materials Co.’s SE Taft Terminal in Orlando, Florida.
NSSGA created the Safety Excellence Awards in 1987
to promote safe working conditions and practices. The
awards recognize, on an annual basis, individual oper-
ations with exemplary safety records among NSSGA
member companies.
The recipients of NSSGA’s Sterling Safety Gold Awards
include Iddlings Quarry Inc. in Mifflinburg, Pennsylvania;

PHOTO COURTESY OF THE INTELLIGENCER AND WHEELING NEWS-REGISTER

Midwest Minerals Inc. in Pittsburg, Kansas; and Specialty
AEP’s Windsor Coal Co. He later Granules Inc. in Hagerstown, Maryland.
rose to be vice president of opera-
tions of AEP’s Appalachian mining
operations, the White House says.
In addition, Zatezalo worked HARD NUMBERS
in Australia for Broken Hill Pro-
prietary Ltd. as a general mine In a study by the
manager. He is a mining engineer-
ing graduate from West Virginia
University, where he received the
1977 West Virginia University
68% Mine Safety & Health
Administration, it was
determined that, of injuries
to miners with two years or less experience,
David Zatezalo 68 percent (903) occurred to miners with
Student Foundation Merit Award.
In the interim, Wayne Palmer, who previously served Labor less than one year of experience, while only
32 percent (418) occurred to those who had
Secretary Alexander Acosta as chief of staff, was appointed as the
worked at a mine between one and two years.
acting head of MSHA. Palmer served as the U.S. Department of
Labor‘s chief of staff for four months, overseeing the department’s
budget and employees across hundreds of sites.

60 PIT&QUARRY October 2017 pitandquarry.com

Submit a Nomination for the 2018
Hall of Fame

Know a
deserving
candidate?

Nominate someone for the Pit & Quarry Hall of Fame who has contributed significantly
to the aggregate industry. Aggregate producers, equipment manufacturers,
dealers and association representatives are all eligible for nomination. Posthumous
nominations will be accepted, as well, and a selection committee will review
all nominations and determine who will be inducted into the hall.

To submit your nomination, visit:

Pitandquarryhalloffame.com
MSHA
&THE LAW
MSHA CHANGE COMING GRADUALLY
W
ith the 2016 election of
a president who made
deregulation and smaller
government a hallmark
of his campaign, there has been a great
deal of interest in the mining community
about how that governing philosophy will
impact mine safety enforcement.
While the first seven months of the new
administration have been anything but
boring across the entire spectrum of the
federal government, there is still a lot to
find out about the course the Mine Safety
& Health Administration (MSHA) will
take moving forward. With that said, there
have been some early signals of change.
The most obvious signals relate to
MSHA’s projected rulemaking goals for
2017. According to the regulatory agenda
published in July 2017, MSHA has removed
all deadlines from its crystalline silica
and underground proximity detection
rulemaking efforts.
Prior to the election, those rulemaking
efforts were at the top of the agency’s agen-
da. In fact, the previous administration
had targeted April 2017 for release of its
proposed rule for crystalline silica. This
rulemaking process was expected to
consume substantial agency and industry
resources. The fact that the battle has
been avoided, at least temporarily, has
set a different tone for 2017.
This different tone is also reflected in
the agency’s decision to delay the exten-
sion of the working place examination
regulation. While this decision can cer-
tainly be credited in significant part to
intensive industry efforts to alter or stop
the impact of this new regulation, the
fact remains that the agency has publicly
acknowledged the need to give operators
time to implement the more extensive
recordkeeping and logistical requirements
of the new standard.
62 PIT&QUARRY October 2017
BY BILL DOR AN A ND M A RGO LOPEZ
Consider, too, the public statements of does finally step in to the job, there will
a number of MSHA district managers who be significant encouragement from the
have pledged there will be a cooperative mining industry that a number of key
“go-slow” approach to enforcement once issues be promptly considered. Some of
the regulation finally takes effect. the most compelling of these issues will be:
◾ Whether to maintain or withdraw the
AGENCY LEADERSHIP agency’s current pattern of violations rule
Of course, the real indicator of change ◾ Whether and when to restart the crys-
will be the course that is charted by talline silica rulemaking process
the new assistant secretary of labor for ◾ To address industry concerns regarding
MSHA. As of this writing, the nomi- inspection and inspector consistency
nee for that position has still not been ◾ To address conflicts between head-
officially named. While it is anticipat- quarters and the district regarding area
ed that the new assistant secretary will guarding
come from the mining industry – and ◾ Whether to re-formulate and re-pur-
will have a strong understanding of the pose the Small Mines Office
compliance challenges facing operators ◾ To review and revise the application of
– until that person is in place and mak- old regulations in light of new technology
ing decisions, there will probably not be ◾ To make a final decision regarding the
any dramatic adjustments. status of the pending workplace exam rule
In the meantime, the
The next assistant secretary daily nuts-and-bolts op-
will assume control of an eration of the agency will
continue to be directed by
agency that is seeing a the district managers. In that
substantial transition in its regard, it is likely the agen-
inspector ranks. cy’s enforcement focus will
continue to be its primary
That assistant secretary will assume priority, so it will be business as usual.
control of an agency that is seeing a For instance, a general review of
substantial transition in its inspector MSHA statistics during the first five
ranks, due to a considerable number of months of the new administration in-
retirements of senior inspectors over the dicates that the agency issued 84 “high
past few years. There will also be a num- dollar” citations and orders (producing
ber of slots to fill in agency headquarters civil penalties over $10,000) to metal and
leadership positions. nonmetal mines. Only 60 such citations
Until a new nomination is made, and orders were issued for the same pe-
Secretary of Labor Alexander Acosta riod in 2016. The enforcement train is
has appointed Wayne Palmer, formerly continuing to move down the tracks. P&Q
his chief of staff, as acting assistant sec-
retary of labor to run the agency. Palmer Bill Doran and Margo Lopez are with
will become deputy assistant secretary the national labor, employment and
for policy once a permanent assistant safety law firm Ogletree Deakins.
secretary takes the helm. william.doran@ogletree.com
When the new assistant secretary margaret.lopez@ogletree.com
pitandquarry.com
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64 PIT&QUARRY October 2017 pitandquarry.com

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pitandquarry.com October 2017 PIT&QUARRY 65

 DOUG LAMBERT
With a career spanning four decades,
Doug Lambert has experienced the ag-
gregate industry from the standpoints of
a producer, a manufacturer and a dealer.
Family ties brought Lambert into the in-
dustry, and his various experiences have
provided him with a unique perspective
that’s served him well – in addition to the
customers he’s served – over a period of
nearly 40 years.
What can you tell us about your family’s history as an
aggregate producer?
My grandfather and several of his brothers started back
in the mid-1930s, and at some point in the 1940s they
formed Lambert Brothers Crushed Stone. As far as I
know, they were the largest crushed stone company in the
United States in the early 1950s. They were mainly in Ten-
nessee and Virginia and did a lot of Gypsy camp kind of
crushing for dams and road projects.
In 1956, talks with Vulcan [Materials Co.] started
with my great uncles. They organized a very complicated
merger with several other crushed stone companies in the
Southeast. That led to the Vulcan we know today, or the
construction aggregate part of it at least.
How did your start at
Vulcan Materials come
about?
Through family history, be-
cause my dad worked for Vul-
can from the time the compa-
ny was officially Vulcan. He
worked for Lambert Brothers,
and he worked at Vulcan
from the beginning. That’s all
we ever knew. We were born
with limestone in our blood.
I started working there
Visit PITANDQUARRY.COM/DOUGLAMBERT
for our full conversation with Doug Lambert,
and check out additional photos from
Lambert Brothers Crushed Stone in this
month’s A Look Back section (page 64).
66 PIT&QUARRY October 2017
Sales and Applications Engineer
Superior Industries
I learned teamwork [in
college]. Swimming is a
lot like tennis or golf in
that you’re swimming
as an individual yet
supporting a team.
fresh out of college in 1980. I worked in engineering. The
way I tell people about my start is that I held the dummy end
of the tape with the survey crew. I held the prism or the rod
while others did the math.
Between 1980 and early 1995, I did quality control, plant
operations, ready-mix concrete, stone sales.
We learned that you were on a championship college
swimming team. How did the experience prepare you
for a career in our industry?
I learned teamwork. Swimming is a
lot like tennis or golf in that you’re
swimming as an individual yet
supporting a team. Also, a college
athlete in any sport is typically not
afraid to work hard. In swimming,
you’re working out four hours a
day and covering 15,000 to 20,000
yd. per day. You get a lot of repe-
tition and opportunities to do it
right. In our industry, you unfortunately don’t have that
many opportunities to get it right.
FIVE THINGS
FIRST JOBS—Baling hay during the summer on
a relative’s farm and mowing the lawn at Vulcan
Materials’ Midsouth Division office.
TOP TRAVEL SPOT—Almost any mountain cabin and
PHOTOS COURTESY OF DOUG LAMBERT
Hilton Head Island
HOBBIES—Photography and hiking
SPORTS TEAMS—University of Tennessee
swimming, football ...
BOOKS—Military history or biographies; “Phantom
Warrior,” by Forrest Bryant Johnson; “The Red
Circle,” by Brandon Webb; and “Unbroken,” by Laura
Hillenbrand
pitandquarry.com
OCTOBER AD INDEX
Advertiser Page Phone Website Advertiser Page Phone Website
Advanced Detection pg S12 414-672-0553 www.adsdetection.com Luff Industries Ltd. Back 888-349-5833 www.lufindustries.com
Systems Cover

AirGon LLC Inside Back 256-461-8289 www.airgon.com Major Wire Industries pg 39 450-659-7681 www.majorwire.cc
Cover
Martin Engineering pg S13 800-544-2947 www.martin-eng.com
Allen Villere pg 18 985-727-4310 www.allenvillere.com
Martin Sprocket S-Inside 817-258-3000 www.martinsprocket.com
Am Cast Inc. pg 42 888-993-2772 www.amcastonline.com Back Cover

Atlas Copco pg 28 800-732-6762 www.atlascopco.com Mideco pg 50 +61 3 8873 www.mideco.com.au

0200
Austin Powder pg 60 216-464-2400 www.austinpowder.com
Minet Lacing S-Back 336-434-0363 www.mltnorthamerica.com
Baldor pg S5, 41 479-646-4711 www.baldor.com Technology Cover
Bunting Magnetics Co. pg 30 866-750-8662 www.buntingmagnetics.com
Montabert pg 29 866-588-8690 www.montabertusa.com
CDE Global pg S17 919-535-3205 www.cdeglobal.com
Precision Pulley & Idler S-Inside 800-247-1228 www.ppi-global.com
C.L. Dews & Sons pg 34 877-339-7339 www.dewsfoundry.com Front Cover
Foundry & Machinery
REMco pg 31, 47 925-447-0805 www.remcovsi.com
Control Concepts USA pg 54 860-928-6551 www.speedswitch.com
Schurco Slurry pg 25 904-356-6840 www.schurcoslurry.com
Cowin & Co. Inc. pg 24 205-945-1300 www.cowin-co.com
Screen Machine pg 57 740-927-3464 www.screenmachine.com
Crisp Industries Inc. pg 40 800-315-0871 www.crispindustries.com
SEW Eurodrive pg 49 864-439-7537 www.seweurodrive.com
Deister Machine Inside Front 260-426-7495 www.deistermachine.com
Cover Shell Oil Co. pg 13 713-241-6161 www.shell.us
Co. Inc.
Sturtevant Inc. pg 27 781-829-6501 www.sturtevantinc.com
Douglas Manufacturing pg 5 205-884-1200 www.douglasmanufacturing.com
Superior Industries pg S18-S19 800-321-1558 www.superior-ind.com
Elrus Aggregate pg 33, 35 888-535-7877 www.elrus.com
Tandem Products Inc. pg 38 800-533-0509 www.tandemproducts.com
Systems
Telsmith pg 45 262-242-6600 www.telsmith.com
Eriez pg 26 888-300-3743 www.eriez.com
Terex Washing pg 16 +44-0-28-87- www.terex.com/washing
Fine & Co. LLC pg 44 312-278-0600 www.ineandcompany.com
Systems 718-500
Haver & Boecker pg 37 800-325-5993 www.havercanada.com
ThermoTech pg S7 877-693-7693 www.thermotechinc.com
Hoyt Wire Cloth pg S11 717-394-6871 www.hoytwirecloth.com
Van der Graaf pg 3, S3 888-326-1476 www.vandergraaf.com/
Kespry pg 43 650-434-5048 www.kespry.com DrumMotor

KPI-JCI & Astec Mobile pg 15, 17, 605-668-2524 www.kpijci.com Wirtgen America Inc. pg 6-7 615-501-0600 www.wirtgen-group.com/
Screens 19, 20-21 america

Rob Dino ADVERTISING INFORMATION If you’d like to place advertising in

Fulop Vitanza Pit & Quarry magazine is the leading Pit & Quarry, contact Group Publisher
information source for the aggregate Rob Fulop at 855-460-5502 x3741,
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pitandquarry.com October 2017 PIT&QUARRY 67

 A Look Back
P H O T O S F R O M P I T & Q UA R R Y ’ S HI S T O R I C A L A R C H I V E

George Lambert,
pictured at center wearing
a hat and with a hand
on his hip, talks with the
Lambert Brothers Crushed
Stone crew while setting
up a plant. According to
Doug Lambert, a sales
and application engineer
at Superior Industries who
is the grandson of George
Lambert, Lambert Brothers
used the existing trees as
supports for the plant.

A Lambert Brothers
Crushed Stone plant in operation.

PHOTOS COURTESY OF DOUG LAMBERT

The location is unknown. Learn
more about the history of
Lambert Brothers on page 62,
where Pit & Quarry features
Superior’s Doug Lambert.

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

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

68 PIT&QUARRY October 2017 pitandquarry.com

TRIED, TESTED AND PROVEN

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IN THE FIELD FOR OVER 38 YEARS

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 A SUPPLEMENT TO

CONVEYING &
MATERIAL
HANDLING

PRODUCER PROFILE:
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 CONVEYING
& MATERIAL HANDLING

A
WIN
for everyone
Lehigh Hanson’s unique overland conveyor system
connecting a new quarry with an existing cement plant
offers high-production potential while striking the right chord
with the community.

BY MEGAN SM A LLEY
TABLE OF

A
long project is underway at Lehigh Hanson’s operations in Union
Bridge and New Windsor, Maryland. CONTENTS
About 4.5 miles long, to be exact. S1 OPERATION PROFILE:
Lehigh Hanson knew for years that its limestone quarry in LEHIGH HANSON
Union Bridge, Maryland, would likely run out of reserves by about 2020. So the
company purchased land in New Windsor to eventually develop a new quarry S8 PROJECT PROFILE:
that could keep operations going at its Union Bridge cement plant. SOUTH CAROLINA
Pit development has already begun at the New Windsor Quarry, and the PORT TERMINAL
company hopes to start operations there in the first quarter of 2018. S14 MOBILE CONVEYORS
“There is really good limestone here in the area,” says Andrew Rigler, safety
manager of the north region at Lehigh Hanson. “It’s a very clean stone with few S20 CONVEYOR SAFETY
impurities. We don’t find heavy metals that we have to wash out. It has a good S22 NEW EQUIPMENT &
PHOTO BY MEGAN SMALLEY

ratio of calcium to silicon to iron.” TECHNOLOGY

THE DILEMMA S24 A LOOK BACK
While the New Windsor Quarry is fairly close to the Union Bridge cement
plant, the two locations are a few miles apart. Lehigh Hanson needed to find a COVER PHOTO COURTESY OF SUPERIOR INDUSTRIES

way to move crushed materials from the new quarry to the old cement plant. As

pitandquarry.com October 2017 PIT&QUARRY S1

 CONVEYING
& MATERIAL HANDLING

a solution, Lehigh Hanson invested in a

series of conveyors, including a 4.5-mile-
long overland conveyor, to connect the
quarry with the cement plant.
The producer considered a few other
solutions, including rail and trucks. But
purchasing an overland conveyor system
seemed like the most practical option
given the operating capacity the new
quarry will require.
“We talked about trucks, and it would
take a significant amount of trucks per
day,” Rigler says. “Most over-the-road
trucks can haul 20 tons maximum, but
we need to truck 19,000 tons of stone Conveyor No. 4
per day.” inside the jumbo cover.
Had the producer opted to use trucks
rather than a conveyor, it would have
demanded about 950 truckloads per
day. This would have affected traffic in The New Windsor Quarry
the surrounding communities, as well as
For more than 10 years, Lehigh ures about 850 acres, will feature
increased the need for laborers.
Hanson discussed plans for the a two-pit design. The company
And while a railcar holds about 100
development of its New Windsor began to develop the north part of
tons of material, going that route would Quarry as its Union Bridge the pit, which will be operational
have required about 190 railcars. The rail Quarry approached the end of its first. After 20 years, the com-
option appeared to be affordable, but it reserves. pany will reclaim the north half
would have had a negative effect on the “Our footprint at Union Bridge of the pit and begin work on the
communities. did not allow us to extend [the south side of the pit, which has an
Rigler estimates that a string of railcars quarry] further than what we had,” expected 80-year life span.
going back and forth between the quarry says Andrew Rigler, safety man- The site features a Hazemag
and cement plant would block multiple ager of the north region at Lehigh impact crusher, rated at 2,500
intersections at a time, particularly mak- Hanson. “We were hitting a point metric tph. The gyratory crusher
where we were too narrow in the at the Union Bridge Quarry is rated
ing the rail system a concern for EMS and
deepest part of the mine for safe at 1,500 metric tph.
school bus drivers.
operations. We maxed out the “We went with the impactor
Overall, the overland conveyor solu- length of the quarry, and our width because of the reduction rate we
tion seemed to be the favored option both remained determined for us by a would get out of it,” says Greg
in the community and among Lehigh county road and a stream.” Johnston, quarry site supervisor
Hanson executives, as the option featured The company’s Union Bridge at Heidelberg Technology Center,
the fewest detriments to the community. Quarry has been in operation since who serves as a manager for the
The communities of New Windsor and the 1940s. While it’s still opera- development of the New Windsor
Union Bridge both appreciate Lehigh tional and has about five years of Quarry. “The impactor also doesn’t
Hanson’s transparency and openness reserves left, the company has require a secondary crusher –
with them on their plans. slowed its work there. there’s just one reduction. The
When Lehigh Hanson transi- size it makes gets it straight to the
“The fact that [Lehigh Hanson] chose
PHOTO BY MEGAN SMALLEY

tions to the New Windsor Quarry finish grinding mill plant.”

the conveyor over rail and truck hauling
was huge for us,” says Neal Roop, mayor
of New Windsor. “[Lehigh Hanson] chose
the best of three options to have the small-
est impact on the town of New Windsor.
I couldn’t have imagined trucks going
in 2018, the company will refocus
operations and only turn to the
Union Bridge Quarry for contin-
gencies in the event of issues at
startup.
The new quarry, which meas-
Additionally, the New Windsor
Quarry will feature a maintenance
building with three large bays for
mobile equipment work and two
small bays to work on equipment,
along with a break room.

S2 PIT&QUARRY October 2017 pitandquarry.com

 CONVEYING
& MATERIAL HANDLING
through town every two minutes or rail
going through every hour. The fact that
the company did what it had to do to get
limestone from New Windsor to Union
Bridge in the best possible manner, I give
them a lot of credit for that.”
HORIZONTAL CURVE
A conventional conveyor remains in a
straight line, typically measuring be-
tween 100 ft. and 1,000 ft. according to
Beumer Group, which partnered with
Lehigh Hanson on its overland conveyor.
Lehigh Hanson’s key conveyor, however,
is a horizontal curved trough conveyor
measuring more than 21,000 ft.
“The most unique design feature on
this is all of the steel we designed that is
capable of going around a horizontal and
a vertical curve,” says Brad Williams, vice
president of systems at Beumer Group.
“And the design is a challenge.”
Overall, the Lehigh Hanson conveyor,
A view of Lehigh
Hanson’s Union
Bridge Quarry, with
the cement plant in
the distance.
S4 PIT&QUARRY October 2017
Lehigh Hanson’s
key conveyor is a
horizontal curved
trough conveyor
measuring more
than 21,000 ft.
dubbed conveyor No. 4, features 27 verti-
cal curves and five very long horizontal
curves in order to get the arch shape,
Williams says.
Beumer first began design on the
project in fall 2014, engineering and
fabricating the structure. Beumer also
helped Lehigh Hanson to develop a
route for the conveyor, coming to the
location in central Maryland by fall
2015 to begin construction.
While conveyor No. 4 serves as the
longest single connection between the
New Windsor Quarry and Union Bridge
Cement Plant, Beumer installed a series
of three traditional conveyors along with
the one horizontal curve conveyor in
order to bridge the two sites.
“Beumer supplied three conveyors
in addition to the overland conveyor,”
Williams says. “Conveyor No. 4 is the
overland conveyor, and the traditional
conveyors are named conveyor No. 2,
conveyor No. 3 and conveyor No. 5.”
Conveyor No. 2, a 54-in.-wide con-
ventional conveyor, stretches 880 ft. and
carries limestone from Lehigh Hanson’s
Hazemag crusher to a transfer tower and
then onto its overland conveyor.
Near that transfer tower, conveyor
No. 3 serves as a 54-in.-wide, 112-ft.-long
emergency stack-out conveyor. This
conveyor allows limestone to be con-
veyed to a stockpile in case the overland
conveyor is down for maintenance or
PHOTO BY MEGAN SMALLEY
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 CONVEYING
& MATERIAL HANDLING

About horizontal
curve conveyors
The horizontal curve overland
conveyor technology is not Conveyor No. 4 is seen here
bound by topography like tra- going toward another transfer
tower. This is the head end of
ditional, straight conveying the long belt, which travels
systems. over the top of a stream that
According to Brad Williams, divides Maryland’s Carroll and
the vice president of systems Frederick counties.
at Beumer Group, the overall
amount of conveyor steel,
belting and components can
be reduced through optimized
routing and the use of horizon-
tal curves.
“It allows for the elimina-
tion of transfer towers that
must be built every time a
traditional straight conveyor
transfers to another conveyor
to change direction,” Williams
says. “These transfer towers
the plant cannot load certain limestone up and down hilly terrain. In addition, a
are expensive to fabricate
and install. Elimination of the into the plant. jumbo cover hides aboveground portions
transfer points also allows Conveyor No. 5, a 54-in.-wide tra- of the conveyor to keep it hidden from
for reduced maintenance and ditional conveyor that stretches 870 ft., public view and prevent material from
operation costs, as there is takes limestone from conveyor No. 4 into flying off. This also reduces dust and noise
no dust-collection system the Union Bridge Cement Plant. pollution, making the community happy.
to install and maintain at the “These three [traditional] conveyors “We came up with a solution where
transfers.” are all straight and a good example of addi- a lot of [the conveyor] is buried under-
The technology also elimi- tional conveyors that usually accompany ground in a concrete tunnel,” Williams
nates the need to run electrical a long, overland-type conveyor to form says. “And the portions that are abo-
power out to each transfer
the entire system solution,” Williams says. veground blend into the surrounding
tower, where motors would
The construction of the entire setup environment with the jumbo cover. So if
be necessary to power the
traditional conveyors, Williams required about 2.8 million pounds of the conveyor is underground, it’s hidden;
adds. Chute and liner main- fabricated steel and 47,000 ft. of belt if it’s aboveground, it’s hidden.”
tenance at each transfer is material. The system features 600-hp
also eliminated. And because drives with large reducers at the heads COMMUNITY INVOLVEMENT
there are no transfer points and tails of the conveyors. Throughout the construction of the
to design, the conveyor can “It requires a lot to power a more than overland conveyor and pit development at
stay very close to the ground, four-mile-[long] conveyor,” Williams says. New Windsor, Lehigh Hanson remained
reducing costs versus elevat- When the series of conveyors is fully in highly connected with community mem-
PHOTO COURTESY OF KYLE HUGHES

ing a traditional conveyor to
allow for transfer material.
“To be honest, I think this
technology could work in a lot
more applications,” Williams
continues. “But people are
more aware of straight con-
veyors and the use of transfer
towers.”
service, it will be able to move up to 2,750
tph at a speed of about 5.5 yd. per second.
Beumer estimates it should only take a
matter of minutes for crushed material to
travel from the New Windsor Quarry to
the Union Bridge cement plant.
The overland conveyor also goes
aboveground and underground, sloping
bers in both New Windsor and Union
Bridge. The company hosted a few open
forums and public meetings, as well as
workshops at its office in Union Bridge
to address any concerns community
members might have.
“We found that workshops were an
effective tool,” says Kent Martin, plant

S6 PIT&QUARRY October 2017 pitandquarry.com

 The conveyor system will
move 2,750 tph at a speed of
5.5 yd. per second.
members at least once a week during the start of the conveyor
project, the calls have since subsided and come every couple
of months now.
“Since we’ve been so transparent [through] the entire process,
the people who have had a negative outlook have tended to see
us as good neighbors who will be honest with them,” Rigler says.
The communities of New Windsor and Union Bridge both
appreciated being involved in the decision-making process.
“I had the plant manager’s number, the PR executive’s
number and the safety manager’s number for when I had
problems,” Roop says. “Whenever I had a concern, I would
make a quick call about that and it would be handled within
minutes if not within the first hour. I can’t ask for a better
response than that.” P&Q

manager of the north region at Lehigh Hanson. “In the work-

shop, we had different stations manned by experts. People
could come in, go to the station where they had the question
and get questions answered. They had one-on-one time, and
we were able to hear concerns.”
One of those concerns the company learned about during
the workshops was that community members wanted to make
sure the color of the jumbo cover on top of the aboveground
portions of the conveyor blended in well with the surrounding
environment. To address that concern, Lehigh Hanson allowed
community members to look at different painted slabs of ply-
wood to gauge what colors might work for them.
Lehigh Hanson also developed a website specifically to
update community members about the construction of the
overland conveyor and its New Windsor quarry. The website
features a project overview, details about the conveyor path and
details about the new quarry. It also offers a way for viewers to
sign up for text alerts regarding blasts and road closures. In
addition, Rigler added a few drone videos to the website to
show progress on the conveyor project.
“The website and social media have been tremendous
tools for us,” Martin says. “I’ve learned in my experience as
a plant manager that if the community understands what’s
happening, there’s more acceptance of projects. Everyone
so far has been impressed with our posts. The community
members might not always like what we’re doing, but if they
understand the project better, they accept it.”
While Rigler received calls from concerned community

pitandquarry.com October 2017 PIT&QUARRY S7

 CONVEYING
& MATERIAL HANDLING

Ship to
SHORE
Highly mobile conveyor technology is
unloading and distributing millions of tons
of aggregate in a vital project.

BY CA ROL WASSON

T
he South Carolina Ports
Authority (SCPA) is deep
into the construction of
the only permitted new
container terminal on
the East and Gulf Coasts:
the Hugh K. Leatherman Sr. Terminal,
which is targeted to open in 2019.
Citing the project as its largest cap-
ital improvement initiative to date, the
SCPA’s goal is to better accommodate the
bigger container ships traveling through
the newly expanded Panama Canal. The
facility will ultimately handle up to 1.4
million cargo boxes annually, boosting
the SCPA’s current containerized cargo
capacity by more than 50 percent.
Construction on the 280-acre site is
designed for substantial mitigation of
from the vessels while also conveying
the material and placing it in short lifts
within a large containment area. When
filled, that area will be paved and used
to store incoming and outgoing cargo
containers.
“We’ve made big investments in high-
ly mobile loading and unloading convey-
ing systems so we can custom-configure
offloading services to meet the needs
of any project,” says Carver Laraway,
president of Carver Companies.
Carver Companies operates flexible,
versatile equipment designed to handle a
variety of vessels and materials, Laraway
says, adding that he accesses equipment
that Minnesota-based Superior Indus-
tries manufactures.
PHOTOS COURTESY OF SUPERIOR INDUSTRIES

community and environmental impacts. OFFLOADING SYSTEM on a previous ship-unloading project.

Notably, the SCPA wants to avoid the
emissions, dust, noise and congestion
of bringing in nearly 4 million tons of
aggregate fill material via trucks.
Instead, 70,000 tons of crushed stone
are shipped each week on a rotating series
of barges from a quarry in Newfound-
land, Canada. Carver Companies, an
East Coast marine offload specialist,
handles the unloading of aggregate
SPECIFICATIONS
To design the system, Laraway worked
closely with Jerry Kern, aggregate sales
consultant for General Equipment, a
Superior Industries dealer.
Operating offices in North Dakota
and Minnesota, General Equipment
maintains a large inventory of equip-
ment for rental and sales. The dealer
had worked with Carver Companies
Laraway says Kern was instrumental
in the layout and design of the system.
Also, Laraway stresses that General
Equipment had the units in stock and
could deliver as requested.
After all the equipment was delivered
to the site, assembly of the system took
about a week.
“I’m big on buying American-made
equipment, and the Superior equipment

S8 PIT&QUARRY October 2017 pitandquarry.com


is top-notch,” Laraway says. “Plus, the
support Jerry Kern gave us was an ex-
treme blessing.”
Offloading at a rate of 1,000 to 1,300
tph, Carver Companies is transloading
aggregate material from incoming ships
to a 105-ft. x 440-ft. stationary barge
that’s outfitted with four hoppers.
“It takes an average of 80 hours to
unload one ship, and about 14 months
to complete the entire offload project,”
pitandquarry.com
Laraway says.
Cranes with 20-ton clam buckets load
material into hoppers. Under each hop-
per is a 42-in. x 360-ft. Superior Zipline
conveyor, which is a pre-engineered,
modular overland conveyor that’s de-
signed for quick, tool-less installations
and ease of relocation.
According to Superior’s engineers,
the Zipline conveyor is a lower-cost al-
ternative to conventional “spec-by-spec,”
TeleStacker conveyors give
Carver Companies the ability to
maintain material specifications
from ship to stockpile.
highly engineered overland systems
because it is designed with off-the-
shelf components for easy replacement
of idlers and pulleys. The system also
features a modular design that allows
for easy structural additions or deletions
when required.
A belt feeder on each hopper regulates
the feed to each Zipline conveyor at
350 tph. Running parallel to the barge,
the Zipline conveyors feed an onshore
October 2017 PIT&QUARRY S9
 CONVEYING
& MATERIAL HANDLING

Carver Companies
requires an
average of 80
hours to unload
one ship.
42-in. x 150-ft. TeleStacker conveyor,
a multi-functional telescopic radial
stacking unit that can load, unload and
stockpile. The unit allows operators to
maintain material specifications from
the ship to the stockpile.
From the telescopic radial stacker,
material is transferred to a containment
area by a Superior Trailblazer conveyor, a to working status in about an hour. Above: The Trailblazer conveyor folds
500-ft. preassembled portable groundline With a gravity-style take-up built in or out in an accordion fashion from
its chassis. A small crew is required
system that transports from site to site in into the trailer structure, the Trailblazer to position supports. Below: The
one 84-ft. towable load. The Trailblazer conveyor simply folds in or out in an targeted open date for the Hugh K.
allows rapid deployment from the road accordion fashion from its chassis, with Leatherman Sr. Terminal is 2019.

S10 PIT&QUARRY October 2017

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 CONVEYING
& MATERIAL HANDLING

Carver Companies is
offloading aggregate
The company material from incoming
ships at a rate of up to
currently has 1,300 tph.
three offloading
operations moving
material along the
East Coast.
a small crew required to position the
supports. Beyond this groundline system,
Carver Companies uses a series of porta-
ble jump conveyors to transfer material
where needed in the containment area.
The portability of these conveyors allows
the crew to shift units in and out of the
lineup as required.
Within the 2,000-ft. x 2,000-ft. con-
tainment area, Carver Companies uses
two additional 42-in. x 150-ft. TeleStacker
conveyors to properly distribute material,
readying the site for future paving. As
the project requires placing material in

S12 PIT&QUARRY October 2017 pitandquarry.com

 running. That’s a big advantage over the further growth because it has the right
labor, overtime and fuel associated with mobile conveying equipment. P&Q
using wheel loaders to move material.”
Currently, Carver Companies has Carol Wasson is a veteran
three offloading operations moving freelance writer for the
material along the East Coast – and aggregate and construction
Laraway says his company is poised for equipment industries.

short 4- to 5-ft. desegregated lifts, the NEW!

stackers are constantly moving about
the site.
The FD axle setups on the stackers
allow for easy movement and rotation.
Additionally, General Equipment as-
sisted Carver Companies in acquiring
two used track-mounted “tuggers” to
MARTIN® QB1™ CLEANER HD,
aid in safely moving the stackers where the next generation of belt
needed over terrain that may not always cleaning technology!
be level or firm.
TRY IT RISK FREE TODAY!
POISED FOR GROWTH If our system doesn’t perform
In the past, Laraway had always been as stated above, simply return
concerned about the costs related to it at any time for full credit.
multiple handling of material.
“Trucks would come to the dock
and dump the aggregate material on the
ground,” Laraway says. “A loader and an
operator would push up the piles while a
material handler and an operator would
scoop it up and load it on the barge. That
is hardly efficient. call 309.852.2384 or 800.544.2947
“Today, we can relocate our systems email qb1@martin-eng.com
wherever they are needed,” he adds. visit martin-eng.com
“Once our mobile conveying system is
® Registered trademark of Martin Engineering Company in the US and other select locations. © 2017 Martin Engineering Company.
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the operator flips a switch and it’s up and

pitandquarry.com October 2017 PIT&QUARRY S13

 CONVEYING
& MATERIAL HANDLING
GOING MOBILE
A number of operators are turning to mobile stockpile conveyors
to complement their fleet of mobile crushers and screens.
BY A DRIAN DONNELLY
F
rom port terminals to quar-
ries, conveyors and feeders can
been found transferring large
amounts of material due to their
operating efficiency and cost savings.
Conveyors are a cost-effective means
of transferring or stockpiling material.
When used in the
aggregate
S14 PIT&QUARRY October 2017
industry, mobile conveyors offer oper-
ators an efficient, reliable, robust ma-
terial-handling solution while offering
less downtime and a greater lifespan.
The abundant list of conveyor types
and options available to operators are a
testament to the benefits they bring to
operations. Differing discharge heights,
transfer lengths, condition of terrain,
availability of power, frequency of repo-
sitioning, throughput and budget are all
factors that have driven the market to
create a range of mobile conveyor
models. Various conveyor solutions exist
in order to meet different challenges
faced by operators, not to mention the
never-ending list of materials that are
being transported.
Quarry operators constantly strive
for improved productivity while at-
Differing discharge heights, transfer
lengths, condition of terrain, availability
of power, frequency of repositioning,
throughput and budget are all factors
that have driven the market to create a
range of mobile conveyor models.
pitandquarry.com
 Mobile stockpile conveyors
can be used to complement
a fleet of mobile crushers
and screens.

tempting to bring their overall cost
per ton down. For this reason, quar-
ries have turned to the use of mobile
crushing and screening equipment
much more frequently in the last few
decades. Having a mobile plant that
follows the quarry face has become
a more common sight in operations
across the globe to the extent that its
utilization is no longer questioned. It is
now a well-proven, operational model.
The transition from bringing the
plant to the material rather than trans-
porting material to the plant has obvious
PHOTOS COURTESY OF ADRIAN DONNELLY
stockpile material, operators have
turned to mobile stockpile conveyors
to complement their f leet of mobile
crushers and screeners.
CONVEYOR STOCKPILING
BENEFITS
With short discharge conveyors gener-
ally found on most mobile screeners or
crushers, sites that traditionally employ
By introducing
wheel loaders to move or stockpile
material tend to be constantly moving
material from the screener or crusher
that can only handle a small stockpile.
Material is moved from one stockpile to
another larger stockpile, and then onto
loading the trucks. Effectively, quarries
that employ this system handle finished
products at least twice.
By introducing mobile conveyors
into their processing line, operators
can now leave crushers and screens
running, moving finished product just
once with the wheel loader straight to

cost-saving benefits, but what about the
material being processed? Static con-
veyors relied upon to move hundreds
of tons per hour and that have been the
mainstay of many quarrying operations
for decades now find themselves moving
further away from the action.
To benefit from the efficiencies
and cost savings resulting from the
integration of conveyors to move or
the delivery trucks. Ultimately, the
mobile conveyors introduction of conveyors results in the
elimination of the double handling of
into their material in many cases. Therefore, this
processing line, cuts an operator’s cost per ton.
operators can now OTHER REWARDS
leave crushers and Production improvement proves to
be another advantage enjoyed by op-
screens running. erations using conveyors to create

pitandquarry.com October 2017 PIT&QUARRY S15

 CONVEYING
& MATERIAL HANDLING
Mobile conveyors offer operators an
efficient and reliable material-handling
solution that reduces an operator’s
dependency on haul trucks or wheel
loaders.
stockpiles. With crushers and screeners
no longer starved, operators can focus
on continuously loading feed material,
which allows conveyors to create larger
stockpiles in a much smaller area. This is
achieved by stockpile conveyors’ ability
to reach much higher discharge heights.
Stockpile conveyors also represent a
significant financial saving alternative,
freeing vital funds to help a business
expand. In addition, fuel consumption
S16 PIT&QUARRY October 2017
is drastically reduced compared with
other methods of operating.
Furthermore, conveyors can di-
minish the need for high-priced labor.
Conveyors have the ability to operate
at maximum efficiency every hour of
operation with minimal supervision,
thus reducing labor costs further.
CONSIDERING
CONVEYOR MODELS
Even when a quarry operator decides to
use a mobile conveyor solution, there
are further considerations to take into
account: does the operator opt for a
wheel or track-mounted conveyor?
Every operator has different needs and
challenges to overcome.
First, consider the chassis format.
Depending on how an operator wants to
integrate the conveyor into an existing
system and how he or she wishes to
stockpile will determine the conveyor
type the operator is seeking. There are
pros and cons to every conveyor format.
The track option is perfect for
operators who frequently reposition
their conveyors. A track stockpile is a
self-propelled, independent unit that
can be easily and quickly maneuvered
across rough terrain with increased
operator handling. However, it may not
pitandquarry.com
be the ideal product for the creation of
radial stockpiles.
The mobile stockpiler gives the op-
erator the added advantage of a radial
stockpile function. These must be towed
by another self-propelled vehicle on site.
Another solution is to combine
both formats into one unit. A radial
track stockpiler encompasses a track
unit with radial stockpile functionality.
ADDITIONAL
CONSIDERATIONS
Operators must also consider other
factors such as loading methods and
applications. If the conveyor were to
be loaded directly by an excavator or
wheel loader, then a feed conveyor
would best suit this application. If an
operator wishes to load directly with
a wheel loader on all three sides of the
hopper but does not want the extra cost
of constructing ramps, then a low-feed
Mobile conveyors
can eliminate the
double handling
of material in a
number of cases.
track stockpile is a fit. If an operator
wishes to run a constant feed of material
yet retain the ability to track parallel to a
barge, then a conveyor with 360-degree
slew functionality would provide the
flexibility required.
In addition, the manner in which
operators wish to power their con-
veyors varies owing to application
and material being transferred. Other
determining factors may include the
availability of diesel or electricity, the
current power source being used, the
ability of the customer’s service staff,
throughput required and the operator’s
past experiences.
The biggest advantage of a diesel/
hydraulic-driven conveyor is that it
can be operated in remote locations
because it’s self-contained with only
fuel being required.
Diesel/hydraulic-powered units
tend to be simpler to service than elec-
tric-driven counterparts.
Yet, the advantages of electric-pow-
ered equipment over diesel models
extend well beyond the obvious savings
on diesel fuel with significant savings
on operating and maintenance costs.
They also provide dependability and
uptime. P&Q
Adrian Donnelly is marketing
manager at Edge Innovate.

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 CONVEYING
& MATERIAL HANDLING
Conveying a proper
safety message
There are many factors to consider to make sure
aggregate workers are safe around belt conveyor systems.
“
Y
ou and your employees
are at risk of being in-
jured by a belt conveyor.”
With those words,
Jerad Heitzler opened a webinar on belt
conveyor safety. Heitzler is the Foun-
dations training manager at Martin
Engineering, and his safety webinar
was hosted by the National Stone, Sand
& Gravel Association.
Heitzler detailed the importance
of safety best practices when working
around conveying equipment, and his
presentation drove home the point that
injuries and fatalities from conveyor
accidents and other mining incidents
have a number of negative effects on an
operation – including to a company’s
bottom line.
“Make sure workers have hard hats,
safety shoes and safety glasses, and in
some cases hearing protection is import-
ant,” he says. “Gloves are a good idea, and
in certain applications, fall protection is
needed.”
Heitzler also stresses the importance
of wearing no baggy clothing and no
hooded sweatshirts around conveyors.
No jewelry, he says, and keep hair short
or confined.
GUARDS
A large part of Heitzler’s safety webinar
focused on conveyor guarding. One
important point is that the guard itself
should not be a hazard. Consider these
S20 PIT&QUARRY October 2017
BY DA RREN CONSTANTINO
takeaways:
◾ The guard should not exceed 50 lbs.
◾ It should not have sharp edges.
◾ Hinges should not create a pinch point.
Heitzler suggests remembering the
acronym “AUTO”: No one should be
able to reach Around, Under, Through
or Over a guard.
And, it’s an Occupational Safety &
Health Administration rule – and a
generally good idea – that a guard be
installed in such a way that a tool is
required to remove it.
“Foundations for Conveyor Safety:
The Global Best Practices Resource
for Safer Bulk Material Handling” is a
book published by Martin Engineering
Each conveyor guard panel, left, should
not exceed 50 lbs. so they can be eas-
ily handled. Also, improperly installed
guards, above, create serious safety
hazards.
that details many aspects of conveyor
safety, including best practices for the
design and construction of guards for
belt conveyors. Heitzler touted the book
during his presentation. The book notes
some of the following best practices in
respect to guards:
◾ Guards should not be designed to be
walked or climbed upon. Either construct
guards as if they are walking/working
surfaces (grating) or provide a crossover.
Keep workers safe
around conveyors
by mitigating
carryback, dust
and spillage.
pitandquarry.com

Emergency pull stops are an essential
safety feature on any belt conveyor
system.
◾ Guards that are hinged should take less
than about 17 lb.-ft. of force to open or
close, and hinge and latch designs should
be corrosion- and dirt-resistant.
◾ To allow inspection, the open area in
the guard’s mesh should be 50 percent
or more.
◾ Floating guard panels should be de-
signed with a minimum of four mounting
points, preferably in the corners.
◾ Where there are openings in the guard
panel (for example, for lubrication access)
they should be bordered with frame ma-
terial to eliminate sharp edges.
◾ Guards utilizing electrical interlocks or
remote noncontact sensing technology,
such as RFID tags, should be tested for
interference from other electrical signals.
CARRYBACK,
DUST AND SPILLAGE
Fatality and injury rates in mining have
PHOTOS COURTESY OF MARTIN ENGINEERING
dropped dramatically since the 1930s.
However, Heitzler notes, the decline
has plateaued somewhat since the early
1990s. He stresses the importance of
making safety a priority and says the
most effective way to keep workers safe
around conveyors is to:
◾ Mitigate cleanup and maintenance.
◾ Mitigate carryback, dust and spillage.
When you have carryback, dust and
pitandquarry.com
spillage, he says, your risk of being hurt
around a conveyor dramatically increases.
The following are identified as best prac-
tices for the cleanup of fugitive material
around belt conveyors:
◾ Install and properly inspect, adjust
and maintain the systems to prevent or
minimize fugitive material.
◾ Invest in systems to prevent the escape
of fugitive materials such as carryback,
dust and spillage. There is a prompt and
significant return on investments for
those systems that prevent the escape
of fugitive material and thus reduce the
expenditures for conveyor cleanup and
component replacement.
◾ New systems can be designed to allow
safe cleaning under the conveyor in
areas of anticipated high accumulation
of fugitive materials. In those areas, the
conveyor can be elevated and guarded
to allow cleaning to be done safely and
at less frequent intervals.
◾ Employ available technologies to replace
or supplement manual cleaning.
◾ Use wash-down systems, skid-steer
loaders, vacuum trucks and other equip-
ment to meet cleaning requirements while
minimizing labor. When using powered
equipment, watch for other personnel
working in the vicinity; use a spotter
when moving.
TRAINING
“The key to training is to get the trainee
to modify [his or her] behavior – to do
things differently so you get the results
you need,” Heitzler says.
Data does not support the need for
hands-on training. It’s more important to
simply keep the trainee engaged, he adds.
Some training best practices include:
◾ A small class size encourages interac-
tion. A class of 25 individuals (or fewer)
typically works best, especially when
incorporating activity-based learning
into the training program.
◾ Instructors should be subject-matter
experts who can deliver content in a
classroom setting.
To keep workers safe around conveyors,
employ available technologies to replace
or supplement manual cleaning.
◾ Some regulations require trainers to
have special qualifications.
◾ Draw on participants’ own knowledge
and experience about safety and health
issues.
◾ Incorporate a variety of learning
principles, methods and activities to
enhance learning for all.
Also, Heitzler stresses that when
it comes to belt conveyor safety, it is
important to go above and beyond
satisfying the requirements of govern-
ment agencies such as the Mine Safety
& Health Administration. P&Q
Five safety points
According to Jerad Heitzler,
Foundations training manager at
Martin Engineering, mining com-
panies and their employees have
a responsibility for each of the
following:
1. Personal protective equipment
(PPE)
2. Policies, procedures, protocol
3. Safety equipment, such as
guarding
4. Training
5. Developing effective ways to
keep workers safe
October 2017 PIT&QUARRY S21
 CONVEYING
& MATERIAL HANDLING

Equipment and technology

Reduce belt spillage,
premature wear
ASGCO added a semi-ceramic pul-
ley lagging to its pulley lagging product line,
featuring 40 percent coverage. The ceramic
tiles are embedded in rubber on all sides and
separated by a horizontal groove for dispelling
water and dirt. The pre-chemical backing pro-
vides an exceptional bond for rubber-to-metal
applications. They feature high-grade alumi-
num oxide ceramic, pre-chemical backing
and rounded corners. The product delivers
increased traction between the conveyor belt
and pulley, and there is 3 mm of neoprene
compound vulcanized into the bottom side of
the lagging to increase the bonding strength.
www.asgco.com
Separate cartridge from the belt
MARTIN ENGINEERING introduced a new family of
heavy-duty conveyor belt cleaner designs, engineered
so the blade cartridge can be pulled away from the belt for safe
access and replaced by a single worker. Martin developed the
Safe to Service (STS) blades to secure both primary and sec-
ondary cleaners rigidly to the conveyor mainframe. External
servicing reduces confined-space entry and eliminates reach-in
maintenance. Dual tensioners separately adjust either end of
the constant angle radial pressure (CARP) blade on the primary
cleaner and the cushioned reversible blade on the secondary
cleaner. It’s designed for conveyor speeds up to 6.1 mps and belt
widths from 18 to 120 in. www.martin-eng.com

Mount sensor on
multiple idler styles
SUPERIOR INDUSTRIES INC. added a new Speed
Sensor to its conveyor component accessories
offering. The Speed Sensor monitors the speed of a
conveyor belt by producing electronic pulses inter-
preted by a PLC or Superior Speed Sensor module.
The unit’s sensors help operators control conveyor
shutdowns, monitor belt slippage and trigger warn-
ing systems. Fitted for CEMA C and D idlers, Superior
Speed Sensors are available for belt widths ranging
from 24 to 72 in. They can be mounted on a clean
side roll (CSR), which has flexible mounting and
can be mounted on any belt width conveyor. Other
mounting options include a return roll or troughing
wing roll. www.superior-ind.com

S22 PIT&QUARRY October 2017 pitandquarry.com

Rubber mends ripped belts
Repair belt tears with MLT’S Fix’N Go, which uses
50-cu.-meter rubber. Fix’N Go has a higher abrasion
resistance than most conveyor belts, the company
says, and the product doesn’t impact its flex-
ibility and resistance to elongation and tensile
strength. It’s available in boxes of 2 meters or
20 meters, along with screws. MLT-specific screws are
self-drilling and self-tapping: They spread the carcass
threads without cutting them. It’s available in anti-abra-
sion and heat-retardant versions. To install, users will
need a battery, electric or pneumatic drill or screwdriv-
er, along with a belt skiver. It works in a variety of situa-
tions, including with longitudinal, transverse and band-
edge tears. If there’s a hole that’s larger than Fix’N Go,
users can put the product side by side to cover the rip.
www.mlt-lacing.com
Replacing the universal joint
TWIN SPRING COUPLING’S new drive train
coupling, the TSC8300, is warrantied to 300
ft.-lbs. of torque. This product will allow cus-
tomers with smaller torque requirements that need
the torque with increased flexibility to get both in one
product. Its applications include axle, PTO, drive shaft,
steering, conveyor belts and practically anywhere a
uni and bearings are used. The simple design allows
the coupling to be scaled up or down to suit the appli-
cation and torque requirements. The flexibility of the
springs allows for more degrees of movement without
damaging drive shaft or components, while at the
same time being able to absorb shock and energy. The
coupling can be used in the auto, mining, agriculture
and industrial industries.
www.twinspringsoupling.com

Pipe lineup expanded

HARDOX WEARPARTS added the Duroxite
100 pipe to its Duroxite overlay product
line. According to the company, the finished
pipes have the same high wear resist-
ance as Duroxite plate products.
Consistent wear properties are guar-
anteed throughout the pipe down
to 75 percent of the overlay thickness as
opposed to just the surface of the overlay.
The remaining 25 percent of overlay is
the transition layer necessary to maintain
good bonding to the base plate. The com-
pany says an optimal carbide composition
ensures homogenous bonding between
the base metal and overlay adding to its high wear ized flanges for easy installation in existing equipment.
resistance and long service life. The Duroxite 100 pipe is Finally, the pipe can be ordered with square-to-round
available in 6- to 36-in. diameters, and the lengths can transitions, elbows, T- or Y-shaped connections, or as
be cut to order. In addition, the ends can have custom- long sweeps. www.hardoxwearparts.com

pitandquarry.com October 2017 PIT&QUARRY S23

 A Look Back
C O N V E Y IN G A N D M AT E R I A L H A N D L IN G S U P P L E M E N T

Thor Power Tool’s

Cincinnati Rubber Division’s
two-city-block-long
conveyor belt is covered
in snow as it carries raw
material from the quarry
to the plant at a Midwest
brick maker. The 2-ft.-wide
elliptical traveled 1,492 ft.
The date of this picture is
unknown.

Conveyor C-1 leads

rock from the pit crushing and
screening plant, where two
lengths of 48-in.-wide B.F.
Goodrich conveyor belting
bring material to plants
in Akron, Ohio.

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

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

S24 PIT&QUARRY October 2017 pitandquarry.com

 s
bil r
pa rde
i ti e
Ca -O
-To
de
Ma

POWER TRANSMISSION
STOCK & MADE-TO ORDER

HEAVY-DUTY
CONVEYOR PULLEYS

IDLERS
CEMA C, D, E

MATERIAL HANDLING
CONVEYORS
& COMPONENTS

Scan for more information

CONVEYOR BELT
LACING SYSTEMS

any splice, any belt

anytime, anywhere
SUPER-SCREW®
NEW GENERATION SPLICE

fix’n go®
THE EASY SOLUTION

MS®
MECHANICAL FASTENERS

info@MLTnorthamerica.com
336-434-0363 • www.MLTnorthamerica.com

INNOVATION USING SCREWS