Quarry May 2019

Why simple measuring devices are proving invaluable in crusher liner replacement.

MULTI-ACTION CONE CRUSHER RANGE EXPANDS Innovative crushing technology extends to more applications with new 220kW model.

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MEASURING THE VALUE OF LINER PROFILE GAUGES

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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

MAY 2019

KAMMP: A SIMPLE, EFFECTIVE BELT SOLUTION A quarrying operation devises a novel solution for detecting and removing tramp metal.

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IN THIS ISSUE MAY 2019

VOLUME 27, ISSUE 05

FEATURES 18 ROCK SOLID PROGRAM Why maintenance programs should have long-term solutions in mind, not just immediate problems.

20 CONDITION MONITORING CM systems are proving their worth in industry - but companies are still uncertain how to utilise them.

23 SUPPLIER REVAMPS HEAVY MACHINERY WEBSITE

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LINER PROFILE GAUGES Why simple measuring devices are proving invaluable in crusher liner replacement.

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MULTI-ACTION TECH Innovative crushing technology expands to more applications with new 220kW model.

Komatsu Australia is redeveloping its website to provide producers with enhanced information and services.

26 GOOD SUPPORT SPRINGS Darren Toth explains why good support springs are vital to the performance of vibratory equipment.

34 RUBBER TORSION SPRING MOTOR BASES The rubber torsion spring motorbase has a long history. Richard Sharp explains why it is a critical part of the extractive process.

45 BUMPER PROGRAM FOR 2019 CONFERENCE

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AS SIMPLE AS KAMMP Malcolm Sawers discusses a novel solution for detecting and removing tramp metal.

Why simple measuring devices are proving invaluable in crusher liner replacement.

MULTI-ACTION CONE CRUSHER RANGE EXPANDS

30

MEASURING THE VALUE OF LINER PROFILE GAUGES

28

24

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

Innovative crushing technology extends to more applications with new 220kW model.

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‘WALKABLE’ SUBURB How a century-old quarry is being transformed for the benefit of future generations.

A combination of instructive and motivating presentations, and site visits, are in the planning stages for the IQA’s national conference.

MAY 2019

KAMMP: A SIMPLE, EFFECTIVE BELT SOLUTION A quarrying operation devises a novel solution for detecting and removing tramp metal.

COVER ADVERTISER: The new 220kW Metso MX3 cone crusher was launched at bauma 2019.

It is the latest addition to Metso’s MX multi-action cone crusher range.

Turn to page 28 or visit metso.com

EVERY MONTH 04 FROM THE EDITOR

41 FROM THE IQA CEO

06 FROM THE PRESIDENT

42 IQA NEWS

08 NEWS THIS MONTH 16 PRODUCT FOCUS

News from Queensland, South Australia and Western Australia

40 IQA CALENDAR

46 GEOLOGY TALK Aggregates and seismic awareness

Quarry May 2019 3

EDITORIAL

THE ‘QUIET’ DRIVE TOWARDS A SMARTER, ELECTRIC FUTURE

O

n the eve of the federal election campaign there was debate between members of the Australian Government and the Federal Opposition about the latter’s electric vehicle (EV) policy – in particular, an aspirational target that EVs should constitute 50 per cent of all new car sales by 2030. Prime Minister Scott Morrison accused his opponents of waging “a war on weekends” by denying Australians the right to buy diesel SUVs and stripping tradies of diesel utes.

This faux indignation faded before the official sound of the campaign starter gun because it became clear (particularly if it’s to meet its emissions targets under the Paris Agreement) that the Federal Government’s own modelling on EVs assumed a similar goal. Toyota and Hyundai debunked the scaremongering, saying ecomodels of utes and SUVs would be plausible by 2025. The key will be in the take-up by consumers.

If our pollies had done their homework, they’d know that eco-models of vehicles aren’t new. Electric/diesel hybrids have worked in quarries and mines the world over for the past decade. Diesel machines still outnumber electric/ hybrid versions and the “jury” (ie the extractive sector) is still out on whether a hybrid machine provides a significant return on investment. However, that hasn’t stopped original equipment manufacturers (OEMs) – Caterpillar, Komatsu, Volvo CE, Kleemann, Keestrack, Terex, John Deere, LiuGong – from pursuing cleaner, non-diesel technologies. Sandvik recently bought US battery-mounted underground vehicle manufacturer Artisan (see page 9) and Epiroc has flagged fitting its underground and tunnelling fleet with electric drives and battery cells.

Volvo CE has long had aspirations for the world’s first “emissions-free quarry”.

It realised this concept in late 2018 when it trialled electric loaders and haul carriers and a hybrid excavator with

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quarrymagazine.com

construction materials giant Skanska at a site in Sweden. The encouraging results prompted the company to launch the first of its new all-electric compact earthmoving vehicle range at bauma last month in Munich, Germany.

Indeed, bauma featured record numbers of electric and battery cell plant prototypes and concepts, which would have been unthinkable at the same show a decade earlier. Many of the suppliers stated the drive towards an electric future is being propelled not just by regulation but practicality – there has been a 97 per cent reduction in pollutants in the exhaust stream in diesel engines since 2000 but there really isn’t any more wriggle room in that space.

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

THE QUEST FOR AN ELECTRIC FUTURE IS BEING PROPELLED BY PRACTICALITY, NOT REGULATION.

Editor Damian Christie damian.christie@quarrymagazine.com Journalist Tim Robertson tim.robertson@gunnamattamedia.com Advertising Sales Toli Podolak sales@quarrymagazine.com

Eco-models are the “tip of the iceberg”. The gradual phasing out of diesel for electric drives, batteries and other alternatives in earthmoving and other mobile plant will eventually transfer to fixed plant. Some Australian mines are already experimenting with the integration of renewable energy and battery generation in their operations, in part because of high electricity and diesel fuel charges, but largely because it’s just smart business practice – in spite of erratic government climate and energy policies.

Quarry is published by: Gunnamatta Media Pty Ltd Locked Bag 26, South Melbourne, VIC 3205 AUSTRALIA

It may not seem like it but there is an “industrial revolution” quietly going on behind the scenes – thanks to the endeavours of OEMs. Politicians can argue about the impracticalities of EVs and the need for a reliable energy mix but most have jumped the gun without doing the research. The quarrying sector, in spite of politics, will embrace and adapt to progress more readily as these technologies become more practical, widespread and affordable.

Press releases damian.christie@quarrymagazine.com

DAMIAN CHRISTIE Editor

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

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.

Disclaimer: The views and opinions expressed by authors are not necessarily those of the publisher. All statements made, although based on information believed to be reliable and accurate at the time, cannot be guaranteed and no fault or liability can be accepted for error or omission.

Gunnamatta Media Pty Ltd strives to report accurately and fairly and it is our policy to correct significant errors of fact and misleading statements in the next available issue. Any comment relating to subjective opinions should be addressed to the editor where the opposing position may be published to encourage open debate.

The publisher reserves the right to omit or alter any advertisement and the advertiser agrees to indemnify the publisher for all damages or liabilities arising from the published material.

A brief introduction to Komatsu conveyor systems Komatsu conveyor systems offer an economical and productive solution, particularly for deep pit, confined space or environmentally sensitive quarrying and processing applications. Following Komatsu’s acquisition of Joy Mining in 2017 to form Komatsu Mining Corporation, the company significantly expanded its product line to include a range of conveying, crushing and processing products.

Drawing on a heritage of more than 100 years of conveyor systems development, Komatsu now has the expertise to provide materials handling solutions suitable for a wide range of quarrying, mining and civil construction applications.

Komatsu Conveyors are derived from a product line that Joy Global acquired from the Continental Conveyor Corporation in 2007.

Komatsu’s Joy HAC installation has ensured the trucks could remain in-pit and has extended the quarry life by more than 30 years.

In Australia, a HAC has recently been successfully installed at a sand and gypsum processing plant in Australia, as a solution to issues with sticky materials that could not be resolved using other vertical lift systems.

More than 1000 conveyor systems have been supplied worldwide to multiple industry sectors. Two solutions ideal for quarrying applications are High Angle Conveyors (HACs) and Curved Overland Conveyors. n

HIGH ANGLE CONVEYORS (HACS)

Since the early 1980s, HAC systems have proven to be a versatile and economical option for elevating or lowering materials from one level to another at extremely steep angles.

HAC systems use standard conveyor belting, idlers, drums, so replacement of components is quick and easy. HAC systems in place around the world have demonstrated high availability and low maintenance costs.

Each HAC system is purpose-designed to suit each application. Belt widths typically range from 600 mm to 3000mm, and conveying angles can be anything from -35° (downhill) to 90° (vertical).

A prime example of a successful HAC installation is a limestone quarry in the USA, that was facing closure due to increasingly steep truck haulage out of the pit, making operations uneconomical.

n

CURVED OVERLAND CONVEYORS

Curved overland conveyors are an ideal solution to quarrying and processing applications where materials have to be transported through environmentally sensitive or built-up urban areas, including around natural landscape features or existing infrastructure.

Recently, Komatsu has designed and is now commissioning long and complex turnkey curved overland conveyor systems for major quarries in Thailand and the UK. These projects required in-depth consultation with quarry operators, local authorities and other stakeholders, resulting in successful solutions to difficult challenges.

For a major installation in the UK, Komatsu provided a feasibility evaluation study into a curved overland conveyor system, and continued providing technical support throughout the entire project.

This has successfully overcome a number of challenges, including environmentally sensitive flora and fauna, as well as aesthetic considerations such as height restrictions to make the new operation almost invisible from surrounding urban areas.

1300 566 287 | komatsu.com.au

PRESIDENT’S REPORT

COUNTERING INCORRECT PERCEPTIONS ABOUT THE INDUSTRY The Institute of Quarrying

H

aving worked in the quarrying industry for nearly 20 years now, there have been occasions when I have reflected on the uniqueness of the industry and what really should be referred to as the “quarrying community”.

I have been in situations where people outside the industry have questioned its uniqueness and made statements suggesting that we are the same as the mining industry – or no different to other manufacturing or heavy industries in Australia or worldwide. This really couldn’t be further from the truth.

While I recognise I’m writing to the converted, it is concerning that much of the general population’s perception is of little difference between our industry and others. It’s regularly said that people’s perception is their reality; for the quarry industry, this is our challenge, to change this perception to match reality.

As the same issues continually surface year on year – eg significant opposition to development applications (even in government-designated or appropriately zoned areas), attraction and retention of skilled workers, additional requirements for environmental management to other industries or developments (often in situations where the quarry may provide the only conservation of habitat within an area) and a complex, varied legislative environment – these all add up to delays, additional costs to business and the consumer, and declining access to good quality quarry resources.

Our quarrying community has a diversity of professions and an ever evolving culture, with the growth of the Women in Quarrying network and new generations entering the industry.

Fundamentally, the industry is a close group of people, across many disciplines, that are passionate about the extraction of quarry resources for the benefit of the broader community.

Making big rocks into little rocks requires knowledge and skill and

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Australia

at times strength, persistence and endurance.

Like many industries, we have an ageing workforce, many of whom have worked in quarrying for a significant portion of their careers. Once you’re exposed to the industry and develop a passion for its process, people and other unique characteristics, you never want to leave!

So given there are many positives to our industry, why are we still being challenged by the same issues? Have we not learnt from the past? Has society’s expectations and the army of keyboard warriors stopped us from telling our success stories?

In past months, the IQA has had numerous speakers on social media at branch events and conferences; they have discussed the impact of social media on industry in general.

A common thread from these presentations is the need to get correct information out to key stakeholders, including government, to counter “fake news” and ensure those attempting to turn perception into reality via these social media channels don’t get the air time they’re seeking, with no-one to correct them, and also take these negative discussions offline to a more personal viewpoint.

You may have noticed a shift in the IQA’s social media presence in recent months. This is no coincidence. We have identified the need to use these highly effective channels to get our message out to members and the community at large about the benefits of both the quarrying industry and IQA events and membership. So if you see a post from us on your favourite platform, please like, share and/or comment, to help us influence and communicate the true reality of an engaging, rewarding and important industry and community.

CLAYTON HILL President Institute of Quarrying Australia

Educating and connecting our extractive industry

quarry.com.au GIVEN OUR INDUSTRY HAS MANY POSITIVES, WHY ARE WE STILL CHALLENGED

BY THE SAME ISSUES?

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

FAMILY COMPANY ANNOUNCES PARTNERSHIP WITH OEM “WE ARE CONFIDENT WE WILL SEE MORE MCLANAHAN PRODUCTS IN THIS MARKET AS A RESULT OF THIS NEW PARTNERSHIP.” STEPHEN WATTERSON

Lincom Group’s Peter Godwin (left) shakes hands with McLanahan’s aggregate systems APAC regional sales manager Neil Treseder at the bauma launch of the UltraWASH modular plant.

Australian plant supplier Lincom Group and multinational sand washing solutions manufacturer McLanahan Corporation have formally announced a new joint venture.

Lincom is now the Australian distributor for McLanahan’s sand and aggregates processing range.

This includes equipment tailored to washing and classifying, tailings and water management and dewatering.

“As a leading provider of material processing equipment, we are always looking into the best quality equipment for our customers and to machine plant that complements the range we already successfully provide,” Lincom Group CEO Stephen Watterson said.

“McLanahan Corporation is a global provider with a reputation of top quality, with the highest standards for engineering and manufacturing.”

Lincom Group will provide modular solutions, including the UltraWASH, UltraSAND and UltraFines product range to the Australian and Papua New Guinea markets. It will also distribue McLanahan’s screw washers, other wet processing equipment and stationary aggregate crushing and screening equipment.

“At Lincom, product quality and reliability are key to our success; people know they can depend on Lincom,” Watterson said. “McLanahan equipment is also known for its reliability and long service life, along with their extensive experience and

knowledge in the processing industry.

We are confident we will now see more McLanahan products and installations in this market as a result of this new partnership.”

Both Lincom and McLanahan are family-owned companies and, according to Watterson, share many of the same core values, such as integrity and an emphasis on safety.

He said Lincom’s partnership with McLanahan would increase the Australian firm’s range of product offerings and add to its reputation for expertise and helping customers achieve plant productivity and efficiency.

Lincom Group has purchased McLanahan’s UltraWASH, which was recently launched at bauma 2019 in Munich, Germany.

The McLanahan modular wash plants are assembled from washing modules and produce up to five products, including three clean aggregate and two washed sand fractions. •

McLanahan Corporation’s Michael W McLanahan (foreground, left) signs paperwork with Lincom’s Roy Watterson.

TECH PARTNERSHIP PROMISES WORKFLOW EFFICIENCY Komatsu Australia has announced a partnership with international industrial data collection and analytics company Skycatch Inc, aimed at automating construction processes, enhancing visual intelligence capabilities and providing robotics solutions.

The Everyday Drone Solution is now a key component of Komatsu’s SmartConstruction program, which aims to improve workflow efficiency and provide users with leading time to data without needing ground control points. This allows operators to integrate precision aerial data into their workflow.

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Quarry May 2019

“We are now using the Everyday Drone at the start of projects to collect whole site information for pre-tender and bidding capability, comparing against 3D design surface to provide fleet and project managers with real, accurate information viewed in the SmartConstruction application,” Komatsu Australia’s SmartConstruction national technology solution expert manager Aaron Marsh said.

Skycatch founder and CEO Christian Sanz said his company was “proud to offer a better way of accessing precision data on-site”. He said traditional methods were cumbersome and time-consuming.

The Skycatch Every Day Drone.

Komatsu recently tested its drone solutions by surveying six quarries in five days for different customers. The data was post-processed in the cloud and sent to customers the next day. •

COUNCIL FINED FOR BREACHING LICENCE THRESHOLD Tamworth Regional Council has been fined $15,000 by the NSW Environment Protection Authority for allegedly operating without a licence at its Spains Lane Quarry.

Sandvik has acquired the Californian-based Artisan Vehicle Systems, an OEM manufacturer of battery-powered underground mining equipment.

In August 2018, EPA officers visited the quarry after reports of excessive dust emissions and discovered a large quantity of material being excavated and stored at the quarry.

It is alleged the quarry operated in excess of its annual licensing threshold of 30,000 tonnes from 2016 to 2018, without holding the required Environment Protection Licence.

“The quarry extracted more than 30,000 tonnes of material over two consecutive financial years, including 34,000 tonnes in one year and 60,000 tonnes in another,” the EPA’s regional operations manager Lindsay Fulloon said. “For this level of activity, council should have applied for an Environment Protection Licence, which it hadn’t done.”

Tamworth Regional Council has now taken steps to cease its operations at the site to ensure it does not exceed the licensing threshold. It has applied for a licence. It also now has a reporting system in place to ensure similar breaches aren’t repeated.

“Since the breach was identified, we are now producing monthly tonnage reports from our quarries,” Murray Russell, Tamworth Regional Council’s manager of infrastructure and projects, told Quarry. “These reports can be reviewed against our road works program, in order to anticipate the total tonnage that is likely to be required from each site each year.

“If the projected tonnage from any one site is approaching the 30,000-tonne threshold, we are able to alter our work program in order to avoid another breach.

“This may include sourcing gravel from alternative pits, or altering our roadworks program in order to decrease the demand from that pit (ie stagger planned re-sheeting work in that area over more than one year).”

According to the EPA, the council has co-operated with the investigation from the outset and has no prior history of offences. The EPA has also

SANDVIK ACQUIRES ELECTRIC VEHICLE OEM

Tamworth Regional Council was unaware of the annual licence threshold of 30,000 tonnes at its Spains Lane Quarry.

accepted the council’s defence that the breach was not a deliberate act.

Russell explained that the Tamworth City Council was initially unaware of the EPA’s licensing requirements.

“Council have traditionally operated many small-scale gravel extractions, typically between 2000 and 10,000 tonnes per annum, so our staff have not ever had an awareness of the 30,000-tonne threshold for requiring a Pollution Control Licence,” Russell told Quarry.

“Over the years, a number of our smaller roadside quarries have been abandoned, and our larger sites have been used more extensively. A recent works program focusing more heavily on one part of our road network has seen gravel demand increase at the Spains Lane Quarry, and resulted in Council inadvertently exceeding the 30,000-tonne threshold,” he said.

Russell said that one of the key lessons learnt from this experience (which other privately owned quarries can stock of) is that incremental changes over time can ultimately result in operations inadvertently exceeding a compliance threshold.

“You may not have an awareness of that [ie the compliance threshold], because each incremental change does not appear to be significantly different from the year before,” he said.

“You need to be aware of those compliance thresholds, and how they relate to your quarry operation at any point in time. By gathering appropriate information about your operation, timely decisions can be made to ensure compliance at all times.” •

Artisan’s core technology is battery packs, electric motors, power electronics and software and control systems.

It is a leader in battery electric vehicles currently operating in underground mining.

The company, founded in 2010, was initially focused on commercial trucks, but soon turned its attention to underground mining. Its zero emission battery-powered loaders and haul trucks can eliminate diesel fumes and the requisite ventilation infrastructure required to make underground sites safe.

In June last year, Sandvik opened its state of the art Battery Electrification Innovation and Development Centre in Turku, Finland. The company has been open about its ambition to become the market leader in battery electric vehicle solutions.

Artisan will now be a business unit in the load and haul division within Sandvik Mining and Rock Technology.

“The area in which Artisan is located is a frontrunner in electric vehicle development”, Mats Eriksson, president of Sandvik Mining and Rock Technology’s load and haul division, said.

“Our new R&D foothold there will complement the skillset we have in Finland. The combination of know-how and skills creates a very strong platform.” •

An Artisan Vehicle Systems batterypowered underground loader.

Quarry May 2019 9

NEWS

INTERNET OF THINGS DAUNTS SOME COMPANIES A recent survey conducted by global engineering and infrastructure advisory company Aurecon has revealed a lack of knowledge about the Internet of Things and blockchain in the built environment. It found almost 60 per cent of Aurecon’s clients and property industry representatives believed their organisations were not undertaking enough research and planning for the Internet of Things (IoT). It also found that although 40 per cent were interested in using blockchain for business, they were unsure how to apply it.

The IoT refers to the connections in a smart building that link devices and sensors, analytics, machine learning, business systems, the cloud, productivity and artificial intelligence. It is anticipated the IoT will gradually become an integral part of devices, plant and equipment in the quarrying space.

Peter Greaves, Aurecon’s buildings of the future leader, said the data demonstrates that the built environment understands the value of the IoT and blockchain but lacks the confidence to select the right technologies.

The report - Easy Life, Complex Technology - also investigates how buildings will utilise the IoT for improving building and equipment maintenance to increase efficiencies in business operations and amplify business performance.

The paper can be viewed at the Aurecon website: aurecongroup.com

INFRASTRUCTURE, TRAINING BIG WINNERS IN BUDGET THE FEDERAL GOVERNMENT WILL BOOST CONSTRUCTION SPENDING BY $100 BILLION FOR THE NEXT DECADE.

With Australia in election campaign overdrive, the Federal Government has pledged to boost infrastructure and overhaul vocational training to strengthen the economy.

“A strong economy needs ongoing investment in roads, rail, bridges, dams and ports,” Treasurer Josh Frydenberg told parliament in his budget speech. He announced the government would boost infrastructure spending to $100 billion for the next decade; about $42 billion of that will be spent in the next four years. This includes an increase in the Urban Congestion Fund from $1 billion to $4 billion, and a $500 million Commuter Car Park Fund aimed at improving access to public transport hubs and taking tens of thousands of cars off the roads.

The state by state breakdown of transport upgrades for road and rail includes $7.3 billion for New South Wales, $4 billion for Queensland, $6.2 billion for Victoria, $622 million for the Northern Territory, $1.6 billion for Western Australia, $2.6 billion for South Australia, $313 million for Tasmania and $50 million for the ACT. In his budget reply speech, Opposition leader Bill Shorten highlighted numerous projects that did not receive funding in the budget.

“Labor has transport plans and projects ready to go in every state and territory: cross-river rail in Brisbane; Western Sydney Metro; suburban rail loop in Melbourne; the Bridgewater bridge in Tassie; South Road in South Australia; MetroNet in Perth; upgrading the roads around Kakadu; and phase two of the ACT light rail,” Shorten said.

Ken Slattery, the chief executive officer of Cement Concrete & Aggregates Australia (CCAA), told Quarry the CCAA welcomed the 2019 federal budget “as a generally positive and responsible approach to the issues facing Australia’s economy”.

“On the positive side,” Slattery said, “the return to budget surplus is a very welcome sign of government expenditure being brought back under control. This, coupled with planned reductions in taxation will help restore consumer confidence.

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Last month’s budget unveiled funding for the Gateway and Pacific Motorways.

“We particularly welcome the government’s commitment to increased infrastructure spending with meaningful investments in rail capacity development and growing productivity that will provide welcome opportunities for the heavy construction materials industry.”

Slattery cautioned, however, that these initiatives may not “compensate for the impact of the previously announced cuts to immigration levels which will put further pressure on an already weakened housing market”.

The Federal Government will reduce the annual migration intake of permanent migrants from 190,000 to 160,000 in the 2019-20 financial year.

Frydenberg also announced a $525 million skills package to overhaul vocational education and training (VET), including the creation of 80,000 new apprenticeships in areas where there are skills shortages by 2024.

The government committed about $132.5 million over four years for the establishment of a new National Skills Commission, which would be tasked with delivering long-term reform to the VET sector.

Slattery said the CCAA also welcomed “the significant boost to investment in vocational education and training”.

The Federal Government has also expanded the instant asset write-off to businesses with a turnover of up to $50 million and proposed a cap increase from the legislated $20,000 to $30,000.

Further information about key projects by state and territory is available at the Department of Infrastructure, Regional Development and Cities website: investment. infrastructure.gov.au •

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NEWS

PLANS TO TRANSFORM FORMER SITE INTO HOLIDAY PARK A former sand quarry on the Sunshine Coast is set to become a family ‘glamping’, camping and caravan tourist park. The 42ha site is surrounded by a 30m to 100m wide bushland buffer, set back from the Bruce Highway, Tanawha, and is currently undergoing rehabilitation works.

Riversleigh Super Pty Ltd and Habania Pty Ltd, the companies respectively owned by brothers Peter and John Shadforth, are undertaking the works. The brothers managed the quarry for 30 years and recently lodged an impact-assessable development application (DA) with the Sunshine Coast Council.

The DA contains plans for 461 short-stay accommodation sites made up of 306 general sites, 125 recreational vehicle sites and 30 ‘glamping’ (ie ‘glamorous camping’) sites. The repurposed site would also include a communal recreation building, children’s playground and recreational dam.

The rehabilitation is expected to take up to three years. Peter Shadforth told the Sunshine Coast Daily that he would decide after that whether the family companies would develop the site or open it up to a third party. The Shadforths recently met with neighbours to discuss their plans.

During a pre-lodgement meeting in May last year, the Sunshine Coast Council noted that there were no fundamental concerns with the proposed use from a strategic planning perspective. •

SITE PRESENTS NATURALIST WITH GRANITE KEEPSAKE “IT WAS ONE OF THE MOST EXCITING REQUESTS WE’VE RECEIVED AT THE QUARRY.”

A quarry has paid the world’s foremost naturalist Sir David Attenborough the highest compliment after he recently professed his fondness for an igneous rock found in the English midlands.

Tarmac’s Mountsorrel Quarry in Leicestershire, England, recently learnt that Sir David Attenborough has long admired the Charnwood region’s unique pink granite.

In an interview on BBC Radio Leicester, Attenborough told presenter Ben Jackson that the rock helped him earn a scholarship to Cambridge University. He had a prized collection of Mountsorrel granite samples that he donated to the University of Leicester’s geology department when it was founded in 1951.

On learning that he no longer had samples, Jackson contacted Tarmac to inquire whether it would be possible to acquire a piece of the pink granite.

Tarmac selected a large piece of granite and polished it so that all the special geological features were visible. Tarmac then invited Jackson to the quarry to collect the sample and learn more about the site’s history.

“The sample was much larger than Ben was expecting, but we wanted to make sure Sir David could appreciate the rock properly, given his obvious passion and enthusiasm for the region’s geology,” Warren said.

“After Ben’s visit, we sent the sample to Sir David the next day with some information about the history of Mountsorrel Quarry,” Warren said.

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Mountsorrel Quarry’s works manager Trevor Warren says it was a privilege to correspond with Sir David Attenborough.

“It was definitely one of the most unusual and exciting requests we’ve received at the quarry,” Trevor Warren, Mountsorrel Quarry’s works manager said. “We were thrilled to hear of Sir David’s interest in Mountsorrel granite and jumped at the opportunity to send him a sample.”

Jackson had the opportunity to visit different areas of the quarry, including the primary crusher, the asphalt plant and railhead at Barrow-upon-Soar. He aired an account of the site visit on his radio program shortly afterwards.

The Rivershore Resort’s ‘glamping’ tent on the Sunshine Coast.

Located in Leicestershire, Tarmac’s Mountsorrel Quarry supplies granite to major construction projects across the UK.

In late February, the Mountsorrel Quarry team received a letter from Attenborough, thanking them for the “magnificent” and “superb”

BBC Radio Leicester’s Ben Jackson with Sir David Attenborough (right). Image © Sophie Cook, Twitter.

sample. He also wrote of his experience studying the local geology, recounting a time when he discovered garnets – the crystals often found in metamorphic rocks – on a dig.

“I’ve been a keen geologist all my life and, like many people, have enjoyed Sir David’s work,” Warren said. “I never thought I would have the opportunity to correspond with him directly, especially over something as close to me as Mountsorrel.

“It’s a real privilege to know that despite travelling the world far and wide and seeing some amazing sights, Sir David still remembers the unique and special qualities of our Mountsorrel granite.”

With thanks to Quarry Management (UK) for its assistance with this story.

Visit agg-net.com •

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

HEAVY-DUTY PUMP FOR A VARIETY OF APPLICATIONS Tsurumi’s KTZ415 pump has a motor output of 15kW, which allows it to pump volumes of up to 2000 litres per minute. The KTZ415 can cope with sandy water, groundwater and rainwater. The water may also contain stones with grain diameters of up to 12mm. The pump is pressure-resistant to a submersion depth of 25m and has a pressure port with a diameter of 100mm (4”) on the outside thread.

For more information: Australian Pumps Industries, aussiepumps.com.au

EFFICIENT, COMPACT SAND PLANT The McCloskey Washing Systems Compact Sand Plant (CSP) 120 has a 3.6m x 1.5m (12’ x 5’) dewatering screen and can produce two grades of sand. It has a self-regulating cyclone tank, complete with built-in float system and anti-turbulence sections. The cyclone removes clays, silts and slime from sand and brings it to specification. The CSP 120 is suited to various applications, including aggregates, mining, industrial sands and recycling. Its other benefits include simple and fast assembly times, ease of operation, low maintenance and an overall reduced footprint.

For more information: MSC Group, msc.net.au 888 Crushing & Screening Equipment, 888cse.com.au

HIGH-OUTPUT, ECONOMICAL CRUSHER The Metrotrak plant features the M-series single-toggle jaw crusher. With an aggressive crushing action and a high output, it has a hydraulically adjusted, fuel-efficient direct drive chamber as standard, which allows users to quickly and easily change the size of finished product with minimal running costs.

The Metrotrak offers easy maintenance and access via centralised hydraulics and electrics, and a newly designed bypass chute with internal access and platforms. Additional machine serviceability options are also available, such as the product conveyor that lowers to ground level.

For more information: The Lincom Group, lincom.com.au

QUICK ASSEMBLY, FASTER PROCESSING With a shorter lead time than fixed plants, the UltraWASH modular plant is assembled from containerised washing modules and produces up to five products, including three clean aggregates and two washed sand fractions. Installation requires lifting the pre-assembled modules out of a shipping container, setting them in place, erecting walkways and connecting the water and electrical hoses. Additional modules – eg the UltraSCREEN, UltraSCRUB and UltraCRUSH – can be added to create a complete dry and wet processing plant.

For more information: McLanahan Corporation, mclanahan.com.au The Lincom Group, lincom.com.au

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Quarry May 2019

Chevron-MegaPipe® IPCC in combination with steep-angle conveying systems – an ideal opportunity for more efficient haulage in open-pit mines.

Up to the mid-term life of a hard rock open-pit mine haul-truck fleets offer the significant advantages of relatively low initial capital costs, redundancy and flexibility. But when a pit has reached a certain depth, the increasing costs of truck haulage will inevitably lead mine operators to start searching for alternatives.

A stationary pipe conveyor system linked to a crusher station at the bottom of the mine is just such an alternative solution – and in fact offers many advantages. The tail station (tension station) is based at the bottom and the head station (drive station) is located at the rim of the open pit. Depending on the inclination, the conveyor bridges are mounted perpendicular to the benches of the open-pit mine. An inclination of up to 40° is possible and a service cab driven by a rope winch is provided for maintenance and inspection along the structure. What’s more, the Chevron-MegaPipe ® steep-angle conveying system can also be designed for large-scale conveyance applications.

The system’s key components are the world’s largest and heaviest profiled pipe belt, which was developed by ContiTech with a max. diameter of 900 mm, a width of 3,200 mm and a strength of 9,500 N/mm, and the innovative DirectDrive® concept from Siemens. These drives come in a proven design with installations of 6 MW and more.

The Chevron-MegaPipe® steep-angle conveying system brings numerous benefits: • System inclination angles of up to 40° • Conveying capacity of up to 8,000 t/h • Material: pre-crushed ores, coal or overburden with a grain size of up to 350 mm • Mine depth of up to 500 m • Vertical and horizontal conveying curves possible • Fewer heavy-duty trucks required • System fully operational in inclement weather conditions (e.g. fog, snow or rain) • Extensive automation of conveying system possible • Significant minimization of noise, dust and CO2 emissions • Reduction of operational, personnel and investment costs (capex/opex)

If you require any more information about this advantageous solution, simply get in touch:

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PRODUCT FOCUS

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

VERSATILE WASHING, SAND RECOVERY SOLUTIONS The AggWash 60 incorporates screening, scrubbing, sizing and recovery of sand on one modular chassis and produces up to six grades of saleable sand. It has been designed to maximise yields from feed materials with efficiently designed system processes that keep running costs at a minimum for quarrying and recycled aggregates producers. While the AggWash 60’s readily portable format makes it particularly suitable for greenfield applications, contractor use and temporary planning permission sites, operators more used to static installations will still appreciate the small footprint and minimal site preparations required.

For more information: Terex Washing Systems, terex.com/washing/en Terex Jaques, terex.com/mps/en-au/

HIGHER LOAD RATING, IMPROVED SERVICE LIFE The double tube (DT) idler features an inner and outer tube construction for increased rigidity and higher bearing insulation. The inner tube insulates the bearing from vibration, reducing misalignment and increasing the life of the bearing. As the outer shelf wears, the inner tube maintains the structural integrity of the roller. The DT models are available in belt widths up to 305cm (120”) and equipped with bearing sizes up to 60mm.

For more information: Superior Industries, superior-ind.com 888 Crushing & Screening Equipment, 888cse.com.au

VIBRATION ANALYSIS SERVICE Haver & Boecker’s Pulse vibration analysis service is designed specifically to monitor the health of vibrating screens, to ensure optimum screening performance and equipment durability. The program detects irregularities that could translate into diminished performance, decreased efficiency and increased operating costs for the vibrating screen. The reporting and historical tracking of the machine’s performance gives operators the information needed to minimise downtime and maximise productivity and profits. The Pulse system uses an industrial grade tablet computer that connects wirelessly with eight tri-axial sensors. The sensors attach to key places on the equipment and send up to 24 channels of data to the tablet, which displays a real time view of the machine’s orbit, acceleration, deviations and more.

For more information: Haver & Boecker Australia, haveraustralia.com.au

POWERFUL, EFFICIENT, ECO-FRIENDLY EXCAVATOR The EC300E is a powerful, efficient machine designed to reduce fuel consumption and increase productivity. Engine speed is reduced to idle when controls are inactive for a pre-set time (between three and 20 seconds). This reduces fuel consumption and noise for nearby workers.

Volvo CE’s ECO mode optimises the hydraulic system to reduce flow and pressure losses, resulting in improved fuel efficiency without loss of performance in most operating conditions. ECO mode is automatically selected, but can be switched off via the keypad. A hydraulic-hybrid version of Volvo CE’s EC300E was launched at bauma 2019.

For more information: CJD Equipment, cjd.com.au

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Quarry May 2019

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MAINTENANCE

SIX STEPS TO A ROCK SOLID MAINTENANCE PROGRAM

The efficient running of a quarry operation is dependent on the upkeep and maintenance of both fixed and mobile plant and equipment. In turn, maintenance also requires a commitment on the part of the operator to address long-term solutions, not just immediate problems.

Y

ou’ve done the research, planning and finally made the purchase of your new piece of processing equipment. Now what? It is time to start planning a maintenance program and practices that ensure the maximum availability of your equipment and reduce total production costs. Putting in place these standard processes will maintain years of continuous and efficient operation.

Regardless of your site or equipment, maintenance programs should all have similar objectives. These include: • Being proactive, instead of reactive.

• Ensuring the equipment can be operated safely and efficiently.

• Ensuring targeted reliability of equipment at rated capacity.

• Maximising the useful life of equipment.

• Performing equipment improvements to minimise production costs while increasing production quality and capacity.

• Ensuring training is provided to effectively perform/support maintenance activities.

It is important to understand the key factors needed to develop a successful, “rock solid” maintenance program. Start by developing a standard process to maintain the operating quality, safety and efficiency of your processing equipment. On average, 20 to 25 per cent of total production costs for most operations are maintenance costs.

By putting together rock solid maintenance processes and practices, operations can ensure maximum availability of the equipment and reduce total production costs.

1. REGULAR EQUIPMENT INSPECTIONS Operations should establish a formalised process for fixed and mobile equipment inspections, define inspection tasks and create a checklist of items to be reviewed during inspections. These checklists will help verify that the equipment is operating safely and efficiently. This establishes the maintenance program as proactive, rather 18

Quarry May 2019

A sand operation ought to run like clockwork – if operators have correctly developed a process to track the program’s effectiveness.

than reactive. With a proactive maintenance program, the company will know what consistent maintenance activities to perform to identify and repair equipment before it breaks down. Often, this could be as simple as performing equipment maintenance according to the manufacturer’s schedule or best practices.

2. RECORDING DEFECTS, REPAIRS It is important to keep a log of maintenance tasks that need to be completed and ones that have been completed. This way, an operator can effectively prioritise its time and money to address the maintenance tasks that could impact uptime and reduce production.

Whether electronic or something as simple as a whiteboard, an operator needs to effectively communicate what tasks need doing and where in a maintenance process the organisation is. This way, site personnel are clear on the maintenance tasks that have been performed and what else still needs done.

3. PRIORITISING REPAIRS If not addressed, what repercussions will maintenance issues have for the site? Are they going to cause downtime for a day? A week?

Everyone from operators to executive management hates to hear that a machine is not going to be functioning for any amount of time. Prioritising repairs that will keep the machine running should be at the top of the list.

It is important that everyone from plant personnel to supervision understands the importance of preventative maintenance tasks to keep equipment running. It is always important to communicate machine repairs or defects to management, so they can plan operations around making the necessary fixes.

4. SCHEDULING REPAIRS Scheduling maintenance at least a week in advance is usually a good rule. All affected parties should be informed of the maintenance required and the time it should take. There

should be consideration about the best time to work on the machine. Is there a time the machine isn’t active? Is there a time that another machine could step in until maintenance is complete? Scheduling maintenance should be an integral part of an operation to keep the site running at full capacity, while being scheduled at a time that will minimise any impact to plant production and sales.

5. GETTING IT RIGHT FIRST TIME The first thing to examine is how much an hour of downtime really costs an operation.

It is important to fix the machine correctly the first time to prevent future downtime. Time and resources are already being committed to fixing it once; surely the obvious conclusion is to fix it properly. Operators should take the time to research and diagnose the nature of the problem and how to fix it. Fix the disease, not the symptoms. If a machine is leaking, the spill shouldn’t just be mopped up – the cause of the leak needs to be pinpointed

and fixed. Following a maintenance program correctly can be seen in a dollar amount on the bottom line.

6. PROGRAM EFFECTIVENESS A maintenance program can only be considered rock solid if it is improving the site. How can you tell? Operators need to develop a process that allows them to track the program’s effectiveness. Is the plant seeing increased uptime? Are production levels improving? This also allows operators to prioritise their focus on certain areas or machines. Is there a continued pattern in maintenance activities? Is there another option to consider to extend the wear life?

When looking back on effectiveness, it is also important to consider the time spent on repairs. How could the repair be undertaken more quickly next time? What lessons were learnt from this repair that could be used in future repairs? Should additional training be provided on maintenance activities to make them more efficient? These are all questions

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that can be answered at the end of the analysis of a maintenance program.

By keeping these six things in mind, quarry operators will be well on the way to developing a rock solid maintenance program. From a well developed program, operators can maintain the operating quality, safety and efficiency of the fixed and mobile equipment through a more proactive approach to maintenance. It also allows them to prevent costly failures and to maintain control of processing plants through effective maintenance planning. By practising good maintenance processes and practices, operators can ensure maximum availability of their equipment and ultimately reduce total production costs.

A rock solid maintenance program supports productivity and cost improvements that will make an operation more efficient and profitable. • Source: McLanahan Corporation

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MAINTENANCE

Components equipped with sensors are central to the drive systems used in machines and equipment.

CONDITION MONITORING:

FROM INDUSTRY 4.0 TO THE ‘DARK FACTORY’ While condition monitoring systems are continuing to prove their value in industrial applications, Ian Pledger explains that many companies are still unsure how CM should fit into their Industry 4.0 strategy and the automated ‘lights out’ factory.

M

ost process industry sectors today have implemented some sort of condition monitoring (CM) strategy or CM systems within their process plant, even if it’s just CM for process-critical rotating equipment and machines.

The sectors that seem to be adapting best to CM are those that cannot afford the high costs associated with production downtime, perhaps due to unforeseen machine breakdowns. These sectors include metal processing, paper mills, mining, quarrying and cement, and power generation (including the generation of energy from waste).

Outside of the process industries, discreet manufacturers in the automotive, aerospace, wind power and rail industries are also benefitting from the implementation of CM systems. In fact, any business that utilises electric motors, gearboxes, air compressors, fans, conveyors and pumps can benefit from CM services. In recent years, the

20

Quarry May 2019

bearings manufacturer Schaeffler Group has provided vibration monitoring services to the health sector where heating, ventilation and air conditioning systems in blood storage facilities need to be monitored on a continuous 24/7 basis.

Measuring vibration is one of the most widely used CM techniques for detecting and diagnosing equipment faults. Vibration monitoring systems are among the most reliable methods for monitoring the condition of rolling bearings and for detecting the early onset of damage to bearings and other machine components. Schaeffler has many years of experience as a manufacturer of bearings, and a provider of CM systems and vibration analysis expertise.

Most CM systems to date have been used as local systems, collecting vibration data from machines and using analysis algorithms and a rolling bearing database to check for signs of wear, defects or other unusual behaviour. While this works very well

for many companies, it is now possible to share and compare local machine condition data, via the cloud, with other similar items of equipment across a plant, or better still, with other equipment at multiple plants within a business, wherever they are located globally.

SKILLS, KNOWLEDGE, EXPERIENCE The latest cloud-capable CM systems, such as Schaeffler’s Smart QB and SmartCheck, offer a suitable platform for managing and processing “Big Data”. These CM systems are quick and easy to install and set up, with the user requiring no specific skills or knowledge of vibration diagnosis.

With the Smart QB fixed online monitoring system, when changes occur in the condition of the equipment, the system automatically generates plain text messages on a display, providing the user with clear instructions for action, enabling any corrective maintenance work to be

undertaken and any replacement parts to be ordered if required. These “automatic fault assessment� CM systems are groundbreaking, as they do not require specifically trained vibration experts to analyse the data.

With ready to use, pre-set measurement configurations, these CM systems are helping users identify the main causes of faults, eg bearing damage, imbalance and temperature increases. For general changes in vibration patterns that cannot be clearly attributed to one of the above, the CM system can request, via the cloud, additional analyses from a specialist.

The advantages are that analysis can now be carried out anywhere at any time, with the expert being located anywhere in the world within a company or externally. Similar equipment can be compared across global manufacturing plants, to compare and/or develop trends.

ENABLERS FOR DIGITAL SERVICES Components such as bearings are used

The Schaeffler SmartCheck offers a suitable platform for managing and processing “big data�.

The Smart QB online monitoring system notifies operators of changes to equipment condition.

in important parts of plant and machines, which produce critical information about conditions and movements. Schaeffler is continuing to invest heavily in research and development and has incorporated sensors, actuators and control units with embedded

software into its products including rolling bearings and linear guidance systems.

With these new digitalised, Industry 4.0 technologies, it is now possible for these products to collect and process valuable data on the condition of a machine or

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MAINTENANCE

process and then convert this data into added value services.

The cloud-capable SmartCheck CM device, for example, allows a simple and flexible point of entry into the digitalisation of machines and equipment based on vibration monitoring.

Components equipped with sensors are central to the drive systems used in machines and equipment – they record data and are the fundamental “enablers” of these digital services. Schaeffler’s aim is to continuously transform conventional mechanical products such as bearings and integrate these into the digital world. This represents an important step towards a future in which not only complex systems but also simple assemblies and machines will have easy access to digitalisation and the Internet of Things (IoT).

The recorded vibration data from bearings can now be transferred via a flexible Schaeffler gateway to the cloud, where the company’s rolling bearing domain expertise is made usable in the form of digital services. For example, automated rolling bearing diagnosis and “remaining useful life calculations” can be used to provide precise information on the condition of the bearing and therefore of the machine or process being monitored, which in turn allows specific actions to be recommended. It will even be possible to use actual load data to adjust to operational machine processes in real time.

But what are the implications for the workforce? Over the next decade, engineers will spend less time diagnosing faults on The Smart QB fixed online monitoring system automatically generates plain text messages on a display, providing the user with clear instructions for action.

machines and process plant, as this data will be collected and reported on automatically using smart CM systems. Collected CM data can be provided in a format suitable for whoever needs to see it within the business or global group. Different process engineers, maintenance staff, machine operators and senior plant managers will cherry pick what information they need from this pool of machine and process data and use it as they see fit to make improvements to processes, machine efficiencies and ultimately business profit.

There are some drawbacks to implementing modern CM systems but these should not prevent companies investing in CM. The cost of the CM system itself and its implementation can appear relatively high at first. However, the cost of implementation is likely to decrease over the coming years as these systems become easier and faster to install, and less costly to develop in the first place. As CM technologies mature, the price of CM systems will decrease. Small, affordable CM devices such as the SmartCheck are already making investment payback periods significantly shorter.

“LIGHTS OUT” We could eventually see a “dark factory” situation emerging, whereby machines, automated plant and robots carry out all their work in an energy efficient, “lights out” scenario, and there is little or no human intervention required, except when a CM alarm limit on a machine or process is reached, new raw material is required for the process, or a machine breakdown occurs.

Industry 4.0 and the IoT will continue to drive the way CM technologies are developed. CM will remain at the forefront of fault diagnosis. • Ian Pledger is a service engineer at Schaeffler UK. Article courtesy of Quarry Management (UK). Visit agg-net.com

MAINTENANCE

SUPPLIER REVAMPS HEAVY MACHINERY WEBSITE TO AID WITH PRODUCTIVITY

A

heavy machinery website is expected to be a bonus for equipment users in quarries, mines and civil construction, with the aim of boosting productivity.

Earthmoving machinery supplier Komatsu Australia has redeveloped its website – komatsu.com.au – to world’s best practice principles to provide its customers with swift access to information and services.

The revamped website enables direct access to its Komatsu Australia’s customer support centre, with a live one-on-one webchat function, enhancing customer service.

The website is designed to open portals to all essential Komatsu services, including after sales support and Komatsu’s exclusive customer enhancements in Komtrax and SmartConstruction.

Special attention has been paid to providing an intuitive user experience with easy navigation and search functions. These will help producers find equipment information and specifications.

The website has a news function and a direct link to an offers page which provides users with first access to purchase opportunities.

Users also have the option to subscribe to Komatsu’s free e-newsletter.

“On-line customer interaction has been expanding exponentially in all industries including ours,” Komatsu’s national marketing manager Wafaa Ghali said.

“Our challenge has been to combine electronic communication with person to person service which has been a hallmark of

Komatsu’s success with its customers.”

“Providing our customers with a user-friendly website with an intuitive interface has been a priority. A customer who wants to research a specific piece of equipment will find the site recognises that requirement and gives priority to the inquiry.

“And any time when a customer wants to seek clarification, it takes only a simple button push to access the Komatsu Customer Support Centre.”

Ghali said the website would fast track access to Komatsu. It will also link to Komatsu’s partners and affiliates to create a complete chain of services.

Komatsu’s revamped website is now live. • Source: Komatsu Australia

Since 1989 Red Star has been devoted to wire cloth and screen media production in China, and is renowned for its high durability, precision and impactresistant products, which have been widely implemented by clients across US, Europe, Australia and the MiddleEast. As of 2016, Ying Hui and Red Star have set up a joint venture warehouse in Melbourne, in order to provide the quickest response time to meet all the demands of our Australian customers.

Visit our mobile-friendly website to check stock and order efficiently. We help your business run faster.

n Phone: 0401 459 289 n Email: yinghui.international@gmail.com n www.hhjv.com.au

MAINTENANCE

MEASURING THE VALUE OF LINER PROFILE GAUGES

Replacing the inner liners of a crushing plant has traditionally been an arduous yet precise process. As Lew Dilkes explains, electronically profile-cut liner wear profile gauges are now being employed to ensure the crushing profile is correct for the specific application.

C

one crusher liner profile gauges have gained significant interest among quarrying producers in recent years.

There are three gauges available in the crushing market: the mantle wear profile gauge (Figure 1); the bowl liner profile gauge (Figure 2); and the “A” dimension gauge (Figure 3).

There are many stages of crusher wear liner manufacture that can influence the wear life of the manganese steel crusher liner. The optimum mechanical properties, including wear, are obtained by professional foundry method design, good control of chemistry, controlled foundry melting practice – including furnace charge integrity – optimum grain size (inoculation) and heat treatment.

Having all these procedures correct leads to the start for achieving optimum wear life.

Before the manufacture process begins, it is critical the casting method design will ensure the entire wear profile will be sound.

Many foundries save costs by reducing the number of feeder risers, leading to varying degrees of internal shrinkage (a significant cost saving area for the foundry). Internal shrinkage can be either micro or macro and is often both.

This is a significant factor leading to reduced wear life, and is often not recognised by the end user. The defective area is usually worn away before the liner is removed. The reduced wear life is often incorrectly blamed on the material chemistry.

The initial design of the wear liners is controlled by the original equipment manufacturer (OEM). To allow the OEM to compete in the world market, a “one size fits all” concept is adopted for the wear liners, usually including fine, medium and coarse.

This is rarely the best option for the final customer, who has to adapt their crushing plant to suit the large variety of crushed rock products required in the Australian market.

Crushing Equipment, in conjunction with its parent company Foundry Group, maintains 24

Quarry May 2019

Figure 1. The mantle wear profile gauge.

Figure 4. Measurement of the HP300 mantle.

Figure 2. The bowl liner profile gauge.

Figure 5. Measurement of the HP300 concave.

Figure 3. The “A” dimension gauge.

a disciplined approach to the manufacture of all supplied crusher wear liners.

With the confidence of a final product leading to consistent liner wear life for each application, the company can focus on customised improvement at individual crushing plants. This is where the use of wear profile gauges begins.

Crusher liner wear profile gauges that have been recently used include the HP300 mantle (Figure 4) and the HP300 concave (Figure 5).

CONE LINER WEAR GAUGE The cone liner wear profile gauge is electronically profile-cut to represent the liner wear profile, and is used for the following: 1. To confirm the start-up crushing profile is correct for current crushing application.

2. To measure the wear rate during the crushing life and determine the optimum change-out time.

The cone liner “A” dimension profile gauge is used for the following: • To check mantle “A” dimension to ensure the liner is suitable for current crushing application.

• To check the concave and bowl liner “A” dimension to ensure the liner is suitable for the current crushing application.

• To modify the “A” dimension to duplicate existing liners in service.

• To modify the “A” dimensions to use excess closed side settings (CSS) not required for existing crushing requirements.

The “A” dimension starts at the standard size for all liners to meet the crusher design maximum CSS.

• To manage liner wear life.

The “A” dimension gauge is an easy method to check the “A” dimension noted on all crushing cone liner drawings.

The “A” dimension starts at the standard size for all liners to meet the crusher design maximum CSS. Should the maximum CSS not be required for the crushing application, the difference between the maximum and that required at the quarry can be added to the “A” dimension (mantle and concave), taking into account the applicable crushing chamber design criteria. This adds to the liner wear life.

An example of the wear profile gauge used to measure worn cone liners.

CRUSHER LINER WEAR GAUGE The crusher liner wear profile gauge is used to inspect worn mantle and concave.

These examples are the same for all other cone crushers.

Inspection can be carried out on new liners to confirm the wear face profile, in the crusher during the life cycle to determine the changeout time, and to monitor the wear rate during service and maximise wear life.

The gauge aligns with the liner seating face (main shaft and bowl) and the top of the liner, which usually has minimum wear.

The final stage to achieve optimum wear life is liner design, to ensure the maximum amount of consumable wear material is available for crushing (grams/tonnes crushed).

The maximum thickness of wear material available and the crushing zone length achieve this. Ensuring the liners are matched to give an even wear profile is also a key factor. • Lew Dilkes is the technical sales and quality manager for Crushing Equipment.

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MAINTENANCE

MAINTAINING SUPPORT SPRINGS IN VIBRATORY EQUIPMENT

Vibrating screens and feeders are only as effective as the small parts and components that underpin them. Darren Toth explains why good support springs – and ongoing spring maintenance – are integral to the performance of vibratory equipment.

P

oor motion in vibrating screens and feeders can occur for many reasons, but one is arguably the easiest to prevent and yet seems the least understood – the adverse effect of support springs (the springs on which the machine sits) behaving differently from one side of the machine to the other. The motion of the equipment will vary between the left and right sides, increasing the internal stresses within the machine, reducing its service life. It will become a greater challenge to maintain.

What do support springs do? They allow free movement of the vibrating machine and isolate most of the unit’s vibration from its supporting structure. Something that is not broadly understood, however, is that they also magnify the vibration of the machine.

While typically only by a few per cent, this magnification (caused by a dynamic response of the screen’s mass combined with the springs) occurs at each corner and will only be equal around the unit if the compression on each of the springs is equal.

A difference in spring compressions (between the left and right side on the equipment) means a difference in the amplitude of vibration (from one side to the other), which leads to excessive internal stresses within the machine body that are different to those typically considered in the machine design. To worsen matters, a variation in spring compressions (ie spring heights) forces a slight twist into the machine, creating yet another dynamic response that contributes to these adverse internal stresses!

TIPS FOR SUPPORT SPRINGS What can be done to ensure a machine’s support springs aren’t causing it to fail prematurely? Consider the following tips: • Check your spring heights. Make sure equivalent springs (ie springs in the same location along the screen but on opposite sides) have a similar free height and then end up at similar heights (within 5mm – note some 26

Quarry May 2019

Steel coil springs installed on one side of a vibrating screen.

Rubber springs are amongst the three most common types of springs seen on quarry sites.

equipment manufacturers’ requirements may differ) under the static load of the machine. If the height difference is greater than 5mm (or the variation recommended by the supplier) from one side to the other, then use packers to load up the springs that are sitting higher. In configurations where the springs in a set are parallel (typical of fixed plant but also in some mobile), ensure they are at similar heights.

• Keep your springs clean. Debris and fines build-up should be cleared from springs.

• Never run a screen or feeder with broken or collapsed springs. Have at least two new spares on hand to remove the temptation to continue operating with broken springs while waiting for replacements. If you replace a set of springs and don’t have spares, consider buying extras at the same time.

• Be consistent. Always replace equivalent springs in pairs (ie if a spring is replaced on one side of the screen, replace the spring in the same location on the opposite side).

• Make sure springs can be easily inspected.

• Monitor. As part of your regular checks,

measure the heights of the springs while the equipment isn’t running (as they are under the weight of the machine) and record them. After each check, compare the spring heights with those previously recorded so that changes are identified. It will be obvious when a spring has catastrophically failed and, in most cases, will be evident when they are on the “way out”.

If there is suspicion about a spring, either replace it or lift the machine up and check the free heights of equivalent springs. Also compare these to their original (new) height.

SERVICE TESTING Following these guidelines will not only keep your machines running evenly by minimising the equipment’s internal stresses, it will also help maximise the service life of springs without compromising the health of the machine. The life of a set of springs is that of the one most stressed. Keeping the spring heights consistent means stresses in the springs will also be consistent. That means a longer service life.

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Support springs allow free movement of the vibrating machine and isolate most of the unit’s vibration from the surrounding structure.

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Wheel Loaders

A screen mount bracket, with another example installed on a screen (right).

As well as selling various components for screens and feeders, including different types of springs, businesses also offer the service of testing vibrating equipment to identify adverse motion, from an equipment longevity perspective, and ways to improve performance.

When a machine is running unevenly, we need to look for the various causes. If the springs are in good condition and their static heights are reasonably similar from one side to the other, it becomes easier to identify the cause of the adverse motion. If the springs are in poor condition and/or vary significantly in height (left to right), it can often mean an additional site visit is required before there can be recommendations to correct the unit’s motion. This adds to the service and means the machine will run poorly for a longer period.

The three most common (but not the only) types of springs seen on sites, on vibrating screens and feeders, are steel coil springs, rubber springs and screen (or oscillating) mounts. Although they differ in their construction, they all perform the same function on vibrating equipment, and their behaviour is governed by their deflection from their free height when under the weight of the machines they support.

In all cases, the laden height of the spring is simply the vertical distance between the surface of the mounting bracket sitting on top of the spring and the surface on which the spring is sitting.

The design intent for vibrating machines is for them to wear out after many years of reliable service, rather than fall apart due to fatigue. In many situations, regular consideration of screen and feeder support springs in a site’s maintenance checks will make the difference between years of reliable service and premature failure.

Once a vibrating screen or feeder is running well, which is how every machine should start life, the most likely cause for it to run poorly is the adverse effects of changes in the support springs. • Darren Toth is the director of ToThinkEngineering.

Email darren.toth@tothink.com.au or visit tothink.com.au

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CRUSHING

MANUFACTURER EXPANDS ITS MULTI-ACTION CONE CRUSHER RANGE The latest addition to a multi-action cone crusher ‘family’ promises to reduce the costs of ownership and ‘supercharge’ productivity for medium-sized aggregate operations.

O

n the opening day of bauma 2019, Metso unveiled the MX3, the latest addition to its innovative multiaction cone crusher “family”. The MX3 is designed to offer improved productivity and lower operating costs to mid-sized quarry operations. It was one of several innovations launched at the company’s stand in Germany.

In 2017, Metso launched the MX4, the first model of the MX series. According to Metso, the MX4 was designed to redefine the way extractive personnel think about cone crusher performance, with claims of enhanced efficiency, wear parts utilisation, safety and automation. Since that launch, about 50 MX4 crushers have been sold worldwide. Some are operating in Australian quarries.

Metso’s Australian vice-president of aggregates Shaun Fanning says quarry operators in Australia are already experiencing the benefits of the MX’s multiaction technology.

“Our customers are getting some remarkable results with the MX4,” he said.

“Some of our industry’s major players have really embraced this unique technology.

We currently have several MX4 crushers in operation and being commissioned.”

According to Fanning, customers are being supported by Metso’s Australian service team, which is fully trained in the technology.

“Members of our team are always on hand to help customers with machine commissioning, diagnostics, optimisation and repairs,” he said. “The knowledge and experience of our people, combined with the best technology on the market, is what makes the big difference to our customers.”

The newly released MX3 is a scaled-down version of the MX4, sharing the same design principles and technology. Like the MX4, it delivers high reduction ratios, with refined, in-spec end product shape and consistency.

Members of the engineering team have said MX cone crushers are designed with one objective – to reduce the total cost of ownership while “supercharging” productivity.

28

Quarry May 2019

SPECIFICATIONS

MX4

MX3

Maximum power

315kW (400hp)

220kW (300hp)

Maximum throughput

400-600 tonnes per hour (tph)

300-420 tph

Maximum feed size

257mm

230mm

Head diameter

1175mm

1050mm

Length

3700mm

3400mm

Width

2840mm

2490mm

Height

2930mm

2845mm

Weight

21 tonnes

16.6 tonnes

All dimensions and weights include crusher and subframe, motor subframe, guards and feed arrangements..

MULTI-ACTION TECHNOLOGY Fanning says the patented “multi-action” technology is an innovative way to automatically optimise crusher operation.

MX crushers can simultaneously adjust their settings with a rotating bowl above their cavity and a hydraulic piston inside the machine’s fixed shaft. Dynamic setting adjustments can be made when the crusher is operating under full load conditions, without the need to stop production.

The MX’s multi-action design enables dynamic setting adjustment and wear

compensation using a high pressure hydraulic piston, minimising interruptions to production. The piston also provides fully automated machine protection against damage from uncrushable objects and overloading. The combination of rotating bowl and piston adjustment enables optimised wear part utilisation.

Metso representatives state the MX series offers operational cost savings of 10 per cent or more, compared with traditional cone crushers. Savings in wear components, coupled with effective and continuous

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

crushing action, provide a valuable starting point to bring down the cost per tonne.

The MX crushers feature a robust design based on Metso’s experience over the years with its Nordberg MP, HP and GP series cone crushers. They are designed for challenging operating conditions, with very hard and abrasive feed material. An advantage of MX crushers is quick and easy wear component change-outs. All the wear parts are accessible from the top of the machine, allowing a complete change-out in two to three hours.

WEAR PART UTILISATION Fanning says the MX series delivers highly effective wear parts utilisation rates – up to a 25 per cent longer liner life compared with conventional crushers.

Optimal cavity design, stroke direction and an effectively distributed crushing action combine to provide a highly optimised rock-on-rock crushing motion. Together with the machine’s multiaction technology, this results in extended intervals between maintenance and higher production rates. Quality characteristics of all sized end product fractions stay consistent throughout the lifetime of the wear parts.

The smart optimisation of the multi-action technology is the key to reaching the desired end product shape and particle size distribution while eliminating waste. End products can be measured as often as 10 times per second and shown directly on the crusher’s automation display.

The modern automation system keeps crushers operating optimally, with automatic wear compensation. Plant personnel can adjust and monitor machine parameters such as material cavity level, crusher speed, power setting and piston pressure via an intuitive user interface panel.

Crushing quality can be monitored via Metso’s VisioRock Compact, which measures real time production through a photo particle size analyser linked to the crusher’s automation system. Its Modbus interface enables quick access to particle size distribution from cameras mounted above the crusher’s output conveyor.

Combined with purpose-made lifting components and wear part tightening tools, the MX is said to be a “big win” for operator safety.

Fewer human/machine interactions for adjustment and maintenance offer a safer working environment for machine operators and maintenance staff. The machines have also been designed with the environment in mind. There is no lead in the MX’s counterweight design and no backing is required to set the liners. Machines can be equipped with Metso’s offline oil filtering system, which keeps oil clean for extended periods.

FIELD TRIALS A French aggregate producer has been testing a pre-production prototype of the MX3 at its Peyrolles quarry since April 2018.

Mathieu Kasprzak, the operations director of Durance Granulats, was extremely satisfied with the performance of the new machine.

In January 2018 the company also commissioned an MX4 in a secondary crushing application.

According to Kasprzak, the MX4 is achieving the company’s production targets while delivering about 12 per cent in energy savings. • Source: Metso Australia

Motorbase - Crushers

Motorbase - Screens, Feeders

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CONVEYING

KAMMP: A SIMPLE YET

EFFECTIVE CONVEYOR BELT SOLUTION Tramp metal plagues all quarries and can create a bottleneck in a site’s crushing, screening and conveying circuit. Now, a Hanson quarrying operation has devised a simple, ingenious solution to detect metal in the primary crushing phase. Damian Christie spoke to Malcolm Sawers.

T

he IQA’s Excellence in Innovation Award, sponsored by Trimble Aggregates, recognises an individual’s contribution to excellence and innovation in the quarrying industry. The contribution can be for innovation in design, production, operations, automation, plant design, maintenance or processes as a single event – or for a long- term contribution.

The 2018 award went to Malcolm Sawers and Michael Benic, the maintenance supervisor and former quarry manager respectively, of the Hanson Construction Materials Kulnura Quarry, 80km north of Sydney, and about 30km from Gosford, on the New South Wales Central Coast.

Hanson Kulnura Quarry extracts and processes basalt, which is then crushed into blue metal in quantities of 10mm and 20mm to make concrete aggregate, principally for Sydney’s concrete market and also internally for Hanson’s local concrete operations. The plant at Kulnura Quarry has an annual output of about two million tonnes.

It was the second consecutive year that the quarry has collected the Excellence in Innovation Award. In 2017, night shift supervisor Stephen Raines won the award for his development of a laser module to cast a bright green line on the ground that enabled night time operators to correctly reverse their haul trucks to receive loads from the front-end loader at the face. This reduced prolonged cycle times and enabled the haul truck drivers to undertake up to four load trips per hour.

DETECTING TRAMP METAL In 2018, the award was presented for another exclusive yet simple solution to a common problem that plagues all quarries: the adequate detection of metal contaminants – such as wear and tear components, bits and bolts dislodged from bucket teeth or drill heads – that circulate within the conveyor system and can enter and cause damage to crushers and other plant.

Most quarries will have metal detectors 30

Quarry May 2019

Two versions of the KAMMP device (pictured) have been installed on conveyors 1 and 7 of Kulnura Quarry’s crushing, screening and conveying circuit.

installed on a conveyor; the belt will come to a stop once the tramp metal is identified.

The operator will then have to move along the conveyor walkway, searching for the metal on the belt and sifting through the rocks by hand until it is found. This can be no easy task if the belt has travelled an extra 10 to 20 metres before it is brought to a stop. At night or in low light periods, this task is even more laborious, and the metal may not be found at all.

Magnets are sometimes used as a solution to detecting and capturing tramp metal, but they are not always reliable and, in turn, can be an expensive and complex investment. As Malcolm Sawers explained, “What we found with the magnet is that if there is tramp metal sitting under large rocks on the conveyor, they will just go past the magnet. The magnet just doesn’t have the power to pull out the metal from under those larger rocks.”

Sawers has worked at Kulnura Quarry for nearly 30 years. He started as an apprentice in 1990 and has worked in a variety of roles.

Today, he is the maintenance supervisor, overseeing the good condition and upkeep of the site’s fixed and mobile processing plant,

and its earthmoving equipment. Although he has been in his current role for about 20 months, he was convinced there had to be a simpler, better way to reduce the downtime on tramp metal on the conveyor belt.

“I said one day, ‘There has to be some sort of system to mark the area, like a paint …’ It was just an idea! I would have thought somebody else had already designed something that we could install but when I started looking around there was nothing out there on the market. There are other systems which drop a beanbag but we thought of something simple – just mark the location and keep on going.”

Sawers and Benic discussed a solution and the logistics required to put a system in place.

The end result of these deliberations was the Kulnura Automatic Metal Marking Paint – or KAMMP. KAMMP is essentially a device that dispenses paint whenever metal is sensed on the belt, accurately marking the position where the metal has been detected as the belt is brought to a halt. It has been installed on conveyors 1 and 7 of Kulnura Quarry’s

crushing, screening and conveying circuit.

The operator can then look up and down the belt for paint marks; where paint marks are present, the metal will be in the vicinity and can be found and removed. KAMMP can also detect multiple instances of metal; in the past, metal detectors might stop the belt for one piece of stray metal but fail to detect other pieces on the belt.

The paint – described by Sawers as a “rock coding ink” – is sold in pressurised 20-litre canisters in a variety of colours. His maintenance team has tested the ink in pink, which is better captured by night lights, and white during the day. They have used up one canister in the first 12 to 14 months. Sawers and his team have also experimented with a fluorescent paint for night work.

While only one worker was required to scour the conveyor belt for tramp metal before the installation of KAMMP, Sawers said it was not a good use of that worker’s time and energy.

“It was just the amount of time. A worker has to try to extrapolate where the metal could be

Michael Benic (left) and Malcolm Sawers (right) are presented with the IQA’s innovation award by Trimble’s Dale Cameron (centre).

The mixture of paint and water is drawn from a pressurised 20-litre canister (right) beside the conveyor and the adjacent control box.

and then go quite a distance up and down the belt to find the metal. KAMMP has cut down the time frame significantly, so the operator will walk up there, work out the location reasonably quickly and find the material.”

According to the submission for the Excellence in Innovation Award from Hanson, it was estimated that prior to the installation of KAMMP, it could take an operator up to three minutes at a time to locate tramp metal. Over a year, the metal detection stops and manual picking would accumulate to downtime of 89 hours.

Now that KAMMP is active, it is estimated that an operator can usually find the metal within 20 to 40 seconds – with a near 100

per cent success rate. This has reduced the downtime by nearly two-thirds – to a mere 30 hours per year – and promises an extra 60 hours (or almost three days) of crushing time per year. In particular, KAMMP has reduced the amount of metal stops in the secondary plant because metal is being located more frequently in the primary plant and taken out of the processing circuit much earlier.

In the bargain, 60 hours of extra crushing time equates to $300,000 more product per annum – all from a paint marking innovation that cost Kulnura Quarry about $6300 to install.

“After we installed the system and started monitoring the amount of downtime, it definitely opened our eyes, especially with

SOLVE YOUR MATERIAL FLOW PROBLEMS

CONVEYING

the amount of time saved,” Sawers said of the small investment.

“KAMMP is relatively inexpensive, compared to other options in the industry.”

MORALE BOOST In turn, KAMMP has, in reducing the manual handling required of operators, had safety benefits. Fewer metal stops and reduced time on the conveyor catwalk decreases the possibility of serious trip hazards, exposure to the elements (eg skin protection from the sun in summer, and also risk of injury from cold, rain and wind, particularly at night, in the winter). In turn, Kulnura Quarry has credited KAMMP with raising the morale of the operators who have been responsible for detecting metal on the conveyors – they know they will have a near certain chance of locating the metal and spending considerably less time in the open looking and sifting through rock on the belt.

“We have had positive feedback from everyone,” Sawers said. “It’s made the operators’ lives a lot easier, and amongst our maintenance team. We haven’t had to do any upkeep with the system, it’s all been very reliable.”

According to Hanson’s submission for the Excellence in Innovation Award, KAMMP has the potential to be implemented more widely in the quarrying and concrete sectors. “Whilst primarily it would work best for quarries there are benefits for it in other manufacturing processes, especially when needing to detect and find metal is critical,” the submission read.

Sawers said Hanson has discussed installing KAMMP at other operations. “I’m not sure if anyone else has it in place as of yet but there’s still talk with some of the other quarries,” he said.

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AWARD RECIPIENTS Sawers and Benic were nominated for the IQA’s Excellence in Innovation Award, supported by Trimble. Dale Cameron, the Australia/ New Zealand sales manager of Trimble Aggregates, presented the award to them at CMIC 18 in Sydney last September.

“We were happy to be nominated,” Sawers said. “Mick Benic thought it was definitely a good idea – but sitting in the IQA conference and hearing your name being called out for winning the Innovation Award in front of a lot of your peers was very exciting.

“I had no idea that we would win the award. I was ecstatic, it was very exciting to be recognised for something like that, and hearing all the feedback from a lot of colleagues and other people in the business.”

In addition to a trophy, the award offers Sawers the opportunity to undertake a study tour for continuing professional development purposes. He said he still has to decide exactly where and when he will go. “I’ve been talking with Trimble and some other suppliers about what other conferences are happening around the world and how I can get the most benefit out of it.”

Sawers encourages fellow IQA members to apply for the IQA Awards in 2019. He also believes his industry peers should not be afraid to suggest ideas for the improvement of processes and systems at their sites.

“Sometimes the simplest things can really make a difference,” Sawers said, summing up what a great innovation KAMMP has been for Hanson Kulnura. “Try to put forward your ideas, get support from your management team, get them behind your idea. Don’t be afraid to put your ideas forward.”

For more information about the 2019 IQA Awards, and how to apply for an award or nominate a peer, visit quarry.com.au, click on ‘Networking’ and then ‘Awards’. •

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CONVEYING

THE MERITS OF RUBBER TORSION SPRING MOTOR BASES IN SCREENS

The rubber torsion spring motor base has a lengthy history. Richard Sharp explains how it came to be devised and why it is such a critical part of extractive and broader industrial processes.

T

he first rubber torsion spring motor base for vibrating screens was developed in Australia in the late 1980s. It was based on the rubber torsion spring design credited to Hermann J Neidhart in the 1940s.

At that time, a rubber torsion spring unit was attached to a simple base plate. This was clamped to a predetermined angle, about that of the required torque for the functional specifications of the application.

On vibrating screens, when connecting the drive vee-belts directly to the screen excitors, it results in the pulley to pulley centres not being fixed. That is, the pulley centres change when the screen starts and stops (during resonance) as the screen body is mounted on steel coil springs for isolation purposes. This results in drive belt slippage in the start-up phase, and high vee-belt and pulley wear will happen.

CATEGORY A AND B MOTOR BASES A “Category A” motor base with a pre-loaded rubber torsion spring allowed the drive pulley to follow the action of the screen in resonance, maintain sufficient belt tension to avoid belt slippage and reduce the force transmitted to the supporting structure. This helped to extend vee-belt life, as well as the drive and driven pulley life, and resulted in lighter motor support structures, as the mass of screen was not being applied during resonance.

It should be noted that motor base designs fall into two distinct groups: • The “Category A” (Figure 1), which allows for the electric motor to be connected directly to the outer section of the rubber torsion spring.

This allows for a resilient mounting and is ideal for applications such as vibrating screens or feeders when the vee-belts are connected directly to the excitor drive. The downside is the compression of the rubber cord under load allows misalignment of the drive and driven pulleys. To overcome this effect an alignment bearing is fitted to the drive side. This is referred to as a “dynamic application”.

• The “Category B” (Figure 2), which has the electric motor connected to the inner section of the rubber torsion spring. In turn, this is

34

Quarry May 2019

Figure 1. On a Category A motor base, the electric motor is connected directly to the outer section of the rubber torsion spring.

Figure 2. On a Category B motor base, the electric motor is connected to the inner section of the rubber torsion spring.

connected via bearings to the side plates of the motor base. The outer section of the spring is linked to a tensioning device for fitting and/ or changing drive belts and applying torque to maintain drive belt tension. This design is for static applications. That is where the drive and driven pulleys are fixed.

By the early 1990s, most vibrating screen drives rarely exceeded 30kW. However, once the market demanded larger motor bases for bigger screens and feeders with drives requiring motors 37kW and larger, it was obvious an improved mechanical adjustment was required.

Fully enclosed and lubricated mechanical tensioning devices were then developed.

These have the benefit of being able to purge old grease and lubricants at regular intervals (eg twice a year) and remain failure-free.

These designs have lasted 20 years.

DUAL SPRING MOTOR BASES Category A motor bases are without exception single spring (single pivot) in their design.

However, Category B motor bases (Figure 3) can be both single and dual spring arrangements. The criteria are safety and mechanical design.

All large overhead motor base designs are dual spring and operate in a parallel configuration to lift the mass of the motor and tension the belts in a safe and efficient manner.

Figure 3. Category B motor bases can be both single and dual spring arrangements.

The design also minimises horizontal movement during this process.

Horizontal (alongside) drives will also use dual springs, when the mass of the motor is unsafe to use a single spring (pivot). These are referred to as H-series (HA) drives.

The late 1990s saw greater emphasis on pump and crusher drives up to 630kW. Fitting, adjusting or changing out vee-belts and/or pulleys had major safety issues – particularly with larger overhead drives. These were all mounted on conventional jacking screws.

Overhead drives are more likely to present safety issues than those at the ground level. In most cases, reaching up above chest height is considered “part of the job”. Increasing the force required by adding a length of pipe is also considered “part of the job”. All of these add to personal risk and injury. Common accidents include strain injuries, falls and bruising.

In addition, mechanical problems due to design and/or corrosion should not be overlooked, eg an inability to make parallel the drive and driven shafts, to face drive and driven pulley, and to achieve and maintain the correct drive belt tension as per the belt manufacturer’s specifications.

COST SAVINGS In today’s market, labour is the single largest cost and companies strive for efficiencies and cost reductions. So, why do some end users ignore cost-effective designs that can reduce labour costs?

Leverlink had a mining client that accepted as normal practice that it took a full eight hours, and four men plus a crane, to change out a set of vee-belts on a large pump drive. All of its pumps were conventionally mounted on jacking bolts.

Leverlink designed a Verti-lift (VL) motor base to fit the existing pump base frame, used the existing vee-belts, and recommended a new guard that could be removed by two men without the use of a crane. Windows were included in the guard at belt mid-span for checking belt tension or re-tensioning.

The initial design included details such as ensuring the drive and drive shafts were parallel and that the drive and driven pulleys were faced. Unless the motor was removed or perhaps new pulleys fitted they would remain so at each and every belt change-out.

The cost savings were undeniable. Two men in two hours now did what took four men and a crane eight hours. The payback period was well within the extractive producer’s financial model and it went on to install some 30 additional pump motor bases.

MOTOR BASE DESIGN LIFE The design life of Leverlink’s VL and HA series is 10 years. This estimate is based on the rubber cord service life used in the spring. Other factors that may be of influence include maintenance, environment and installation.

Motor bases can also be rebuilt and refurbished. This may extend their service life to 30 years or more. Many extractive sites recognise the cost benefits. • Richard Sharp is the managing director of Leverlink.

SUSTAINABILITY

HISTORIC SITE TO BECOME

‘WALKABLE’ SUBURB The former Cave Hill Quarry in Lilydale in Victoria’s Yarra Valley is being transformed into a new, vibrant suburb. Tim Robertson visited the site which is now into the second year of a 15-year development project.

O

n 9 May, 1901, the first Australian parliament was opened at the Royal Exhibition Building in Melbourne. This World Heritage-listed building had been constructed 20 years earlier; erected in just 18 months, it hosted the 1880 Melbourne International Exhibition, the first World Fair in the southern hemisphere.

Among other things, these fairs were catalysts for extraordinary feats of construction (eg Gustave Eiffel designed and built his tower as the entrance to the 1889 World Fair) and the Royal Exhibition Building has become one of the city’s most enduring and iconic landmarks. Built by David Mitchell, father of the world-renowned soprano Dame Nellie Melba, it embodied the hope and optimism of late 19th century Victoria, still basking in the plenty of the gold rush era. Mitchell, a Scot who immigrated to Australia in 1852, supplied the limestone from his Cave Hill Quarry in Lilydale in Victoria’s Yarra Valley. He also built several other notable Melbourne landmarks, including St Patrick’s Cathedral and the Scots Church in Collins Street. Even now, his limestone can be found in gardens across

36

Quarry May 2019

The 25ha, 120m pit, circa February 2018. About eight million cubic metres of material will fill the hole, on top of 105,000 tonnes of a 50–300mm rock for the drainage blanket.

the country in the form of the much beloved Lilydale toppings.

The quarry was one of the primary sources of limestone in Victoria from its establishment in 1878 to its closure in 2015. The site’s historical significance can still be seen in its physical fabric: Mitchell constructed an extensive battery of pot kilns in response to the limitations of intermittent burning technologies, which enabled roundthe-clock production.

These heritage features – painted by one of Australia’s best known painters, Arthur Streeton, in 1935 – will be incorporated into the $2 billion residential and mixeduse development, which is expected to eventually house 8000 residents. The 162ha property was bought from Belgian multinational Sibelco in late 2016 as part of a joint venture with Bayport, Intrapac

and Brencorp Properties. On a tour of the site, Daniel Petroni, development manager at Bayport, told Quarry that the old kilns would form the centrepiece of the future Heritage Quarter, home to farmers’ markets, paddock-to-plate-style eateries and space for family-friendly events.

QUARRY REHABILITATION “There are plenty of examples where quarries of 30m to 40m have been successfully rehabilitated and developed on. This is the first quarry of its depth (100m plus) anywhere in the world that’s been rehabilitated with a plan to build on it,” Petroni told Quarry as we stood overlooking the 25ha pit. “Originally, the quarry was 120m deep.”

All the material that will be used to fill the pit will be sourced from within the site.

“Sibelco extracted around 13 million cubic metres and only around 25 per cent was removed from the site. The other nine million cubic metres was placed into overburden mounds,” Petroni said. “About eight million cubic metres will go back into the hole.”

McCloskey equipment, supplied by MSC Group, is being used for all the on-site crushing and screening. The McCloskey J50 V2 jaw crusher, with its high jaw speed, ensures better reduction and faster processing of material through the crushing chamber. The McCloskey C44 V2 secondary cone crusher has a high material capacity and throughput.

The McCloskey R155 reclaimer has an open feed hopper and heavy-duty apron feeder, making it well suited to processing bulky material. The McCloskey S190 secondary screen features adjustable screenbox angles that allow adaptability to a wide range of material applications. Rounding out this mobile circuit is the agile and robust TS4065 tracked stockpiler. The tracks offer on-site mobility and the metre-wide belt ensures maximum capacity. It also integrates easily into the McCloskey range of crushers and screens.

“To date, in terms of product, Bayport have produced a 50–300mm normal-style rock for the rock drainage blanket. They have done roughly 105,000 tonnes of that,” MSC Group’s Victorian sales manager Ian McCartney told Quarry.

“They’ve also produced 12,000 tonnes of a 50mm aggregate and 40,000 tonnes of a 40mm class 3 product. They’ve also processed topsoil and screened stockpiles of old material and other bits and pieces.

And there remains a lot more work to be done.”

McCartney said that in the early stages of the project the McCloskey machines played an important role in cleaning up the site.

“When it was a working quarry, all the overburden - the topsoil, the rock and the rubble - all that other stuff was pushed off to get the lime. So, all that stuff was around the quarry, which technically wasn’t waste, but it wasn’t the used product either.

This overburden needed to be sorted and screened and crushed to make material out of,” McCartney said.

LONG-TERM PROJECT It is estimated that the quarry pit will take six years to fill, but it’s a 12- to 15-year development project for the group, Petroni said.

The old kilns and silos will be restored, repurposed, and eventually incorporated into the Kinley development.

The Caterpillar 390F L hydraulic excavator is being used in conjunction with Cat 773 G trucks.

A circuit of McCloskey machines, supplied by MSC Group, in action during the first phase of rehabilitation.

Quarry May 2019 37

SUSTAINABILITY

David Mitchell constructed an extensive battery of pot kilns in response to the limitations of intermittent burning technologies, which enabled round the clock production.

Once the quarry is filled, the spoil will be left to settle for at least three years. The work is being undertaken under the supervision of the project geotechnical consultants Tonkin and Taylor.

“There have been several similar developments on other quarries that are much shallower than this – maybe up to 40m deep,” Roger Olds, principal geotechnical

engineer at Tonkin and Taylor said. “They’re usually quite challenging in terms of getting the right materials and so forth. But this one is unique in the depth and the stresses that are applied to the soil at the base of the pit.”

In an effort to forestall any problems, the ground is being over-compacted. As part of this process, a heavy-duty pump operates 24 hours a day, seven days a

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week, pumping 1.8 million litres of ground water per day. Ordinarily, soil needs to be compacted to 98 per cent density on commercial projects and 96 per cent on residential. But the soil at the former quarry is being compacted to a minimum of 101 per cent and an average of 103 per cent.

Bayport has turned to Caterpillar, a supplier with which it has had a relationship with since the 1960s, to help it complete this unique project. Two Caterpillar 825K compactors and two Cat 19-tonne vibratory rollers – a CP76 padfoot and a smooth drum CS78 – are being used at the site to provide superior compaction as each layer of the quarry is filled to the specified density. Each compactor has a GPS record for ease of operation, helping operators to distinguish between areas that have been compacted and those that still require attention.

There are also seven large Cat 773 50-tonne dump trucks carrying material from the top to the bottom of the quarry.

The largest of the machines on-site is the Caterpillar 390F L hydraulic excavator,

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which is one of two 390s on-site. This machine ensures production numbers remain high, while reducing operating costs and providing the power, fuel efficiency and reliability to maximise productivity. The excavators are used in conjunction with Cat 773 G trucks, guaranteeing that haul material can be loaded at a lower cost per tonne. The latest additions to the Cat fleet at Cave Hill are the D8T dozer and the Cat 982M series wheel loader.

PARKLAND SUBURB Upon completion, the land will hold about 3000 new residences and a host of local retail, community and commercial facilities.

The old quarry will become Kinley, a new suburb set among natural parkland.

The first 35 premium lots were released in October 2018 through an on-site ballot. The first stage release is adjacent to Hull Road, Lilydale with selected lots enjoying views to the Dandenong and Yarra Ranges. In mid-March, the second stage was released, featuring 11 lots ranging in size from 400m²

The McCloskey J50 V2 jaw crusher feeds the R155 reclaimer at Cave Hill Quarry.

The fixed crushing, screening and conveying circuit remains intact.

to 526m² with a selection of frontages.

The developers envisage Kinley being a “walkable suburb” where people are in pedestrian proximity to vibrant infrastructure such as retail, culture, restaurants, education and general street life.

In much the same way that the Exhibition Building stands as a testament to a particular period of Melbourne’s history, Kinley embodies the contemporary mood.

Australia, it’s sometimes said, was the first suburban nation; the dream of owning a home in a leafy suburb, away from the hustle and bustle of the city, is something of a national obsession.

Moreover, Kinley, as the last major parcel of land east of the capital, offers a rare opportunity for many more people to realise that dream. •

2019 IQA EVENTS ACT BRANCH

NORTH QUEENSLAND BRANCH

VICTORIAN SUB-BRANCH

12 July Dinner meeting (Venue TBA) 15 Nov Dinner meeting (Venue TBA)

30 May 25 July 12 Sept 21 Nov

17 July AGM and dinner meeting (Venue TBA) 30 Nov Races day (Venue TBA)

14 May Technical and dinner meeting, Tablelands 21 May Technical and dinner meeting, Mackay 19 June Safety & Health Seminar, Townsville 26 July Annual Golf Day, Cairns 13 Aug AGM and dinner meeting, Townsville 13 Sept Annual golf day, Townsville 8 Oct Technical and dinner meeting, Townsville 30 Oct Technical and dinner meeting, Cairns 15 Nov Christmas Party, Townsville

QUEENSLAND BRANCH

SOUTH AUSTRALIAN BRANCH

17 May IQA Annual Golf Day, Oxley Golf Club 14 June Quarrying Safety & Health Conference, Brisbane 7 Aug Dinner meeting & AGM, Brisbane Sept (Date TBA) CMEMC 2019

24 May Technical and dinner meeting, Adelaide 12 July Women in Quarrying Conference, Adelaide Pavilion 30 Aug AGM/dinner, National Wine Centre

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

NEW SOUTH WALES BRANCH 15 May NSW Health & Safety Conference (Venue TBA)

NSW CENTRAL WEST SUB-BRANCH 14 June Women in Quarrying seminar

NSW ILLAWARRA SUB-BRANCH

CENTRAL QUEENSLAND SUB-BRANCH 19 July Annual golf day, Rockhampton

VICTORIAN BRANCH

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

WESTERN AUSTRALIAN BRANCH 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

16 May Student presentation night

PDP WORKSHOPS & EVENTS To register for the courses outlined below and for further information, visit quarry.com.au, click on link to ‘Education’, followed by ‘Upcoming Professional Development Programs’.

IQA 62ND ANNUAL CONFERENCE GMHBA Stadium, 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 affecting 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

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Quarry May 2019

GEOLOGY & GEOLOGICAL PROCESSES WPDP 13 May 2019 Many product technical issues encountered by operators can be traced back to source rock properties and the selection of suitable raw materials. A basic understanding of geology, geologic processes, and rock types allows an operator to extract the most from their reserve on-site, determine future site viability, comply with product quality specifications, identify and manage geotechnical issues, and limit future product technical claims or issues. This webinar is suitable for managers, supervisors, technical/laboratory managers, and operational management employed or seeking employment in the industry.

ALKALI AGGREGATE RESPONSE WPDP 27 May 2019 Many product technical issues encountered

by operators can be traced back to source rock properties and the selection of suitable raw materials. Having a basic understanding of alkali aggregate reactivity (AAR) allows an operator to determine greenfield site suitability, comply with aggregate quality specifications, identify and manage AAR issues, and limit future product technical claims. This webinar is suitable for managers, supervisors, testers and operational management employed or seeking employment in the industry.

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

FROM THE CEO

SETTING THE TONE FOR EFFECTIVE SAFETY BEHAVIOUR As an industry we all know how paramount safety, and a culture of safety, is. Being aware of areas where injury can occur, building systems and safety measures to prevent injuries and training staff to ensure we have an incident-free workplace is nothing new.

The leadership behaviours we display can be more complex than the procedures we put in place and they have a big impact on the safety culture in our workplace. When it comes to safety, leadership should not be looked at in a hierarchical sense. Leadership is about the way we behave and act. There are numerous behaviours for which we can all take personal responsibility for that will influence a culture of safety.

Behaviours such as role modelling compliant and safe behaviours set the tone of what is expected from the team.

These behaviours: • Recognise and reward our colleagues for their actions in effective safety behaviour.

speakers, a DNRME update and other presentations on practical issues affecting 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

MANUFACTURED SAND WPDP 17 June 2019 Manufactured sand is increasingly used in the construction materials industry as the availability of natural sand deposits declines.

This webinar outlines the uses and typical properties of manufactured sand, and briefly covers operational issues during production and use of the product. This webinar is suitable for managers, supervisors, testers and operational management employed or seeking employment in the industry.

PERFORMANCE IMPROVEMENT WPDP 24 June 2019 This webinar doesn’t require an in depth knowledge of statistics, pareto analysis, or six-sigma. It provides the grassroots basic tools that will help participants to identify opportunities and manage through

• Encourage everyone’s active participation, collaboration and sharing of ideas in safety decision-making, and empower everyone on the team to take personal responsibility for safety.

• Challenge team members to think about safety and possible safety issues in different ways.

• Encourage everyone to listen to each others’ opinions, to speak up and be open to discussion and debate.

These behaviours can all define effective safety performance and can come from everyone in the business. These behaviours should be nurtured and encouraged, especially when it comes to safety.

The training and ongoing professional development of our teams is a key part of developing our leaders. If you are thinking about safety, think about the structure of appropriate and regular training.

The IQA can support organisational

the improvement cycle. It is suitable for managers, supervisors, operational employees, and operational management employed or seeking employment in the industry.

QUALITY CONTROL & STATISTICS WPDP 8 July 2019 Effective quality control forms an essential part of professional quarry production processes. Conformance with specifications, predictability, and repeatability of product results helps quarry managers to control costs and ensure repeat business. This webinar is suitable for managers, quarry/ laboratory supervisors, testers, and operational management employed or seeking employment in the industry.

QUARRYNZ 2019 ILT Stadium Southland Invercargill, New Zealand 17-19 July 2019 Registrations for the annual joint conference of the Aggregate and Quarry Association of New Zealand and the Institute of Quarrying New Zealand are now open to delegates, partners, sponsors and distributors. The conference is an opportunity for all those involved in the industry to interact and

development strategies and workforce training plans that can align directly to risk and safety. For more information, contact admin@quarry.com.au KYLIE FAHEY Chief Executive Officer Institute of Quarrying Australia

exchange ideas, take the opportunity to hear the experiences of guest speakers and to socialise with old friends and colleagues and to make new contacts. The theme of the conference will focus on the region’s contribution to the New Zealand economy: Southern Rock anchoring NZ. The social program will include three functions, tickets for which will be included in delegate and partner registration packages. For more information, visit quarrynz.com

COST MANAGEMENT FOR QUARRIES WPDP 22 July 2019 With increased pressure on productivity, profitability, efficiency and asset utilisation, the focus on cost control has never been more important. Quarry managers are the front line in cost management. Daily decisions directly influence monthly profit outcomes. This webinar defines the various cost terms used in the industry, discusses how they are influenced, and provides potential system solutions to increase cost and performance visibility. It is suitable for managers, supervisors, operational employees, and operational management employed or seeking employment in the industry.

Quarry May 2019 41

IQA NEWS

The Institute of Quarrying Australia

QUEENSLAND BRANCH NEWS Feedback from Queensland WIQ conference, 21 March 2019 Was it worth the time?

“Absolutely, the presentations were very motivational and it was a good opportunity to network.”

“I thought the conference was great value for women in the industry – in particular for women outside our business to network.”

Lauren Charlton discusses Boral’s diversity activities.

The Queensland branch’s WIQ co-ordinator and conference MC Karen Normanton.

What did you take away from the day?

“While conferences like this point out both the shortcomings and the advancements in diversity in our industry, I can definitely see the improvements and opportunities for women in the industry over the last decade, and this is nothing short of remarkable, to the point where women are taking the lead in starting businesses in the quarrying industry. Great to see and hear the success stories.”

Would you go again?

“In a heartbeat!”

Queensland Women in Quarrying Conference, Brisbane Karen Normanton, the Queensland WIQ co-ordinator and the conference MC, said feedback (above) from the 2019 WIQ conference delegates was that the event was the most successful yet. The line-up of expert industry speakers covered a variety of topics from social media, career planning, diversity, to indigenous business supply to industry.

The opening speaker was IQA CEO Kylie Fahey, who falls into the 16.5 per cent of CEOs in Australia who are female. Kylie urged delegates to “get outside your comfort zone and find where the magic happens. Share a story”. Kylie’s decision to enrol in a stand-up comedy course “many moons ago” was her story to share!

The presentation by Adrian Caneris from Biodiversity Assessment and Management (BAAM) – titled “Quarries and ecology – The good, bad and ugly side of both” – showed that quarries are actually preserving wildlife populations – both flora and fauna – within their buffer zones.

Sarah Morgan from the Vaxa Group, explained how to use social media to connect with the local community, customers and stakeholders. Mary Thompson told her story – “From Macquarie to my quarry” – of her career as a quarry business owner to 42

Quarry May 2019

The panel discussion comprised (from left): Michelle Connelly (facilitator), Kelly Jury (Hastings Deering), Kartini Oei (NAWO), Alison Price (NAWIC), and Mary Thompson (McLeod Rail).

her current role as the CEO of McLeod Rail, a Victorian-owned and operated rail track maintenance contractor.

Lauren Charlton, from Boral, the conference’s platinum sponsor, reported on her company’s diversity activities, while Suzannah D’Juliet, the safety operations executive manager for Hastings Deering, also outlined her company’s flexibility and inclusion program.

Angela Schilling’s passion for her “Kindness Project”, which implores everyone to be “kinder to each other”, also made for an inspirational session and conference highlight.

Michelle Connelly from the CPR Group, the Queensland WIQ’s major supporter, facilitated a panel discussion including speakers from throughout the day. This was the perfect wrap-up to a very enjoyable and worthwhile conference program.

The IQA’s Queensland branch is grateful to the sponsors of this year’s conference for making the day so memorable: CPR Group, Boral, Groundwork Plus, Holcim, CCAA, 888 Crushing & Screening Equipment, MinProvise, and Hy-Tec Industries.

Young Members Network site tour The Queensland branch’s Young Members Network hosted a site tour in the Brisbane

Nineteen Young Members toured Komatsu’s Wacol facilities on 26 March.

region on 26 March. Nineteen participants boarded the coach and travelled to Komatsu’s Wacol facility where Alec Harries, Komatsu’s major account manager for civil construction and quarries, met them. The group toured the heavy machine assembly facility, the refurbishment facility and the oil testing and analysis laboratory which tests more than 500 samples per day. The group had the opportunity to view a high capacity LEAN workshop set-up, with several mine spec electric dump trucks in different assembly stages at the time. The oil testing facility provided insight on the complexity of oil testing, the equipment used and the impact foreign elements in oil have on heavy machines and some failure modes. Komatsu treated the group to morning tea after an exhaustive presentation explaining Komatsu’s SmartConstruction technology.

The group then travelled north to the Rockworx Keperra Quarry, where quarry manager Quinton Leed gave the group a presentation about the history and future plan of the quarry and a high level overview of the operation. Quinton illustrated the key products that the site sells, the challenges of the granite the quarry team extracts, and the community impacts of the operation. The group toured the quarry and observed the mobile crushing plant and challenging geology present in the pit.

As the last port of call, the group travelled across the road to the Hanson Ferny Grove Quarry, where they met quarry manager John

IQA NEWS practice in dedicated player bays with drinks and snacks. Ritchie Bros sponsored the event and presented Luke Blanchard and Jai Hunt (both from Fulton Hogan) with the winning prizes. Each received a player pass to the branch’s annual golf day, which will be held at Oxley Golf Club on Friday, 17 May.

Paul Coughlan escorts branch members to the site of the Brisbane Airport New Parallel Runway.

Quarrying Safety & Health Conference, Brisbane The Quarrying Safety & Health Conference will be hosted at the Brisbane Convention & Exhibition Centre on Friday, 14 June. The one-day conference is sponsored by Komatsu and Astec Australia, and co-hosted by the IQA, the CCAA and the Queensland Government’s Mines Inspectorate. The conference also includes a trade exhibition.

This year’s technical program includes: • Case studies by Andrew Macqueen, the head of safety, environment and quality for Wagners; Kristin Devlin, risk manager for Hanson; and Rakeev Ramankutty, the general manager of Sunstate Cement.

The plans for Brisbane Airport’s new runway.

• Skills for Australia update – skills required in the extractive industry.

Taylor. John presented a detailed overview of the quarry and an illustration of its versatile and dynamic crushing plant, followed by a tour of the quarry. At the site lookout point, the group could see the scale of the operation from a bird’s eye view.

• Current status and future of critical control management in the quarrying industry.

The YMN is grateful to Komatsu, Hanson and Rockworx for agreeing to the tours of their sites and for providing an excellent learning opportunity for the Young Members Network.

• Education for the extractive industry.

By Darko Cvitanovic Queensland branch YMN co-ordinator

Site tour, Brisbane Airport Members of the Queensland branch visited the Brisbane Airport New Parallel Runway project in April. Project director Paul Coughlan escorted the group to the runway site, explaining that work began on the site in 2012.

The major stages of construction are now in progress and it is on track to open in 2020.

Once complete, Brisbane will have the best runway system in Australia, effectively doubling its capacity.

The new runway is a key piece of infrastructure that will enable the continued growth of Brisbane and the region. It is anticipated that by 2035 the new runway will lead to the creation of 7800 new jobs and contribute an additional $5 billion in annual economic benefits to the region.

After the site tour, the group rallied at Golf Central, adjacent to the airport, for some golf

• Inspectorate updates, legislation and competencies.

• Findings of crystalline silica/improvements.

• Collision management risk evaluation for mobile equipment.

• Drone technology.

Registrations for the conference are now open. Visit the IQA website – quarry.com.au – or contact the Queensland branch secretariat, tel 0419 782 688 or email qld-admin@quarry.com.au

By Jennifer Milward

NORTH QUEENSLAND BRANCH NEWS Safety & Health Seminar, Townsville The annual Quarrying Safety & Health Seminar, co-hosted by the IQA and the Queensland Department of Natural Resources, Minerals and Energy, will be held from 9.30am at Rydges South Bank, Townsville on Wednesday, 19 June.

The seminar program includes presentations on a variety of topics from expert speakers including: • An Inspectorate update, legislation updates and competencies.

• Findings of crystalline silica/improvements.

The Institute of Quarrying Australia

• Drone technology.

• Critical control management in the quarrying industry.

IQA CEO Kylie Fahey will report on the Institute’s education strategy for the extractive industry, and is keen to meet with as many members and industry colleagues as possible during her visit to the region.

The seminar will conclude at 4.00pm, followed by informal drinks and snacks through to 6.00pm. To register, visit the IQA website – quarry.com.au – or contact the Queensland branch secretariat, tel 0419 782 688 or email qld-admin@quarry.com.au

By Jennifer Milward

SOUTH AUSTRALIAN BRANCH NEWS Young Members Network site tour On Friday, 5 April, South Australia hosted its first Young Member Network (YMN) function for the year. Fourteen Young Members visited two very different sites in SA’s Kanmantoo area. Both sites provided very informative and educational tours, each with a different aspect to the operation that is atypical of most quarries.

The group met in Mount Barker before boarding a bus to the Hillgrove Resources Kanmantoo copper mine. With copper not usually on a quarry repertoire, it was an intriguing learning experience for YMN members. Luke Angel, the mine superintendent, and Hayden Arbon, the senior mine geologist, gave the tour group a very informative overview of the operation and its processing systems.

All members were amazed at the size and depth of the open cut pit, with Hayden explaining that the depth and steepness of the pit faces were only possible due to the geotechnical strength and nature of the rock resource, which is well understood and controlled by the team at Hillgrove. It was a very impressive sight and certainly a credit to the Hillgrove team, with considerable pit optimisation over its mine life. The site is coming to the end of its 10-year mine life, and the team explained that the site has two months of pit production, and 18 months of ore processing left. They explained what the rehabilitation steps would be, and possible end of life uses, including hydroelectricity.

The second site of the day was Hanson’s Kanmantoo Quarry, which produces concrete and sealing aggregates, and a range of dimension stone products. The guides were quarry manager Larry Neal and Hanson’s Quarry May 2019 43

IQA NEWS Kanmantoo is Hanson’s only site globally that manually handles stone. This was really an “eye opener” for the YMN members.

Fourteen Young Members visited two very different sites in SA’s Kanmantoo area.

After finishing at Kanmantoo, the group headed back to the Barker Hotel to evaluate and discuss the site visits further. With a diverse group dynamic, and representation from a variety of companies throughout SA, this debrief time presented some very rewarding networking opportunities for YMN members. It was also an opportunity to welcome freshly joined IQA members Jake Schmidt and Zach Sims from Clare Quarry to the Institute and they were presented with their Membership certificates.

The first SA YMN event for the year was a well received and successful function, with good attendance and some very valuable insights and networking. With a number of different possibilities discussed for future YMN events and a number of passionate and motivated YMN individuals involved, the year promises to be positive and absorbing.

The impressive view of the Hillgrove Kanmantoo copper mine.

WESTERN AUSTRALIAN BRANCH NEWS The fifth annual Bowling Stone Lawn Bowls Challenge and sundowner was held on Friday, 22 March at South Perth Bowls Club. It was a fun-filled evening of spirited competition amongst colleagues and peers, as well as a great opportunity to socialise and network, as more than 80 members and their guests formed teams to compete for one of the most sought after titles in the industry.

Young Members inspect Hanson’s bluestone production area.

territory sales manager Daniel RensburgPhilips, one of the YMN members. Larry gave the attendees a detailed overview of the site operations, covering some interesting site developments, such as Hanson’s acquisition of the site a few years ago, and the very detailed process of starting a new extractive mineral lease and mine plan.

Perhaps the most anticipated part of this site visit, was the tour through the Kanmantoo bluestone production area and its range of various dimension stone products. Daniel discussed the very labour-intensive, hand crafted process and the “art” and history behind the Kanmantoo bluestone business. He explained what the company’s challenges are in the management and production of these niche products, using literally bare hands and hard work. YMN members were amazed at the variety and quality of the dimension stone products produced, and as it stands,

44

Quarry May 2019

The competition and rigorous exercise got the appetites working, so it was fortunate that Steven Della Bona continued the tradition of being the “Italian barbeque king”, cooking up a feast for everyone.

IQA NEW MEMBERS

“We are the champions!” Hanson’s Gaskell Quarry team successfully defended their Bowling Stone title.

This year, the aim was to knock off the reigning champions in Hanson’s Gaskell Quarry team, especially as Hanson is also in possession of the golf trophy. Nonetheless, the Gaskell Quarry team, represented by the ever so specially dressed Bruce Hardy, Waed Searson, Darren Morris and Damien Hardy, defied the odds and successfully defended their title. They were followed closely

by Equipment Placement in second place and Italia Stone Group in third. The NABA (last place) was “proudly” taken out by CJD Equipment.

The perpetual Bowling Stone trophy was hand-crafted and donated by Italia Stone Group. This event is also proudly sponsored

by Tinus and his team at Italia Stone Group.

The WA branch’s next meeting is breakfast at Beaumonde on the Point, East Perth, on 8 May. For more information, visit quarry.com.au or contact the WA branch secretariat, tel 0417 027 928 or email wa-admin@quarry.com.au

By Celia Pavri

IQA BRANCH CONTACTS ACT

Peter Hewson: 0429 001 476

NSW

Gemma Thursfield: 0402 431 090

Northern Gemma Thursfield: 0402 431 090

GRADE

NAME

BRANCH

Associate Associate Associate Associate Member Associate Associate Member Associate Associate Associate Associate Associate Associate

David Henry Young Mervyn John Hain Michael James Jackson Luke James Martyn Benjamin Joseph Grose Clinton Richard Sutton Jordon Luke Staker Bradley Godden Dean Heath Rickards Brendon James Mayo James Nicholas Johnston Amanda Minaro Michaelle Millsom Michelle Rowe

WA QLD QLD VIC QLD QLD NSW VIC VIC QLD NSW NSW NSW NSW

Hunter Gemma Thursfield: 0402 431 090 Illawarra

Dylan Treadwell: 0418 632 057

Central West Mitchell Bland: 0428 462 987 NT

Darren McKenna: 08 8988 4520

QLD

Jennifer Milward: 0419 782 688

Gladstone Jennifer Milward: 0419 782 688 Townsville Jennifer Milward: 0419 782 688 Cairns SA

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

Tasmania Nicholas Palmer: 0418 126 253 Victoria

Eli Carbone: 03 8637 4723

Vic Sub-branch Craig Staggard: 0407 509 424

WA

Celia Pavri: 0417 027 928

The Institute of Quarrying Australia

BUMPER PROGRAM PLANNED FOR 2019 CONFERENCE

A combination of instructive and motivating presentations, and site visits, are in the planning stages for the IQA’s national conference later this year.

T

his year’s Institute of Quarrying Australia (IQA) national conference will be held in Geelong from Tuesday, 1 October to Thursday, 3 October.

The conference theme is ‘The Future of Quarrying’. It aims to support and supplement the IQA’s vision to educate and connect the extractive industry.

“We are looking to ‘enable’ our members with the latest in technology and products to be as effective, efficient and safe as possible,” the conference chairman Brad Rooney told Quarry. “The quarrying industry has historically been a very hands-on business and everyone gets in the trenches to make the business successful.

“This conference will put a range of tools in the hands of our quarrying people to assist with reducing cost, making activities easier and more efficient, and to enable our people to be more informed about what is happening on their quarry sites.”

SITE VISITS The conference program is being designed to deliver valuable educational, networking and promotional content to support the extractive industry. There will be a number of high profile speakers presenting sessions on developments in technology for mobile equipment, the drill and blast process, and the crushing and screening circuit.

Issues such as new and emerging technologies, resource constraints, health and safety, and community and regulatory requirements will all be explored in the conference program.

“The speaker program is going to be the real draw card this year,” Rooney said. “It will be highly relevant and steeped in content to support the theme of ‘The Future of Quarrying’.

“The three evening events [Hitachi’s welcome reception, Komatsu’s gala dinner and Caterpillar’s gala dinner] are always highlights of our magnificent conference. The networking and ‘working together’ feel of the conference is a real highlight for all suppliers and delegates who come together.”

The conference will include site visits to

The convention centre at GMHBA Stadium will provide exhibitors with maximum exposure during the conference.

the new crushing and screening plants at Boral Australia’s Deer Park Quarry, and Barro Group’s Point Wilson Quarry, near Geelong.

“Boral Deer Park has recently invested significant capital in building a state of the art, new crushing plant,” Rooney, who is a Boral employee, said. “Given that crushing plants last a very long time [30-plus years], there will be a number of people who will really enjoy seeing this new plant. They will see new and modern ways to reduce noise, dust and to maximise throughput, which will be of significant interest to the quarrying industry.”

“Barro Point Wilson will also showcase a new crushing plant, which is only four years old. Our crusher enthusiasts will be very interested to see the developments in only four years, along with the design characteristics of a local business, as opposed to a large multinational.”

TRADE EXHIBITION The exhibition hall at GMHBA Stadium (formerly known as Kardinia Park, the home of the Geelong Cats AFL club) has been designed to ensure exhibitors gain maximum exposure during the conference.

All delegates will have to pass through the exhibition to attend the opening address,

The national conference in October will include a site visit to Boral’s new crushing and screening plant at Deer Park Quarry.

plenary sessions, award presentations and other official conference events.

“The IQA expects 400-plus delegates for this year’s conference, so for exhibitors we invite them to take this exclusive opportunity to showcase their businesses’ products and services and to leverage the benefits of this captive audience,” Rooney said.

“We encourage exhibitors to reach out to customers and invite them to their exhibition booths or maybe out for a coffee.”

To register for the conference, and for further information about sponsorships and exhibiting, visit conference.quarry.com.au •

By Tim Robertson

Quarry May 2019 45

GEOLOGY TALK

AGGREGATES AND SEISMIC AWARENESS

The clean-up effort following floods at Tegra’s Jugiong Quarry, near Gundagai, NSW, in 2010. Despite the disaster, Tegra was able to meet concrete demands.

The San Andreas Fault follows the line of trees through this photograph.

Earthquakes and natural disasters don’t just have a terrible social impact – they can also severely disrupt the smooth running of aggregate operations. Bill Langer dispenses some advice for operations on being better prepared for seismic and other tumultuous events.

operations in the Gulf Coast area took up to two weeks to assemble skilled personnel from the grieving workforce.

Producers can do many things to be ready for an earthquake (or other natural disasters, eg floods, storms, bushfires): • Individual facilities might benefit from a seismic safety audit by engineering professionals.

• Spare parts can be positioned at plants themselves, or at central locations.

• Standby sources of power-generating equipment, and portable processing facilities can be identified and advance lease or purchase agreements made.

• Large producers with multiple plants can plan for intracompany transfer of product, personnel and equipment after a disaster.

• Aggregate, asphalt and concrete producers can make intercompany mutual aid agreements, similar to those commonly used by police and firefighting agencies.

A plausible estimate of damage to the aggregate, concrete and asphalt industries following a disaster in your area, combined with prudent advanced preparations, should facilitate a timely response by the aggregate and related construction industries. •

T

he more seismic-aware society [is], the better prepared people will be to minimise the effects of an earthquake.

Following my article last month on the damage from the 1906 San Francisco earthquake, it’s fitting to examine ways aggregate producers can be more seismic-aware. These are based on the ShakeOut Scenario, a wide-ranging exercise conducted to identify the physical, social and economic consequences of a magnitude 7.8 earthquake on the San Andreas Fault in southern California.

My conclusions for the ShakeOut were extrapolated from the observations of an experienced aggregate operator of the impacts caused by the magnitude 6.7 Northridge earthquake (1994).

Some aggregate, concrete and asphalt companies in earthquake-prone areas design and construct their facilities to withstand earthquakes and conduct regular inspections to ensure their facilities remain in sound operating condition. Facilities that take these precautions may suffer little or no damage during an earthquake. In contrast, poorly maintained operations could be severely damaged – some beyond repair.

46

Quarry May 2019

Large earthquakes can cause significant damage to buildings and infrastructure.

Emergency repairs and long-term reconstruction may require large amounts of aggregate, asphalt and concrete.

Being seismic-aware helps reduce the response time for emergency repairs. For example, after the 30 November, 2018, magnitude 7 earthquake in Anchorage, Alaska, all eight major transportation corridors that had been severely damaged were reopened within five days.

Bringing damaged facilities online after a quake depends heavily on spare parts and new equipment. For example, new crushers and screens may be in demand by both the aggregate and recycling industries.

Making concrete and asphalt requires materials from upstream cement plants.

Damage to those facilities could limit the ability of local producers to meet demand.

Similarly, power, water, gas and fuel outages will affect production.

Equally important, many of the skilled workers needed to operate aggregate and related facilities could be affected by the quake and tending to personal needs. For example, after Hurricane Katrina, aggregate

Bill Langer is a consultant geologist.

Email bill_langer@hotmail.com or visit researchgeologist.com

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