Quarry Mar 2019

Why digital data capture and analytics are becoming a vital part of the quarrying process.

MARCH 2019

BIGGER DOZER’S WORKLOAD OFFSETS OPERATION COSTS

‘NEXT GEN’ EXCAVATORS, LOADER ‘DRESS TO IMPRESS’

A homegrown operator reports more productivity with purchase of larger dozer.

A multinational manufacturer launches its next wave of earthmoving machines.

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NETWORK-CONNECTED QUARRY IMPROVEMENTS

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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

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IN THIS ISSUE MARCH 2019

VOLUME 27, ISSUE 03

FEATURES 21 TOMORROW’S CONSTRUCTION FLEET Subtle but significant changes are occurring in construction fleets - which will drive efficiency, safety, economy.

24 BIGGER DOZER’S WORKLOAD OFFSETS COSTS A homegrown operator has substantially increased productivity with the purchase of a larger dozer.

25 LOADER BOOSTS LITHIUM PRODUCTION

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NETWORK LINKS Digital data capture and analytics are becoming a vital part of the quarrying process.

26

‘DRESSED TO IMPRESS’ A multinational manufacturer has launched its next wave of earthmoving machines.

An earthmoving and haulage company is using a 35-tonne wheel loader to handle lithium at a remote WA mine.

34 EXCAVATORS PROVE THEIR METTLE ABROAD A pair of crawler excavators have demonstrated their reliability and economy in a South African coal mine.

36 ABS MAKES DOWNHILL WORK EASIER, SAFER An automatic engine braking system is helping an aggregate producer handle some very steep haul roads.

38 AN ODE TO THE ORDINARY Solutions can be found in the tiniest and mundane objects, according to Cecelia van der Merwe.

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‘GOING ELECTRIC’ A global OEM has announced its compact earthmoving range is about to go ‘all-electric’.

Why digital data capture and analytics are becoming a vital part of the quarrying process.

The extractive industry has lost one of its stalwarts at a relatively young age.

45 ENVIRONMENTAL PERFORMANCE SCHEME The Queensland Government and the CCAA have launched a reward scheme to recognise the environmental work of quarries.

MARCH 2019

BIGGER DOZER’S WORKLOAD OFFSETS OPERATION COSTS

‘NEXT GEN’ EXCAVATORS, LOADER ‘DRESS TO IMPRESS’

A homegrown operator reports more productivity with purchase of larger dozer.

A multinational manufacturer launches its next wave of earthmoving machines.

26

NETWORK-CONNECTED QUARRY IMPROVEMENTS

24

16

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

40

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EVERY MONTH 04 FROM THE EDITOR

42 IQA CALENDAR

06 FROM THE PRESIDENT

44 IQA NEWS

08 NEWS THIS MONTH

News from Queensland and Western Australia

14 PRODUCT FOCUS

50 GEOLOGY TALK Beringia: The Siberia to Alaska bridge

Quarry March 2019 3

EDITORIAL

ARE YOU PREPARED FOR THE FOURTH INDUSTRIAL REVOLUTION?

T

wo reports about innovation and disruption recently crossed my desk. Deloitte Access Economics’ Tracking the Trends explored the key issues for mining companies as the fourth industrial revolution gathers pace (see page 12).

transparency and future project planning. To paraphrase the Deloitte report, mining companies have recognised they must adapt not only to the technical “disruption of industry” but the disruption from “changing standards and attitudes”.

Aurecon’s Easy Life, Complex Technology paper reported that up to 60 per cent of building and property industry professionals believe their organisations are unprepared for the Internet of Things (IoT) – or understand how it could assist their businesses.

The quarrying industry isn’t immune from these issues but there are encouraging signs it’s not far behind.

Volvo CE, for example, has successfully trialled the world’s first “emissionsfree” quarry with a fleet of all-electric load and haul plant (see page 30). It is inevitable that as quarries adopt more cost-effective, “friendlier” technologies and processes, internal and external stakeholders will gradually appreciate the scale of their contribution to the built environment.

While these reports examine the mining and built environments, their points are salient for the quarrying industry. The IoT is applicable to numerous industries in the way it links artificial intelligence (AI), machine learning, automation, analytics and the cloud to business systems.

Many of these concepts exist in the quarrying environment. Many suppliers to the industry already offer AI, machine learning and analytics as part of fleet management packages and mine planning programs (eg the Trimble load and haul connected solution outlined on page 16 enables quarries to measure the outputs of their workers, plant and equipment). Further, devices and sensors on processing plant and equipment can identify the potential for blockages and stoppages, or warn operators when parts need replacement.

Much of these new technologies are readily available, either as standard or as options, and the producer doesn’t have to invest much capital in them at all – either financial or intellectual.

However, it is likely large and small aggregate producers, like their mining and building counterparts, still have a way to go before they understand exactly how the IoT functions and can assist their operations.

For example, Deloitte reports that miners are already investing significant capital in new technologies to not only raise productivity and improve efficiencies but address broader issues of risk, safety, diversity, sustainability,

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Quarry March 2019

At the local level, we’ve previously reported on the “digital quarry” approach implemented at Stonemaster Quarry in Brisbane between Fulton Hogan, Position Partners, Donnelly Blasting Services, and Cement & Aggregate Consulting. It’s a great example of an integrated technical approach to quarrying from different parties and to paraphrase Deloitte again, a “digitisation” of the supply chain – ie of organisations along the chain breaking down “operational silos” and achieving efficiencies, enhanced asset utilisation and higher productivity.

Further, Aurecon has reported that fantastic opportunities beckon in the future as engineers explore innovative ways of strengthening and “smartening” roads (eg through self-healing concrete, solar panels, illuminated road markings, etc). As generators of the raw product, why couldn’t quarries contribute to this space?

The IoT sounds daunting but it’s not to be feared or dismissed. Is your organisation ready? And should you think about how you can tailor the IoT to your operations?

DAMIAN CHRISTIE Editor

quarrymagazine.com Official publication of the Institute of Quarrying Australia Publisher Coleby Nicholson Associate Publisher Angela Han

THE INTERNET OF THINGS LINKS AI, MACHINE LEARNING, AUTOMATION, ANALYTICS AND THE CLOUD TO BUSINESS SYSTEMS

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Quarry is published by: Gunnamatta Media Pty Ltd Locked Bag 26, South Melbourne, VIC 3205 AUSTRALIA Phone: +61 3 9696 7200 gunnamattamedia.com info@gunnamattamedia.com Design & Production Manager Jo De Bono art@gunnamattamedia.com Accounts Paul Blewitt finance@gunnamattamedia.com Subscriptions info@gunnamattamedia.com Press releases damian.christie@quarrymagazine.com Copyright: All material appearing in Quarry is subject to copyright. Reproduction in whole or in part is strictly forbidden without prior written consent of the publisher.

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PRESIDENT’S REPORT

EDUCATION PATHWAYS FOR WORKERS IN A DEMANDING MARKET The Institute of Quarrying

T

he industry is now truly into the swing of things in 2019. In talking with many of our members there is a real sense of optimism around market conditions for the coming 12 to 18 months.

While there may be some uncertainty with respect to upcoming state and federal elections – and therefore funding for major projects – there is a great deal planned and in the pipeline.

With some exciting projects included in the Federal Government’s 10 Year Infrastructure Investment Pipeline (which you can view at buildingourfuture.gov.au), the industry will as always play an important part in the progress of the nation, providing essential construction materials to enable delivery of these key projects.

Given the anticipated demand for construction materials, which in some regions may be unprecedented, the stipulation for skilled workers is going to be at the forefront of quarrying businesses, including our network of suppliers.

The Institute is currently reviewing its educational content to ensure it remains relevant and can provide the necessary skills that the industry and IQA members need to respond to the opportunities and challenges that market demand brings.

Highlighting the benefits of our industry to the community and also making it an attractive industry to work in are also on the agenda – not only for us but other industry organisations.

We are competing for resources within a limited pool, which in the present time offers probably the greatest choice of any generation with respect to career options.

A lot more work is required in this space but when we succeed in

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Quarry March 2019

Australia

attracting workers, we need to ensure we can retain them and continue to assist with their skills development.

The IQA’s vocational and tertiary education pathways will provide support for those engaged in the industry, whether they are new entrants or long-term industry participants.

This also applies to our network of suppliers which contribute greatly to the industry and our membership. The IQA is reviewing content to ensure educational offerings in this sector of our industry are provided.

Members wishing to inquire or participate in any of our educational offerings should contact the IQA CEO Kylie Fahey via email: ceo@quarry.com.au The International Presidents’ E-Branch Project that I have previously discussed (see Quarry 2018; 26[9]: 12) is also progressing, with a business case currently being developed for sign-off by the International Presidents in April 2019.

The aim is to have this e-branch established by late 2019 or early 2020, providing the broader international quarrying community, including existing IQ members, with access to online educational content.

Stay tuned for further updates on this exciting project, being led by the IQA and the Institute of Quarrying UK! Have a safe and productive month ahead!

CLAYTON HILL President Institute of Quarrying Australia

Educating and connecting our extractive industry

quarry.com.au WE ARE COMPETING FOR RESOURCES IN A LIMITED POOL AT A TIME WHEN THE CURRENT GENERATION IS SPOILED FOR CHOICE WITH RESPECT TO CAREER OPTIONS

The Institute of Quarrying Australia’s goals are: 1. To provide world class professional development for the extractive industries.

2. To establish an Australasian Academy of Quarrying.

3. To align service offerings with industry needs.

IQA CONTACTS: Chief Executive Officer Kylie Fahey PO Box 1779 Milton BC QLD 4064 Phone: 0477 444 328 ceo@quarry.com.au Company Secretary Rod Lester Phone: 0408 121 788 rgl@rlester.com.au Finance Officer Gemma Thursfield Phone: 0402 431 090 gemma@quarry.com.au Web Maintenance, Graphic Design, ePrograms, IT Support Ryan Spence Phone: 0422 351 831 ryan.spence@quarry.com.au General, membership and financial inquiries should be directed to admin@quarry.com.au or phone 02 9484 0577.

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NEWS

NATIONAL ‘COUP’ FOR MOBILE PLANT DEALER ‘WE AIM TO PROPEL SANDVIK MOBILES TO NEW HEIGHTS IN AUSTRALIA.’ DARREN RALPH PORTER GROUP

Porter Group is the new dealer for Sandvik mobile crushers and screens (pictured) across all of Australia.

Porter Group has been appointed by Sandvik Rock & Technology as the national dealer for its range of mobile crushers and screens.

The relationship between Porter Group and Sandvik was initially formed in New Zealand and dates back to 2009.

Porter Group already had the distribution rights for Sandvik mobile plant in Western Australia. It has been the WA dealer for the product for nearly a year.

Established in 1945, the Porter Group has more than 50 retail locations across New Zealand, Australia, Papua New Guinea and the United States. In addition to the Sandvik mobile plant, the company distributes Hyundai Construction Equipment, ASV, Terex Trucks, Furukawa, Madill and NC Engineering products for the quarrying, mining, recycling, landfill, forestry, industrial and agricultural sectors.

As part of the new arrangement

with Sandvik, Porter Group has also been appointed as the mobile distributor for Papua New Guinea and surrounding islands.

“The latest extension of the Sandvik relationship is an important progression for the brand in the region,” Darren Ralph, general manager of Porter Equipment Australasia said. “Sandvik mobiles are global leaders in technology and productivity and this development will ensure that the product is brought to the customer base efficiently. We aim to provide Sandvik mobiles with a platform to propel the brand to new heights in Australia.”

A statement from Sandvik Rock & Technology indicated that the collaboration with Porter Group is in line with its commercial ambitions to develop its presence in the Australasian mobile plant market.

“We are pleased to appoint Porter Group as the [Sandvik] mobiles distributor for the Australian market,” Joe McCormack, the area sales manager for Sandvik Mobile Crushers and Screens said. “Our relationship with Porter Group has grown successfully over the years and we are delighted to extend our agreement to include the whole of the Australian territory.” •

LONG-TERM PARTNERSHIP COMES TO AN END After nearly three decades, Hitachi Construction Machinery (Australia) [HCMA] will no longer distribute John Deere’s branded and manufactured construction, forestry and compact machinery in Australia.

According to a HCMA spokesperson, as the joint businesses have expanded over the years, so too has each company’s priorities in various markets around the globe.

“We thank John Deere for the partnership that has been enjoyed over the last 29 years but ultimately we believe this change in distribution will allow HCMA to increase our focus on our brands, and provide an improved experience to customers across Australia,” HCMA managing director David Harvey said.

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Quarry March 2019

Between now and 1 May, HCMA will work closely with Deere to ensure a smooth transition to Deere’s newly appointed Australian construction and forestry dealers. From 1 May, RDO Equipment will be appointed the authorised John Deere Construction & Forestry dealer in New South Wales, Victoria, Queensland, South Australia, Tasmania and the Northern Territory.

In Western Australia, AFGRI Equipment will be the authorised dealer. AFGRI Equipment chairman Patrick Roux said that the company has been a distributor of John Deere agricultural equipment for more than 50 years and welcomes the opportunity to extend its services to the construction and forestry equipment spaces.

“With the contract now signed, we are very enthusiastic to prove ourselves worthy

End of an era: Hitachi and John Deere have enjoyed a 29-year partnership in Australia.

of this appointment and have already actively started to recruit and appoint specialist staff, so we can get off to a cracking start come 1 May,” Roux said.

AFGRI’s inventory of Deere construction plant and equipment will be situated across five sites in WA: Geraldton, Albany, Esperance, Boyup Brook and Perth. •

CONSENT CHANGES LINKED TO COMMUNITY FUND Multiquip Quarries and Goulburn Mulwaree Council are pursuing a Voluntary Planning Agreement (VPA) as part of the former’s bid to increase production at its Ardmore Park site.

Ardmore Park Quarry, in Bungonia, 25km southeast of Goulburn, New South Wales, produces basalt rock and river sand. Under the current consent, Multiquip is permitted an annual output of 400,000 tonnes. It wants to increase to 580,000 tpa.

The application will be decided by the NSW Independent Planning Commission.

The VPA sets out Multiquip’s road maintenance obligations. It calls for the company to contribute 3.85 cents per tonne per kilometre (c/t/km), indexed by inflation, to the council for its haul route. This covers 3.4km of Oallen Ford Road to Bungonia, a 300m section of Mountain Ash Road to Jerrara Road and 14.6km of Jerrara Road to Marulan South Road.

The amount is more than the 3.74c/t/ km the company proposed but less than the 4.62c/t/km usually imposed.

The agreement also imposes other obligations, eg: • Multiquip will rehabilitate pavement less than 10 years old before transport operations begin.

• The company will fund and complete resealing of half the haul route, either in-kind or financially, before transport starts. The council

Hanson Australia’s Bass Point Quarry, on the New South Wales south coast, has had the terms of its consent altered to allow an increase in early morning truck movements.

Under a VPA, Multiquip Quarries could pay about 4c/t/km for its haul route.

will fund and re-seal the other half.

• The council will commission a road safety audit after roadworks have been completed, with Multiquip to address any safety issues.

• Multiquip will fund and complete structural assessment of bridges and culverts on the route.

Multiquip also proposed that a portion of the funding be contributed to a Bungonia community fund that could be used for local projects.

Goulburn Mulwaree Council has stated that it prefers a separate fund, managed by a committee, which could be modelled on that of other quarries in the area, and that is tied to road levies because the amount would increase with the quarry’s production.

The company’s managing director Steve Mikosic told The Goulburn Post that he’d work with the council on whatever funding model was adopted and would continue to liaise with the community on projects. •

FORMER QUEENSLAND QUARRY, NOW PRIME REAL ESTATE, SOLD The former Hamilton quarry, on the north bank of the Brisbane River, has recently been sold to an arm of the Queensland Government.

Queensland Urban Utilities purchased the 5610m² site at 330 Kingsford Smith Drive, Hamilton.

“The property is zoned ‘Special Purpose (Utilities Services)’, and we are still considering our development plans for the site,” Queensland Urban Utilities spokesperson Sarah Owens said.

“It is likely to be used for water

EARLY MORNING TRUCK MOVEMENTS APPROVED

or sewerage infrastructure in the future as we cater for population growth in the Brisbane CBD and in suburbs such as Hamilton, Eagle Farm and Pinkenba.”

Under the new arrangements, 27 trucks per hour are able to leave between 5:00am and 6:00am, while the movements in the following hour have been increased to 38.

From 7:00am to 10:00am, the current limit of 40 trucks will remain, as will the limit of 23 trucks per hour from 10.00pm to 5.00am. The daily limit of 500 trucks per day is also unaltered.

“This modification will provide greater flexibility to manage product dispatch activities to Hanson’s concrete batching plants and road construction markets by reducing the time trucks spend in peak traffic flows which would in turn benefit commuters travelling towards Wollongong and Sydney, ” a Hanson spokesperson said.

The NSW Department of Planning and Environment agreed to the changes because the additional truck movements “would not result in significant impacts beyond those previously assessed and approved”.

Hanson previously agreed to Shellharbour City Council’s request to establish a 50km/h speed limit and suspend 24-hour trucking on weekends.

Bass Point Quarry currently produces up to four million tonnes per year of high quality basalt products •

In 1891, the Hamilton Divisional Board used the waterfront site as a quarry, which produced road fill for works on Breakfast Creek Road.

It was subsequently used as a reserve by police and as a council depot. The property was reportedly sold for about $5.5 million, according to reports in The Courier Mail. • Quarry March 2019 9

NEWS

GLOBAL MARKET STILL COLD ON RECYCLED AGGREGATES A new report on the global recycled aggregates market Recycled Construction Aggregates Market Forecast, Trend Analysis & Competition Tracking – Global Insights 2018 to 2027, prepared my Fact.MR - predicts that markets will remain bullish in coming years.

The main market drivers are urbanisation and related infrastructure development and an increased focus on environmental conservation.

According to the report, “[r]apid urbanisation, and proliferation in construction and infrastructure development activities allude significant amount of waste being generated worldwide, which has been a key environment concern among industrialists. Continued emphasis on the environmental conservation has further instigated the critical need for recycling and reusing construction materials”.

The report found that there is more of an emphasis on the environmental benefits of recycled construction aggregates and effective waste management in developed countries. In some regions, this is being translated into government policy and regulation.

Under the Waste Framework Directive, the European Union aims to recycle about 70 per cent of construction and demolition (C&D) materials by 2020.

There is a distinct lack of government initiatives in developing countries. “The government interventions including policies for waste management is still in limbo in some of the developing countries,” the report stated. “Compared to pace of urbanisation in developing countries, the measures for [C&D materials] management [is] sluggish.”

Further challenges, like the lower affordability of recycling and reuse of construction aggregates, continue to impede developing markets.

For more information, visit: factmr.com •

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Quarry March 2019

MILESTONE FOR HORNSBY QUARRY REHABILITATION ‘IT TOOK ALMOST A CENTURY TO DIG OUT HORNSBY QUARRY BUT ONLY 18 MONTHS FOR US TO FILL IT AGAIN.’

After 18 months, the last truckload of spoil from the NorthConnex tunnel project has been delivered to Hornsby Quarry.

PHILIP RUDDOCK

“This is an important day, bringing us a big step closer to achieving our dream of creating the ‘Centennial Park’ of the north,” Hornsby Shire mayor Philip Ruddock said.

HORNSBY SHIRE COUNCIL MAYOR

More than one million cubic metres of clean fill have been tipped into the quarry – the equivalent of 450 Olympic-size swimming pools. The last truckload of spoil was deposited into the void on 25 January, 2019.

“It’s amazing to see how much the quarry has transformed over such a short period of time. It took almost a century to dig it all out but little more than 18 months for us to fill a major part of it in again.”

The completion of NorthConnex’s role in the remediation project comes after the New South Wales Government committed $100 million in funding to the redevelopment of the Hornsby Quarry and Westleigh Waterboard site following boundary changes during failed amalgamation attempts.

Berowra federal Liberal MP Julian Leeser told a press conference that the quarry was an example of what could be achieved when multiple levels of government work together.

“Not only are we reducing traffic congestion by taking 5000 trucks off Pennant Hills Road and getting people back to their families sooner and safer – we are also transforming this dead space into a recreational park which will be enjoyed by many future generations,” Leeser said.

NorthConnex will spend the next few months removing its equipment from the site and carrying out remediation works, including the resurfacing of Bridge Road between Roper Lane and Peats Ferry Road. It will hand the keys to the site back to Hornsby Shire Council in the middle of the year.

Council’s plans for the next stage of the rehabilitation are well advanced, with a development application for the required earthworks soon to be submitted.

This will determine the general

The last truckload of spoil from NorthConnex has been delivered to Hornsby Quarry.

shape of the park to be created. It will be placed on public exhibition before being approved.

“Council is committed to seeking detailed input from the public, to make this a park that is designed by the community,” Ruddock said.

“This is going to be the centrepiece of our recreational facilities for generations to come and we are determined to get it right.”

There will be further public consultation as the project continues, up to its anticipated completion date in 2023.

Hornsby Quarry was established in the early 1900s, originally as a breccia hard rock quarry for private businesses. It was acquired and operated by CSR Construction Materials from 1959 but ceased operations in the late 1990s and was later purchased by Hornsby Shire Council in 2002. In October 2014, the council unanimously agreed to redevelop the site into a recreational space.

The spoil management project began in 2017. At the peak of activity, the maximum number of spoil haulage trucks accessing the site per day was about 385 (or 770 vehicle movements) – or 35 trucks delivering about 700m3 of spoil per hour. The spoil from the NorthConnex project was deposited into the void courtesy of a $9 million, four-stage conveyor.

All tiers of government funded the in-fill project to the tune of $7.33 million. •

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NEWS

CHANGES TO END OF LIFE PROPOSAL FOR CLAY PIT CSR Group has submitted a notice of change to the development application for its Warner Quarry in southeast Queensland – outlining the future shutdown of the site and the development of homes, parks and residential infrastructure there.

The application was lodged with Moreton Bay Regional Council in September 2018.

Warner Quarry has been in operation since the 1970s and will continue to be for the foreseeable future. The quarry produces a clay resource, which is supplied by road to the CSR brickworks in Oxley and Darra.

The change to the DA comprises a new preliminary approval application that proposes residential development of the CSR quarry up to a maximum density of 20 dwellings per hectare, totalling approximately 500 homes.

DELOITTE REPORTS GOOD NEWS FOR EXTRACTIVE INDUSTRY DELOITTE’S SECOND REPORT EXPLORES THE KEY TRENDS FACING EXTRACTIVE COMPANIES IN THE FOURTH INDUSTRIAL REVOLUTION

Two recent reports from Deloitte Access Economics point to 2019 being a strong year for the quarrying industry. In one paper, it has forecast infrastructure spending to peak at almost $40 billion.

Since 2015, there has been an increase in the value of infrastructure projects. This growth is expected to be driven by a number of large New South Wales projects, including the $8.3 billion Sydney Metro Northwest, the $4.9 billion Pacific Highway upgrade from Woolgoola to Ballina, the $3 billion NorthConnex and the $2.1 billion Sydney CBD light rail.

“Although the healthy project pipeline will continue to support elevated levels of infrastructure activity, we expect calendar year 2019 to be the peak for this cycle,” Deloitte partner and report lead author Stephen Smith said.

The Warner Working Group has been established with members from community, schools, industry, government and CSR. Its first collective achievement, if the DA is accepted, is the protection and preservation of seven hectares of vegetated land.

“The factors that have supported the current surge in infrastructure spending are beginning to wane.

There are fewer assets left to privatise, and the slowing housing market is weighing on property tax collections.

That said, the NSW state election, scheduled for March, creates the prospect of additional projects entering the database.”

In addition, infrastructure to facilitate the development, new road entries, and bikeways and pathways has also been proposed.

Deloitte’s other report explores the key trends facing extractive companies (mainly miners) in the fourth industrial revolution. It also

Since the change to the DA is not classified as “minor”, the assessment process will restart. It is expected that council will issue a new information request. This means the public notice period is expected in mid-2019. •

Series producer Lucy Addario told The Kiama Independent that the location was “the perfect backdrop ... The stunning rock formations and the open expanse enforced the sense of isolation and danger for our characters in crisis”.

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Quarry March 2019

predicts that the industry is poised for greater growth than it has seen in the last decade, but cautions that the industry’s challenges are diverse.

“Australian mining companies must not only adapt to the disruption of industry from a technical viewpoint, but the disruption being brought about by changing community standards and attitudes towards mining,” Deloitte’s national mining leader Ian Sander said.

“In this new world order, miners will not attract talent, investment or community support if they only focus on communicating the discrete value they currently bring to communities,” he said. “Miners need to go a step further by developing differentiated business models designed to drive long-term value for their organisations and for the Australian community.” •

‘TOOTHBRUSH’ HERITAGE SITE CO-STARS IN AUSSIE TV SOAP Bombo Headland Quarry, in Kiama, New South Wales, had a “starring” role in long-running Aussie TV soap Home & Away on 18 February.

Preparations have begun early for the post-working life of Warner Quarry.

Deloitte’s latest papers forecast growth in the mining and infrastructure sectors.

The quarry is famous for its clusters of 5.5m high iconic hexagonal basalt columns, standing adjacent to the

coast. It has appeared on film a few times. Foxtel’s Coast Australia most recently explored its working history.

Bombo Quarry – nicknamed the “Toothbrush” by locals – first opened in 1881 and supplied its 260 millionyear-old basalt deposit for roads and rail ballast to Sydney.

A conservation order was placed on the site in 1983 and it was listed on the NSW State Heritage Register in 1999. It is co-owned by the NSW Department of Planning and Infrastructure and Sydney Water. •

PRODUCT FOCUS

To submit new product and equipment releases, email: damian.christie@quarrymagazine.com

CUSTOM-DESIGNED IMPACT BEDS Leverlink’s dynamic impact beds are custom-built to each site’s specific requirements, with an emphasis on structural integrity, belt preservation and leakage prevention. The dynamic suspension system dissipates kinetic energy to protect the belts and structure of the conveyor systems. The fixed wings prevent leakage, which reduces waste and minimises clean-up while also assisting in eliminating health and safety issues.

Leverlink’s protective coating ensures the plant will last longer, even in the harshest environments.

More information: Leverlink Australia, leverlink.com.au

GAUGES SAVE TIME, MONEY Crushing Equipment’s cone liner wear profile gauges are electronically profile cut to represent the line wear profile on crushing application liners. Before commencing, operators use the gauge to confirm the crushing profile is correct for the specific application. In addition, it can be used to measure the wear rate during crushing life and determine optimum change-out time.

The gauge aligns with the main shaft and bowl of the liner seating face and the top of the liner.

Applicable wear profile gauges are currently being sent to quarries supplied by Crushing Equipment. If suitable for their requirements, the cost will be around $100 each. Potential time and cost savings can be significant.

More information: Crushing Equipment, crushingequip.com.au

CRUSHER WITH INCREASED MOBILITY, FLEXIBILITY The Tyler F-class portable plant features a base frame that easily attaches to a custom-built chassis. The plant includes a hydraulic system that raises the vibrating screen to its inclined operating position.

These two features allow producers to move and set up the portable F-Class in less than 30 minutes in nearly any location. Each F-Class is equipped with Haver & Boecker’s Ty-Rail quick-tensioning system, which can halve the time for screen media change-outs.

More information: Haver & Boecker Australia, haveraustralia.com.au

TROMMEL WITH BESPOKE SOLUTIONS The MDS M515 heavy-duty rock trommel, available in static and mobile options, has been redesigned to suit Australian conditions. It is ideal for separating rock from clay overburden, armoured rock and gabion material, and can produce three products with outputs of up to 420 tph.

The M515 incorporates a more powerful Caterpillar 4.4 engine pack, ripstop belts on every conveyor, a reinforced hopper floor, and two solid interchangeable drums for easy change-outs.

More information: Screenmasters Australia, screenmasters.com.au

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Quarry March 2019

crusherscreen.com

IMS PM 1050-16Tb Track Pugmill Crusher & Screen can offer for Sale or Hire the IMS Track Mounted Pugmill and high production Blender. The

Crusher Screen can now offer IMSworking Track Pugmill is fitted withmode, a 2400mm long x 1360mmand wide and 835mm Pugmill&hydraulically folds upthe from modewhich to operational is high production available with deep pughead with 640mm twin mixers producing up to 480 tonne per hour.

The machine offers quick fully hydraulic water only option or a fully integrated computerized system with attached cement hopper and bulk silos set up betweenintransport operating mode and19-74 the advantage of self loading and Whensystem. not required as a available mobile and or semi mobile from tonne also controlled by site themobilization. pugmill control Pugmill the head can be removed and used as a 16 meter track conveyor or attach a screen box adding total flexibility.

John Andersen +61(0)424 181 056 | Chris Wong +61(0)424 180 860 Fax: +61(0)7 3036 6400 | Email: info@crusherscreen.com | www.crusherscreen.com

The IMS track mounted blender can be used to blend another two products with the pugmill or used as a high production blender with production up to 1000 TPH. The blender also has its own mixer which hydraulically moves to the side when not required, the mixer option is ideal for blending soils and compost materials etc. crusherscreen.com

IMS PM 1050-16Tb Track Pugmill Crusher & Screen can now offer the IMS Track Pugmill which is fitted with a 2400mm long x 1360mm wide and 835mm deep pughead with 640mm twin mixers producing up to 480 tonne per hour. The machine offers quick fully hydraulic set up between transport and operating mode and the advantage of self loading and site mobilization. When not required as a Pugmill the head can be removed and used as a 16 meter track conveyor or attach a screen box adding total flexibility.

IMS manufacture a wide range of conveyors and feed hoppers, from ship loaders to high production 24-30 meter link conveyors, wheel & track conveyors up to 30 meters long with loader feed hoppers and twin power options.

John Andersen +61(0)424 181 056 | Chris Wong +61(0)424 180 860 Fax: +61(0)7 3036 6400 | Email: info@crusherscreen.com | www.crusherscreen.com

LOAD & HAUL

A HOLISTIC VIEW OF NETWORK

CONNECTED QUARRY IMPROVEMENTS

Under pressure to juggle productivity and improvements with cost-effectiveness and profitability, quarrying operators and managers are increasingly reliant on digital data capture and analytics tools via network-connected devices and web-based reporting to smoothly run their operations.

T

oday’s aggregates executives have much to keep them up at night. Like most business leaders, the pressure to maximise returns while decreasing overheads is constant.

But executives in the aggregates industry also face increasing pressure to improve operational efficiency, sustainability and safety performance, while maintaining a competitive advantage and exploring new revenue streams. Add to that the desire to make technology decisions that can drive improved efficiency and cost performance, and it’s a wonder these decision-makers have any time for rest.

With so many priorities to juggle, how do quarry executives lead their teams and operations into the future? What levers can they pull to make significant productivity improvements, enhance transparency across the organisation to reduce waste, and optimise operations?

Fortunately, a fresh perspective on operations management and advancements in quarry technology is transforming the aggregates industry. A combination of automated data capture using networkconnected devices and web-based reporting and analytics tools will help support the quarry of the future.

These technologies give “C-level” executives greater visibility across extraction, processing and load-out, as well as enhanced transparency for smarter inventory planning and forecasting.

Advanced analytics and reporting tools 16

Quarry March 2019

are also providing deeper insights into processes across the organisation by looking at current data compared with historical data and forecasts or targets. With an understanding about what’s happening in their quarries and accurate forecast data, leaders will have the ability to better plan production over various time horizons, to closely track productivity and performance across their entire operation, and to drive organisational change in new and exciting ways.

MEASURING OUTCOMES You may have heard these wise words from business management guru Peter Drucker before: “If you can’t measure it, you can’t improve it.”

It all comes down to the fact that if you can’t measure something, and know the results, it’s very difficult to achieve sustainable improvement.

The good news is, measuring outcomes in quarry operations is easier than ever with the proliferation of the Internet of Things (IoT) and network-connected devices.

Automated capture and measurement technologies are the foundation of the connected quarry and the quarry of the future, because they can very accurately measure data and share that information in near real time. This includes on-board loader scales to measure payload, belt scales that record production, haul truck monitors to optimise the haul cycle and other tools that track production activity to optimise material

movement (see Figure 1).

Improvements to asset and fleet management technology also make it efficient to track everything from high valued powered equipment to towed and nonpowered assets and fleet vehicles.

With this information, managers have access to detailed activity reports that can help the organisation better manage asset performance and costs.

Another example is the Trimble load and haul management connected solution, which automates data capture of the extraction process using the Loadrite X2350 excavator scale to record pit extraction tonnage and measure load cycles, while Trimble’s H2250 haul truck monitor tracks truck fleet and material movement.

The integrated solution eliminates the need for paper tally sheets and automatically counts, records and breaks down haul truck cycles. These capabilities remove the chance of human error and keep operators focused on safe and productive materials

Figure 1. The typical haul truck cycle (left) versus the optimised haul truck cycle.

movement. They also improve safety and maintenance needs by monitoring speed and tyre pressure, capturing hours of operation and providing payload measurements.

AUTOMATED DATA CAPTURE Loader scales, belt scales and fleet and asset solutions are critical building blocks for efficient and productive quarry operations.

These interconnected sensors and smart scales make it possible to deliver visibility across operations.

Managers can then measure actual production versus sales forecasts and share that analysis with regional managers and executives up the chain. Using this information, they can then identify potentially costly bottlenecks, find areas for improvement and identify opportunities to

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MOBILE AND TRACK CRUSHING AND SCREENING PLANTS

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PO BOX 142, ACACIA RIDGE, QLD, 4110 • 1300 278 322 (1300 ASTEC AUS) • astecaustralia.com.au

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LOAD & HAUL

apply best practices for running more efficiently.

“In the connected quarry, we rely on automatic data capture as the first step to measurement and increasing visibility across operations,” said Johan Smet, the general manager of Trimble’s aggregates division.

“By removing the human element of monitoring, we remove the burden of errorprone manual data collection and tedious transcribing and tallying.

“These capabilities give executives insight to answer critical questions about operations, because they see what’s happening at a granular and aggregated level. This gives them greater visibility, transparency, and error-free and timely data to make smarter decisions.”

Numerous questions – eg how much downtime did we have last quarter? Are we maximising margins? Are we maximising sales? Are we minimising inventory and write-offs? Are we reducing safety risks and controlling overloading to prevent community complaints? – can be answered by leveraging automated data capture tools such as Loadrite’s weighing systems and pulling that data into a centralised database such as InsightHQ for systematic reporting and analysis.

“Answers to all of the most important questions start to come into focus with automated data capture as the foundation,” Smet said. “Gathering data you can trust,

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without the hassle of chasing down multiple reports from multiple locations, is the first step towards making better business decisions.”

DATA USAGE The next phase is putting systematic processes in place to figure out what to do with the information collected. What may have worked in the past, such as relying on spreadsheets or homegrown systems, is no longer adequate to manage these large or complex data sets.

The key is relying on powerful, more agile reporting and management tools that can aggregate data collected across the manufacturing operation to provide a complete, 360-degree operational view.

Cloud-based applications that can compile data collected across the enterprise from crushers, loaders, excavators and trucks give managers and executives an accurate and detailed understanding of their processes. Web-based management tools are ideal because they can be accessed anywhere with an internet connection and on any mobile device.

With productivity, availability and performance metrics about extraction, processing and load-out functions at their fingertips, managers have the detailed information they need to make smarter dayto-day decisions.

Not only that, executives have a high level,

360-degree view of operations and the ability to dive deeper into specific quarry data when needed.

“Imagine all of the data from across 12 sites that make up a region being aggregated into one number or a couple of numbers,” said Kevin Vonesh, the worldwide strategic accounts manager for Trimble Loadrite.

“Having the ability to drill down into a report to see if there was a metric in the red and drilling down further and seeing there’s a plant with its main crusher down – that’s what C-level executives need to see to make effective change happen.”

Web-based reporting tools such as Trimble’s InsightHQ help teams meet these challenges. InsightHQ allows users to identify issues and respond much more quickly than reporting that relies on manual processes and generally shows a narrow view of individual metrics.

“We see many C-level executives who are disconnected because the information is not readily available and accessible, and often not reliable,” Vonesh said. “That’s what we’re doing with InsightHQ. We’re providing the ease of use and the ability to see that information and use that data in the day-today decisions of running the organisation.”

REAL-TIME DATA The advantage of continuous monitoring and access to real-time data is that performance and optimisation provide immediate feedback.

Ongoing analysis and insight is much more valuable than a once-a-month reporting exercise that includes data about total tonnage, operating rates or what products are being produced, for instance.

With comprehensive web-based tools, executives can log in to their management portal to see live reports about key processes and sub-processes across the business, with very accurate measurements broken out by machine, product and customer.

Users can then look deeper to investigate load-out obstacles – or they can view changes over time, adjust reports for individual quarries and regions, or by shift, day, week, month or year.

Greater access to real-time data across quarry operations will continue to give leaders the ability to respond to issues much more quickly and to optimise productivity, availability and performance of their products.

Australia’s leading designer and manufacturer of rubber torsion spring motor bases.

Motorbase - Crushers

Trimble’s H2250 haul truck monitor tracks truck fleet and material movement.

Motorbase - Screens, Feeders

“By making the information about operations much more accessible via a cloud-based model, executives can quickly see efficiencies achieved with belt scales, loader scales, excavator scales or haul truck scales, which all adds up to saving the business money,” Vonesh said.

With a better understanding of the operating parameters due to intelligent data collection and smarter data analysis, executives can quickly see how changes to capacity will affect other phases of operation.

SMALLER QUARRIES, BIG INSIGHT With smaller quarry operations there’s even greater pressure on operators to keep costs in check and maintain transparency across the site.

“In Europe especially, we see smaller quarries in tighter concentration because aggregate is very expensive to transport across long distances,” said Patrick Gruber, strategic accounts manager for Trimble Loadrite in Europe and the Middle East.

“When competition is intense, leaders have to make pricing decisions quickly while making sure costs are under control.

Detailed monitoring of daily production, stock on hand and forecasting is critical.

“Access to this data ensures operators produce the right product at the right time to meet demand.”

Greater transparency gives executives the ability to make informed decisions that can help quarry operations reach new levels of productivity and efficiency.

Executives may determine, for example, that a site may benefit from fewer but higher capacity trucks to transport maximum throughput. Other sites may benefit from adding additional smaller trucks and the increased flexibility in capacity that brings to react to demand fluctuations.

In every case, seeing the impact from a change in one area of the mine on overall production will improve decision-making.

In each scenario, C-level executives are responsible for identifying productivity improvements made possible through

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LOAD & HAUL

With real-time information, managers can adjust plant, hours, modes and sales and can see how these changes will affect current production and future orders. C-level executives can then solve multi-site inventory issues far in advance before a customer experiences a problem.

“Improved planning technologies make it possible to fine-tune production to market needs, maximising the output of desired products and minimising the output of byproducts,” Smet said.

“This analysis can all be done looking at the real capability constraints of the plant.

Whether this leads to a more diverse product portfolio depends on the range of market needs, but it will certainly lead to a portfolio that better matches those needs and improves overall profitability.”

The Loadrite 360 application can contribute to safely speeding up truck cycle times through the weighbridge to improve customer service. (Above) The Loadrite 360 connects the loader and scale house to provide data sharing of load-out jobs.

investments, supporting a trial and rolling out the change throughout the operation.

For example, teams may determine a bottleneck in load-out and re-evaluate their scale house processes.

By rolling out Trimble’s Loadrite 360 application, for example, companies can transform the process to safely speed up truck cycle times through the weighbridge, to improve customer service. The LR360 connects the loader and scale house to provide data sharing of load-out jobs.

Essentially, jobs are automatically sent to the loader operator, so they know precisely what products and what weight each truck requires before it arrives at the stockpile. This holistically improves load-out operation and safety through performance metric tracking, automation and real-time job visibility. In addition, the Loadrite 360 reduces the need for manual data entry, which improves operator job satisfaction and reduces errors.

“These technologies give executives the breadth and depth they need to drive improvements across every aspect of the business – from the pit to the gate, from the CEO to the operator,” said Gruber.

“If load-out is identified as a bottleneck, tools like Loadrite 360 can improve it, with further improvement down the supply chain.

“Loadrite 360 empowers the operator because they can finalise the load with a click on the scale, the data is automatically sent into the management portal, and the job is closed. Reports are then 20

Quarry March 2019

made accessible via the cloud.

“This means the truck doesn’t even have to go back on the weighbridge before leaving the quarry. This saves time and is safer because drivers are not leaving their truck cab, and by making load-out smoother, you can load trucks faster.

“These tools empower teams to be more productive through automation, accurate measurement and reporting.

“Plus, when teams have access to accurate data at a granular level and at a high level, they can make smarter decisions.”

‘OUTSIDE THE GATE’ PLANNING In addition to managing internal operations, executives must have a constant eye on balancing their cash flow and managing financial performance across multiple individual quarries.

This is challenging when orders are continually changing and manual, spreadsheet-driven reporting can’t keep pace.

On top of that, building a forecast report that shows materials demand in different time intervals is an incredibly tedious process.

Today, however, automated data capture technologies and cloud-based reporting systems such as Trimble’s PlantDemand, are changing that. PlantDemand provides managers with a “single source of truth” when it comes to aggregate, asphalt and concrete production and inventory planning and forecasting.

‘DIGITAL NATIVES’ Technology is also helping C-level executives keep pace with a changing workforce.

Many aggregate and construction professionals are retiring, putting pressure on organisations to fill the skills gap and bring young professionals into the business.

Leveraging technology innovations and automating many manual tasks across quarries will help attract the next generation of quarry professionals, who have grown up using technology and are “digital natives”.

With continuous monitoring and a single system to view and report on quarry production and inventory information, individual employees and managers will be more engaged, better equipped and therefore more successful.

Even more, C-level executives can establish a culture of success and innovation built on real data, empowerment, greater accountability and communication.

“Technology helps shorten the learning curve across almost every business, and people like to work with new technology,” Vonesh said.

“You can’t teach 20 years of experience in two weeks, but you can explain to new hires how to interpret what the system is reporting and help teams benchmark themselves against targets and use those targets to improve.

“Teams want to do a good job and technology can help by automating some of those mundane tasks, and they’ll learn things, so they can keep their skills current.” • Source: Trimble

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LOAD & HAUL

HEAVY-DUTY DOZER

LAUNCHED WITH MACHINE CONTROL

K

omatsu has released the D375Ai-8 “intelligent” dozer, the first heavy dozer incorporating the fully integrated intelligent Machine Control (iMC) system.

The 73-tonne D375Ai-8 is powered by a US EPA Tier 4 Final diesel engine, rated at 455kW in forward gears and 558kW in reverse.

Its applications include quarrying, heavy construction and mining.

According to Michael Hall, Komatsu Australia’s mining product manager, the iMC version of the dozer can carry out bulk and final trim dozing in fully automatic mode from start to finish.

While this is Komatsu’s first large dozer fitted with integrated machine control, the concept has been successfully used on its smaller and mid-sized dozers across Australia in the past three years.

“The concept has been shown to significantly increase productivity and efficiency – up to twice as productive as dozers fitted with ‘bolt-on’ third-party machine control systems, according to Australian users and operators – while reducing the cost of each metre of material moved,” Hall said.

“For quarrying and construction operations it can be used in bulk earthmoving, as well as final grade work, sand and gravel extraction projects and site restoration works.

Komatsu’s iMC is also another step on the path to fully autonomous dozer operation.”

The D375Ai-8 incorporates a standard fully integrated Global Navigation Satellite System.

“Because the machine control system is fully integrated, it eliminates the need for coiled cables between machine and blade,” Hall said. “The operator or service technicians don’t have to climb up on the machine to remove and replace antennas or masts, and there’s no requirement for daily connections and recalibrations.

“An enhanced sensor package combined with an intelligent logic system provides for high accuracy in a fully integrated system without the need for traditional blademounted sensors.”

The iMC system automatically controls 22

Quarry March 2019

SPECS - D375AI-8 OPERATING WEIGHT

72.9 tonnes

ENGINE

Komatsu SAA6D170E-7 engine – 455kW (net, in forward gears), 558kW (net, in reverse)

BLADE CAPACITY

18.5m3 (semi-U), 22m3 (full U)

MACHINE CONTROL

Fully integrated Komatsu factory-fitted intelligent Machine Control (iMC) system.

blade elevation and tilt according to target design data, using common industry standard design data software and systems.

“With these machines, not only can the automatic machine control features be used for final grading, but also for bulk dozing, a capability that’s unique to our intelligent dozers,” Hall said.

“Loading of the blade at the start of the cut is controlled via set parameters. During the pass, if the load on the blade increases, automatic blade control manages the load and minimises shoe slip, ensuring effective dozing at all times.

“Then, when the material level approaches the target design surface, the machine reverts to fine blade control for close final grading.

“Highly experienced dozer operators have reported that, with this technology, they can be more productive than before – placing material faster and with more accuracy.”

Dozing progress can be checked using the integrated as-built mapping display, which collects surface data by continuously measuring elevations. This data is also communicated to the planning software, to enable monitoring of material movement by planning and management personnel.

The intelligent dozer technology is also readily integrated with Komatsu’s SmartConstruction offering, which combines drone-based survey and site management systems and cloud-based information offerings to design, plan, construct and manage quarrying operations.

“When Komatsu released its first intelligent dozer, the 20-tonne D61EXi/PXi-23 construction dozer in 2014, the technology

was described as fully scalable to other machines in our dozer range,” said Hall.

“We proved this with the release of three additional iMC dozers, and now we’ve extended the technology to the D375Ai-8.”

The D375Ai-8 is based on the recently released D375A-8, which features a fuelefficient, low emission engine, increased reverse power and enhanced chassis and track frame durability to deliver lower operating costs per metre of material moved.

The Tier 4-compliant diesel engine reduces fuel consumption through a heavyduty exhaust gas recirculation system, a hydraulically driven radiator cooling fan and auto-idle stop.

Production efficiency is enhanced through increasing engine power by 20 per cent when in reverse, thus reducing cycle time in downhill dozing applications.

The dozer’s other features include automatic transmission with lock-up torque converter for reduced fuel consumption and greater powertrain efficiency, automatic gearshift transmission, better visibility to the blade and ripper, and maintainability enhancements.

“The D375A-8 was a significant advance in dozer technology in terms of improved performance, productivity, operator comfort and ease of maintenance,” said Hall.

“Our new D375Ai-8 intelligent dozer takes that technology to the next level through its integration of machine control and its benefits to all types of dozing operations.” • Source: Komatsu Australia

LOAD & HAUL

WHAT DOES TOMORROW’S

CONSTRUCTION FLEET LOOK LIKE?

D

riverless cars, big data, the Internet of Things (IoT) – all signs the world is changing, and specifically the way we manage construction is changing.

Today’s construction fleet may appear similar to 10, 20 or 30 years ago, and traditionally the industry has been reluctant to adopt new technologies.

However, there’s no denying that change is coming and, over the next several years, there is likely to be more of a shift in the construction fleet than we’ve seen in the past few decades.

According to the World Economic Forum, “unlike other industries, the engineering and construction sector has been slow to adopt new technologies, and has certainly never undergone a major transformation. As a result, productivity has stagnated over the last 40 years, or in some cases, even declined.”1 Take a look around any modern construction site and you’ll probably have a hard time relating the machinery you see to the high-tech world of IoT. However, subtle but significant changes are occurring within construction fleets, which are changing the way construction is managed and implemented.

These changes are helping to drive increased efficiency, enhanced safety and lower costs.

The vast majority of advancements in construction fleets over the past several decades have centred around the equipment itself: more efficient engines, more practical and cost-saving adaptations and add-ons, and increased power have improved the productivity of construction equipment over the years. However, the key to the next wave of construction fleet enhancement lies in digitisation.

The IoT is changing the way we do business in almost every conceivable way.2 The construction industry has yet to make a universal shift towards this technology, but where it has been adopted, significant results can be expected.

In their 2016 paper for the World Economic Forum, Castagnino, Rothballer and Gerbert wrote: “Wherever the new technologies have properly permeated this fragmented industry, the outlook is an almost 20 per cent reduction in total life cycle costs of a project, as well as substantial improvements in completion time, quality, and safety.”3

Digitisation of the construction fleet has the potential to affect it throughout its life cycle, from design phase to operation. Here are just a few examples of the way technology has the potential to change tomorrow’s construction fleet: • Building information modelling (BIM). As opposed to the traditional two-dimensional drawings upon which construction has traditionally been based, this 3D modelling gives real dimension to the height, width and depth of a site, as well as the elements of time and cost. While this technological revolution isn’t a change to the construction fleet itself, it will significantly impact the ways in which the fleet operates.

• Digital design. Intelligent software helps to design machinery and equipment more effectively, identifying potential issues before they arise, picking up on potential failures and saving on costly redesign.

• Tracking and sensing. Machinery, parts, materials and equipment are tracked from pick-up to delivery, and throughout their use on the construction site. This reduces errors, increases accountability and optimises flow throughout the construction process.

• Monitoring. Sensors and tracking technology allow construction managers to monitor the performance of their construction fleets, identifying potential hazards and risks to productivity, and better managing downtime with needs-based (rather than arbitrary schedule-based) servicing and repairs – effectively reducing downtime and costs on repairs and maintenance.

• Cloud, software and data. Software and cloud services that integrate with construction fleets can analyse data from sensors and trackers to make an almost limitless number of improvements to the entire construction process. From monitoring the health of workers to reducing the risk of accidents and decreasing downtime; or from effectively identifying potential risks to the schedule to co-ordinating fabrication, delivery and installation of materials on-site to avoid roadblocks, data plays a critical role in the technological advances of tomorrow’s construction fleet.

At first glance, tomorrow’s construction fleet of excavators, wheel loaders and haulers may not appear to change drastically with technological advancement – at least not from the outside. But as digitisation revolutionises the construction landscape, small and almost invisible changes will be made to these machines that dramatically improve the way the construction industry operates. • Source: CJD Equipment REFERENCES & FURTHER READING 1. Castagnino S, Rothballer C, Gerbert P. What’s the future of the construction industry? World Economic Forum, 4 April, 2016. weforum.org/agenda/2016/04/ building-in-the-fourth-industrial-revolution/ 2. Harris M. LX, IoT and the CommBank trade-chain experiment. LX Group, 2018. lx-group.com.au/lx-iotcommbank-trade-chain-experiment/ 3. Castagnino S, Rothballer C, Gerbert P. op.cit.

Quarry March 2019 23

LOAD & HAUL

BIGGER DOZER’S WORKLOAD OFFSETS OPERATIONAL COSTS

O

ne of Australia’s largest and most innovative quarry operators has substantially increased its productivity with the purchase of a larger bulldozer.

Benedict Industries replaced its Komatsu D375A-6 bulldozer at 15,000 hours with a new D475A-5EO model, expecting an increase in operational costs to match its increased workload.

However, the 40 per cent increase in productivity has more than offset the operational costs, which are less than expected.

“When we initially discussed the purchasing of the D475, we budgeted on a fuel burn of about 110 litres per hour,” Benedict’s operations manager Brett Jarvis said. “To date, the machine has been averaging 80 litres per hour.”

According to Jarvis, the new machine has achieved an unexpected additional benefit.

“The D475 weighs about 40 tonnes more than the previous Komatsu bulldozer, so the amount of sandstone oversize we are producing is a lot less,” he said.

Benedict is one of Sydney’s largest quarrying and recycling companies. It operates the new D475 at its 75-hectare Mittagong site where processed sandstone is washed into concrete sand for the fast-growing Sydney and Illawarra construction markets.

The D475 is one of 25 Komatsu heavy machines operated by Benedict in a total fleet of more than 60.

Jarvis said relationships matter in a company in which a significant number of its 200 employees have more than two decades of service. “It’s all about relationships,” he said. “We rely on the strength of our commercial partnerships to make our business more efficient.”

Jarvis says the D475 was configured and commissioned by Komatsu’s team, led by the New South Wales major account manager Paul Chenery.

“Our needs are very specific and because of his close relationship with us, Paul was able to provide exactly the combination of machine and attachments we required, especially as we are now quarrying harder sandstone,” he said.

Purpose-built solutions, combined with specific Komatsu on-site operator training, 24

Quarry March 2019

Benedict Industries’ Geoff Johnston (left) and Rob Loiterton with the new Komatsu D475A-5EO bulldozer.

have been instrumental in providing efficiency gains.

Komtrax, Komatsu’s complimentary remote monitoring service, used almost universally

by Benedict across its Komatsu fleet, has been extremely useful in gauging machine utilisation and achieving productivity gains.“I’ve been able to mentor our equipment operators on the importance of selecting the right work mode to reduce idle times and fuel burn by simply monitoring Komtrax,” Jarvis said.

“It comes as a surprise to some of our operators that I can monitor the performance of the machines without being on-site.”

In the tough business of quarrying and recycling, Benedict is gaining a strong reputation for innovation at all levels – and for its focus on community and environmental issues. It has partnered with developer Mirvac to redevelop its Moorebank sand quarry into a marina, residential and commercial centre, to the benefit of local communities.

Recognising the increasing community need for recycling, it has put on a fleet of free-to-hire covered box trailers, so people can more easily transport their waste to recycling facilities.

In conjunction with Symbio Wildlife Park in Helensburgh, NSW, Benedict has also planted

more than 1000 eucalypt trees at its Menangle and Sandy Point quarry sites, which will be used as feedstock for koalas at the wildlife park. Another 1000 trees are yet to be planted.

“Urban expansion will place increasing demand on our services and one of our major goals is to identify and secure new sites in strategic areas,” Jarvis said.

In 2019 Benedict is to open two new recycling sites, at Smeaton Grange and Girraween, each strategically placed to meet growing community requirements.

“Where required, some of our plants are now working double shifts, up to 18 hours a day,” Jarvis said.

“The demand on machine reliability has never been greater.” • Source: Komatsu Australia

LOAD & HAUL

WHEEL LOADER BOOSTS

LITHIUM PRODUCTION AT WA MINE

A

n earthmoving and haulage company is using a 35-tonne Volvo Construction Equipment (Volvo CE) wheel loader to assist with lithium production at Galaxy Resources mine in Ravensthorpe, Western Australia.

Australia is one of the biggest producers of lithium, accounting for about half the world’s supply. With the global lithium battery market predicted to grow at 12 per cent from 2017 to 2024, demand for the rare metal is booming.

Ravensthorpe Haulage, an earthmoving and haulage company based in Western Australia, is using an L260H wheel loader from Volvo CE to assist with the mining and processing of lithium at the Galaxy Resources site, one of Western Australia’s largest lithium mines. The 35-tonne wheel loader loads 5000 tonnes of lithium daily.

“Our operators like the L260H wheel loader’s performance. It’s powerful for loading and provides good visibility, which enables them to be more precise when operating,” said Wayne Daw, owner of Ravensthorpe Haulage. “Plus, operators say the ergonomic seat and control positions allow them to work in comfort.”

The L260H is fitted with a powerful 310kW Stage 3 Volvo D13 engine to deliver more power and torque – by up to five per cent on earlier H-series models. It also offers a 15 per cent increase in payload and larger bucket sizes, and is capable of a 2343Nm torque at low engine speeds to minimise emissions and fuel consumption.

The vehicle has a high breakout force of 284kN, a dump height of 3.1m and a 50mm longer wheel base, along with Z-bar linkage for strong, powerful digging in hard materials.

The L260H’s load-sensing hydraulics are designed to enhance the responsiveness of attachments and improve the lifting and lowering speed of the boom.

For faster cycle times, the new HTL310 transmission works in harmony with the powerful engine and axles, and the new converter delivers increased torque output, resulting in better performance.

The loader is equipped with two bucket options – the rock bucket and the rehandling bucket. The 6.4m³ rock bucket features a longer floor and can hold 11.5 per cent more

CJD personnel with members of family-owned Ravensthorpe Heavy Haulage during handover of the L260H.

material than before, resulting in up to 25 per cent greater productivity.

The redesigned 7.3m³ rehandling bucket is easy to fill, and the convex sides minimise spillage, for up to five per cent greater productivity.

On site since June 2018, the L260H loads lithium into a plant for processing, and helps load the final product into stockpiles.

Daw says most of the processed lithium is shipped to clients in China.

Ravensthorpe Bulk Haulage has a fleet of eight Volvo CE machines, which are all working at the Galaxy Resources lithium mine.

“We selected the L260H wheel loader for its reliable performance,” Daw said. “We also appreciate Volvo’s strong aftermarket service support.”

The L260H was launched in the Australian market in 2018. It is a two-pass loader, purpose-built for tough jobs, and has been upgraded with innovative technology and increased payload capacity for greater productivity compared to its predecessors in the H-series range.

The loader can be fitted with an optional boom suspension system (BSS) to enhance productivity by up to 20 per cent. By absorbing shock and reducing bounce and bucket spillage when operating on uneven terrain, the BSS enables faster cycle times and extends the machine’s lifetime.

The L260H can be fitted with Volvo CE’s optional Co-Pilot intelligent machine service.

Co-Pilot is an onboard 254mm (10”) touchscreen display system that powers intelligent machine services such as load assist, dig assist, compact assist and pave assist to deliver real time information.

Each Volvo Assist program helps operators monitor progress and output in real time, enhancing productivity.

CJD Equipment is one of Australia’s leading privately owned equipment suppliers and the Australian distributor for Volvo Construction Equipment. Its relationship with Volvo CE has endured for more than 25 years.

This strategic partnership provides businesses with access to Volvo’s everexpanding line of construction equipment, with machines and features designed specifically to cater to the requirements of each industry segment.

CJD Equipment’s dealer network supports Volvo CE customers, with branches throughout Australia. Together, Volvo CE and CJD Equipment offer numerous services, including telematics machine monitoring and parts availability, plus local knowledge and global experience – all of which optimises productivity while minimising operational costs. • Source: CJD Equipment

Quarry March 2019 25

LOAD & HAUL

‘NEXT GENERATION’ EXCAVATORS, WHEEL LOADER IMPRESS AT TRADE SHOW A multinational manufacturer has launched a range of ‘next generation’ excavators and wheel loaders with new technologies and functionalities into the Australian market. Tim Robertson spoke to Caterpillar personnel about the benefits of these vehicles in the quarrying application.

A

t the National Construction Equipment Convention at the Sydney Showgrounds last November, attendees from the quarrying, mining and civil construction sectors were the first in the world to observe and trial Caterpillar’s “next generation” 36-tonne class excavators and the new Cat 950 GC wheel loader. The launch provided exclusive knowledge of the latest advancements in equipment and technology in the quarrying and civil construction sectors.

NEXT GENERATION 336 EXCAVATOR The next-generation 336 and 336 GC excavators promise increased operating efficiency, lower fuel and maintenance costs, and improved operator comfort compared with previous models.

The new excavators offer unique combinations of features designed to match operators’ productivity and cost targets.

“The 336 now comes with a new cab, seat and touchscreen display, longer maintenance intervals and ground level servicing that lower your maintenance costs by up to 15 per cent,” said Robert Leo, Caterpillar’s product application specialist for hydraulic excavators.

“An improved power system with the inclusion of the electro-hydraulic main control valve, electronic in-line pump and cooling system can also improve fuel efficiency by up to 15 per cent more per unit of work.”

Leo said the 336 was “well suited to the quarry application with its heavier 7.5-tonne counterweight for increased lift and stability” and “an optimised boom and stick for durability”.

26

Quarry March 2019

He added that other features – such as FOGS guarding, side bumpers, LED lighting, a 360-degree Birdseye camera system, Caterpillar’s Payload technology “as standard”, reverse fan, full-length track guards, heavy-duty final drive and bottom guards and a swivel guard – make the 336 “ready to tackle the most severe quarry applications”.

He said the Cat 336 featured standard integrated Cat Connect Technology – an intelligent suite of hardware, software and dealer services designed to help producers run more profitable operations. This technology falls into six categories: • Cat Link, which gathers data generated by the assets and job sites.

SPECS – CATERPILLAR ‘NEXT GEN’ 336

336 GC

336

Engine

Cat C7.1 ACERT™

Cat C9.3B

Gross power (ISO 14396/SAE J1995)

Tier 4 Final: 205kW* 234kW

Operating weight

36.5 tonnes

37 tonnes

Max digging depth (6.5m boom, 3.2m stick)

7530mm

7530mm

Max reach at ground level (6.5m boom, 3.2m stick)

11,060mm

11,060mm

Max reach at ground level (6.5m boom, 3.2m stick)

7070mm

7070mm

*195kW Tier 3 engine for Australia and New Zealand.

Caterpillar showcased its range of products and services at the National Construction Equipment Convention in Sydney last November.

• Cat Grade, which automates machine functions and guides operators to achieve targets in rough, fine and finish grading. It helps operators to grade faster in fewer passes.

• Cat Payload, which brings load weighing and real-time feedback to the cab, eliminating trips to the scale and improving operator accuracy and speed.

• Cat Compact, which delivers advanced measurements and real-time guidance inside the cab to help operators meet compaction targets faster, more uniformly and in fewer passes.

• Cat Detect, which improves operator awareness of the work environment, reducing the chance of accidents. It also helps prevent unauthorised use of equipment.

• Cat Command, which enables operators to run equipment from a remote location on- or off-site, making work safer and more comfortable.

Since it was launched, Caterpillar has been receiving positive feedback from its customers.

“They’re saying great things about the new 336 next gen machines,” Leo said. “They’re commenting that the 336 Cat next gen digger is more fuel-efficient and more productive, which is delivering an improved bottom line to their business.

“Customers cannot believe that Cat is offering a machine that is full of standard technology and improved service and maintenance features as standard.”

THE 950GC WHEEL LOADER The new Cat 950 GC wheel loader combines low operating costs with the durability, reliability and economy of proven Caterpillar components to deliver productive performance in a wide range of five-tonne wheel loader applications.

“The GC is an affordable loader that has very few limitations. It’s a low-entry-price-point loader with the usual Caterpillar DNA,” said Dick Mars, Caterpillar’s product application specialist for the Asia Pacific region and India.

“It has the market’s highest loader arm clearance (a nonhigh lift comparison and higher than the M-series) and a fuelefficient Caterpillar C7 engine, matched with the Caterpillar 4F3R countershaft transmission.”

The 950 GC’s features include: • Heavy-duty frames.

• Cat Z-bar linkage.

• Performance series buckets.

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LOAD & HAUL

• Fuel-efficient Cat C7.1 engine.

• Powerful load-sensing hydraulics.

• Spacious, air-conditioned cab with intuitive controls.

• Support from Caterpillar’s worldwide dealers.

The 950 GC loader is well suited for stockpiling, load and haul work, hopper charging and truck loading.

Mars said Caterpillar had been showcasing the loader at demos along Australia’s east and west coasts and received positive feedback and orders from its customers.

“We have received orders from Victoria, New South Wales, Queensland and Western Australia,” he said.

“The feedback to date from key customer demonstrations has been that the power and productivity and fuel efficiency were similar to other Cat five-tonne wheel loaders.

“The price point is very acceptable for this type of loader and, above all, operators like the simplicity of use.” •

SPECS – CATERPILLAR 950GC WHEEL LOADER ENGINE

CAT C7.1

Power rating (max gross power per ISO 14396)

170kW@2000 rpm

Operating weight

18.7 tonnes

Wheelbase

3300mm

Dig depth

86mm

Standard bucket

3.3m3 GP with BOCE

Dump clearance

3012mm

Bucket B pin height

4188mm

Standard machine specs, including 3.3m³ GP with BOCE and 26.5R25 TR516 tyres.

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LOAD & HAUL

TRIAL AT ‘EMISSION-FREE QUARRY’

DECLARED AN OUTSTANDING SUCCESS Having recorded encouraging results from a joint research project at Vikan Kross Quarry, near Gothenburg in Sweden, Volvo Construction Equipment has subsequently announced that all of its compact earthmoving machines produced from 2020 will feature electric engines.

T

he Electric Site system was part of a study in the last quarter of 2018 between Volvo CE, construction materials giant Skanska, the Swedish Energy Agency and Sweden’s Linköping and Mälardalen universities to create the world’s first “emission-free” quarry.

Drawing on the Volvo Group’s electromobility and automation expertise, the research project sought to electrify each transport stage in a quarry – from excavation to primary crushing and transport to secondary crushing – although a negligible amount of diesel power would still be used.

The system, which incorporated electric and autonomous Volvo machines in a real production environment for 10 weeks, was expected to deliver a 95 per cent reduction in carbon emissions and 25 per cent reduction in total cost of operations.

New work methods and site management systems would also form a complete site solution. New technology encompasses machine and fleet control systems and logistic solutions for electric machines in quarries.

In late 2018 Volvo CE and Skanska revealed the results from Electric Site at Skanska’s Vikan Kross Quarry were even better than anticipated.

The tests showed a 98 per cent reduction

30

Quarry March 2019

Volvo CE’s fleet of autonomous HX2 battery-electric load carriers.

in carbon emissions, a 70 per cent reduction in energy costs and a 40 per cent reduction in operator costs.

The results also indicated that the Electric Site project could help Volvo CE achieve its vision of work sites that are 10 times more efficient, with zero accidents, zero unplanned stops and zero emissions.

Together, these results support the potential for a 25 per cent reduction in the total cost of operations. However, as the prototype machines were part of a research project, the parties were cautious about

making guaranteed predictions.

“We’ve made incredible progress, learnt a lot and seen huge potential in the Electric Site solution’s environmental, efficiency, safety and cost benefits,” said Uwe Muller, chief project manager for the Electric Site at Volvo CE. “In fact, we have decided that we want to learn more, so we will extend our test period with Skanska until the end of the year [2018].

The results we have seen so far confirm that this research project is a step towards transforming the quarry and aggregates industry and creating emission-free quarries.”

Skanska president and CEO Anders Danielsson said: “With climate change reshaping our industry, we need to find new, sustainable solutions and build partnerships with organisations that have different competencies.

“Our ambition is that this collaboration with Volvo CE will help us and our customers to reduce our carbon footprint. The power of partnership will make it happen.”

PROTOTYPES IN FOCUS The Electric Site project involved eight HX2 autonomous, battery-electric load carriers, which transport the material from the primary mobile crusher to the secondary static crusher.

When it came to energy use per tonne, the HX2s demonstrated they could help Volvo CE make major strides towards achieving its vision for work sites 10 times more efficient.

The second generation prototypes incorporate shared technologies and components from across the Volvo Group.

They use a lithium ion battery to power two

The base machine for the EX1 is a Volvo EC750 crawler excavator that has been upgraded to incorporate an electric motor in addition to the diesel engine.

electric motors that drive the machine; an additional electric motor drives the hydraulics.

The HX2 is fitted with a vision system that allows it to detect humans and obstacles in its vicinity. It can follow an adjustable, preprogrammed GPS path.

The LX1 prototype electric hybrid wheel loader delivered more than a 50 per cent improvement in fuel efficiency at the quarry, plus significant reductions in emissions and noise pollution compared to its conventional counterparts.

Its job was to organise the piles of material at the site. The LX1 incorporates a driveline

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that consists of electric drive motors mounted at the wheels, electric-driven hydraulics, an energy storage system, a significantly smaller diesel engine and new machine architecture, including a new design of the lifting unit. This combination enables the substantial gain in fuel efficiency.

The 70-tonne, dual-powered, cableconnected EX1 excavator prototype loaded the primary crusher. The base machine for the EX1 is a Volvo EC750 crawler excavator that has been upgraded to incorporate an electric motor, in addition to the diesel engine.

At the quarry, the machine was plugged

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into the grid, so zero emissions were emitted.

If the cable is connected, the EX1 will automatically start in electric mode. If the cable is not attached, it will start in diesel mode. The EX1 is operated in exactly the same way as a conventional Volvo excavator.

“At Volvo CE, we believe in a sustainable future and we are doing our best to build the world we want to live in,” Volvo CE president Melker Jernberg said. “The Electric Site is one example of how we are trying to achieve this.

“With this research project we are combining intelligent machines, automation and electromobility to challenge traditional ways of working in the quarrying industry and explore new alternatives.

“We will now further mature the technologies involved and the reliability of the concept. Developing, testing and validating prototype machines with a customer at an early stage in the process speeds up development and ultimately brings more value to us and our customers.”

ELECTRIC LAUNCH In an industry-first move, Volvo CE has subsequently announced that in 2020 it will start launching an electric range of Volvobranded compact wheel loaders (L20 to L28) and compact excavators (EC15 to EC27).

In turn, it will cease the diesel engine-based development of these models.

With this move, Volvo CE is the first construction equipment manufacturer to commit to an electric future for its compact machine range.

This follows an overwhelmingly favourable reaction from the market after the successful unveiling of numerous concept machines in recent years, and through close work with its customers. The move is also aligned with the Volvo Group’s strategic focus on electromobility in all business areas.

The first two compact electric machines will be unveiled at bauma in April (see boxout), followed by a staged market by market introduction and ramp-up in 2020.

While company personnel have stressed that

diesel remains the most appropriate power source for its larger machines, it has also been conceded that electric propulsion and battery technology is proving particularly suitable for Volvo’s smaller equipment.

With research and development investment now focused on the rapid development of its electric compact wheel loaders and excavators, Volvo CE is taking a step towards diesel-free compact equipment in the future.

“Volvo CE is delivering on its commitment of ‘Building Tomorrow’ by driving leadership in electromobility and delivering sustainable solutions that support customer success,” Jernberg said.

“The technology we have been developing is now sufficiently robust and this, together with changes in customer behaviour and a heightened regulatory environment, means that now is the right time to commit to electromobility in our compact equipment ranges in the future.” • Source: Volvo CE

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‘BUILDING TOMORROW’ – VOLVO CE AT BAUMA 2019 Visitors to next month’s bauma 2019 exhibition in Munich, Germany, will be given a glimpse into Volvo CE’s technological vision, with a showcase of its latest machines and integrated services.

Demonstrating the breadth of the Volvo Group, Volvo CE will be joined at bauma 2019 by sister companies Volvo Penta, Volvo Trucks and Volvo Financial Services.

The companies’ participation will be more than a static display – it will be a live event.

Under the theme of “Building Tomorrow”, Volvo’s 2293m2 indoor stand and 5870m2 outdoor stand will be, according to company press materials, a “non-stop interactive performance” featuring its complete product and service portfolio.

Volvo CE will use bauma as the stage to launch the first two models in its compact hydraulic-electric machines, following its announcement earlier this year that from 2020 it will cease the diesel engine-based development of its compact loaders and excavators, and launch a new range of electric machines in the L20 to L28 and EC15 to EC27 series.

In line with the company’s current global campaign, new excavators will be launched at the show, from its compact EC-series

Volvo CE’s electric compact wheel loader will be one of the new all-electric machines to be launched at bauma.

excavators to the new EC750E high reach demolition excavator. The EC300E hydraulichybrid excavator and an EC220E unit that features Volvo’s Active Control automated boom and bucket movements (for a more efficient digging process) will also be launched at the show.

In all, there will be 50 machines on Volvo’s two stands, grouped into the sub-themes of “load”, “dig”, “haul”, “pave”, “innovation” and “service”. Of these, Volvo Services has a much greater emphasis than ever at this

year’s bauma, with every machine supported by a dedicated service offering via touch screens and other displays.

Melker Jernberg, Volvo CE’s president, will jointly host – along with the presidents of Volvo Penta and Volvo Trucks – an international press conference during the show, in which they will introduce new products and outline the company’s plans for innovation.

In the company’s outdoor area, there will be a machine show set to the soundtrack from Volvo CE’s mini-film Pump It Up, featuring Hollywood star Dolph Lundgren, plus operators’ club competitions and live action displays on the further developed “Dig Assist” solution and attachments.

Throughout the event, in the inside display area, a professional master of ceremonies will conduct entertaining presentations (in German and English) focusing on the company’s product and service solutions, and there will be video cubes displaying a range of customer interviews, facts and figures. An innovation area will highlight Volvo CE’s developments in automation, connectivity and electromobility. • Source: Volvo CE

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LOAD & HAUL

With an operating weight of 90 tonnes, the R 976s are developed and produced at Liebherr-France SAS in Colmar, France.

EXCAVATORS PROVE THEIR METTLE IN HARSH AFRICAN CONDITIONS A pair of crawler excavators have demonstrated their reliability and economy in a South African coal mine.

34

Quarry March 2019

W

ith a fleet of more than 130 machines, the Liviero Group is South Africa’s largest privately black-owned multi-disciplinary construction group and a provider for mines that supply power plants across the nation.

The group has 17 Liebherr-branded machines in its fleet: one L 580 wheel loader, three PR 764 crawler dozers and 13 crawler excavators, including an R 970 SME, eight R 976s, two R 980 SMEs, an R 9100 and an R 9150.

It has recently purchased two new R 976 crawler excavators for overburden, coal mining and loading dump trucks in the Keaton Energy coal mine in Middleburg, in the north-east of South Africa.

After more than 2000 operating hours, the two crawler excavators have demonstrated their cost-effectiveness and reliability in operation. Each excavator is equipped with a 7.2-metre boom, a 2.9m stick and a 5.2m3 heavy-duty bucket.

With an operating weight of 90 tonnes, the R 976s are developed and produced at Liebherr-France SAS in Colmar, France. They have Liebherr-designed diesel engines with an output of 400kW, which complies with Stage IIIA/Tier 3 emission standards.

The R 976s are being used specifically for overburden, as well as for loading dump

trucks in the mine. The 40-tonne dump trucks are loaded in four passes. With an average fuel consumption of 48 litres per hour, the excavators achieve an output of 280m3 per hour for 20 working hours per day. In a very hostile working environment, these machines have, to the satisfaction of Liviero Group personnel, proved their efficiency, cost-effectiveness and reliability in operation.

With an optimised hydraulic system and intelligent operation, the R 976 crawler excavator promises more productivity in earthmoving and quarrying work. Thanks to its kinematics and hydraulic power, the R 976 is capable of higher breakout and digging forces, even in extreme applications.

The operator cab provides a comfortable, spacious and ergonomic workspace to allow for more productivity. Mounted on viscoelastic elements, the cab is not subject to vibrations. Fully automatic air-conditioning and a high resolution touchscreen also enhance the operator’s comfort.

The operator has optimum visibility of the surrounding area thanks to a standard rear-view camera and a lateral camera, as well as an optimised upper carriage design. For enhanced safety, the R 976 also has a fully removable laminated windshield under the roof and a secure

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LIEBHERR R 976 CRAWLER EXCAVATOR

RTO 40727

ENGINE

Liebherr D9508 A7 SCR 8-cylinder V-engine (4-stroke diesel)

ENGINE OUTPUT (PER ISO 9249 OR SAE J1349)

Tier 4 Final: 400kW@1800 rpm

EXHAUST GAS RECIRCULATION (EGR)

SCR system (Selective Catalytic Reduction) emission standard Stage IV

BACKHOE BUCKET CAPACITY

2-6.6m3

WIDTH

2150mm

DIG DEPTH

7450mm

REACH AT GROUND LEVEL

12,300mm

DUMP HEIGHT

8250mm

BREAKOUT

49,456 kgf

SHOVEL CAPACITY

4.4-6.5m3

OPERATING WEIGHT

85-93 tonnes

TRANSPORT LENGTH

13,800mm

TRANSPORT HEIGHT

5100mm

WIDTH

4730mm

GROUND CLEARANCE

682mm

TRACK LENGTH

5960mm

TRACK PAD WIDTH

600mm

SPEED

2.7-4.3 km/h

emergency exit at the rear of the cab.

Liebherr has decades of experience in the development and production of earthmoving machines for the quarrying industry, including crawler excavators, wheel loaders and crawler dozers.

With innovative designs and major components produced by Liebherr, the machines can be deployed with great efficiency and performance in the most challenging and difficult environments.

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LOAD & HAUL

AUTO-BRAKING SYSTEM MAKES WORK EASIER, SAFER DOWNHILL RUN

T

he automatic engine braking system on Komatsu HD325-7 dump trucks is helping a New Zealand quarry safely and efficiently handle some of the steepest downhill haul roads in the business – even when fully loaded.

GBC Winstone’s Belmont Quarry, near Lower Hutt, supplies high grade aggregates for roadworks and construction throughout the wider Wellington region.

Unlike most quarries, which draw material from a pit, Belmont is extracting its material from the top of a hill, then carting it downhill to the crushing and processing plant.

According to Belmont Quarry manager Shane Hagai, this downhill haul road is one of the steepest in the business.

“We have two inclines, one of about eight per cent and the other about 10 to 12 per cent, so good braking on the trucks is key to our process,” he said.

The haul distance is 1.4km, with about a 15-minute turnaround time.

About three years ago, Belmont Quarry opted to replace its previous haul trucks with two Komatsu HD325-7 trucks – based primarily on their unique braking capabilities.

The HD325-7s – along with others in Komatsu’s mechanical dump truck range – feature an Auto Retard Speed Control (ARSC) system, which provides sturdy braking power when travelling downhill, even when fully loaded.

The ARSC allows the operator to simply set the downhill travel speed and go down slopes at a constant speed, allowing the operator to concentrate on steering.

Speeds can be set at increments of 1km/h to match the optimum speed for the slope.

In addition, since the retarder cooling oil temperature is always monitored, speed is automatically lowered if the oil gets too hot.

“With that built-in engine braking, the trucks handle our inclines really well, absolutely without a doubt,” Hagai said.

“The operators just select the maximum travel speed to come down the hill safely, and they’ll come down at that precise speed.

When I’m following them down the hill, the brake lights never even come on; the guys and girls only need to touch the brakes when approaching the bins to tip off.”

36

Quarry March 2019

The HD325-7 is equipped with an auto-braking system that allows the operator to set the downhill speed and travel at a constant pace.

In addition to the two HD325-7s, Belmont also runs a Komatsu HM400-3 articulated dump truck, which Hagai brought in from GBC Winstones’ Otaki Quarry – where he’d previously been manager – in late 2016. “The HM400 has an auto-retarder system, and that works fine here,” he said.

Komatsu’s HM400 auto-retarder system works off the accelerator pedal: when the operator takes pressure off the pedal, the auto-retarder works immediately to slow the truck, no matter what speed it’s doing.

Retardation is cancelled simply by applying pressure back on the accelerator, so operators often need to use the pedal for retarding only.

“We’d had that truck at Otaki when I was managing it, but I could see the need for it here at Belmont, based on its braking power,” Hagai said. “We’ve had many articulated trucks here at Belmont over the years, but we found they just weren’t safe for our conditions, even with exhaust brakes. There are no concerns with the HM400.

“While the articulated truck is mainly helping with carting from the main pit, it also gives us good opportunities for stockpile

work, with its manoeuvrability and ability to climb stockpiles.”

For the past few years, Hagai has worked closely with Komatsu and its Wellington region service agent Machinery Specialists.

“We’re still getting very good reliability with the trucks here; if anything comes up, it’s just little things, nothing major,” Hagai said.

“And if we need something, Machinery Specialists and Komatsu’s Porirua branch is only about 40 minutes away with a phone call, so that works out really well.”

Hagai and his operational team at Belmont also find the KOMTRAX remote monitoring system useful, not only for preventative maintenance but also to assist with operating efficiency.

“Certainly, we use KOMTRAX for monitoring the trucks’ operating data and component health, but we also get the emails showing us how we are going from an efficiency point of view. We use these in our toolbox talks, and have a bit of banter about who’s got the greatest idle times, and that sort of thing,” he said. • Source: Komatsu Australia

LOAD & HAUL

The TA400 is the largest articulated hauler that Terex Trucks manufactures. It weighs 10 tonnes more than the TA300.

UPGRADED ARTICULATED HAULER TO ROLL INTO BAUMA 2019

T

erex Trucks’ recently updated TA300 articulated hauler will soon be making its first international tradeshow appearance at bauma in Munich, Germany, next month.

Visitors to the bauma 2019 exhibition, which runs from 8 to 14 April, will have the chance to get up close to the newly upgraded articulated hauler. This will be the first time the machine has been displayed at an international trade show and it will take pride of place on the company’s outdoor stand. The Terex Trucks team will show visitors how the company’s two articulated haulers – the TA300 and the TA400 – can lower the total cost of ownership and deliver high productivity at jobs, including largescale construction projects, infrastructure developments and quarries.

“Bauma is the world’s leading construction machinery trade fair, and as such, it’s a showcase of virtually every machine in the industry – but for Terex Trucks, it’s all about the articulated hauler,” said Paul Douglas, the managing director of Terex Trucks.

“The articulated hauler is the only product Terex Trucks manufactures – so therefore we’re able to focus all our attention on this machine. We are the experts in all things articulated hauler.

“That’s one of the key messages we want to get across at bauma 2019 – we specialise in robust, reliable articulated haulers. We will also be discussing the investments and improvements we’ve made in our product line and our growing dealer network. All of this, which is underpinned by our long-standing expertise in the field, has helped us to make sure our articulated haulers are even more

Terex Trucks’ updated model of the TA300 articulated hauler will make its debut at bauma in Germany next month.

productive and reliable. Terex Trucks is the strongest it’s ever been.”

Douglas described bauma as “the perfect opportunity” to display the upgraded hauler in front of a global audience. He said the updated TA300 “boasts improvements in fuel efficiency, performance, productivity and operator comfort”.

Since August, the TA300 has incorporated the new EP320 transmission, which comes with two additional forward gears – eight in total – as well as four reverse gears. This helps to ensure smoother gear shifting and thereby greater operator comfort.

Until now, the TA300 has been been incorporated with six gears, including three reverse gears, with a maximum of 50 kilometres per hour (km/h).

In addition to the two forward gears, the TA300 promises a five per cent improvement in fuel efficiency, as well as enhanced performance, productivity and operator comfort. It is also now equipped with long life transmission fluid, which has helped to increase the length of time between oil

maintenance intervals from 1000 to 4000 hours. The hauler’s maximum speed has also increased from 50km/h to 55km/h, enabling producers to achieve faster cycle times, reduce the cost of operation per tonne and minimise fuel consumption.

“The TA300 is one of our staple products, hence why we worked long and hard to make it even better for our customers,” Douglas said. “The upgraded TA300 was rigorously tested for nearly two years internally and by operators on real job sites, working in a variety of conditions.”

Douglas added his team would also use the show to inform visitors about the TA400, “the biggest articulated hauler we make. In terms of maximum payload, it’s 10 tonnes bigger than the TA300”.

The TA400 features a fully automatic Allison HD4560 transmission assembly with integral retarder mounted directly to the engine, planetary gearing and electronic control with six forward and one reverse gears.

A glimpse into its latest products won’t be the only thing that Terex Trucks will be offering at bauma 2019. The Scottish manufacturing company will also be hosting a press event and Douglas and his team will be on site to discuss product news, market conditions and future plans.

“Terex Trucks is currently expanding its presence in key markets, and Bauma will be a good opportunity for us to meet and attract new customers and dealers,” Douglas said.

The Terex Trucks Generation 10 TA300 and TA400 articulated haulers are available in Australia through the Porter Group. • Source: Terex Trucks

Quarry March 2019 37

SMART BUSINESS

AN ODE TO THE ORDINARY To achieve something today, it’s believed you have to think big and out of the ordinary. However, as Cecilia van der Merwe argues, innovations and solutions can be found in the tiniest and most mundane objects – and no thing can ever be considered “small” if it contributes to a greater whole.

W

ith the average person spending about 2208 hours on the toilet in their lifetime, the “water closet”, while ordinary, is inarguably one of the most vital inventions in human history. Its flush valve does very little to inspire poetry but urban dwellers the world over sure do need that flush valve to work.

The toilet is an example of the mundane in motion. Whether it be a power line or the inner workings of your smartphone, an abundance of little unexceptional parts are operating interdependently to forge something rather exceptional. The pieces in themselves may not be all that pretty, but the product of their synchronicity can be something magical.

Sometimes our jobs are not all that sexy.

We work in the dark, behind the spotlights, ensuring the mechanics run smoothly. But, is that the sole and main purpose of our jobs, to only make sure that everything works?

Should we simply seek to design things and spaces that are functional, efficient, safe, and utilitarian, and risk having a world of the ordinary? Or should we go beyond the maths and sciences of our solutions and create memorability and experience?

In today’s fast-paced world, full of creative, shiny new technology there seems to be little or no room for the mundane. Nobody wants a world of the “ordinary” but, as these unremarkable and seemingly unnoticeable things help run our world 24/7, the fact remains that we need them.

So, the question begs: How do we make the ordinary extraordinary?

JUDGING A BOOK BY ITS COVER First impressions matter. Ask artists who design book covers, manufacturers specialising in product packaging, or architects and engineers who design building facades for a living. These are professions and businesses hinged on the idea that first impressions are important - and it’s true.

The way we package our products and services is one of the biggest factors that drive businesses and connect us with our customers. They all matter. But it’s how the 38

Quarry March 2019

China’s Great Wall still stands intact today, thanks to a mortar mixture of sticky rice flour and slaked lime.

product or the inside of a building lives up to expectations that ultimately determines its legacy. Design and performance should go hand in hand, not one without the other.

That’s essentially what Frank Lloyd Wright was saying in his iconic axiom “form and function are one”. His mentor Louis Sullivan believed form should follow function – that a building should take on the shape of the purpose it plans to serve. But Wright voted for a more organic relationship between the two, where physical space is the genesis of inner purpose. Experience blends seamlessly with design; the highest achievement is integration and continuity, where all the bits grow as one interconnected, living design.

EVERY BIT COUNTS The way a building functions should give justice to how it is designed, and vice versa.

The job of an engineer, designer or architect is to strike that perfect balance between performance and presentation, allowing infrastructure to be more than just bricks, but a place that tells and preserves memories and stories. If a product looks good, but it doesn’t do good, chances are consumers will turn a blind eye.

There’s no such thing as a “little thing”

if it’s optimally serving a greater purpose.

Particularly in today’s design world where there is a “slick and streamlined” rule, every bit counts. From the tiniest tweak in your software programming to the choice of PVC piping, every small design decision is crucial to the overall design and has the capacity to make a difference, good or bad.

Because it’s just a little thing, we often shrug it off, thinking that it’s not going to have an effect. Or so we thought. What we fail to realise is that the greatest superpower of these little ordinary things is the opportunity for the unexpected. When the majority fail to pay attention and identify the possibilities, others will seize the chance to innovate and surprise. And no one sees it coming – take it from Google, Facebook, Airbnb, Uber, and Snapchat.

“Most of the world thinks that the fantastic innovations coming out of Silicon Valley are just short of magic,” says Disrupt or Die author Jedidiah Yueh.

“But if you look at them from the right point of view, they start out looking ordinary. I’m not saying anyone can do it. It takes brains, guts and determination to succeed. But it is far more accessible than people think. It just depends on your point of view.”

WRITING ORGANISATIONAL RHYTHMS The boring can be brilliant if the big picture is celebrated. “I’m helping put a man on the moon” was how a NASA janitor framed his job during the great space race of 1962. Because his work was clearly contextualised within a greater mission, he knew he was helping to write history in some way, big or small.

It’s crucial that our messages are meaningful and well articulated so our people see their contributions’ worth. What we believe and say about the work we do inevitably becomes the soundtracks that write the rhythms of our organisations.

Design and engineering is a constant case of trailblazing that requires not only our former stories be told, but that our pens be poised to write some new ones. “People appreciate that they live in a warm building or have bridges to cross,” says author and structural engineer Roma Agrawal, “but they don’t appreciate how they came to be there. You can live in a city that works really well, and a country that works really well, but you only hear about engineering when it goes wrong.

‘Engineering works’ are the reason trains are delayed.” This is why she thinks our stories need to be told and celebrated.

The toilet’s mundane appearance belies its extraordinary impact on humanity. Though early toilet systems were used by several ancient civilisations, including the Romans, the flush toilet did not become mainstream until the 19th century through Alexander Cummings’ S-shaped pipe design that ensured water could be permanently retained and prevented sewer gas (and consequently foul odours) from entering buildings.

The toilet, along with proper sewerage systems, is credited with saving hundreds of thousands of lives from disease outbreak, including cholera.

If Dr Percy Spencer had not stopped to question the melted candy bar in his pocket when exposed to his tested magnetron device, the microwave would not have been invented.

Had builders of the Ming Dynasty not infused their mortar with sticky rice, the Great Wall of China may not have been still standing, intact and weed-free, today. 1, 2

So, let’s not despise the small things. They are in fact the bedrock of our built worlds.

Let’s not only take time to salute these little engineered unsung heroes (and the engineers who tend to them). Let’s see the immeasurable value in seeking out the ugly and unsexy. Innovation doesn’t have to be an overhaul but an incremental change one day, one flush valve, at a time. • Cecilia van der Merwe is a mechanical engineer at Aurecon in South Africa.

REFERENCE & FURTHER READING: 1. Moore M. Great Wall of China’s strength comes from sticky rice. In: The Telegraph (UK), 30 May 2010. telegraph.co.uk/news/worldnews/asia/china/7785842/ Great-Wall-of-Chinas-strength-comes-from-stickyrice.html 2. Yang F, Zhang B, Ma Q. Study of sticky rice−lime mortar technology for the restoration of historical masonry construction. In: Acc Chem Res 2010; 43(6): 936–944. https://pubs.acs.org/stoken/presspac/ presspac/full/10.1021/ar9001944

THEN & NOW

PETER BARRO:

AN ENDURING LEGACY In late 2018 the extractive industry lost one of its stalwarts and advocates at a relatively young age. John Mitas reflects on the life, work and passion of Peter Barro.

P

eter Barro was born on 29 June, 1957, and passed away on 25 October, 2018.

His passing is an enormous loss for his wife Christine, his sisters Rhonda and Elena and brother Raymond, the Barro Group employees and the quarrying industry as a whole.

Peter was an executive director with the Barro Group and was instrumental in securing strategic stone and sand resources, putting the company in a strong position for decades to come. His legacy to the Barro Group, his family and the extractive industries will endure.

Peter was always destined to follow in his father’s footsteps, and started work in the laboratory at the company’s Bacchus Marsh Quarry and in different roles at Point Wilson and Sunshine quarries. His formal training in the extractive industry was complete when the Victorian Quarry Manager’s Board issued him with the Quarry Manager’s Superintendent Certificate. This enabled Peter to manage any quarry in Victoria.

Peter found his niche within the family business and the skills he brought forward will benefit the company for many years to come.

The identification, retention and development of the Barro Group raw material assets and his passion and personal involvement in crushing plant selection, design and output were outstanding contributions. One could see in the most recent plants an artistic flair, with respect to both shape and blending of colour, in the processing plants’ layout.

You were well aware of the pride and respect Peter held for his late father David and his Uncle Mark, as well as his wife, siblings and Ian Alexander when it came to the outcomes achieved by the family business.

In conversations with Peter, he would always associate the Barro Group as a private business in competition with the public companies. He identified with and was extremely proud of the humble beginnings of the family’s business, the significance of its 40

Quarry March 2019

While he spent a lot of time wearing black, Peter’s fashion sense could also be quite colourful!

loyal workforce and its managers.

Peter understood the important role that small businesses play in the economy and he was always willing to help those business partners survive. Over the years, Peter forged long partnerships that were based on respect, loyalty and trust. Peter’s “yes we can” attitude delivered fair outcomes for the Barro Group and its partners.

‘MINISTER FOR DETAIL’ Peter was a driving force behind the innovation of sand extraction below the water table without having to dewater sand pits.

With a shortage of sand resources for booming infrastructure projects in Victoria, the approach would provide much-needed sand resources, which can be extracted with a much smaller footprint and less impact on the environment and ground water resources.

Peter was acutely aware of the economics for the extractive industry and was always prepared to take on governments of the day in relation to unnecessary red tape, access to resources and the approval process. He articulated the benefits of a strong quarrying

industry to infrastructure projects and the Victorian economy and community.

When you met Peter, he would smile, lean forward and physically draw you into the conversation. It was always evident that he had a deep knowledge of the industry and its participants. He was inquisitive by nature and always searching for information.

Peter was charismatic, charming, funny and innovative. He was the negotiator, the dealmaker, and loved nothing more than spending time in the field with his people, his plant and his sand pits and quarries.

Peter loved people; he was gregarious, and the guy everyone wanted to be with.

He was happy in any company – whether at catwalks and fashion shows supporting Christine, quarrying and industry events, wining and dining with Melbourne “royalty”, or generously supporting charities at the Spring Racing Carnival.

Peter was an amazing father to his son David and a loving husband to Christine. He was very proud of Christine’s achievements, her recognition within the fashion industry, her business acumen and her personal inner

strength. His generosity and fun-loving spirit knew no bounds.

Christine’s heartfelt words in the “celebration of life” distributed at Peter’s funeral gave us an insight into the loving marriage and his ability to bring light and laughter to the darkest points of the room.

He brought people together, marrying one talent to another’s resources. He was “the connector” – the man who took no credit for the clever couplings that often bore transformative results.

Peter’s obsession with the smallest technicalities of stuff earned him the tongue-incheek title “The Minister for Detail”. Be it in the making of wine, the signing of a commercial contract or the creative design of a new quarry, he always believed a rigorous attention to the “micro” detail made for the “macro” success.

His need to find a better way was allconsuming, but when he did conceive of smarter “doing” and determined that he would bring it to immediate fruition, he proved all the naysayers wrong.

Nevertheless, he never sought to lord it

over anyone. He just loved the game of it all, shaping and shifting the landscape of accepted norm, whether in business, design or a distant town.

‘MAYOR OF MERRIJIG’ Peter would see the food industry in action and want to replicate it with his own genius inventions, for example, the wood-fired oven he designed in dry stone in Merrijig, at the base of Mount Bulla.

From the inner glow of its beehive dome, Peter would feed his tribe with a spread of Saltimbocca that slid into an evening smorgasbord of pizza. The locals would drift in and out, indulging in Peter’s hilarity, gourmet hospitality and good advice on how to run a business and a local bureaucracy.

For serially agitating them into civic activity, they declared Peter the default “Mayor of Merrijig”, a title he indulged with full authority every Easter, when his four-day festival of eating and drinking drove into town and turned it upside down, with more constructed follies and counselling on business.

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Peter loved colour – he spent a lot of time in black, but he was spectacular in colour, and wore it well. He literally lit up a room. His presence always ensured the event went up several notches, and conversely was not quite the same without him.

Peter Barro was an industry icon. We will reflect upon the loss of his presence, wisdom, social and culinary skills, distinctive welcoming voice and sense of humour, and his interest in his family’s wellbeing and finally the industry’s general wellbeing. For all of us who knew Peter, his passions and characteristics will endure for the rest of our lives. • This feature was prepared from extracts prepared by Christine Barro, Ron Kerr and Bruce Edwards, and from interviews with Basil Natoli, Mike McCann, Rob Snowden and Craig Cahill.

John Mitas is the managing director of John Mitas Consulting and the immediate Past President of the Institute of Quarrying Australia. Email: johnmitas40@gmail.com Article courtesy of Sand & Stone, the periodical of CMPA Victoria. Visit cmpavic.asn.au

2019 IQA EVENTS ACT BRANCH 15 Mar 12 July 15 Nov

Dinner meeting (Venue TBA) Dinner meeting (Venue TBA) Dinner meeting (Venue TBA)

QUEENSLAND BRANCH 21 Mar WIQ Queensland Conference, Brisbane 2 April Site visit to Brisbane Airport’s second parallel runway 17 May Annual Golf Day, Oxley Golf Club 14 June Quarrying Safety & Health Conference, Brisbane 7 Aug Dinner meeting & AGM, Brisbane Sept CMEMC 2019

CENTRAL QUEENSLAND SUB-BRANCH 13 Mar

19 July

Technical and dinner meeting, Rockhampton Annual Golf Day, Rockhampton

NORTH QUEENSLAND BRANCH 12 Mar Dinner meeting, Cairns 14 May Dinner meeting, Cairns

21 May Dinner meeting, Mackay 19 June Safety & Health Seminar, Townsville 26 July Annual Golf Day, Cairns 13 Aug Branch AGM, Townsville 13 Sept Annual Golf Day, Townsville 8 Oct Dinner meeting, Townsville 30 Oct Dinner meeting, Cairns 15 Nov Christmas Party, Townsville

SOUTH AUSTRALIAN BRANCH 24 May Technical and dinner meeting (venue TBA) 12 July WIQ SA Conference, Adelaide Pavilion 30 Aug AGM/dinner, National Wine Centre 8 Nov Pullman Adelaide Hotel

VICTORIAN BRANCH 16 May

Student presentation night

VICTORIAN SUB-BRANCH 7 Mar 30 May 25 July

Dinner meeting, Bendigo Dinner meeting, Wang Miliwa Dinner meeting, Bendigo

12 Sept 21 Nov

Dinner meeting, Ballarat Dinner meeting, Bendigo

WESTERN AUSTRALIAN BRANCH 22 Mar ‘Bowling Stone’ Challenge, South Perth Bowling Club 8 May Breakfast meeting, Beaumonde on the Point, East Perth 28 June Brikmakers clay brickworks site visit and sundowner 7 Aug Breakfast meeting, Beaumonde on the Point, East Perth 3 Sept AGM and dinner meeting, Imperial Court Restaurant 22 Nov Annual golf day, Joondalup Resort

All dates and venues for the above branches are correct at time of press. Not all branches had confirmed their activities/ dates. For further information about IQA branch activities, contact your local branch representative (see IQA branch contacts on page 44) or visit quarry.com.au

PDP WORKSHOPS & EVENTS To register for the courses below and for further information, visit: quarry.com.au/Education/ProfessionalDevelopmentProgramsCalendar.aspx

WORKER HEALTH IQA 62ND ANNUAL CONFERENCE Geelong Football Club, Kardinia Park Geelong, Victoria 1-3 October (Tuesday to Thursday), 2019 “The Future of Quarrying” will be the theme of the IQA’s annual conference which this year will be hosted at the home of the Geelong Cats AFL Football Club. The conference program will focus on numerous topics, including: the maximisation of limited natural resources through technology; the benefits of effective management of workplace diversity; new developments in emerging fixed and mobile plant technology; environmental and economic trends impacting on the industry; and much more. In a first, the conference program will be hosted on a Tuesday, Wednesday and Thursday.

For more information, visit quarry.com.au

42

Quarry March 2019

15 March 2019 Managing hazards associated with worker health is critical in establishing and implementing an effective safety management system. This area of health and safety is getting added attention within all regulatory jurisdictions due to the increasing incidence of death and serious illness from work-related exposures. This webinar provides information on site worker health hazards including dust, noise, hazardous substances and psychosocial hazards, exposure monitoring and health surveillance, effective management of worker health hazards, and what should be in a worker health plan (in line with a relevant jurisdiction’s mining legislation, WHS legislation and duty of care requirements).

It is suitable for managers, supervisors and key support personnel.

Visit quarry.page.link/WH

MANAGING PSYCHOSOCIAL HAZARDS IN THE WORKPLACE 22 March 2019 Bullying, harassment, stress and physical violence are far too common in modern workplaces. Creating and maintaining a supportive workplace culture is critical to identifying and managing these hazards in the workplace.

This webinar will give you some tips on how to identify these problems in the workplace, what you need to do to address the problems, and how to create and maintain a supportive environment that does not tolerate unacceptable anti-social behaviour. It is suitable for quarry managers, supervisors, human resource officers, and health and safety officers. The facilitator is Wayne Scott.

For more information, visit quarry.page.link/MPH

The Institute of Quarrying Australia

HAZARD AND RISK IDENTIFICATION PRINCIPLES 29 March 2019 Hazard and risk source identification are key steps in risk management. Hazards and risk sources that are not identified can lead to the risks those hazards present not being well controlled – or not being controlled at all – if they eventuate. Robust identification and initial appreciation of hazards and risks are therefore critical steps in comprehensive and effective risk management processes.

This webinar will outline definitions and interpretations, benefits of comprehensive hazard and risk source identification, potential consequences of inadequate hazard and risk source identification, common hazard and risk source identification methodologies, and an introduction to alternate hazard and risk source identification methodologies.

The facilitator is Hamish Beattie. For more information, visit quarry.com.au/Public/ Education/InfoSheets/wPDP/Hazard_and_ Risk_Identification_Principles.aspx

BAUMA 2019 8-14 April 2019 Munich, Germany As a driving force behind innovation and success in the global construction machinery industry, bauma attracts visitors from more than 200 countries to Munich every three years. The world’s leading trade fair is the perfect platform for generating business between producers and suppliers and tapping international markets, and to see the most important new developments from around the world. Bauma 2016 covered 605,000m² of exhibition space, comprising 3425 exhibitors from 58 countries. The event welcomed 583,736 visitors from 219 countries, 138,929 of whom were from the mining sector. A number of familiar brand names will be amongst the exhibitors who supply to the extractive industry, eg allmineral, Astec Industries, Bonfiglioli, Caterpillar, CDE Global, Doosan, Dressta, Haver & Boecker, Hitachi Construction Machinery, Hyundai Construction Equipment, Isringhausen, Kleemann, Komatsu, Liebherr International, Montabert, McCloskey International, McLanahan Corporation, Metso, SANY Group, the Terex group of companies, Topcon Positioning Group, Trimble, Volvo Construction Equipment, Wirtgen, and many more. For more information and to register, contact the bauma visitor hotline, tel +49 899 491 1348, email info@bauma.de or visit bauma.de

PRINCIPLES OF EMERGENCY MANAGEMENT PLANNING AND RESPONSE 12 April 2019 All Australian and New Zealand quarrying legislation either implies or specifies that quarrying operations must have a plan to respond to emergency situations. Those plans must be appropriately comprehensive, resourced, tested and updated. This webinar is designed to introduce principles and methodologies of quarry emergency planning and response, including definitions, interpretations and legislative requirements and all aspects of emergency management and response, including planning, resourcing, testing, reviewing and updating. It is suitable for quarry managers, supervisors, leading hands and other employees with responsibilities for the planning for and management of emergencies. The facilitator is Hamish Beattie. For more information, visit quarry. com.au/Public/Education/InfoSheets/wPDP/ Principles_Emergency_Management_ Planning_Response.aspx

CCAA INDUSTRY INSIGHTS BREAKFAST MEETING 12 April 2019 Brisbane, Queensland Join the CCAA for the next instalment of its Queensland Industry Insights breakfast series. This not to be missed event will explore key political and economic insights for Queensland that will impact on the construction materials industry’s outlook for the year ahead. For more information and to register, contact Vanessa Finnerty, CCAA, tel 07 3227 5200 or email vanessa.finnerty@ccaa.com.au

QUARRYING SAFETY & HEALTH CONFERENCE 14 June 2019 Brisbane Convention & Exhibition Centre The Quarrying Safety & Health Conference, which is co-hosted by the CCAA, the IQA and the Queensland Department of Natural Resources, Mines and Energy (DNRME), is now into its 17th year. This year’s day-long event will include thought provoking keynote speakers, a DNRME update and other presentations on practical issues impacting the quarrying industry. The conference will be held in the Boulevard Room at the Brisbane Convention & Exhibition Centre.

For more information and to register,

contact Cassandra Koutouridis, CCAA, email cassandra.koutouridis@ccaa.com.au or Jennifer Milward, IQA, tel 0419 782 688 or email qld.admin@quarry.com.au

CCAA CONCRETE PRACTICE COURSES & WORKSHOPS 21-22 May, Sydney 5-6 June, Melbourne 19-20 June, Brisbane 2-3 July, Adelaide 24-25 September, Perth This course - developed in consultation with the industry for the industry - has been designed to provide participants with a detailed understanding of concrete material and behaviour in relation to physical properties, production, placing and associated on-site operations such as reinforcement and potential causes of failure. It comprises of two parts: (i) 14 eLearning modules that have been developed to enhance the industry’s knowledge of concrete and featuring embedded activities and assessments in a sequential, easy to follow, and easy to navigate format; and (ii) workshops held around the country that will feature presentations from industry experts, Q&A panel sessions with industry experts, group work and case studies, and a final assessment. Participants will be required to complete all modules prior to attending the workshop (as learnings will be referred to and enhanced during the two-day workshop) and should allow five to six weeks to complete all of the modules. Registrations will close five weeks prior to each workshop and attendance at the two-day workshop is a requirement to complete the course. A personalised certificate will be issued upon successful completion of parts 1 and 2 of the course. The cost of admission is $1800 (inc GST) for CCAA members and $2200 (inc GST) for non-CCAA members. For further information, contact the CCAA’s learning and development manager Ceridwen Jones, tel 02 9667 8319, email ccaaeducation@ccaa.com.au

IQA NEW MEMBERS GRADE

NAME

Associate Member Member Associate Member Member Associate

Jack Farry Luk Roelandts Kylie Ann Long Leigh Vaughan Michael Ensor Rochelle Flack Justin Andrew Kennedy

BRANCH QLD QLD QLD VIC NSW NSW VIC

Quarry March 2019 43

IQA NEWS become one of the most sought after titles in our industry!

This will be a fun-filled evening of spirited competition amongst colleagues and peers as well as a great opportunity to socialise and network. It also presents a chance to knock Hanson off its sporting prowess pedestal – as it is currently in possession of both the 2018 Bowling Stone Trophy and the 2018 Golf Trophy!

About 100 delegates attended the second Queensland WIQ conference in 2018.

QUEENSLAND BRANCH NEWS Women in Quarrying conference: #quarriesrocktomorrow The line-up of speakers for the third annual Queensland Women in Quarrying conference, to be held at the Glen Hotel, Eight Mile Plains, Brisbane, on Thursday, 21 March is sure to attract a full house of delegates.

IQA CEO Kylie Fahey and James Cuthbert, the general manager of Boral subsidiary companies Allens Asphalt and RSG, will open the conference. Cuthbert will report on Boral’s diversity activities.

The keynote speaker is Mary Thompson, who will discuss her inspiring story of making the transition from quarry owner to managing director of McLeod Rail – by her own account, an unconventional journey by road and rail.

Michelle Connelly speaks on behalf of the CPR Group at the 2018 WIQ conference.

Association of Women in Construction.

The conference is being kindly sponsored by the CPR Group, the major supporters of the WIQ Queensland branch, as well as Boral (platinum sponsor), Groundwork Plus, 888 Crushing & Screening Equipment, Holcim Australia and Cement Concrete and Aggregates Australia (gold sponsors) and Minprovise and Hy-Tec (silver sponsors).

For those that find the rigours of competition too onerous, come along to cheer on mates and partners and enjoy an evening of socialising, refreshments and a special barbeque cooked by the branch committee members.

Tinus Nagel and his team at Italia Stone Group are the proud sponsors of this event.

To register, contact the WA branch secretariat, tel 0417 027 928, email: wa-admin@quarry.com.au or jump onto quarry.com.au

By Celia Pavri

The conference is open to all IQA members and other interested parties in the industry.

To register, visit the IQA website – quarry. com.au - or contact the Queensland branch secretariat, tel 0419 782 688 or email qldadmin@quarry.com.au

Date claimers for 2019 • 13 March: Technical and dinner meeting, Rockhampton.

The Bowling Stone trophy has become one of the most ‘sought after’ titles in the extractive industry!

• 21 March: WIQ Queensland Conference, Brisbane.

IQA BRANCH CONTACTS

Other speakers and topics on the day include:

• 2 April: Site visit to Brisbane Airport’s second parallel runway.

ACT

Peter Hewson: 0429 001 476

• Rebecca McGlashen, director of the Semper Group, on career planning.

• 17 May: Annual Golf Day, Oxley Golf Club.

NSW

Gemma Thursfield: 0402 431 090

• Adrian Caneris, the managing director of Biodiversity Assessment and Management on fauna, water and engineered environments.

• 14 June: Quarrying Safety & Health Conference, Brisbane.

Hunter Gemma Thursfield: 0402 431 090

By Jennifer Milward

Central West Mitchell Bland: 0428 462 987

• Madonna Thomson, director of Jagera Daran on community and heritage solutions.

WESTERN AUSTRALIAN BRANCH NEWS

• Suzannah D’Juliet, the executive manager for safety operations at Hastings Deering, on a workable flexibility and inclusion program.

Bowling Stone challenge The WA branch’s first social event for 2019 is the fifth annual lawn bowls challenge – aka the Bowling Stone! – which will be held on Friday, 22 March, 2019, from 5.00pm to 9.00pm.

Townsville Jennifer Milward: 0419 782 688

The branch committee encourages you to put together a team of four or nominate individually to compete for what has

Vic Sub-branch Craig Staggard: 0407 509 424

• Kartini Oei, the Queensland committee chair of the National Association of Women in Operations.

• Alison Price, the president of the National

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Northern Gemma Thursfield: 0402 431 090 Illawarra

Dylan Treadwell: 0418 632 057

NT

Darren McKenna: 08 8988 4520

QLD

Jennifer Milward: 0419 782 688

Gladstone Jennifer Milward: 0419 782 688 Cairns SA

Chris Wilson: 0438 134 752 Marie Cunningham: 08 8243 2505

Tasmania Nicholas Palmer: 0418 126 253 Victoria WA

Eli Carbone: 03 8637 4723 Celia Pavri: 0417 027 928

The Institute of Quarrying Australia

SITES ENCOURAGED TO NOMINATE FOR REWARD SCHEME QUARRIES WITH A RECOGNITION LEVEL (AS OF FEBRUARY 2019):

Two of Boral’s quarries – including its Dundowran site – last month received EPIQ status for their compliance and environmental programs in the past 12 months. Image courtesy of Google Maps.

Queensland’s Department of Environment and Science, in partnership with the IQA and Cement Concrete and Aggregates Australia, has launched a reward scheme to recognise quarries that demonstrate good environmental performance.

The voluntary site-specific scheme, known as EPIQ (Environmental Performance Indicator Queensland), rewards and provides opportunities for recognition to quarries that meet and exceed EPIQ’s environmental performance criteria.

Research conducted by the Department of Environment and Science (DES) and the CCAA found that 85 per cent of quarry operators wanted to be rewarded and recognised for good environmental management.

“The Queensland quarrying industry has been highly motivated to work with the department over the past two years to participate in the research project and attend workshops to co-design a scheme that is tailored to their industry,” Dr Charis Anton, the DES’s senior project officer for behavioural insights, told Quarry. “This shows a commitment within the industry to work with the department to improve environmental performance across the industry.”

In 2018, a series of workshops attended by quarry operators, industry bodies and government and community representatives co-designed the EPIQ scheme. It was officially launched on 30 October, 2018 and will run for 12 months as a trial.

EPIQ is open to all privately-owned quarry sites in Queensland that have not had any compliance issues in the past 12 months, exceed the requirements of one or more of their environmental authority conditions

SILVER RECOGNITION LEVEL Boral Resources (Queensland) Dundowran Quarry

and can demonstrate a commitment to best practice.

Date issued: 4 February, 2019

Successful participants receive a gold, silver or bronze medallion, which can be used to promote their quarry. Sites in the EPIQ scheme are published on the DES’s website.

Environmental authority condition beyond requirements:

FIRST AWARDS GRANTED Twenty-four quarry sites have currently registered their interest and four full applications have been received, of which three were eligible for reward and recognition.

In January, Hanson’s Nerang site became the first site to receive public recognition.

• Blast monitoring.

• Complaints management.

Criteria met: • Clear process for handling community complaints.

• Community liaison/engagement.

• Embedding environmental management practices across the workforce.

“Hanson’s Nerang site was awarded a Bronze medallion for their blast monitoring program, community complaints handling process, environmental management system, efforts towards continually improving their environmental management on-site and waste recycling,” Anton said.

• Environmental management system implemented on-site.

“In February [this year], Boral Resources’ Dundowran site was awarded a silver medallion for their blast monitoring program, complaints management, community liaison group, embedding environmental management practices across the workforce and environmental management system.

Hanson Construction Materials Nerang Quarry

BRONZE RECOGNITION LEVEL Date issued: 15 January, 2019

Environmental authority condition beyond requirements:

“Boral Resources’ Wellcamp site also achieved a grey recognition level for having had no compliance issues in the previous 12 months,” she said.

• Blast monitoring.

Detailed information about the EPIQ scheme’s guidelines and criteria, including listings of sites in the EPIQ scheme, can be found at the department’s website: https:// environment.des.qld.gov.au/management/ env-policy-legislation/quarry-industry-rewardrecognition/

• Environmental management system on-site.

Criteria met: • Clear process for handling community complaints.

• Evidence of continuous improvement/ innovation.

• Waste recycling.

Quarry March 2019 45

GEOLOGY TALK

BERINGIA: THE SIBERIA TO ALASKA ‘BRIDGE’

A map of Siberia and Alaska showing Beringia as the tan areas. Image courtesy of the US National Park Service.

It is believed North Americans’ forebears migrated from Asia via the land bridge.

An inquiry from a secondary school student about the impact of geology on humans has prompted Bill Langer to revisit the theory behind ‘Beringia’, the supposed ‘land bridge’ between Siberia and Alaska …

Bering proved otherwise. Peter the Great, the Russian tsar from 1682 to 1725, recruited Bering to lead an exploration of the eastern borders of the Russian Empire.

Before the expedition, maps of Siberia sometimes contained a large landmass across the water from Siberia to Alaska, in line with what de Acosta wrote. However, Bering’s expeditions in 1724 and 1741 established that there was no land bridge connecting Siberia and Alaska.

On his 1778 expedition, Englishman Captain James Cook confirmed the presence of Alaska and produced detailed maps of the Alaskan coast. The results of his exploration helped enlighten the outside world about the Bering Strait region and lent credence to theories of human migration between Asia and North America.

But it was not until the mid-1920s that scientists would begin to understand how people came to populate North America and ultimately move south out of the Arctic region, all the way to Central and South America.

So, Caty, all of this took place thanks to geology. •

A

little while ago I received an email from Caty, a Year 7 student at a STEM (science, technology, engineering and mathematics) academy in Wisconsin.

Caty was studying geology and how it had changed over the course of time. She asked a number of questions, one of which was: “How does geology influence humans?”

Now, I don’t provide answers to questions from students; I provide ideas for them to consider. I told Caty that during the ice age massive ice sheets locked up water from the oceans, thus making sea level about 120 metres (nearly 400 feet) lower than it is today.

I suggested that Caty look at the Bering Strait between Siberia and Alaska. The average water depth of the Bering Strait is 40m to 50m (130’ to 160’). Therefore, when sea level dropped during the ice age, a land bridge, referred to as “Beringia”, formed as the receding water exposed the sea floor. I suggested Caty look at how Beringia influenced humankind.

Hopefully Caty discovered that the land bridge allowed the forebears of Native Americans to migrate from Asia to North America.1 When the ice age ended, the vast ice sheets melted and liberated billions of litres of water. Global sea levels rose and Beringia slowly grew smaller and smaller. At the same time, the entire Beringian region grew warmer

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and moister. When this happened, the shrub tundra vegetation replaced the steppetundra plants that had dominated the interior lowlands of Beringia.

As the glaciers receded, new routes opened into North America. Woolly mammoths and other large grazing animals followed the steppe-tundra as it moved off Beringia, and the humans in the region (who were hunter-gatherers) followed the migrating herds into the Alaskan interior and the Yukon. Keep in mind that this took place over centuries, and both the game and the humans slowly spread into new territories.

But time marched on, the glaciers continued to melt, and eventually Beringia disappeared under the sea.

As early as the 1500s, European intellectuals were interested in discovering how humans had populated North and South America. One theory suggested that Norsemen migrated across Greenland into North America. Another theory proposed that human life in the New World generated out of mud.

A more realistic answer came in 1590, when the Spanish missionary Fray Jose de Acosta proposed a land bridge between Asia and North America. De Acosta believed the land bridge was still in existence during his lifetime.

In the 18th century, Danish explorer Vitus

AUTHOR’S NOTE 1. Actually, the story of how the Americas were populated is still open to debate but this article pretty much summarises one prevailing theory.

Bill Langer is a consultant geologist.

Email bill_langer@hotmail.com or visit researchgeologist.com

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