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NEW ZEALAND QUARRYING & MINING Volume 13 - No 4 | August - September 2016 | $8.95

Geared for growth Two new Hyundai loaders go to work in the Chatham Islands

Quarrying unique schist

Catering to Otago’s booming building trade

Demystifying quarrying CPD

A guide to Professional Development requirements

QuarryNZ 2016 in pictures

Highlights of the AQA/ IoQ conference in Blenheim INCORPORATING

Aggregate News


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C O N T E N T S

NEW ZEALAND QUARRYING & MINING Volume 13 - No 4 | August - September 2016

INSIDE

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UPFRONT

6 Editorial 8 Upfront 9 QuarryNZ Conference coverage in pictures 13 Mimico Environmental Excellence Awards Q&M Editors award winners – recognising Tomorrow’s Leaders

ON THE COVER 14 Geared for growth – Southern Screenworks expand its line up of Hyundai machinery

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FEATURES

Quarrying 16 Taranaki Shell Rock 20 Quarrying unique schist

Mining

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Keeping up with OceanaGold Talisman a step closer Solid Energy chases small new coalmine Gold mining alive and well in Central Otago Southland’s silica beckons CRP ready to have another go Big mining equipment a slow sell State of the art technolgy in Papua New Guinea Aggregate News Professional development

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AT THE BACK 41 Innovations and products 42 Advertisers’ Index

ON THE COVER: Expansion plans and exciting new projects have seen Southern Screenworks dramatically expand its line up of machinery. When it comes to buying new loaders, the preference is for Hyundai.

See story page 14

32 Q&M August - September 2016 5


E D I T O R I A L

NEW ZEALAND QUARRYING & MINING

Q&M covers news, views and trends from the extractive industries, along with features on projects and people in the industry. www.contrafed.co.nz PUBLISHER

A conference to remember The 2016 QuarryNZ conference in Blenheim had a number of highlights. Among them the brand new theatre next to the convention centre. It was the first time this venue had been used for a conference and it worked very well. It also proved an expensive asset for the local community as new earthquake building regulations came into effect during its build, putting another $4 million plus onto the foundations costs . An interesting fact to come out of the excellent WorkSafe presentations is that it has on its register around 650 quarries, but reckons there ‘could be’ another “1000” extractions sites that come under the new regs out there. The agency refers to them as “outliers”. The technical definition of an outlier is; “An observation that lies an abnormal distance from other values in a random sample from a population”. Is this an example of Wellington calling a shovel a ‘long narrow stick with a flat piece of metal at one end used to shift small quantities of material’? Russell Vickers would say so. Unfortuntaley, Outliers is also name of a celebrated book written by Malcolm Gladwell with a focus on ‘extremely succesful people’ as a blueprint for making the best out of human potential. Anyway, the agency only has three dedicated quarry inspectors, so good luck tracking down these outliers, that’s if they all actually exist? Another highlight was the Mimico lunch on the Friday as the venue was the unfinished ‘Dangerous Skies’ (WW11) exhibit being put together at the Omaka Aviation Heritage Centre. This was another first, as it doesn’t actually open until September and the owners obtained special consent for delegates to enjoy a a delicious sit-down lunch surrounded by a vintage (working) Spitfire and (model) Stuka dive bomber. Well done to the venue and the sponsor Mimico. Guest speaker Keith Quinn is also always a delight to listen to. An excellent presentation by new WorkSafe chief inspector extractives Mark Pizey was another highlight. His industry experience and softly, softly approach went down very well after the franker tones of his predecessor, Tony Forster. Perhaps Mark’s industry ‘understanding’ reflects the number of deacdes has has worked in New Zealand (he’s a Pom) and specifically his time as a mines’ inspector during the infamous 1990s, when successive governments came up with the disastrous policy of industry self-regulation. Auckland’s feral driving behaviour is still a legacy from this policy as the government sweats our traffic police asset. We will feature a profile of Mark Pizey in the September Contractor that will include someofg his QuarryNZ presentation. The articulate Ari Motus from WorkSafe also did a very good job at explaining CoCs (the agency is fearfull it will be inundated with renewals come December) and professional development requirements. All WorkSafe has to do now is simplify its website so we can find the bloody regulation guidelines online. As Ari commented – the fact you can earn CPDs from attending industry conferences and attending workshops (and now there’s an opportunity for industry associations), should raise the attendance levels at QuarryNZ in Auckland next year. One negative from the Blenheim conference. The gala awards on the Friday evening take a lot of organisation and expensive sponsorship (and this includes this magazine own award). Plus delegates and their partners pay good money to attend this event. Yet, for at least three years in a row the technical stage presentations for the major award sponsor Mimico have stuffed up (even after we had rehearsals this year). This year videos didn’t play and PowerPoint presentations went awry. Hats off to MC Steve Davies for keeping the award presentation on track on the night. It is not good enough, and something needs to be done about these embarrassing technical issues before we meet again next year in Auckland for the 2017 awards. QuarryNZ 2016 photo coverage on pages 7-11. Alan Titchall, Editor 6 www.contrafed.co.nz Q&M

Contrafed Publishing Co Ltd Suite 2.1, 93 Dominion Road, Mt Eden 1024 PO Box 112357, Penrose, Auckland 1642 Phone: 09 636 5715 Fax: 09 636 5716 EDITOR

Alan Titchall DDI: 09 636 5712 Mobile: 027 405 0338 Email: alan@contrafed.co.nz GENERAL MANAGER

Kevin Lawrence DDI: 09 636 5710 Mobile: 021 512 800 Email: kevin@contrafed.co.nz ADVERTISING

Charles Fairbairn DDI: 09 636 5724 Mobile: 021 411 890 Email: charles@contrafed.co.nz REGULAR CONTRIBUTORS

Hugh de Lacy, Neil Ritchie, and Peter Owens ADMINISTRATION/SUBSCRIPTIONS

Email: admin@contrafed.co.nz DDI: 09 636 5715 PRODUCTION

Design: Tracey Asher, TMA Design Printing: PMP MAXUM Contributions welcomed. Please contact the editor before sending them in. Articles in NZ Quarrying & Mining are copyright and may not be reproduced in whole or in part without permission of the publisher. Opinions expressed in this magazine are not necessarily those of the shareholding organisations or the publisher. The views expressed in the Aggregate News section of NZ Quarrying & Mining may not represent the views of Contrafed Publishing or its shareholding organisations. VISIT THESE WEBSITES Aggregate & Quarry Association www.quarrying.org.nz Institute of Quarrying (NZ) Inc www.ioqnz.co.nz New Zealand Minerals Industry Association www.straterra.co.nz Extractive Industries Training Organisation www.mito.org.nz Civil Contractors NZ www.civilcontractors.co.nz NZ Ready Mixed Concrete Association www.nzrmca.org.nz Connexis www.connexis.org.nz ISSN 2463-509X (Print) ISSN 2463-5103 (Online)


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U P F R O N T

Urgency over CoC renewals Readers should be very aware that all holders of Certificates of Competency (CoCs) are required to renew their certificates before December 31. Any certificate holder who does not renew before this date will not have a CoC on January 1, 2017, so will not be legally able to manage an extractive site. The Board of Examiners secretariat has been advising all CoC holders to ensure they send their applications for renewal of their certificates into the BoE as soon as possible. Currently it is believed that there are somewhere in excess of 1000 quarries in New Zealand alone, plus other extractive sites that require managers to hold current CoCs. Up until June 2016 there have been approximately 650 certificates issued across all types of extractive qualifications, from quarrying to mining and tunnelling. A number of CoC holders also hold multiple certificates so it is possible that there may be a current shortfall in numbers of somewhere in excess of around 400 CoCs. If readers need to renew their current CoC then I advise them to get their renewal application asap with all of the required information to the BoE Secretariat. Otherwise, they may find that they cannot get their renewal processed before the cut-off date of 31 December 2016. Sincerely, Andy Loader Hon FIQ, Dip Q, Dip OSH, RSP, ASA, MNZSC.

Quarry death prosecutions A South Canterbury quarry firm was fined $54,000 and ordered to pay $100,000 in reparation to the family of an employee crushed to death while operating heavy machinery. Scott Baldwin (43) died at Gordons Valley Lime Company near Timaru on March 19, 2015. He was the manager and sole regular employee on the quarry site. A WorkSafe New Zealand investigation found that Transport (Waimate), failed to identify and manage the clear hazard posed by the quarry machinery. The company previously pleaded guilty to failing to take all practicable steps to ensure the safety of Baldwin and failing to ensure he held a current Certificate of Competence as a quarry manager. WorkSafe found there were no processes in place to stop maintenance of machinery being carried out while the machinery was running, and there were no effective controls for an operator to stop the top motor in an emergency. The company had also made a “significant failure” in not ensuring Baldwin held an appropriate qualification to manage the quarry, says WorkSafe. A month later, in April 2015, a 24-year-old died after being thrown from a laden 45-tonne truck with no door at a Bay of Plenty quarry. It was revealed in the Tauranga District Court in March that – 11 months after this death – WorkSafe had to prohibit work at the same quarry after finding similar health and safety failings that led to the worker’s death. At a sentencing hearing, the employer, Oropi Quarries (OQL) and its sole director Catherine Renner were accused of a “litany of health and safety failures” by the prosecutor. In a reserved judgment, the Judge ordered emotional harm reparations of $100,000 to be paid to the family (OQL $80,000 and Catherine Renner $20,000). He also fined OQL $54,000 and Catherine Renner $9600. WorkSafe outlined to the court 14 steps OQL should have taken to

Trans-Tasman qualification The Trans-Tasman Mutual Recognition Agreement (TTMRA) provides for mutual recognition between New Zealand and Australia of equivalent occupations. This means a person who is registered to practise in an

ensure the victim’s safety. “There were significant issues with vehicle maintenance; failures to train the worker; a lack of policy on wearing seatbelts; and a lack of supervision,” Stewart says. “WorkSafe had the vehicle inspected by independent experts – their reports identified 32 faults with the vehicle ranging from mismatched and over-inflated tyres to a missing door on the cab.”

occupation in Australia is entitled to practise an equivalent occupation in New Zealand after notifying the local registration authority. Those who want to apply for a safety-critical role in mining, tunnelling and quarrying operations and hold an equivalent Certificate of Competence (CoC) in Australia can apply to the New Zealand Mining Board of Examiners (the Board) for a New Zealand CoC under the Trans-Tasman Mutual Recognition Act 1997. Because mutual recognition focuses on the activities authorised to be carried out under each registration and whether or not these are substantially the same or ‘equivalent’, those granted a CoC under the TTMRA will not have been required to demonstrate knowledge of New Zealand’s health and safety legislation as it applies to the extractives’ industry. Further information on CoC requirements is available on the NZ Mining Board of Examiner’s website or by contacting: BoE_Secretariat@worksafe..govt.nz, ph 04 901 0696. 8 www.contrafed.co.nz Q&M

McCaw turns quarryman All Blacks legend Richie McCaw has taken a 10 percent stake in Canterbury’s SOL Quarries. The company has a 15-year permit to extract from a new quarry near Christchurch Airport after two years chasing consents and spending $500,000. McCaw says he knows nothing about the extraction industry, which is one of the reasons he was keen to get involved in the business. It was different to his business ambassador roles, he adds. “Obviously as an ambassador, whether the business survives or goes well or not, you are not really affected, but when you’re a shareholder you take a different sort of interest.” McCaw says he has known SOL co-owner Ben Dormer since playing rugby with him in a Crusaders Colts team 15 years ago.


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QuarryNZ 2016 in pictures

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1. The 2016 QuarryNZ conference opened with the traditional Gough Welcome Dinner, held at the brand new ASB Theatre Marlborough in the heart of Blenheim. It was the first time the venue, designed for musicals and plays, had hosted a dinner.

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2. On display outside the conference was the first new Cat M series excavator in the country, pictured with Scott Bonnington, territory sales manager, Gough Group. This series replaces the K series and features low exhaust emissions (latest European standards) and in-built level-sensors in the boom. Both the M series excavator and loader were realised in other markets two years ago. The M loaders are due to arrive here this month. 3. Westrak stand in action. 4. Also on display outside was this Swedish-made Duztech Coolfog dust controller distributed by Access Environmental Systems and demonstrated by Geoff Svenson who is based in Brisbane.

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5. The Metso ‘orange’ rotary crusher rotor has become a feature of the Mimico stand at QuarryNZ. Pictured: Deane McKenzie (left), aftermarket parts sales and product support, and John O’Reilly from Metso Australia. 6

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Q&M August - September 2016 9


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3 1. Darrin Barr, territory manager, Ryco Hydraulics. 2. AQA chief Roger Parton and Straterra chief Chris Baker taking a break in the AQA corner. 3. Andrew McCoy, CablePrice equipment sales, at the CablePrice stand. 4. Komatsu stand in action. 5. Glenn Powell, Prime Pump with Charles Fairbairn, Q&M advertising manager. 6/7. Real Steel Hard Rock Club happy hour on the Thursday after close of sessions. 8/9. Terex stand and

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1. Wirtgen model display. 2. N  ick Lahman, sales and marketing manager, Texcel, a company specialising in blasting monitoring equipment. 3. M  ark Pizey, WorkSafe chief inspector extractives and High Hazards Unit quarry inspector Philip Fourie (Hamilton). 4. High Hazards Unit line-up (from left): Priscilla Page, inspector (Hamilton); Ari Motus, project manager, High Hazards and Specialist Services; and Charlene Donald, inspector, Gisborne. 5. I nto the cheese at the end of the TransDiesel Awards Dinner (from left): Tony Hunter, Blackhead Quarries; Dr Morgan Williams, a former Parliamentary commissioner for the environment and judge/presenter of the Mimico Environmental Awards; and the talented Steve Davis, the regular QuarryNZ MC.

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6. I t took TransDiesel staff almost 12 hours at the conference to put this very detailed, remote controlled, Volvo/Lego L350F model loader together. The kits sell for around $400 through TransDiesel.

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Bruce Taylor was awarded the prestigious The Institute of Quarrying NZ Award, which formally recognises a long-serving member who is held in high regard because of a long period of outstanding service to the Institute. This Award is, above all, a measure of the esteem in which the nominee is held by his colleagues, and is made in the true spirit of Institute fellowship.


Mimico hosted the Friday lunch for the first time and the fantastic venue was the ‘Dangerous Skies’ (WW11) exhibit still being put together at the Omaka Aviation Heritage Centre. This exhbit doesn’t open until September and the owners obtained special consent for delegates to enjoy a a delicious sit-down launch surrounded by vintage WW11 fighter planes.

Above (from left): Bruce Taylor, Fulton Hogan, collecting the award on behalf of Logan McNaught; Q&M editor and award presenter, Alan Titchall; Shaw McLean supreme award winner; and Tony Hunter, Blackhead Quarries collecting on behalf of Lloyd Stewart.

Mimico Environmental Excellence Awards

Q&M Editor’s Award

Three Canterbury quarries took honours in the quarry industry’s annual environmental awards sponsored by Mimico. Isaac Construction was awarded a Gold for its legacy project at its McLeans Island quarry on Christchurch’s northern outskirts. Silver awards went to Canterbury Aggregates for its commitment to provide its Amberley Beach Quarry as a future community asset; and to Fulton Hogan Miners Road quarry for its leadership in environmental policy and sustainability practice. More information on page 34.

The theme of the 2016 Q&M Editor’s Award was recognising Tomorrow’s Leaders – three quarry workers who are coming up through the ranks within our industry. They were selected from seven nominees for this award provided by a number of companies through the AQA and the magazine. They were Lloyd Stewart, Palmers Industrial Minerals; Shawn McLean, manager, Stevenson Resources, Huntly Quarry; and Logan McNaught, Fulton Hogan, Bell Road Sand Quarry, Bay of Plenty. As the supreme award winner, Shawn took home $1500 and Lloyd and Logan $750 each.

Q&M August - September 2016 13


O N

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C O V E R

Geared for growth Expansion plans and exciting new projects have seen Southern Screenworks dramatically expand its line up of machinery. When it comes to buying new loaders, the preference is for Hyundai.

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trong growth has seen Aylesbury-based Southern Screenworks steadily expand its fleet of Hyundai loaders over the past few years. Its latest purchase, a Hyundai HL770-9 wheel loader is the ninth of its kind in the company’s line up of machinery, alongside five smaller HL760-9 loaders and three Hyundai excavators. Company owner Brett Swain says they’ve been buying a lot of gear in the past couple of years as the company has expanded. Although based just out of Christchurch, Southern Screenworks operates throughout the whole of the South Island, as well as the lower North Island and over on the Chatham Islands. The company’s standard fare is processing, screening and washing aggregates for various roading projects, but in the past few years it has snared a couple of larger, higher profile and more complex projects. The latest big project is in the Chatham Islands. Southern Screenworks is the quarry partner to the Memorial Park Alliance which won the contract to construct the new Waitangi wharf for the NZ Transport Agency. The wharf is the Chatham’s only cargo-handling facility for essential supplies such as diesel for the electricity grid and fuel for the air services. Southern Screenworks is providing 100,000 cubic metres of aggregate to the wharf rebuild. The current wharf is nearing the end of its structural life and needs replacing. The upgrade includes a new commercial wharf and fishing wharf, as well as a 185-metre-long breakwater for wharf protection among other improvements. It’s a significant project and, because of its remote location, one with a unique set of demands. Brett says it was a bit of a challenge to get set up on the island and the day-to-day logistics of having a team of seven on the island also has its difficulties. The crew is established in the lodge and are working on a four-weeks14 www.contrafed.co.nz Q&M

on, one-week-off rotating shift. Southern Screenworks shipped over a crushing plant to process the aggregate. The rock is being sourced from a quarry the company has developed for the project some seven kilometres from the site of the new wharf. Two new Hyundai loaders and two diggers were purchased specifically for the Chatham Islands job. Physical works on the new wharf started at the beginning of the year and the project is scheduled to be complete by the end of 2017. Another significant project Southern Screenworks has recently completed is M2PP, as MacKays to Peka Peka is known. It’s the 18km long, four lane expressway that takes State Highway 1 along the Kapiti Coast to and from Wellington – a vital link in the lower North Island roading network. Operating out of Winstone’s quarry in Otaki, Southern Screenworks put 11 pieces of mobile plant into this project plus an excavator and loader to produce 240,000 tonnes of high-spec M4. “It was a very hard spec to meet,” says Brett. “We brought in new plant from overseas to do this.” The Hyundai loader on this job was also brand new. According to Brett the company is actively looking to grow, so when it wins a big contract, such as M2PP or the Waitangi Wharf, it goes out and buys new gear. Southern Screenworks has been in business for around 22 years now. Started by Brett and Alan King, the company has grown steadily and now runs 10 mobile screening plants. It has its own quarry at Aylesbury, where the company workshop is also located, as well as a number of river consents. The rest of the quarrying is done on contract. One of the company’s longest business relationships is with Porter Group, the supplier of all those Hyundai machines. Brett says they’ve been working together for about 18 years now and have a very good relationship.


Two new Hyundai loaders and two diggers were purchased specifically for the Chatham Islands job.

“They’ve really looked after us when we’ve been in rapid growth,” says Brett. “They’ve been extremely helpful. “We’ve bought a lot of gear in the past couple of years – including four loaders. They’re a good partner for us.” The big drawcard of Hyundai, according to Brett, is the price. He also likes all the new technology incorporated in the machines which makes them very operator-friendly. The newest Hyundai is going into the fleet to replace an older one that has clocked up more than 10,000 hours. “It’s good value for money with the trade,” says Brett. “It makes it worthwhile.” Porter Equipment territory manager for Canterbury and the West Coast, Chris Toase, says the trade is a first for Southern Screenworks. “Due to their growth they haven’t done much trading – they usually

just buy new machines,” he says. “I think this is the first machine they’ve actually traded.” In the eight or so years Chris has been looking after Southern Screenworks he’s seen them purchase a lot of gear. “I’ve seen them grow from just a small screening and crushing outfit to what they are now. They’re a great company – Brett and Alan are a good team, and a real pleasure to deal with.” As for the new HL770-9, along with the latest in Hyundai’s engine technology that ensures reliability and efficiency, the loader boasts enhanced operator comforts. It has improved visibility, adjustable controls for optimum ergonomics, fully automatic climate control, and an advanced audio system with MP3 interface and USB input. It also has an easy-to-read colour LCD display and an integrated load weight system, viewable through the monitor, for improved work efficiency and overload prevention. • Q&M August - September 2016 15


Q U A R R Y I N G

TARANAKI

SHELL ROCK

A quarry nestled in the hills between the regions of Taranaki and Whanganui is one of only a few in the region to produce limestone. By NEIL RITCHIE.

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he Ravensdown Windy Point Quarry has been operating for a little more than 30 years, producing a variety of what it refers to as ‘shell-rock’ products for a variety of customers. “Despite the current downturns in the dairy and oil and gas industries, there’s still forestry, bee farms and road repairs, so we’re still pretty busy, flat out in fact,” says quarry manager Evan Mooney. The 64-year-old believes there’s another decade or so of economic life left in the small quarrying operation that is presently producing about 40,000 to

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50,000 cubic metres of various limestone products every year. “We would like to be doing about 60,000 cubic metres, as we were a few years ago, but that is going to depend on future demand.” The Windy Point Quarry, right on the border between the South Taranaki and Whanganui District Councils, is one of very few quarries in either district to produce a range of aggregates from limestone. “This is the only place we know in this area that produces shell rock and sometimes we still find whole fossilised mussel shells intact. It must have been one hell of a shake-up aeons ago,” says Evan.

Although the colour and composition of limestone varies considerably throughout the country, that quarried at Windy Point is yellowy brown and very hard. Although it is still relatively soft compared to the usual volcanic andesite material found closer to Mount Taranaki. “However, what we produce is approved by the Transport Agency for use. We have to get our product checked regularly, though, every few months or so, to make sure it meets their standards. “And most of the rural and state highway roads in the Whanganui, Waverley and Waitotara areas have been built with shell rock and these have stood the test of time,” says Evan. “At first it was dug out with a dozer, which we are still using, and no screening was required. “Now the metal is ripped out by digger and our current digger, a Hyundai R360, is due for replacement. We’ve worn out two loaders since I’ve been here. >>

The Hyundai HL 770-9 wheel loader empties another load of shell rock aggregate into a truck and trailer unit.


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Q U A R R Y I N G

Left: Quarry worker Aaron Jackson operates the Hyundai R360 excavator.

Above: Ravensdown Windy Point Quarry manager Evan Mooney pictured above the pit from where the shell rock is extracted.

18 www.contrafed.co.nz Q&M

“But the old crusher, a Goodwin Barsby, she’s seen a few machines fade out in her time. And we are still using this crusher, which has being going since before 1985. It does the job perfectly for shell rock … we just scalp off the fines from off the crushed product.” Evan has been the quarry manager at Ravensdown Windy Point Quarry for about 11 years. “It’s just the same shit every day, but that’s okay because we know we are providing some valuable and extensively used products for the locals.” The quarry employs two staff fulltime and a third part-time, produces a range of aggregates – from AP40 and AP65 to race fines, a larger rock as a base course and also offers an oversize material service. Generally, end uses are as roading materials and for the burgeoning “bee metal” market. “Honey is the new gold,” says Evan, referring to the number of bee farms being established in the area. “And there are a lot of repairs going on right now after last year’s floods,” he adds, referring to those events that occurred in and near Waitotara and the more northerly Taranaki town of Opunake last year. There was also flood damage to some of the Stratford district. Towns and nearby farmland were inundated by the flooding, with houses and farmland damaged and millions of dollars of damage done to roads. A bridge on State Highway 3 was damaged, as well as numerous local roads being impacted by hundreds of slips and dropouts. The

total estimated cost to repair and reinstate the affected roads is estimated to exceed $15 million and take well into 2017 or beyond to complete. Regular quarry customers are “everybody really”, he says, from cow cockies and dairy farmers, for farm races and tanker tracks, to roading contractors and others. But the main customers are Fulton Hogan and Downer. The quarry’s history is interesting. First Worsley Transport “discovered” the shell rock, says Evan. Then Waverley Bulk Transport (WBT) took over owning and operating the quarry. More recently WBT entered into a joint venture with the farmer-owned fertiliser company Ravensdown. And now New Plymouth’s Freight & Bulk Transport (FBT) is also involved. And innovative technology is also entering quarry operations, including the Hyundai HL 770-9 wheel loader (featured on this issue’s cover) that sends “reports” of its operations back to Hyundai’s world headquarters in Seoul, South Korea, via satellite. Seoul then notifies the quarry, via the loader, of any likely faults that need to be repaired. “Remote monitoring at its best,” says Evan. “And we have a new set of automated scales on the loader that does all the docket work for all the loads done in a day … this [information] is just downloaded to FBT’s New Plymouth head office every night and billing is automatic. “So we no longer physically write out any dockets, it’s all done by computer.” Q&M


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Q U A R R Y I N G

QUARRYING UNIQUE SCHIST Central Otago has a rapidly expanding economy that has triggered a building boom right across the region, which has opened the way for new aggregate operations. By PETER OWENS.

Above: Cluden Quarry staff 2015: Ernst Jonker, Rodney Wallbank, Lucy Middendorf and Grant Middendorf.

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T

he Otago region has been renowned since the gold rush days of the mid-19th century for the quality of its schist rock as a building material. It was the only local building material available in those heady times and today it is a popular cladding and pavement material around the country. There are about 10 schist quarries in the Upper Clutha area supplying stone to Wanaka, Queenstown and further afield. One of these is Cluden Stone Quarry which has been operating near Tarras for over 25 years. It is owned by Grant and Lucy Middendorf who bought it two years ago and it is now producing about 500 tonnes of cut schist annually. The couple arrived just after the building boom began and they have been inundated with orders from the local construction industry. In order to keep up with demand, the Middendorfs have bought a new $100,000 Italian designed and manufactured guillotine for cutting rock. When the guillotine blade drops the table on which the block of schist sits also drops down and another set of teeth below the rock come into operation. These 24 tungsten-tipped teeth adjust to the shape of the rock so that it exerts 120 tonnes of pressure evenly over the rock surface. Stonemasons prefer schist cut to widths of 150mm for use as cladding. Around half of the processed schist is bought by the local building industry and the rest is sent further north. Otago schist formed around 200 million years ago during the Jurassic period when plate tectonics forced sandstone

Q&M August - September 2016 21


Q U A R R Y I N G

Above Ernst Jonker on the Cluden Steinex guillotine.

and volcanic materials to be buried deep in the earth. High temperatures melted some minerals and realigned them into the linear and platy schist rock that became a distinctive part of the Otago region. The distinctive earthy shades of grey and brown have formed through the separation of different minerals into layers creating colourful variations in tone and shade unique to Wanaka schist. Uplift and erosion have removed the softest rocks, leaving hard and stable rock in place for quarrying. Having already survived millions of years in the harsh Otago climate Wanaka schist will last longer than almost all other materials used in building or landscaping. Grant Middendorf grew up in Queenstown and spent over 10 years in the Army Engineers Corp (RNZE). During this time he trained and earned his initial quarry manager and explosives licences. Since then Grant has accumulated over 20 years of experience drilling, blasting and operating heavy machinery in quarries and mines around New Zealand, Australia and the Pacific. Lucy Middendorf, a qualified geologist, has worked for over 10 years in our mining industry and spent a number of years working in Australia, Armenia, and the Philippines. Although the couple have been living at Lake Hawea for about nine years, 22 www.contrafed.co.nz Q&M

they have been flying in and out of New Zealand for much of that time. Now the Middendorfs say they are very pleased to be able to settle down and work in the one place. At present the only rock mined at Cluden is schist as there is no other local hard rock. The couple have a total of 69 hectares of permitted land in the Cluden Creek area and are planning to develop another area. Q&M


M I N I N G

Keeping up with OceanaGold

The Kiwi operations of OceanaGold Corporation are still contributing significantly to the good results being achieved by the multinational minerals company. By NEIL RITCHIE.

T

he NZX listed, but Melbourne headquartered, company says drilling results at Waihi continue to demonstrate resource expansion opportunities from numerous highgrade targets – including Correnso Deeps, Empire and Daybreak. It also reports drill results at Macraes demonstrate an extension of known mineralisation both to the north and southeast of the previously reported Coronation North resource. So far this year the company has completed more than 16 kilometres of drilling at Waihi using three underground and four surface drill rigs. Underground diamond drilling has focused on reserve and resource drilling of Correnso Deeps and Daybreak and geological and resource models have been updated on these veins. Mine design and planning has been completed in preparation for development, which is expected to start during the third quarter of 2016. Meanwhile, surface diamond drilling has focused on testing the resource potential of the major lodes, linking veins and “stock-work” zones beneath the current open pit. Exploration drilling of other untested targets within the Waihi epithermal is continuing, from both surface and underground platforms. A further 20 kilometres of drilling is currently scheduled for the remainder of this year at Waihi, including further drilling on the WKP prospect in the Hauraki region where previous drill campaigns returned high grade intercepts of 9.7 metres (7.5 metres true width) producing 17.2 grams of silver per tonne and 7.9 metres producing 5.1 grams of silver per tonne, respectively. At Macraes, the company has drilled over 14 kilometres so far this year with a focus on resource development drilling at Coronation North, Coronation open pit, Coronation South, Horse Flat and Frasers Underground targets. At Coronation North, 91 holes have been completed, with a 50 metre by 50 metre drilling pattern, for total coverage over 10,247 metres. And OceanaGold says it is investigating potential extensions to the gold mineralisation to the north and southeast.

24 www.contrafed.co.nz Q&M

Six holes have been completed over 814 metres at the Coronation open pit, as a follow-up on previous intersections, while at Coronation South seven holes have been drilled over 847 metres to investigate the potential for ore shoot repetition between Deepdell North and Coronation. At Horse Flat, five holes have been drilled over 386 metres, targeting the Horse Flat fault for any repetition of the fault drag mineralisation seen elsewhere in the Macraes Goldfield. Thirteen holes, over 1850 metres, have been drilled at Frasers Underground, testing for any “down plunge” extensions and a sheeted vein target. Resource development drilling within the Hydes-Macraes Shear Zone continues to deliver encouraging results. Drilling completed at Coronation North since the start of the year has extended known mineralisation a further 100 metres to both the southeast and north and further drilling is planned for the remainder of the year. Resource development drilling at Frasers Underground has continued to extend Panel 2 “down plunge” and exploration in the 3A Panel area has discovered a sheeted vein system that in the future may be amenable to bulk underground mining. These latest results reflect drilling subsequent to the update provided by OceanaGold in February this year and have prompted company president and chief executive Mick Wilkes to describe them as: “strong ongoing results which further demonstrate the significant resource potential that exists in our assets”. “In addition to expanding our resource base, our exploration programme will provide important inputs to the technical studies already underway at Haile [United States] and Waihi. I am confident these studies will demonstrate considerable additional value given the success of the exploration programme [over US$30 million to date and covering over 100 kilometres] planned for the year,” he adds. OceanaGold expects to produce between 385,000 ounces and 425,000 ounces of gold from the combined New Zealand and Didipio (the Philippines) operations this year. Q&M


Talisman a step closer New Talisman Gold Mines hopes to soon reopen and recommence mining one of the country’s most productive and highest grade gold mines, the Talisman mine in the Hauraki region. By NEIL RITCHIE.

D

ual listed (ASX and NZX) New Talisman recently raised $4.69 million through the issuing of just over 935 million new shares, primarily for the redevelopment of the Talisman. It also says it has struck a relationship that is expected to see a Chinese company, believed to be Amer International Group, take a 70 percent interest in the company. As well, New Talisman has signed a binding agreement with Newcrest Mining regarding the Rahu Prospect. Geological evidence points to the fact that Rahu is the northward extension of the gold mineralisation found at Talisman and is part of the overall epithermal gold system, similar to other gold deposits in the Waihi district. New Talisman is now starting a bulk sampling trial mining programme at the Talisman mine, purchasing equipment and finalising health and safety programmes. And the company expects to be extracting ore sourced from the first of two of the most promising blocks, Mystery and Dubbo, within six months or so, when it reaches the underground working face at the Mystery vein. “The Mystery vein presents one of the most exciting opportunities for the company and has the potential to become a significant source of future production and revenue,” waxes company chief executive Matthew Hill. Once production is underway at Mystery, the company will continue with refurbishment of the Dubbo drive.

Based on current estimates, production is expected to build up to steady state levels of between 650-700 tonnes per month and yielding between 200-220 ounces of gold at an on-mine cost of about NZ$900 per ounce. With the price of gold now exceeding NZ$2000 per ounce the company expects the project will be selfsustaining. “Beyond this there are many opportunities to expand the production base and the company is in the process of evaluating these,” Matt adds, regarding the company’s flagship asset. New Talisman and Newcrest, Australia’s largest domesticallyowned gold miner, recently announced they had signed a binding heads of agreement (HOA), following an earlier non-binding agreement between the two companies dating back to May 2015. Key terms of the new agreement include: The establishment of a joint venture should Newcrest spend $5 million on the Rahu Project, with New Talisman taking a direct 20 percent stake; each joint venture party paying their share of exploration and development costs; Newcrest managing all exploration activity on the Rahu Project, developing and refining exploration targets and testing these with deep diamond drilling. Matt says securing a strong external partner such as Newcrest will help support and fund the company’s longer term growth ambitions. “The company is at a pivotal point in its history... as it transitions from being an explorer to a producer.” Q&M Q&M August - September 2016 25


M I N I N G

Solid Energy chases small new coalmine The West Coast is set to have a new, small, open-cast coal mine, with state-owned enterprise Solid Energy applying to the West Coast Regional Council for the resource consents necessary to develop an area in the Peerless Valley near Reefton. Solid Energy, currently in voluntary administration, wants to set up a one-hectare pit to mine coal from an area adjacent to old open-cast and underground mine workings about two kilometres northeast of Reefton. Between 10,000 tonnes and 15,000 tonnes of coal is targeted. According to Solid Energy’s application to the local council, this small mine will be just east of the small Reddale open-cast mine “where mining is to cease within the next few months” due to ongoing slumping. The proposed new mine will allow Solid Energy to retain affected staff. “The company is currently carrying out exploration activities further to the east. Mining of the Peerless area while adjacent exploration activity is completed will enable seamless operations, continued workforce employment and continuity of coal supplies,” says the Solid Energy application. There will be about eight workers on the site, plus consultants on an intermittent basis, plus some other Solid Energy staff. All overburden will be placed in an adjacent mined-out pit on the conservation estate. It is understood Solid Energy wants to start this new venture very soon after resource consents have been granted and that the new mine will produce quality thermal coal for industrial and commercial customers in the upper South Island and West Coast. Meanwhile, shareholders of Australian listed South Island coal miner Bathurst Resources in late June overwhelmingly approved Singaporebased Republic Investment Management (RIM) taking a greater stake in Bathurst by acquiring at least half of the Wellington headquartered company’s new capital raising of A$4.25 million of convertible notes. If RIM converts the notes to additional shares this could lift its investment in Bathurst above 25 percent, helping Bathurst refinance its current facilities, provide additional working capital for development and the evaluation of “the impending sale process of a major NZ coal producer”, believed to be Solid Energy and its Stockton mine assets that are near Bathurst’s presently mothballed Escarpment coking coal project. By Neil Ritchie. Q&M

26 www.contrafed.co.nz Q&M

Gold mining alive and well in Central Otago For many years, the Ophir district, not far from Omakau in Central Otago, has been very quiet. Apart from the local pub, a few establishments offering accommodation, and some historic stone buildings dated back to the gold rush days of the 1860s, there’s not much there. While the biggest lift for Ophir recently has been its inclusion on the Central Otago Rail Trail, a revival of the gold mining industry in the district should make it an area of national focus. Known as Ophir Mines until 2006, gold explorer Ophir Gold, has announced “encouraging results” from the initial batch of assays from its recent round of exploration drilling in Central Otago. A further drilling programme is planned after winter, as the region can be very cold, even until the end of September. It currently holds the dubious record of the lowest recorded temperature with -21.6 degrees Celsius on July 3, 1995. The region was renowned for its hard-rock gold deposits in the 19th century gold rush era, but technical difficulties made recovery too hard and too expensive. Consultant geologist John Youngson says Ophir Gold recently carried out a follow-up drilling programme on its Wai-iti gold prospect, near Ophir, where it is targeting a Macraes-style hard-rock gold deposit, discovered in the late 19th century. According to Youngson, results from the first batch of samples submitted to SGS Laboratory for assay returned many intercepts, with grades between one gram and 5.25 grams of gold per tonne. He says results from a second batch of samples due in about a month are expected to return further gold-bearing intercepts and confirm the presence of a mineable resource. Youngson says 11 holes were drilled, amounting to 500 lineal metres, at depths of between 24 metres to 51 metres. He says there is alluvial gold within Ophir’s permitted area, but it is “trivial” in quantity, and it is the gold in the schist rock that is being sought. This is similar to OceanaGold’s operation at Macraes in East Otago. That mine has produced over two million ounces of gold since 1990. He also confirms the Wai-iti deposit is considerably smaller than the Macraes deposit, but has the singular advantage of being able to be projected along a strike line for more than a kilometre and offers “significant potential” to increase the gold resource in the future. Ophir Gold is also aware of other gold-bearing structures within its permit which may also be mined in the future. Meanwhile, Youngson adds, the directors of the company have not yet decided whether to develop a mine for themselves or to form a joint mining venture with an existing gold mining company. By Peter Owens. Q&M


Rock solid value Top operators know the value of Metso’s mobile crushing and screening plants. Our contracting solutions offer you true mobility, high capacity, quality end products and reliable operation. With Lokotrack, you have the freedom to crush just about any type of feed material – from hard rock to recycling and demolition debris. And every Lokotrack is backed by Metso’s know-how and distributor support. Simply rock solid. Our distributor Metso www.metso.com/miningandconstruction For more information contact MIMICO. Phone 0800 806 464, www.mimico.co.nz

New Zealand 0800 806 464


M I N I N G

Southland’s silica beckons The Kiwi mining industry may be about to receive a boost from an unusual direction. The Pebbly Hills area of Crown land at Hedgehope on the Hokonui Hills of Southland has become a place of interest to mining investors in China and the United States. This follows the research in the area undertaken by the Foundation for Scientific and Industrial Research, the largest independent research organisation in Scandinavia, commissioned by Venture Southland. The foundation completed a detailed analysis of the Southland silica gravel samples and reported to the southern promotional organisation. For some years Venture Southland has been promoting the potential of a silica industry in Southland, based on earlier research it had commissioned. According to Venture Southland the latest report confirms the presence of high-quality silica deposits, which could be processed to manufacture electronicsgrade and solar-grade silicon. The agency’s ‘Silica Opportunity Profile’ was then passed on to interested parties in China and the United States. According to Venture Southland general manager of

special projects, Steve Canny, there are several parties interested in developing a silica industry in Southland and there are indications the deposits could be worth billions of dollars when smelted into silicon for computer chips and solar panels. Southland has rare “very high” purity natural silica reserves and there are one billion tonnes of high-purity silica in the region, he says. Of that, 350 million tonnes were pebble size and suitable for refining. This is not the first time there have been moves to mine the silica deposits in Southland. Back in 2012 Silicon Metal Industries (NZ) said it intended to convert the deposits in Southland into silicon metal, which is used in the manufacture of rubber tyres and hightechnology products such as solar panels, silicon chips, liquid crystal displays, silicon plastics, light metal alloys and long-life silicon paints. The company had an exploration permit and an access agreement for gravel deposits at Pebbly Hills. That company then undertook a feasibility study and found it would cost $300 million to build a silicon smelter. It did not proceed with the project. However, Steve Canny says that despite

Steve Canny, Venture Southland general manager of special projects

that failed venture, he believes the time is right to mine the region’s silicon deposits. He says there has been a massive increase in the international demand for polysilica and that there have been major changes to the way the silica would be extracted and smelted and significant reductions in costs. By Peter Owens. Q&M

CRP ready to have another go Chatham Rock Phosphate (CRP) is determined to mine phosphate from the ocean floor and is seeking fresh capital to file another application for consent to mine the Chatham Rise. The company’s first attempt last year was knocked back by the Environmental Protection Authority (EPA). For the marine consent re-submission, CRP has taken a totally fresh look at the way it will make an EPA application. This includes using the provisions of the Resource Management Amendment Bill when they are enacted to have the application dealt with promptly and efficiently. CRP is also attempting to restructure its corporate profile, which involves a deal with Antipodes Gold that,

28 www.contrafed.co.nz Q&M

effectively, will be a reverse takeover by Chatham – giving that company a listing on the Toronto Stock Exchange. This exchange is internationally renowned for its support for a wide variety of mining operations. Details of this are contained in a statement in the full year financial results for CRP that says the takeover was expected to be completed by September 30, on the basis that the capital raising achieves sufficient funding. The company reported a trading loss for the year to March 31 of $818,000, a significant reduction on the previous year’s $27.3 million loss after recognising impairments of $18.7 million. CRP admits in its

report that confidence in the company is still affected by the EPA’s rejection of mining consents for Chatham Rise. This affected the share price which plummeted, and prompted measures for a new marine consents submission. “Over the past few months there’s been a steady stream of support from shareholders and new investors keen to support our plans,” the company says. “In total we have now in the last 14 months raised or secured firm commitments for $3 million. This is a remarkable achievement given both the major setback in our circumstances in February last year and the very weak resource market conditions prevailing during most of the ensuing period.” By Peter Owens. Q&M


Big mining equipment a slow sell Solid Energy, which entered voluntary administration in August 2015 in a bid to minimise losses to creditors, has assets for sale across the country. However, the state-owned miner has failed to sell heavy machinery from its ill-fated Stockton mine. in Queensland worth tens of millions of dollars. Hassalls has previously sold vehicles for Solid Energy after it bought the Pike River coal mine and with other sales at OceanaGold’s Macraes mine in Otago and at a Huntly coal mine in Waikato. The move to Burnside Contractors’ yard on the outskirts of Christchurch was not without its problems. About half of the machines were too big to travel intact through the Buller Gorge – the only way out to Christchurch. Some of these were stripped down to their chassis for the journey. So far most of the sales interest has been in the Haulmax trucks. Mining is doing it tough, but interested Australian mine contracting firms and Irish buyers could potentially buy gear cheaper now than during the resources boom. This is according to Steve Wall, who also says Australian beef farmers wanting heavyduty construction equipment could be among the future buyers. By Peter Owens. Q&M

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The heavy machinery and equipment at Stockton mine includes trucks, excavators and bulldozers, which Australian-based Hassalls, a company that specialises in valuing and selling mining industry assets, says is worth $6 million. The fleet includes a rare 2010 Cat 834H Wheel Dozer, Cat Excavators, Cat Artic Trucks, Haulmax Off Highway Haul Trucks and several Cat dump trucks. In April the company promised potential buyers a “smorgasbord of construction equipment... which should ensure we have quick sales.” Buyers were expected from Asia, Dubai, North Africa and Western Australia. However, at print time tenders have not been forthcoming.Back in May Hassalls moved Solid Energy’s equipment from Stockton to Christchurch for viewing and assessment by possible buyers. Steve Wall, Hassall’s general manager, says his company recently sold other mining equipment

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Q&M August - September 2016 29


T E C H N O L O G Y

State-of-the-art technology showcased in Papua New Guinea project

Metso had an opportunity to design and implement cutting edge extraction technology with a large scale project in Papua New Guinea.

30 www.contrafed.co.nz Q&M

M

onier, Papua New Guinea’s single largest producer of construction materials and building products, has upgraded its Nebiri Quarry to increase annual output capacity from 300,000 to one million tonnes. The Papuan government is so pleased with the project that it will serve as a stand-out example of technology when the country hosts the 2018 Asia-Pacific Economic Cooperation (APEC) leaders’ summit. Following a review of submissions from a number of potential suppliers Monier awarded Metso with the Є10.5 million upgrade contract in July 2013. This included design, fabrication, installation and commissioning of the new plant. “The plant configuration requested by Monier was not typical,” says Campbell Johnston, Metso’s director of Systems Sales & Support Systems. “Before attempting any design work for our tender submission, we needed to clearly understand Monier’s space constraints and


Monier’s new, high-tech plant at its Nebiri Quarry in Papua New Guinea is a state of the art example of Metso technology.

their operational requirements. We decided that the best way to achieve that was for our engineers to visit the site. “While sending our engineers over to PNG was a costly exercise, it proved to be a very good move. Based on our team’s first-hand appreciation of site conditions and an exchange of ideas with Monier’s management, they were able to propose an optimised solution.” Delivering the project involved teamwork across three countries, Papua New Guinea, Australia and France. The design and supply of equipment was undertaken by Metso’s team based in France, with plant safety and electrical work complying with Australian OHS regulations and standards. Under Papua New Guinea’s laws Metso also had to set up a local subsidiary in the country. Says Vincent Gibert, the installation project manager from Metso in France: “The key to the success of this project was the excellent cooperation between our multinational team that included representatives from Monier, Metso and our contractors.

Main equipment used in the project ITEM TYPE Primary Grizzly Feeder

VF561-2V

Primary Jaw

C125

Primary Rock Breaker

Hydraulic Rock Breaker

Scalping Screen

CVB1845-3P (Triple Deck Inclined)

Secondary Crusher

NP1213 (Horizontal Impactor)

Tertiary Crusher

HP300

Quaternary Crusher

B6150SE (Vertical Shaft Impactor)

Product Screens

TS3.3 (Triple Deck Triple Slope)

Vibrating Feeders

EME (Out of Balance Motors)

Dust Suppression

Cool Fog

Q&M August - September 2016 31


T E C H N O L O G Y

allows for special orders and extra capacity. The finished plant is capable of delivering nine separate products at a rate of 450 tonnes per hour, which is 100 tonnes per hour more than the contractual requirement. During pre-contract discussions Monier’s management had expressed concerns about intermittent power cuts caused by unexpected demands on Port Moresby’s electricity grid. This meant designing a plant that runs on electricity or diesel generator sets through a programmable logic controller (PLC) and SCADA system. Monier also wanted to be assured that its new plant would operate reliably for the next two decades. To address this, Metso included a five-year equipment protection plan in the contract. Above L-R: Surjit Singh, project engineer, Metso Australia; Robert Palmer, project manager, Metso Australia; and Vincent Gibert, project manager, Metso France during the commissioning of the horizontal impact crusher.

From the outset and throughout the project we performed well together. We shared competencies, information and best practices in each phase from bid to installation.” With the new plant designed to fit into an allocated space near the old plant, the first challenge was making enough room for a construction area on site. Metso got permission to convert a close-by rugby field into a construction zone and equipment was transported from here to the site as completed. Access to the new plant was shared with the existing plants, which required a diligent level of project management, careful planning and strict scheduling by the project team. The new plant includes four stages of aggregate crushing and screening. The first three stages consist of three crushers in series, each followed by a triple deck screen. In the final stage, there is the option to send all, or part of, the product for shaping through a vertical shaft impact crusher. A bonus from this stage is a fine aggregate by-product that can be used as an additive in road base. The plant simultaneously produces up to nine different products at a rate of 350 tonnes per hour and the plant design 32 www.contrafed.co.nz Q&M

The plant of the future “The new plant is very advanced in terms of technology, ease of operation and maintenance,” says Stanley Correa, Monier’s electrical services manager. “On the electrical side, the PLC system design is a real stand out for me. From the maintenance diagnostic tools and monitoring equipment that can pinpoint a problem at its source, right down to the compartmentalised layout and the reporting software.” In operation the plant has proven to be highly efficient, says Metso, using 40 percent less power per tonne than the older plants and delivering three times the output of both the existing plants put together. This has been achieved through the combination of the plant’s high production capacity and a unique design that allows production to continue while sections of the plant are offline for maintenance. Anthony Grimmer, Monier’s quarry manager says in his 35 plus years of mining and quarrying experience throughout Australia and PNG, he has not come across a level of sophistication as good as the new crushing package at the Nebiri Quarry. “In my opinion we can easily claim to have a true ‘plant of the future’. It puts us in a strong position to be selected as a preferred material supplier for PNG’s current and future infrastructure projects.” Q&M


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U P F R O N T

Aggregate News AGGREGATE & QUARRY ASSOCIATION OF NZ

Major messages in Marlborough Marlborough certainly impressed those of us fortunate enough to attend the QuarryNZ conference in Blenheim. From start to finish, the facilities and service were outstanding. The bar has been set very high for Auckland next year. I was pleased to be re-elected in Blenheim to the AQA board, along with existing members Jayden Ellis, Andrea Cave, Tony Hunter, Bruce Taylor, Mike Higgins and Brett Swain. We are also delighted to be joined by industry veteran George Kelcher who will bring the benefit of many years of practical, quarry operations to the board table. I am proud to also be elected to continue as your chair, ably supported by Jayden Ellis as my deputy. This edition of Aggregate News falls right on the time of conference so you will have to wait for the next edition – or watch our website – for more detailed coverage. However, some of the issues that resonated for me included: • The blunt message at the AQA AGM from Steve Ellis of Stevenson Group that his company as a major funder wants AQA to seriously review merging with IOQNZ by the time of the next conference. This is something the AQA board will consider at its next meeting • The concerns around CoC renewals. WorkSafe Chief Inspector Extractives Mark Pizey impressed many at conference with his calm, competent demeanour and he was there from start to finish. He acknowledged a potential ‘train wreck’ in January because too many will not have completed CoCs, especially oral exams. We review this issue inside. • The looming reality of new, tougher standards on silica. New Zealand will soon join Australia in having a 0.1 mg/m3 standard for airborne silica. If you think managing dust to meet that will be a challenge, Ken Slattery, Chief Executive of Cement Concrete Aggregate Australia advised that this level is a quarter that of some

Brian Roche pictured at conference with Ravensdown colleagues from left, Mark Campbell, Paul Johnston, Brian and Mark Simkin.

34 www.aqa.org.nz

Mike Higgins took out Gold for Isaac Construction in the MIMICO Environment Awards.

nations and this is where we are all heading. Given silicosis is widely regarded as a direct cause of cancer, we’ve got to take note of the emerging overseas trend for tougher exposure standards. • I also noted Ken Slattery’s comments about our industry needing to ‘get on the front foot on issues’ and communicate ourselves as an essential industry • That was something picked up by our MIMICO Awards judge Dr Morgan Williams as you’ll see reported. He told our Friday night finale that the aggregate and quarrying industry often operated in an ‘out of sight, out of mind’ way. He noted there are many reasons for this but it does generate risks for society as well as for our industry and anyone involved in infrastructure and construction. Congratulations to all the MIMICO and other award winners. • Also in this edition, you can see the details of what NZTA unveiled at conference about M/4 testing – and how the AQA is proposing to manage this. • You will also see the report on NZTA’s Gerhard van Blerk address. He is promoting a new for New Zealand accelerated weathering test using ethylene glycol to swell smectite clays and weaken susceptible aggregates. If his research centred in the Waikato suggesting changes in fines up to 200% is replicated elsewhere, our industry will have another big issue to deal with. I’d like to thank AQA’s technical adviser Mike Chilton for all his work engaging with NZTA on our behalf on these issues. My wider thanks to Neill Kydd and his local organising committee and all others involved in making the Marlborough conference a Safe, Sound and Solid success. Brian


Flexibility on CPD hours for conference add-ons

A

mid some confusion and concerns around the number of Continuing Professional Development hours accruing for attendance at industry conferences, the IOQNZ brought together a round-table discussion supported by AQA and hosted by MinEx. Mark Pizey, Chief Inspector for Extractives attended along with Priscilla Page, a specialist WorkSafe inspector. Rene Sterk, chair of the New Zealand branch of the Australasian Institute of Mining and Metallurgy, (AusIMM), also contributed. CPD hours will become particularly important from next year once new Certificates of Competence (CoCs)are required to be held by anyone managing a quarry or mine. New A Grade managers need at least 24 hours per year of CPD (16 hours min formal/ 8 hours max informal) and B Grade Quarry managers require 12 hours minimum per year (8 hours min formal / 4 hours max informal.) In line with WorkSafe’s requirements which are set out in a CPD Gazette notice, attendees at the QuarryNZ or AusIMM conferences will receive four hours formal CPD hours. Attendance at AGMs such as IOQNZ, AQA or AusIMM is additional and formal learning hours can be claimed for this. IOQNZ’s immediate past president Gordon Laing put forward an IOQNZ proposal that by attending a range of sessions at an industry conference (plenary, AGMs, workshops and seminars), A Grade managers should be able to qualify for a maximum of ten formal hours and B Grades, six formal hours. MinEx CEO Les McCracken stressed the need to take a principled approach to CPD in order to maintain the integrity of the system. He saw that a fairer allocation than WorkSafe’s current regime would be a maximum of 4 hours for a 1 day conference and 8 hours for conferences of durations two days or more. This would then better align with the current allocation of up to 6 hours for a seminar or workshop. AQA president Brian Roche outlined AQA’s interest in developing the QuarryNZ conference from next year onwards so as to

Mark Pizey has a message for the quarry industry.

add workshops which increased CPD hours for those attending. He says CPD was becoming important and the conference needed to adapt to better reflect that for attendees. Rene Sterk says the AusIMM conference is structured differently than QuarryNZ’s. AusIMM is usually 3 days of technical presentations with short courses and field trips held in the 2 days before and after the conference. AusIMM also manages its own CPD system, rather than having this done under WorkSafe’s auspices. Mark Pizey says he wants to take a flexible approach to CPD hours for New Zealand quarries and mines but any increase in hours for conference attendance has to reflect additions to the conference. He suggested field trips within the QuarryNZ conference, while interesting, were not formal learning sessions though they can count towards informal hours. These field trips could potentially be replaced by workshops on issues such as slope stability or quarry face design, accruing formal CPD hours. Another alternative was to add a half day or more to a conference so attendees could attend 4 hour workshops and get formal CPD credits. Mark Pizey wants CPD workshops to be informative and understandable by people working in quarries and mines. “We need to dispel the myth that you need to be a lawyer to do CPD.” One area Pizey indicates he wishes to look at is the power to exempt people from completing the requirements when there are extenuating circumstances such as a major illness. “If you were unable to complete a given

year’s CPD requirements due to significant, unavoidable circumstances, the Board of Examiners should be able to look at that.” There were comments from both MinEx and IOQNZ board members about the challenge some particularly older quarry workers face in going back into a classroom. Mark Pizey said that anyone who wants to update their CoC needs to complete the required additional unit standards which came out of the Royal Commission on the Pike River coal mine tragedy. However, these are not onerous and the training is available from a number of providers. Both MinEx and WorkSafe are currently running either forums or workshops which include discussion on CPD hours and CoC completions. Mark Pizey says he wants to see more such information workshops and forums around the country on CPD which can accrue formal hours. He says webinars, as recently pioneered by IOQNZ, are also a way to get formal learning and gain CPD hours. Rene Sterk says CoC training needs to be accessible and low cost. AQA and IOQNZ, which jointly run the QuarryNZ conference, have agreed to work together to develop a programme for next year’s Auckland conference and beyond which sees more opportunity for attendees to attend formal learning sessions and gain CPD hours. Mark Pizey says any CPD log book should be submitted to the BoE Secretariat for review and recording. The Secretariat currently provides feedback and advice on log book entries and is happy to talk to anyone who has a question. www.aqa.org.nz August - September 2016 35


Canterbury quarries dominate industry awards

T

hree Canterbury quarries took honours in the quarry industry’s annual MIMICO Environmental Excellence Awards at the QuarryNZ conference in Blenheim. Another Canterbury based quarry company Road Metals picked up four awards including one recognizing health and safety practice. MIMICO Environment Awards judge, former Parliamentary Commissioner for the Environment, Dr Morgan Williams gave Gold to Isaac Construction for what he described as the ultimate legacy project at its McLeans Island quarry on Christchurch’s northern outskirts. Silver awards went to Canterbury Aggregates for its commitment to handover its Amberley Beach Quarry as a future community asset and to Fulton Hogan Miners Road quarry for leadership in environmental policy and sustainability practice. Aggregate and Quarry Association (AQA) chair Brian Roche said the awards recognize the importance quarries placed on good environmental management. “While much of our focus is rightly on health and safety, our industry is also committed to ever improving our environmental performance and we put great value on that and our relationships with the communities in which we work.” Dr Williams said the standout feature of this year’s winners is they full integrate environmental management goals into their operations, not as add-ons. All were privately held, family-based companies with histories of business resilience and of being a good neighbour and environmental steward. He said Isaac Construction was a unique business model where an environmentally focused trust (The Isaac Conservation and Wildlife Trust) owned all the Isaac businesses and land. “The purpose of all commercial activities – quarrying, dairy farming, salmon farming – beyond maintaining robust, innovative businesses, is to finance the conservation goals of the Trust.” He said this model came from a remarkable couple, Sir Neil and Lady Diana Isaac who wanted some Canterbury and New Zealand native flora and fauna and heritage buildings, to be rehabilitated and managed for ongoing community benefit.

MIMICO’s Chris Gray was delighted that the company could host the first-ever lunch in the new WW2 wing of the fantastic Aviation Heritage Museum in Blenheim. Also pictured, conference compere, Steve Davis.

36 www.aqa.org.nz

Three wise men, as judged by MIMICO Environmental Excellence Awards – Bill Pascoe, Canterbury Aggregates, Mike Higgins, Isaac Construction and Peter Savage, Fulton Hogan

Receiving the award at the QuarryNZ conference, Mike Higgins, Isaac Construction Industry manager, paid tribute to Sir Neil and Lady Diana. “They were ahead of their time, believing a business could be built while enhancing the environment. Canterbury and New Zealand are the winners here.” Canterbury Aggregates Amberley beach quarry was another environmental legacy project in the making, said Dr Williams. “They are doing great habitat restoration and have indicated they are committed to bequeathing a fully restored wildlife reserve and community recreation asset to a locally owned trust when quarrying finishes in 25-50 years. The entrants were Bill Pascoe and Hayden Leach. Dr Williams said Fulton Hogan’s award was important as the aggregate and quarrying industry often operated in an ‘out of sight, out of mind’ way. “There are many reasons for this but it does generate risks for society, the infrastructure industry and the aggregate industry itself. Fulton Hogan had invested considerable time and money in submitting on regional and district planning matters, often as part of the Canterbury Aggregates Producers Group, CAPG. Dr Williams said proactive press and television coverage of issues at FH’s Miners Road quarry had provided excellent perspectives on the consent applications from CAPG. “In doing so they have provided evidence to the Canterbury community of the value of the aggregate industry to society and some of the initiatives the industry has been involved with.” Fulton Hogan’s Environmental Manager Peter Savage received the MIMICO Silver award. Road Metals Manager Director Murray Francis acknowledged the company’s first fulltime health and safety manager Amanda Burke in accepting the company’s win in the GBC Winstone Aggregates Safety Award. The company has quarries at Rolleston, Miners Rd Yaldhurst and McLeans Island as well as other South Island locations. Road Metals also won the Institute of Quarrying NZ awards for engineering, operations and quarry leadership.


Living and learning health and safety

K

eri Harrison has not only put herself through her B Grade Certificate of Competence; she’s helping some of her colleagues with their CoCs – and next year it’s her A Grade. The 41 year old is the Health & Safety Manager at Southern Screenworks, a mid-size quarry company operating from its base in Aylesbury less than an hour south west of Christchurch. Dunedin-born, Keri started her working life as medical secretary before working at the Selwyn District Council for 13 years, primarily looking after the council’s extensive gravel reserves and with a health and safety background. She was spotted by Southern Screenworks co-owner Brett Swain who brought her on board two years ago. Keri achieved her National Certificate in Extractive Industries (Mining Administration Surface Extraction B Grade) last year. When she started on her B Grade course, several Southern Screenworks co-workers turned to her for assistance. Some have been in the quarry industry all their working lives to date but had not had to do any training for many years. “The guys have done really well. I provide them with help and support when they need it. It is rewarding to see the guys succeed.” This hands-on approach is not limited to her work role. Keri, her partner Justin, Keri’s daughter Emily and Justin’s children Cody and Jemma all muck in to run the family’s 18 hectare block near Oxford. No doubt Keri’s hands-on role in both doing her own CoCs and helping others is having wider beneficial effects for her role as Health and Safety Manager at Southern Screenworks. Setting up and maintaining a health and safety management system is a big part of her job. She has created an individualised comprehensive safety plan that goes to each work site. The safety plan is returned after each job and reviewed by Keri. Visiting the site and carrying out safety checks during the work supports the safety systems in place. “We have a thorough but easy to follow safety system in place. The guys are understanding of how important it is we manage our risks and that we have a safe workplace.” Keri acknowledges that the new H+S law and accompanying regulations and guidelines can, on occasions, be difficult to interpret. Determining how staff can

Hands-on help – Keri Harrison with Gerard Halloran who is sitting his B Grade CoC this year.

best be supported to achieve this on the company’s quarry sites is a key part of her role. The sites extend as far as the West Coast, lower North Island and even the Chatham Islands. Keri is well supported in her role by Brett who also takes an active hands-on approach to health and safety. “We have been involved in helping other quarry partners with their CoC training requirements and developing quarry management plans,” says Brett. “This is a good reflection on how well respected and knowledgeable Screenworks are in the quarry industry.” The new legislation requires everyone involved with a quarry – from owner to operator and staff – to take responsibility. This sometimes comes as shock to staff,

councils, farmers and others with roles in quarries. “We all have the right to a safe and healthy working environment. There are no excuses. ‘The she will be right’ and ‘I thought it’d be OK’ is not a defence in court.” Keri accepts there is some extra work to do now on health and safety but says that’s what is required. “If it saves your life or that of someone else, isn’t it worthwhile?” For her, it comes down to one simple thing – and it’s what has motivated her to go well beyond what is required and do her B Grade CoC and now her A Grade. “I really care about the guys I work with and I really enjoy working for such a progressive quarry business that has health and safety at the top of its list.”

The Aggregate & Quarry Association appreciates the support of our associate members

www.aqa.org.nz August - September 37


Issues with CoCs acknowledged but no more extensions

S

ome criticism emerged at a Nelson quarry forum in June around Certificate of Competence training. Quarry industry veteran Snow Edgar said people with CoCs for opencast mining were being required to re-do these to work in quarries, when industry organisations were saying there was very little difference between the two sectors. WorkSafe Chief Inspector Extractives Mark Pizey apologised for some inconsistencies in the new H&S requirements. “There is something of a rush to get legislation out and as a result there is work to be done to ensure alignment.” Pizey was unapologetic though on the need to reform H&S in the mines and quarry sector, noting only around 600 of approximately 1600 known sites had nominated managers. “We will probably come to the end of our patience pretty soon in that regard.” MinEx CEO Les McCracken says the industry and trainers needed to tailor training to better take account of the long days worked in the extractives sector. “Most guys in our industry are doing 10-12 hour days, so it’s pretty hard to do training after work.” McCracken warned there would be no further extension on renewing CoCs. If people had not completed the required unit standards, on January 1 any existing CoC would not be valid. Mark Pizey repeated the warning. “My staff won’t be there on 29 December to get you through. So

MinEx’s Les McCracken from MinEx told Nelson forum attendees that it’s difficult to do training in evenings after a 10-12 hour day.

the ice is getting pretty thin.” He noted around 40% of those sitting B Grade quarry manager CoC oral exams were failing. Pizey says the industry needed to understand that the Panel of Examiners are all experienced quarry managers, not WorkSafe staff. The purpose of the oral exam is to find out how the candidate can apply what they have learnt to a “real life” situation, not a test to see how much of the law has been learnt by rote. Trevor Watts of Mines Rescue Service announced to the Nelson forum that his organisation is now working with Nikki Kitchen, until recently Board of Examiners secretary, to provide training on how to get through oral exams.. Peter O’Sullivan of Tai Poutini Polytechnic says his organisation will run A and B Grade CoC training anywhere there are six people ready to train. Tai Poutini is also sending assessors to sites to test the competency of people with 20 or more years’ experience but no qualifications. Most companies were, however, saying they preferred to assess staff against required unit standards.

Industry groups say competency renewals now urgent Industry groups representing the quarrying, mining and contracting sectors are warning site managers now have less than six months to meet new health and safety competency requirements. The Aggregate and Quarry Association (AQA), Institute of Quarrying NZ (IOQNZ), Mining/Extractive Health and Safety Council (MinEx) and Civil Contractors New Zealand say without a lift in renewals, the jobs of those who have not met the new requirements are at risk. They say this provides some risk to the supply of aggregates particularly from smaller producers. The industry bodies say if large numbers of site managers have to stand down on December 31 because they haven’t renewed their A or B Grade Certificates of Competence (CoCs), there are few, if any, trained replacements. They acknowledge some challenges with gaining new CoCs but say all site managers must have achieved this by December 31. New regulations introduced in December 2014 required Certificate of Competence holders to gain up to four new unit standards. Currently, around 40% of those sitting a B Grade CoC, required to manage a smaller quarry or opencast mine, are failing the final oral examination. Chief Inspector Extractives Mark Pizey told the Nelson MinEx forum that WorkSafe has 602 quarry and mine notified site managers but knows of around 1600 sites. MinEx chair Chris Baker say there are some teething issues with renewing CoCs but people who manage quarries, mines and other such sites must have these before the year’s end. “We had a one-year extension this year but WorkSafe has

38 www.aqa.org.nz

made it clear there will be no further extension. Frankly we are not seeking one either. People have to get up to speed on the new health and safety competencies.” AQA chair Brian Roche says it is important to note that around 85% of New Zealand aggregate is produced by bigger suppliers that are generally having fewer issues with meeting the new competency requirements than smaller operators. He says those who still need to pass a new or renewed CoC have to make a choice. “Either you pass the new competencies or come Christmas you will no longer be a CoC holder and not able to manage a site.” He and IOQNZ board chair Les Ward are particularly concerned about the potential impact on the quarry sector, especially smaller producers. “We don’t have a surplus of trained A and B Grade CoC holders. We could see some smaller quarries, in particular, closed as a result,” said Les Ward. Civil Contractors NZ chief executive Peter Silcock agrees that while there are still some issues with CoC renewals especially with his smaller members, the risk of contractors losing access to some aggregate supplies was of real concern. “Our members produce some of their own aggregate but also buy considerable quantities. Employers in the contracting and extractive sector around the country need to ensure site managers renew their CoCs by Christmas.”


TECHNICAL NEWS

AQA Board

M/4 on the move

Brian Roche,

A

move to have all quarries supplying M/4 basecourse for state highway contracts put Quality Assurance systems in place was unveiled by NZTA at the Blenheim QuarryNZ conference. National Pavements Manager John Donbavand said the M/4 specification had been reviewed and an inconsistent approach to quality management was found. NZTA proposes revising the test rate to five test samples for the first 1000m3 produced, with one sample for every additional 1000m3, provided breaks in production are kept to less than 3 months. All samplers would be required to be registered with International Accreditation NZ. Results need to be displayed on a quality control chart. The control charts and associated spreadsheet are developed directly from the Asphalt Plant Accreditation System (APAS) so the content and usage will be familiar to many. An advantage to the producer of using process charts includes being able to visually identify trends and inconsistent production. After AQA’s intervention, it is proposed that AQA manage a QA system to be developed by the Transport Agency, with accreditation also being administered by the AQA. This QA system will be available for all quarries supplying M/4 to state highways.

Chair Ravensdown The proposed system to capture data and enable auditing would be web-based, with quarries entering their own test results. There would be an automatic update of the quarry’s control charts and audit status. If adopted, this system is expected to be running by December 2016. Quarries can instead choose to operate under an alternative established QA scheme (eg. ISO 9001). Donbavand said NZTA wanted to review the M/4 grading limits and at this stage expanding the limits is still being evaluated. The AQA and NZTA will help quarries with training and setting up their QA systems to capture all their test results. NZTA will meet all costs of training materials and workshops to be run around the country. Training would occur from early 2017, with a tentative proposal for all providers to be using the system from July 2018. AQA Technical Adviser Mike Chilton told conference there has been some good feedback from small producers explaining their situation and how the proposed M/4 accreditation scheme and increased testing would affect them. If you have any questions or would like to provide feedback including your operation as an example in discussions, please email tech@aqa.org.nz

Deputy Chair Jayden Ellis, Stevensons Construction Materials

Board Members Andrea Cave Winstone Aggregates

Mike Higgins Isaac Construction

Tony Hunter Blackhead Quarries

George Kelcher Road Metals

Bruce Taylor Fulton Hogan

Brett Swain Southern Screenworks

Technical Committee Chair Stacy Goldsworthy Green Vision Recycling

Greg Arnold Road Science

Jayden Ellis Stevensons Construction Materials

Ethylene Glycol tests promoted

Alan Stevens

A

David Morgan

new to New Zealand accelerated weathering test was presented at QuarryNZ by NZTA’s Principal Technical Advisor (Pavement) Gerhard van Blerk. His presentation started with a photo showing a section of highway having to be dug up because of the premature failure of the aggregate. His research has included the aggregate used in the recently completed Tauranga Eastern Link, a project costing more than $100m. Van Blerk says NZTA was spending a lot of money on such projects. “The multi-million-dollar question is are we going to have to dig them out in 10 years time.” Van Blerk is promoting the use of the accelerated weathering test as a means of identifying unsuitable aggregates to help avoid these premature costly repairs in the future. The proposed T/16 test sees 13.29.5mm aggregate soaked in ethylene glycol (antifreeze) for 21 days to swell smectite

clays if present, therefore decreasing the aggregate’s crushing resistance. A crushing resistance test is performed at 230kN on two samples each of unsoaked and soaked aggregate, the percentage change in fines passing 2.36mm is recorded. Gerhard van Blerk told the Blenheim conference that he was seeing changes as high as 207% when the soaked sample was tested in saturated surface dry (SSD) condition. He noted the aggregates tested were all M/$ quality. NZTA is looking for a maximum of 30% change under the ethylene glycol test, and the test using a different method has already been introduced for some state highway projects. Van Blerk said he thought a 20% limit was too restrictive, indicating the problem aggregates were those with a change above 25-30%. He said the intention was to target high volume projects. www.aqa.org.nz August - September 39

Civil Contractors

Winstone Aggregates

Brett Beatson Ready Mixed Concrete Association

Aggregate & Quarry Association of NZ PO Box 32 019, Maungaraki, Lower Hutt, 5050 Chief Executive Roger Parton tel 04 568 9123 fax 04 568 2780 email office@aqa.org.nz web www.aqa.org.nz


P R O F E S S I O N A L

D E V E L O P M E N T

Demystifying CPD for quarries While a new concept in the extractives industry, Continuing Professional Development is now a key element in maintaining industry roles and competency certificates, including the A and B quarry manager’s certificates. By HUGH DE LACY and ALAN TITCHALL. This is an updated version of a previously published online article.

I

t’s the sort of practice you associate with the professions – doctors, for example, do it throughout their careers – but Continuing Professional Development (CPD) has been extended to Certificate of Competence (CoC) holders in the extractives industry in the wake of the country’s new health and safety regime. While there are quite a few CPD schemes in operation in other industries, this extractives initiative is one of the few in the world that extends down to ‘supervisor’ level. Requirements came into force on January 1 this year. WorkSafe defines CPD as: “The systematic maintenance, improvement and broadening of knowledge, understanding and skills, and the development of personal qualities necessary to undertake duties throughout a CoC holder’s working life.” Some 16 roles Government safety body WorkSafe has gazetted requirements for 16 roles ranging from senior site executives needing to do 120 hours of CPD over their five-year term of the certificate, to winding engine drivers who have to do a minimum of 30 hours over the same period. “Learning must be undertaken across a relevant range of topics within the required competencies in each five-year period. A minimum of two thirds of total hours each year must be formal learning. Up to a third of total hours can be informal learning. What is considered formal and informal learning is found here on pages 5 and 6: http://www.business.govt.nz/worksafe/informationguidance/guidance-by-industry/extractives/documents-images/ cpd-guidelines.pdf. “CoC holders who hold more than one CoC in the same category only need to complete requirements for the most senior CoC they hold. For example, a holder of a B and A grade quarry manager’s CoC need only complete the A grade quarry manager’s requirements.”

Formal and Informal components Formal learning includes attending or delivering seminars and workshops, completing training courses, attending industry conferences, studying for tertiary qualifications, and publishing peer-reviewed papers in industry publications (such as Q&M). This will credit you with 10 hours if not previously presented at a conference, or five hours for a paper that has been presented. Presenting a paper at a conference awards you eight hours for each presentation. For publishing industry ‘articles’ in a magazine,

40 www.contrafed.co.nz Q&M

such as Q&M and Contractor, you can earn a maximum of four hours a year. Informal learning includes reading technical articles, conference papers and publications such as this one, attending field trips, delivering or receiving non-formal in-house training – such as learning to operate a particular machine – reviewing principal hazard management plans and participating in conducting reportable incident investigations. Reading technical and conference papers in Q&M and Contractor magazines will provide you with a maximum of two hours a year. Just attending an industry conference, such as QuarryNZ, will award you with a maximum of two hours for each day. This is in addition to the hours claimed for attendance at conference ‘workshops’. Additional hours earned in one year can be counted towards the following year’s total, but not beyond that. It is important for certificate holders to complete a certain amount of the required hours every year, as they are not allowed to do them all in the last year before the certificate expires. WorkSafe both sets and administers these formal and informal CPD requirements. You can check them out on the WorkSafe website: www.business.govt.nz. On the left side of the home page is a list of Focus Areas. Click on High Hazards. On the left is a list of High Hazards – click on Extractives. Click on NZ Mining Board of Examiners. Still on the left hand side click Continuing Professional Development. You will get a list that includes Continuing Professional Development Guidelines of Extractives. CPD hours have to be recorded in a log-book provided by WorkSafe. This log-book system is still being set up and eventually it’ll go live online, but at the moment it’s a paper system. Each CoC holder is responsible for recording their own CPD activities, and needs to keep evidence of formal activity participation in case they are audited. A percentage of log-books is selected and checked randomly every year for audit, and log-books will also be checked when the holder applies for the renewal of their certificate. “Because this is new to everyone, we are currently working closely with those who are sending in their log-book entries by checking each entry and providing feedback and information,” Ariadna Motus, WorkSafe’s high hazard project manager, told Q&M. “The board secretariat is working with holders to assist, and also holding workshops to explain CPD and answer questions. We are closely monitoring how it is working.” Q&M


I N N O V A T I O N S

Real Steel wins Hardox award Real Steel has been named the first winner of the Hardox Wearparts Award, a competition introduced this year by SSAB to provide recognition to Hardox Wearparts centres for innovativeness and product successes for applications in the aftermarket. Real Steel is one of more than 200 Hardox Wearparts centres located worldwide which provide wear parts and wear services for industries including quarrying, mining, forestry, transport and recycling, among others. For its application, Real Steel worked on site with Sollys Contractors, which was looking for a solution for its rotor discs which were wearing out too quickly. Working together with Real Steel’s wear engineers, they designed a laminated disc made from Hardox 500 and Hardox 550. The result is a total wear life of the rotor that has increased by three times and with 30 percent reduction in production costs. Previously the rotor discs were hard-faced which was time consuming and expensive, says Real Steel. “Our solution extended the wear life while removing the hard-facing and need for re-balancing the rotors,” says Luke Mathieson, managing director, Real Steel. “The solution also created even wear on the rotors.”

Bibsteel range for skid steer loaders Skid steer service is extremely demanding on tyres, the machinery and its operator and Michelin says it has targeted these issues with its latest innovation to the skid steer tyre market – the Bibsteel AllTerrain radial range. The new Michelin Bibsteel All-Terrain radials feature steel casings incorporating three steel ply layers and steel belts for puncture resistance compared with the more common and less-durable crossply tyres. Michelin says its all-steel casing construction is unique in this sector, allowing the tyres to offer better abrasion, puncture and impact resistance – making them ideal for use on debris-strewn sites. “The Bibsteel sets a new benchmark for traction on soft ground with its radial construction and deep open tread design. Michelin’s own trials in North America have demonstrated that this tyre offers a 12 percent increase in traction and up to an 85 percent increase in tyre life compared with the leading cross-ply fitment. “The Michelin Bibsteel has been designed especially for compact construction machines such as SkidSteer loaders which are used in many different applications in New Zealand,” says Andrew Gillam, sales and marketing manager for TRS Tyre & Wheel. “The specific design ensures they will provide superior performance and a longer tread life for skid steer loaders, offering operators reduced downtime and operating costs on their worksites.”

Conveyor belt cleaning Martin Engineering, a specialist in conveyor belt cleaning equipment, has launched a secondary cleaning system that removes nearly all of the carryback left on a belt, including adhesive materials and fines lodged in surface divots and valleys. The Martin Washbox Cleaning System combines water spray and secondary cleaning blades in an enclosed and self-contained unit, draining residue safely away from the work area. “We design systems to eliminate nearly all carryback issues faced by every industry we serve,” says Dan Marshall, product engineer at Martin Engineering. Available in two configurations, a dual cleaner system and a single system, the units are mounted on the conveyor frame directly after the return idler to ensure belt alignment throughout the cleaning process and to allow proper time for moisture evaporation on the return trip. Passing through a powder-coated steel box with top rollers, the belt is gently washed by spray bars equipped with 10 to 30 nozzles delivering 5 to 60 psi (0.34 to 4.14 bar) of pressure, using 5 to 54 gpm (20 to 204 L/min) of potable or non-potable water. The belt is then scraped clean by a polyurethane blade and/or a urethane squeegee blade, set on a tensioner for a tight and consistent blade-tobelt seal. Residue drains safely through an outlet funnel below the box, which can lead to a disposal unit or a settling pond/vessel for introduction of material back into the process. Q&M August - September 2016 41


I N N O V A T I O N S

Clever reflector cleaner for delineator posts A wind-powered device is being developed in South Australia to help maintain visibility and safety for workers on mine sites. The Spinflector is a device to clean reflectors on delineator posts at mine sites to help maintain visibility for machinery operators. Trampas Cutler developed the Spinflector in Port Lincoln, South Australia and has trialled them at an iron ore mine in the state’s Iron Triangle for the past five months without incident. He says that at most mine sites, teams of workers travel almost weekly along major thoroughfares manually cleaning dust and grime from the reflectors, creating safety issues, loss of productivity and additional labour costs. “That interrupts production because they have to put signage in place, they have to have clear radio communications with the trucks to tell them to slow down when they drive past and [there’s] the massive safety issue of them being run over by a machine.” The Spinflector is designed to fit on a 50mm PVC delineator post and contains a series of brushes to clean dust and grime from reflectors. The device has a built-in wind vane to power the brushes. “Even on fairly calm days you’re always going to have the odd gust of

wind and it only really needs to rotate about half a dozen times in a 48hour period to take the layer of dust off and be effective – it just doesn’t allow a build-up of dirt,” says Cutler.

Terex’s new modular recycling jaw At the Hillhead Show in the UK this year Terex Minerals Processing Systems launched its new modular recycling jaw – the MJ400R and also the TSV6203 screen. Terex says the new products represent, “A well proven, cost effective and durable machine in a modular all-electric format with ‘no crawl maintenance access’ to the chamber.” The MJ400R has the Terex TJ2844R single toggle jaw crusher with renowned hydraulic overload protection as standard. It has a fully galvanised steel structure including walkways, steps, guardrails and product conveyor and is CE compliant. Also on display at Hillside was the renowned TSV6203 that is said to handle applications not possible with traditional horizontal screens because it combines the efficient, high g-force El-Jay oval stroke motion with variable slope operation to handle larger deck loads.

The screen adjusts up to 10° in 2.5° increments to best fit the application and optional bottom deck deflector plates increase efficiency. For more information on Terex MPS visit: www.terexmps.com.

Advertisers’ Index Allied Petroleum....................................................................... 29

Metso Minerals Australia........................................................... 27

Bridgestone NZ........................................................................... 4

NZ National Fieldays Society.................................................... IBC

BP Oil NZ.................................................................................... 9 Chevron New Zealand............................................................... 17

Equip2..................................................................................... 19

Hardox Wearparts..................................................................... 23

HG Leach.................................................................................. 13

42 www.contrafed.co.nz Q&M

Mimico....................................................................................... 7 Porter Equipment............................................ OFC, IFC, 3, 14, 15

Real Steel................................................................................. 33 Transdiesel.............................................................................. 11

West-Trak Equipment.............................................................OBC


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Q&M August – September 2016  

New Zealand's Quarry & Mining magazine