European quarrying and aggregates markets set for a big 2026.
06 ASSOCIATION NEWS
The latest updates and engagements from Aggregates Europe for its members.
50 EVENTS
All the key events in the quarrying and aggregates world.
Specials
08 MARKET REPORT
An in-depth look at the events and trends shaping the Spanish aggregates sector.
10 QUARRY PROFILE
SBM supports Heidelberg Materials Mineralik DE with its Nußloch Quarry.
14 SITE STORY
B&A Group engaged CDE to elevate its quarrying operations.
18 SAMOTER 2026
The renowned trade show is set to bring major brands to Verona, Italy, in 2026.
Ecocem founder and managing director Donal O'Riain talks about the company’s bright future in the construction materials sector.
The latest updates and innovations in crushing and screening equipment and services.
Customer demands continue to shape the future of loading equipment.
Hauling equipment is playing a key role in these quarrying customer success stories.
Conveyor solutions are becoming increasingly pivotal to successful quarry operations.
As prices rise, rebuild and remanufacturing solutions are becoming prominent in the sector.
42 TYRES
From buckets to other attachments, operators are looking for versatile solutions to get the most out of their daily tasks.
Strong innovation continues at a pace for global tyre manufacturers.
44 DIGITAL SITE SOLUTIONS
Digital technology is defining a new era of quarry management.
48 RENEWABLE FUELS
Steve Nendick shares his insights into the rise of renewable fuel in the quarrying sector.
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LIAM MCLOUGHLIN EDITOR
EUROPE’S QUARRYING SECTOR GOES ABOVE AND BEYOND IN SECURING A GREENER FUTURE
As we navigate the start of 2026, it’s heartening to see the European quarrying industry winning recognition for its efforts in a number of areas – from developing an extraordinary range of sustainable initiatives to playing a central role in recovery efforts from natural disasters.
In terms of the latter, the Spanish quarrying and aggregates sector is showing signs of growth despite having faced serious challenges in recent years, not least the devastating oods in Valencia in October 2024.
This issue’s market report on Spain highlights how the country’s quarrying sector stepped up from the very rst minute to meet the challenge. Federación de Áridos (FdA) – the non-pro t organisation representing the country’s aggregates producers – has been recognised for its impressive response to the oods.
At the Aggregates Europe Sustainable Development Awards 2025, held in Brussels, Belgium, on 26 November 2025, the FdA won both the Association Initiative Award and the Public Vote Award for its efforts in working with local authorities to address the damage and enable reconstruction in the affected areas.
The Aggregates Europe Sustainable Development Awards 2025 also highlighted the efforts of industry leaders in disciplines such as environmental best practices, local community partnerships, health and safety, economic contribution and added value to society, biodiversity, and communication.
Read all about it in the report on the awards on our association news page.
This issue’s quarry report gives details on how Heidelberg Materials Mineralik DE has ‘reactivated’ its traditional Nußloch site near
Heidelberg, Germany, with new processing technology from SBM Mineral Processing.
The site had supplied raw materials for cement production since the early-1960s, but now provides the Rhine-Neckar region with high-quality concrete aggregates and road construction materials. The move follows the construction in 2023 of a new gravel plant in the quarry. The contract for the complete processing technology was awarded to the Austrian company SBM Mineral Processing. This included primary, secondary and tertiary crushing stages, each with ef cient dust extraction, as well as wet processing of all concrete aggregates and road construction gravel. The plant concept was also required to include sludge and wastewater treatment.
The plant was commissioned in March 2025 and, thanks mainly to the impressive quality of its internally and externally monitored end products, the management at Heidelberg Materials Mineralik DE is already planning for an annual production volume of 400,000 tonnes in the medium term, with concrete aggregates accounting for 60 per cent and road construction materials for 40 per cent.
As the new editor, I would like to pay tribute to Guy Woodford, who has moved to a new position after 11-and-a-half very successful years as editor of Aggregates Business. Many of you would have met Guy and know all about his expertise and enthusiasm for the global quarrying and aggregates industry.
I spent six hugely enjoyable years working alongside him as the assistant editor of Aggregates Business from 2018–24, and it’s great to know he will not be lost to the industry. Best wishes for the future, Guy. LM liam.mcloughlin@primeglobalpublishing.com
Celebrating Europe’s RockStars: The 2025 Sustainable Development Awards ceremony
The Sustainable Development Awards once again took centre stage in Brussels, Belgium, honouring the extraordinary commitment of Europe’s aggregates industry to sustainability.
Despite signi cant travel disruptions caused by airport strikes and transport delays across Brussels, the Sustainable Development Awards (SDA) 2025 saw an impressive turnout of 230 industry professionals, companies, and stakeholders from across the continent.
The strong participation re ected a deep and shared dedication to the values that underpin this prestigious tri-annual event.
Recognising the top achievers in sustainable aggregates production
The SDA Awards continue to celebrate the true RockStars of Europe - those who go above and beyond in advancing the sustainable development of the aggregates sector. The 2025 winners stood out not only for their technical excellence, but also for their strategic
vision in balancing production, environmental care, and community engagement.
This year’s recipients offered outstanding examples of innovation in one or up to nine categories:
• Restoration
• Environmental best practice
• Local community partnership
• Health and safety best practices
• Economic contribution/ added value to society
• Operational best practice, process or product innovation
• Best practice in innovation or recycling, marine or manufactured aggregates
• Special award for biodiversity
• Special award for communication
For the rst time, national associations had their own category to present outstanding projects. These projects balanced sustainability and operational excellence.
Beyond the awards: A platform for learning and leadership
For participating companies, the SDA Awards offer far more than recognition. They provide a valuable platform to showcase best practices at the European level, benchmark achievements, and inspire others across the sector.
Equally important, the Awards foster knowledge exchange - encouraging dialogue, cross-border collaboration, and mutual learning. These moments of connection are critical to strengthening a culture of sustainability that transcends individual projects or companies.
Looking ahead to 2028
As we look to the future, we invite all members to stay engaged with the SDA Awards. Whether through submitting new projects, sharing insights, or attending future ceremonies, every contribution helps reinforce the relevance and impact of this initiative.
We look forward to building on the success of this year’s ceremony and to welcoming even more RockStars of Europe for the next edition on 29 November 2028. AB
The Sustainable Development Awards were held in Belgium.
Images: Aggregates Europe
The awards recognised many case studies of best practice across several categories in the quarrying and aggregates sector.
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Growth on the horizon
Despite numerous challenges, the Spanish aggregates and construction industries are showing encouraging signs of growth.
The Spanish aggregates industry in 2025 is experiencing growth driven by a strong construction sector and increasing emphasis on sustainability and technological innovation, according to ResearchAndMarkets.com (R&M.com), a major business market research consultancy. The same source said the market is also heavily focused on developing recycled aggregates and improving operational ef ciency.
The broader Spanish construction market, which signi cantly in uences the aggregates industry, was expected to grow by 3.9 per cent in 2025, according to R&M.com’s Spain Construction Industry Databook SeriesMarket Size & Forecast by Value and Volume, 40+ Market Segments Across Residential, Commercial, Industrial, Institutional, Infrastructure, City-Level Construction by Value and Cost Structure, Q4 2025 Update
The R&M.com update states that the aggregate base course market in Spain is also projected to grow at an 8.4 per cent Compound Annual Growth Rate (CAGR) from 2025–30. R&M.com said that growth in the construction and aggregate base course market is primarily driven by increased government investment in infrastructure projects, such as road and railway construction, and by a strong residential and urban regeneration market, partly funded by Next Generation EU (NGEU) funds.
The R&M.com update said that the Spanish construction aggregate market was valued at approximately €8.1 billion in 2024 and is expected to continue growing through 2029.
R&M.com said a major trend in Spain's construction and building materials industries is the growing focus on the circular economy. Companies are investing in plants to process construction and demolition waste into highquality recycled aggregates, reducing land ll use and carbon footprint.
Meanwhile, industries are adopting technology to improve ef ciency, health, and safety. Innovations include arti cial intelligence in operations, digital platforms for logistics optimisation, and advanced crushing and screening technologies.
The R&M.com update also said that the market for Spanish lightweight aggregates is speci cally projected to reach €4.5 billion by 2030, driven by climate-adapted urban housing needs. According to the latest estimates from Aggregates Europe (the European Aggregates Association), in 2023, Spain’s 1073 producers operating 1863 extraction sites produced 157 million tonnes of aggregate, with Italy’s estimated 160 million tonnes produced that year the closest European nation comparison.
A key event for the Spanish aggregates sector in 2025 was the VII National Aggregates Congress (VII CNA), held in Córdoba, Spain, from October 22–24. This congress served as a major gathering of the European and global extractive industry, focusing on sustainability, internationalisation, and the essential role of aggregates in development. The event featured the presentation of the 2025 National FdA Sustainable Development Awards and the Mining and Life Foundation Awards, recognising company initiatives in
the circular economy and environmental management. Partners from European projects such as Queen, Rotate, and Scimin were present to share advances in sustainable quarry management and low-emission production.
The Spanish Association for Standardisation (UNE) also participated, highlighting the importance of standards in sustainability and digitisation.
As in previous years, major Spanish aggregates industry players remained highly active in the market in 2025, including Cemex, Holcim, and Cementos Molins (active in the recycled aggregates sector). ACS Group and Ferrovial are leading construction rms driving national demand for aggregates.
At the Aggregates Europe Sustainable Development Awards 2025 held in Brussels, Belgium, on 26 November 2025, Federación de Áridos (FdA) – the non-pro t organisation representing Spanish aggregates producers – won both the Association Initiative Award and the Public Vote Award for its impressive response to the devastating oods in Valencia in October 2024.
One of the most devastating natural disasters in recent European history, a torrential downpour described by Spain's National Meteorological Service as “extraordinary” dumped an unprecedented 491 litres of water per square metre in just eight hours.
Storm DANA (an isolated high-altitude depression) struck a densely populated area of signi cant economic and social importance. The result was devastating: 224 fatalities, three missing persons, and more than 87 affected municipalities.
Led by FdA, the Spanish aggregates sector stepped forward from the very rst minute, working closely with the Valencian
A Cat 374 excavator dropping a ball of stone at Arids Garcia granite quarry near Barcelona, Spain.
Regional Emergency Center and the Waste Management Department of the Valencian Government to swiftly address urgent needs. More than 600 units of machinery and equipment were promptly provided to the affected municipalities.
In its Aggregates Europe Sustainable Development Awards 2025 entry, the FdA said: “Our federation maintained direct communication with the local administration’s waste management department and created a map to identify areas suitable for permanent disposal of all generated waste. Facing a historic and extraordinary challenge, the entire sector worked as one uni ed team—there was no other way. Our technical and nancial collaboration focused precisely where it was most urgently needed, building an extensive network to handle the massive amounts of debris hindering reconstruction.
“Additionally, temporary storage areas were established for various complex waste types, including bulky materials, street-cleaning sludge, sludge mixed with rock, and other inert waste. Coordination was managed by ARIVAL (Valencian Association of Aggregate Manufacturers) and the technical leadership of the Valencian Business Confederation.
“Approximately 120,000 tonnes of waste were collected daily for several weeks, a volume comparable to the region’s annual collection, underscoring the disaster’s magnitude. The entire sector operated as a single team. The impact was severe, but we are rising again.”
FDA director general César Luaces Frades, said the Spanish aggregates sector’s activity is unevenly distributed across the country, with the autonomous communities of Galicia, Castilla y León, and Aragón hosting the largest number of operations.
However, regions such as La Rioja and the Basque Country stand out for having productivity rates above the national average.
“Regional challenges include adapting to stricter environmental regulations and managing resources in areas with intense land-use competition,” Frades said.
“Additionally, the sector's fragmentation into numerous small and medium-sized enterprises poses challenges for investment in technology and sustainability.”
The FdA director general listed the structural challenges facing the sector in his opinion:
•Digitalisation and Industry 4.0 – while the sector has begun implementing technological tools to optimise production and management, digitalisation remains a pending task for many companies.
•Circular economy – the industry actively works to promote material recycling and reuse of construction waste; however, the widespread implementation of these practices remains hindered by a lack of economic incentives and uniform regulation.
•Sustainability and climate neutrality – in line with the sustainable development goals (SDGs), the sector is adopting measures to reduce its carbon footprint, but the associated costs pose a signi cant challenge.
•Unfair competition – the existence of unregulated extractive activities generates unfair competition that affects both product quality and the sustainability of formal businesses.
An aggregates plant in Almería.
Frades said that 2025 was a crucial period for the Spanish aggregates sector’s transformation. He said that the Strategic Aggregates Plan 2030, developed by the FdA, outlines a roadmap comprising six strategic pillars, 33 action lines, and 150 speci c initiatives.
Priority pillars
• Pro tability and competitiveness – priority is given to increasing productivity through technological innovation and improved operational processes.
• Environmental sustainability – companies are focused on transitioning to more sustainable business models, including the use of renewable energies and emissions reduction.
• Regulatory adaptation – alignment with European policies, such as the Green Deal, and national legislation on circular economy and mining will be essential to ensure the sector’s sustainability.
• Innovation and digitalisation – the incorporation of technologies such as “big data” and automation promises to transform the sector, making it more ef cient and competitive.
According to estimates, Frades said aggregate consumption was expected to grow moderately through 2025, driven by a revival in residential construction and infrastructure investment. In addition, the development of large public works projects, partly nanced through the European Next Generation EU funds, could signi cantly boost demand.
“The aggregates sector in Spain faces a mixed outlook. While there are signi cant challenges, such as adapting to stricter regulations and transitioning to sustainability, there are also substantial opportunities for growth and modernisation,” Frades said.
“With initiatives such as the Aggregates Plan 2030 and the sector's commitment to the SDGs, the outlook is optimistic, indicating a more resilient, sustainable future aligned with global market demands.” AB
Image:
FdA
Image: Íñigo de Amescua /ANEFA
Storm DANA struck a densely populated part of Valencia in late October 2024.
NEW LIFE IN FAMED QUARRY
Heidelberg Materials Mineralik DE has “reactivated” its traditional Nußloch site near Heidelberg, Germany, with new processing technology from SBM Mineral Processing. Rather than supplying raw materials for cement production, the plant now provides the Rhine-Neckar region with high-quality concrete aggregates and road construction materials.
Since the early 1960s, the Nußloch quarry has supplied limestone and marl for the Leimen cement plant. However, with the discontinuation of clinker production at the Heidelberg Materials site at the beginning of 2023, the extraction of the high-quality rock also came to an end. Previously, the rock was pre-crushed (0/280mm) by a roller crusher and transported via a 2km land conveyor belt to intermediate silos.
From there, it was transported via a ve-kilometre-long material cableway to the cement plant. Following the restructuring of the Heidelberg Materials Mineralik DE
SBM has supported Heidelberg Materials Mineralik DE to reactivate the Nußloch Quarry in a new chapter for the historic site.
raw materials division in 2023, a new gravel plant was built in the quarry to produce high-quality concrete aggregates and road construction materials.
The existing technical equipment required major investments in new processing technology. During the tendering process, which began in 2022, it quickly became apparent that the site’s clear qualityoriented positioning in the regional market and Heidelberg Materials’ long-standing commitment to sustainability in Nußloch in particular presented real challenges for the participating planners and suppliers.
In mid-2023, the contract for the complete processing technology was awarded to the Austrian company SBM Mineral Processing. This includes primary, secondary and tertiary crushing stages, each with ef cient dust extraction, as well as wet processing of all concrete aggregates and road construction gravel. The customer also required the plant concept to include sludge and wastewater treatment.
Six months after the plans were approved, the old plant was dismantled and the seven-month installation of the plant’s components began in April 2024.
Following completion of the electrical installation, the plant was commissioned in March 2025, representing a total lead time of just under 20 months from order placement through to commissioning.
“The cooperation with SBM was absolutely convincing throughout the entire planning and tendering process as well as the construction phase,” Heidelberg Materials Mineralik DE head of production and technology south and authorised signatory Nicki Beyerle said.
“Our technical speci cations were fully met.
“The project team also actively supported us in achieving our goal of producing high-quality end products based on our raw materials, ensuring our successful market entry as a new regional supplier.”
The gravel plant, which features secondary and tertiary crushers and four production screening stages, was constructed around an existing workshop hall at the Heidelberg quarry in Nußloch.
Wide product range
The new plant uses the existing structures and the ample open spaces around the existing machine hall. The RHS 13/16/4 horizontal impact crusher has been placed on the adapted foundation of the previous primary crusher.
It is equipped with a 60m³ feeder and an ef cient VARK 14/30-2 double-deck primary screen. The primary screen separates the crushed material into 80/800mm and
30/80mm bypass fractions, as well as a 0/32mm pre-screening fraction.
The latter is stocked as unquali ed road construction materials or can be added to rock crushed to 0/200mm. The same applies to the de ned ller fractions captured by the dedusting system in the primary stage. The primary crusher has a feed capacity of 350–400 tonnes per hour (tph). It is fed by large wheeled loaders from the intermediate stockpile or directly by 50-tonne trucks.
A LONG WAY TOGETHER
The material is transported to the higher-level gravel plant via a land conveyor with a 90° transfer station.
Via a fully enclosed, 130m land-andincline conveyor belt with a 90° transfer station, the crushed material is conveyed to a 200m³ buffer silo at the gravel plant on a higher level, where secondary and tertiary crushers and four production screening stages are located. The secondary crusher is a reversible horizontal impact crusher.
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The SBM project team at the o cial handover in Nußloch at the end of March (from left to right): Thomas Grurl (assembly supervisor); Florian Putz (project manager for processing technology); Herbert Schatzl (SBM regional sales manager); Nicki Beyerle (Heidelberg Materials Mineralik DE head of production and technology South); Robert Weinheimer (technical project management and construction planning stationary plants); and Christian Stanzel (deputy head of stationary plants and process engineering).
Designed speci cally for the highly ef cient production of crushed sand and high-quality chippings, the crusher impresses with its large, de ned ne-grain fraction, the cubicity of its end products, and its low operating and wear costs. Placed directly below the buffer silo, the SMR 13/13/4 produces an intermediate grain size of 0/50mm with an hourly output of up to 280 tonnes. Like the downstream tertiary crusher, it is connected to a highly ef cient dust extraction system with a loading silo.
Monitored by belt weighers, the intermediate grain 0/50 is fed to the KS 24/70/2 double-deck washing screen.
It is then separated into the 8/50 fraction, the nal grain fraction of 2/8mm, and the ne fraction of 0/2 mm for further processing.
The latter passes through a CABrex Compact plant from the Austrian CAB Group, which has a hydrocyclone located directly below the washing screen for dewatering. This produces high-quality 0/2mm sand, or 0/1mm if required.
Process water from the washing screen and dewatering is sent to the plant's own wastewater treatment system, which includes an attached chamber lter press for recycling. The washed intermediate grain size (8/50mm) passes through two SBM production screening machines, which produce the remaining nal grain
The SBM RHS 13/16/4 horizontal impact crusher reduces limestone to 0–200mm from a feed size of up to 800mm.
sizes (8/16mm, 16/22mm, 22/32mm and 32/45mm). Any excess grain sizes or end products can be recirculated via a conveyor belt to the SMR 10/5/4 tertiary crusher (0/50mm; up to 80tph) to produce smaller fractions.
The smaller SBM ‘sand mill’ produces high-quality sand and gravel while keeping operating costs low, making it analternative to two-stage tertiary crushing combinations that consist of cone or gyratory crushers followed by vertical impact crushers.
With a production capacity of around 280tph, all end products are stored on stockpiles with a total volume of around 10,000 tonnes in the immediate vicinity of the plant. From there, they are loaded onto company or customer trucks.
Good prospects
Thanks mainly to the quality of its internally and externally monitored end products, the management at Heidelberg Materials Mineralik DE is already planning for an annual production volume of 400,000 tonnes in the medium term at the quarry, with concrete aggregates accounting for 60 per cent and road construction materials for 40 per cent.
Personnel costs are kept to a minimum thanks to largely automated processes: only seven employees are required per shift for the entire operation, including quarrying.
The plant is also designed for crossseasonal operation – production is possible down to -3°C without the need for a complex enclosure.
In terms of sustainability, the plant also meets the high standards of the Nußloch site
with its restoration measures, programmes for preservation, and environmental projects. Shortly after commissioning, the new plant was awarded the Concrete Sustainability Council (CSC) Gold Certi cate for sustainability. AB
Thanks to complex wet processing, the Nußloch delivery sizes are of high quality.
A new recycling standard
A new CDE wash plant is enabling B&A Group to supply high-quality recycled aggregates that meet demand for sustainable construction products.
Bristol & Avon (B&A) Group has reinforced its commitment to the circular economy with a multimillion-pound investment in a state-of-the-art CDE wash plant.
West of England-based aggregates recycling and transport company B&A Group said the plant at its Avonmouth site is set to be the largest of its kind in the UK.
The facility, which began operating in July 2025, marks a major step forward for the company which was bought by construction materials group Heidelberg Materials in May 2024. It expands B&A’s recycling capabilities beyond dry recycling to handling a wide range of washed materials, from sands and gravels to graded aggregates.
The plant uses water and mechanical processes to clean soil of pollutants and unwanted materials and create high-quality aggregates suitable for recycled concrete and asphalt.
B&A’s new wash plant separates, washes and processes up to 400,000 tonnes of excavated waste a year, mostly soils, which comes from construction, demolition and industrial sites, public works and utility projects.
“We had decided we wanted the new wash plant and spoke to several manufacturers, but CDE was our preferred choice,” B&A Group managing director Helen Grif n said. “During the acquisition, we hoped that Heidelberg Materials would support us and agree that CDE was the best wash plant, and they did.”
She said the wash plant diverts more material from land ll, and on-site washing helps meet environmental permit standards and avoids contamination concerns which supports regulatory compliance.
Grif n said that Heidelberg Materials is considering increasing the opportunities to set up recycling hubs on its sites.
In September 2023, Heidelberg Materials UK set up a recycling division headed by managing director James Whitelaw (the former managing director of its aggregates division), as a new business line focusing on recovering and reusing construction and demolition (C&D) waste to support the circular economy and is responsible for organic growth and acquisitions within the recycling sector.
The division includes B&A Group and the Manchester-based construction waste removal and recycling company A1 Services, which was acquired in 2022 and has been rebranded as Heidelberg Materials.
The B&A plant uses water and mechanical processes to clean soil of pollutants and unwanted materials, creating high-quality aggregates suitable for recycled concrete and asphalt. The facility supports B&A’s strategy to increase annual throughput from approximately 250,000
The plant washes and processes up to 400,000 tonnes of excavated waste (primarily soils) a year to provide a reliable source of high-quality recycled aggregates.
to 450,000 tonnes of C&D waste. It also aligns with Heidelberg Materials UK’s wider strategy to conserve natural resources while strengthening its recycling and circular economy capabilities.
The wash plant can process around 2000 tonnes of C&D waste per working day and enables B&A Group to achieve its throughput target of 450,000 tonnes a year.
It can produce a range of washed recycled aggregates suitable for construction use, including: washed pipe bedding (+80mm), washed pipe bedding (40–80mm), washed pipe bedding (20–40mm), washed pipe bedding (10–20mm), washed pipe bedding (4–10mm), washed grit sand (0–4mm), and washed ne sand (0–2mm).
The wash plant recovers, washes and separates waste material on-site.
The washed material is reprocessed to produce recycled aggregates, which B&A Group said meets an ever-increasing demand from the construction industry. The plant’s drainage and water recovery system captures and recirculates the water used, minimising environmental impact.
The bene ts B&A has received from the plant include: providing a reliable source of high-quality recycled aggregates; more waste diverted from land ll, reducing the need for off-site treatment and cutting transport costs; an increase in operational ef ciency due to rapid and continuous processing; and compliance with environmental regulations. A range of waste material can be processed from construction, demolition and industrial sites, public works and utility projects.
CDE wash plant operated by Bristol-based B&A Group is the largest excavated waste recycling wash plant in the UK.
The CDE plant can process aggregates of all sizes and can separate and categorise material by size and composition. Inert and non-hazardous C&D waste can be processed, such as brick, concrete, asphalt, crushed rock, soils and sands.
The plant has increased the number of products B&A Group can offer to its customers. “We’ve been talking about ReadyMix before, but now we produce sand, thus we can go into ReadyMix, which we couldn’t have done without that,” Grif n said.
Founded in 1993 by the late Jimmy Berkely, B&A Group was managed by the Berkely family until the Heidelberg Materials acquisition.
The company now has a team of 70, operates a substantial eet of over 50 vehicles, and has access to over 100 approved sub-contractors. It has become one of the leaders in the south-west of England for land regeneration solutions, material management services,
CDE executive chairman and founder Tony Convery and B&A Group managing director Helen Gri n with the new wash plant.
The
and the supply and transport of recycled and quarried aggregates. Prior to the installation of the new CDE washing plant, B&A Group was focused on dry recycling using screeners and crushers.
The company’s recovery and waste process enables it to use suitable soil and waste material excavated from construction sites and reuse it for valid purposes on other projects.
This prevents the ‘waste’ material from ending up in land ll, as well as reducing the need to harvest new materials from untouched resources.
1. The recycled aggregates from the plant meet an ever-increasing demand from the construction industry.
2. Water and mechanical processes are used to clean soil of pollutants and unwanted materials.
“We try not to dispose of any materials in the recycling process and recover all of it, but the bit we were missing was the wet recycling,” Grif n said.
“The Berkely family had always had their eyes on wanting a wet recycling process.”
She said that the process to select the correct wash plant was conducted carefully.
“It’s a dif cult type of material that we are processing, we are trying to produce a quality product from a waste product,” she said.
“For us, it was [important] how robust a plant could be, and the CDE plant was the most robust. They described it as like a 25-year marriage between the two of us, and they are already thinking of what the plant could be used for in the future. They try to produce plants that have longevity and are future-proofed.
“There was a lot of discussion about additional tanks for hazardous processing and putting another lter press in if we need to, if we move over to processing hazardous waste and soils.”
The CDE project manager responsible for setting up the plant at B&A Group was David Gordon. Installation began in March 2025, with the Avonmouth site remaining in operation throughout the process, and the plant was operational by July. The plant can operate with a team of three people, led by wash plant manager Derek Filipowicz.
“Derek was my yard manager and hadn’t had previous experience with a wash plant, but he’s taken to it brilliantly,” Grif n said.
“I brought him on board about four weeks before the plant was operational to read all the manuals and start working with CDE while we were commissioning, and he’s been really great.”
The geographic areas B&A Group serves cover Exeter in the south-west, Cheltenham and Gloucester, south Wales, Swindon, and Oxford in the east of England.
The wash plant supplies internal sales of materials to the ready-mix concrete business of Heidelberg Materials, as well as external customers, including nearby block manufacturer LGW Group. B&A Group has now achieved the BS EN 12620 standard for any sand going into concrete manufacturing.
“We’re very proud of that because it’s really dif cult for recycling companies to get the British standard for sand,” Grif n said.
“The customers for our new products will be the same people we were supplying the dry aggregates to. A lot of it is going for pipe bedding and drainage.”
B&A Group has just completed a major project, dispatching 13,000 tonnes of higherend material to go into a drainage blanket.
“What I feel more comfortable with now is that our quality is really high, so we’re less concerned with [handling] any application because the [material] quality is high,” Grif n said.
Grif n said that historically recycled aggregates have had something of a poor reputation, but this is now changing, and more companies are contacting B&A Group about using them to replace primary aggregates.
“When you spoke to people, they’d say ‘I’m not going to go for recycled because it’s poor quality, especially if I’ve got an important project or road construction or drainage that’s got to get signed off by the local authority,’” she said.
“I think it’s had a poor reputation, but as time has moved on technology’s improved, the quality’s improved, and I think that’s why we’re seeing an uptake in recycled aggregates now. When you watch the soil and muck arrive, and then it’s washed and you get an exceptionally clean aggregate, I phoned Heidelberg up and said, ‘Who needs a quarry when you’ve got this quality of material?’ That’s what really impressed me, the quality of the single-sized aggregate that came out.” AB
The material processing work ow in detail
The elements comprising the CDE wash plant include an R4500 primary scalping unit, an AggMax 250 scrubbing and classi cation system, an AquaCycle 900 thickener that treats dirty water, an AquaStore that stores clean water, and a ProPress X4-200 lter press that dewaters the sludge for maximum material recovery and dry cake disposal.
Pre-screening: Material initially passes through the R4500 primary scalping unit.
Double-deck screening: The material is then discharged into the high-amplitude P2-75 double-deck screen. The top deck is tted with bolar bars and tines, and the bottom deck is made of steel mesh. The thorough screening process removes excess clay and separates out material larger than 80mm, while a conveyor carries the 0-80mm material forward for further processing.
Metal removal and washing: An overband magnet above the conveyor removes ferrous metals before the material enters the wash box, where high-pressure water improves separation and screening ef ciency.
Fine screening: The P2-75 Pre-Screen removes ne particles under 4mm. Material smaller than 4mm ows by gravity into the AggMax sump, while material larger than 4mm is directed into the RotoMax Log Washer.
The log washer scrubs and breaks down clay-bound aggregates. Process water carries away nes and light contaminants via the AggMax 250’s over ow weirs.
A D1-63 trash screen removes lightweight debris released from the waste aggregate during scrubbing.
Post-screening: Washed aggregates are then rinsed on the H3-45 triple deck, which removes remaining nes and moisture.
Water, clays and nes pass through the bottom deck to the primary hydrocyclones, while post-screened aggregates continue to a secondary magnet that removes any remaining ferrous metals.
Dry screening: The material then passes to the P3-75 dry screen, which separates it into four product sizes: 4–10mm, 10–20mm, 20–40mm and 40–80mm.
Sand classi cation and dewatering: All slurry smaller than 4mm ows into the AggMax sump and is pumped to two primary hydrocyclones. These separate silt and clay from the main sand fraction.
The under ow is sent to the CFCU200 classi er, which separates material by density. Lightweight organics are removed via classi er weirs, improving sand quality for concrete use.
Cleaned sand (<4mm) is discharged to a split dewatering screen, where spray bars remove excess water. Any remaining slurry is treated in a secondary hydrocyclone, and recovered material is returned to the screen. The nal product is a 0-2mm high-quality sand with 12-15 per cent moisture content.
Water management and sludge treatment
The AquaCycle 900 thickener processes up to 900m3/h of water. A deaeration chamber and automated occulant dosing system (AutoFloc) ensure ef cient sedimentation based on real-time variations in silt concentration. Clari ed water passes through a self-cleaning static screen where lightweight and organic debris is captured. Other oating debris is collected by a scum scraper for further treatment at the AggMax 250, where anti-foam dosing takes place.
The 300m3 buffer tank prevents sludge from settling by constantly mixing it with an agitator. This ensures a consistent sludge ow from the AquaCycle 900 to the lter press.
Filter press (Pro Press X4-200): The lter press has 200 plates and a 20m3 capacity. Sludge is pumped into the press under pressure, where ltered liquid is extracted, leaving behind solid lter cakes.
Residual sludge is ushed back to the buffer tank, while the cakes are further dried with compressed air, then discharged automatically. An automatic cloth wash system supports the 10m3 black water tank, keeping ltration ef cient for the next cycle.
Top brands locked in
The biggest construction machinery brands are locked in to take part in the International Construction Equipment Trade Show in Verona later this year.
SaMoTer 2026, held across six show halls and three outdoor areas, is back once again, with organisers Verona ere, in collaboration with UNACEA and CECE, bringing together industry leaders in the future-focused trade show.
“We are organising a truly not-to-bemissed edition of SaMoTer tailor-made for professionals,” SaMoTer event manager Matteo Pasinato said.
“There will be increasingly accessible and dynamic events, where visitors and exhibitors can interact through fullimmersion formats, with live demos and theme-based visitor itineraries.
“A trade fair of this kind simply has to be experienced and not just visited.”
This year’s event, held from 6–9 May, will showcase technologies, solutions and services from key industrial sectors, including quarrying, demolition, earthmoving, crushing, concrete, and road building.
Headlining the exhibition is the return of Volvo Construction Equipment (Volvo CE), which will launch its new range of machinery and services at the Italian trade show.
Volvo CE will be joined by a host of other major brands including CGT, part of the TESYA group and Caterpillar dealer, Doosan Bobcat, Develon, Dieci, Hidromek, Hitachi, Hyundai, Kemroc, Kobelco, Komatsu, Leica Geosystems, LiuGong Italia, Mantovanibenne, Massucco T., Merlo, Messersì, Takeuchi Italia, Oilquick, Of cine Malaguti, Sany, SDLG, Spektra, Sunward Europe Heavy Industry,
Topcon, Simex, Cangini Benne, VF Venieri, Wacker Neuson and XCMG.
The exhibition will also welcome major players from the concrete sector including CIFA, Faresin Formwork, and Simem with demonstrations on the latest production, transportation and installation solutions in the sector.
Attendees to the crushing and demolition section will be able to see the latest products and innovations from Indeco, MB Crusher, Keestrack, Gasparin, Sandvik, Trevi Benne and VTN Europe. Ammann Italy, Sumitomo, and Hanta will feature in the road building showcase with innovations in road infrastructure, paving and maintenance.
The SaMoTer Academy will be held alongside SaMoTer 2026.
The academy is a new project conducted in collaboration with Engim Veneto to provide high-quality training in the construction machinery sector.
“SaMoTer has been the ‘be there’ event for the construction machinery industry for over sixty years by keeping pace with the future,” Verona ere general manager Adolfo Rebughini said.
“The return of major international brands also con rms the consolidated calibre of the project and the market's con dence in its ability to generate value for companies and trade operators.
“Against a background of unprecedented change, driven by digitalisation and automation, SaMoTer 2026 comes forward as the platform where innovation translates into strategies and business opportunities for the entire supply chain.”
SaMoTer 2026 will return to Verona, Italy, this year.
event spans six show halls
Contact:
Ready to ACT DONAL O’RIAIN
Ecocem is poised for an exciting future, with its innovative ACT technology set to be a key part of its global growth strategy.
Donal O’Riain said Ecocem’s investment in new technologies has enabled the company to obtain numerous lowcarbon SCM patents.
Image: Ecocem
Friday 28 November 2025 was a good day for an hour-long conversation with Donal O’Riain, coming just over a week after the major European supplier of low-carbon cement technologies had staged its Materials Science Symposium in Paris, France.
At the symposium's conclusion, Ecocem established a Materials Science Advisory Council to support the development and adoption of low-carbon cement solutions globally.
Comprising 11 of the world’s foremost materials scientists, drawn from top global institutions, the council will build on Ecocem’s longstanding collaboration with the scientists whose research has already contributed to the company’s cutting-edge ACT technology.
Cement accounts for eight per cent of global CO2 emissions, and the council’s mandate is to deliver an annual statement of research and innovation priorities to decarbonise cement and concrete production globally, review and exchange insights from global research programmes, and identify new avenues for collaboration. The council will also provide independent scienti c perspectives on materials and processes to policymakers, standards bodies, and industry groups.
“If we take the right action now, the cement industry can decarbonise globally by 2040, 10 years ahead of schedule, without excessive cost and without carbon capture,” O’Riain said.
“We can already deliver a 70 per cent reduction in CO2 without additional cost.
”What the industry needs is urgent alignment between research, regulation, policy, and practice, to move from demonstration to full-scale, global adoption.
“Policy ambition drives progress and focuses resources and funding. Current policy supports only carbon capture, a single, expensive solution, rather than enabling a range of solutions which together can accelerate CO2 reduction.
“The Materials Science Advisory Council will work to build awareness and provide the independent scienti c insight needed to maximise the industry’s potential to achieve decarbonisation of the sector ten years ahead of schedule.”
Over the past decade, Ecocem has invested more than €70 million in research and development, including its newly opened state-of-the-art Research and Innovation Centre in Chilly-Mazarin, a southern suburb of Paris, France.
Other recent milestones include a new €50 million ACT production plant in Dunkirk, northern France, a further €170 million investment to construct four new ACT production lines in France by 2030, achieving ASTM C1157 certi cation for ACT Technology in the US, af rming its performance, durability and reliability for use in the American market, and partnerships with leading construction rms such as Sisk, Cemex France, Bouygues Construction, Vinci Construction, CB Green, and the Greeceheadquartered Titan Group.
O’Riain said that Ecocem is not a new player on the lower-carbon cement technology scene.
For 25 years, the company has developed and supplied low-carbon cement solutions across Europe. It operates from two plants in France, as well as sites in the Netherlands and Ireland, producing two million tonnes of low-carbon cement each year, 90 per cent of which is ground slag, a ne, grey powder made from water-quenched iron blastfurnace by-product, used as a sustainable substitute for Portland cement in concrete, mortar, and grout. The remaining ten per cent are conventional CEMIII-range cements.
Ecocem’s technology has supported major infrastructure projects, including Le Grand Paris Express, Dublin’s Aviva Stadium, the Paris 2024 Athletes’ Village, and the UK’s HS2. To date, it has helped avoid 18 million tonnes of CO2 emissions, equivalent to the annual absorption of over 800 million trees.
Investors include Saint-Gobain Group, Breakthrough Energy Ventures, and ArcelorMittal.
For a quarter of a century, Ecocem has developed and supplied low-carbon cement solutions across Europe.
In 2025, Ecocem, which has locations in Ireland, France, the UK, the Netherlands and the US, announced more than €220 million of investment in new production capacity and research and innovation facilities to accelerate the commercialisation of ACT and support its ‘Beyond Clinker’ strategy.
O’Riain said that by replacing up to 70 per cent of clinker – the key polluting ingredient in cement – with low-carbon supplementary cementitious materials (SCMs), ACT, the result of a decade of research, signi cantly lowers the carbon footprint of cement (approximately 200kg eqCO2 per tonne compared to 600kg eqCO2 per tonne), while achieving the required strength, durability, and workability in the concrete it is used to make.
O’Riain said low-carbon cements have been used effectively for decades, but scaling them has been a challenge. This, he said, makes ACT a ‘breakthrough’ technology precisely because it multiplies the low-carbon bene ts of traditionally used low-carbon cements, as well as new ones, and allows them to scale as never before.
Unlike many low-carbon cements or carbon capture and storage (CCS) solutions still in early development stages, O’Riain said ACT is built for real-world deployment – fast, scalable and designed to work within today’s infrastructure.
ACT is said to cut clinker use by up to 70 per cent, replacing it with abundantly available, low-carbon materials such as limestone and SCMs. O’Riain said each deployed low-carbon material and SCM is optimised, with combined synergies maximised, allowing the resulting ACT-based product to be utilised far more ef ciently. O’Riain said that ACT delivers cement with the required strength, workability, and durability without changing manufacturing or jobsite practices or incurring a green premium. He said ACT’s compatibility with global standards and infrastructure makes it viable across mature and emerging markets. O’Riain said ACT will accelerate access to scalable low-carbon, low-clinker, competitive cement technology and, if rapidly adopted, can deliver a 50 per cent reduction in CO2 by 2030.
“I remember 35 years ago when people in this industry were saying, ‘There’s no point playing around with this technology. We know how to make money from making cement. We’re more worried about pricing and about disruptors entering the market and taking market share. That’s what we need to concentrate on’,” O’Riain said. “Technical innovation departments didn’t exist in the cement industry.
“When you looked at the cost of CO2 [emissions], it didn’t gure at all. When cement companies looked at the marginal cost of production, they saw something like €20 to €25 per tonne, and that’s all they had to take into account. Now CO2 alone can comfortably add €60 to €80 to that. You’re talking, in today’s market, of €100 per tonne being your marginal cost of production.
“That changes everything in the business, a fundamental structural change. If a cement business tries to operate in the same way with the same technology it’s always used, it will cease to exist.”
O’Riain said the 1997 adoption of the Kyoto Protocol to address climate change by setting the world’s rst legally binding targets for industrialised countries to reduce greenhouse emissions by an average of ve per cent below 1990 levels between 2008 and 2012 was a carbon emissions mindset gamechanger for the global cement industry.
“The cement industry suddenly had a huge problem as a big emitter of CO2. It was saying, ‘What are we going to do?’ I thought good quality alternatives, like slag, would have a tremendous market,” he said.
“It was a good time to get into the cement industry with a low-carbon product, and I thought, in the long term, that it would be a valuable product to have. I wanted to be in control of the decisions around that, so I set up Ecocem and created a completely new team.”
O’Riain said that for the last quarter of a century, the global cement industry has relied on one technology that converts blast furnace slag into a ne ground powder and supplies it as an alternative to cement.
“It’s a very solid business model as the quality of cement outperforms in terms of strength and durability any other types of cementitious materials. In a world without CO2, it would be a very nice technology to stick with,” he said.
“However, we could see 10 to 15 years ago that the lessons we could apply, others could too, so it was a much more competitive environment when it came to getting access to raw material to enable that business model. We knew we had to add some strings to our bow. We started to work on developing new technologies, at rst to optimise what we could do with blast furnace slag, then to apply those lessons much more widely to low-carbon, supplementary cementitious materials.”
O’Riain said the level of resources Ecocem has invested in developing its new technologies over the past decade has led to the company obtaining “well into double gures” of patents in the eld of low-carbon SCMs.
“We still have several patents pending in that area,” he said. “When we went into that area [low-carbon SCMs], we found that no one else was working seriously in it, so we necessarily did new things; there was nobody to copy. There was plenty of opportunity to obtain patents, but we wanted to be selective, as securing patents is expensive.
“All our key technology developments have been patented.
“We now have [ACT] technology that can deliver an up to 70 per cent reduction in the carbon footprint of cement, 90 per cent of which is clinker, at relatively modest cost. It’s a much more competitive solution than anything else out there.
“The only alternative solution is carbon capture and storage, which is not a viable option for the global cement industry because it is too expensive. It’s too dependent on available storage capacity and very generous governments that are going to build infrastructure to transport the CO2 over huge distances to storage locations.”
Securing the wider use of ACT technology in the global cement industry over the next ve years will, O’Riain said, “buy 10 years” for Ecocem and others to nd a rapidly deployable and cost-effective way to cut the nal 30 per cent of cement CO2 emissions without using unaffordable carbon capture and storage.
“We know how to cut two-thirds of emissions, and now we go for the remaining third. We need to change the policies and global consensus around carbon capture and storage,” he said.
“All the conversation is around it, but it’s a waste of time and money to talk about it and invest in it.
An Ecocem production plant in Dunkirk, France.
“You cannot lock everyone in that box and throw away the key.
“We need a much broader range of technological solutions. My own feeling is that we’re at a tipping point as an industry, with carbon capture and storage dying a natural death in two to three years.
“No one likes to be dragged out of their comfort zone, and, in the cement industry’s case, that’s producing Portland clinker [cement]. The industry needs to learn new tricks and skills, understand them at a high level, and apply them ef ciently at scale. That scale-up effort will be a challenge, and government policy can legitimately support it. It’s not about securing large capital grants; it’s about encouraging the adoption of new technologies and further innovation. Then the industry will be able to deploy costeffective new technologies rapidly.
“For market access, we have to change industry standards, including the European harmonised cement standard, EN 197. If that doesn’t recognise your product, it is very dif cult to get it into the market. We now have a decision from the European Commission to revise EN 197, with the new norm being introduced by the middle of 2027, giving all our [low-carbon cement] technologies access to the market. That was a long, hard battle which we’ve won. In parallel, we are not waiting until 2027, as we are building our industrial capacity to produce ACT at scale in Dunkirk, which will be operational by the end of 2026. While we won’t have the European [harmonised cement standard] norm at that stage, we have already achieved technical certi cation in France [to produce and sell ACT cement nationally].”
O’Riain said it is important for Ecocem to handle the “burden of being leaders” in low-carbon cement technologies and to demonstrate how effective they can be for existing and new customers.
“In parallel, we are very comfortable with licensing our ACT technology to anyone seriously interested in using it. What we are saying to the cement industry is, ‘You can try and invent this technology yourself, allowing ten years for that, and make sure you avoid the patents we already have in place.’ Alternatively, sit down and talk with us, and we’d be very happy to license our technology to you. We are having meaningful discussions with a double-digit number of cement companies on that,” he said.
In April 2025, Titan Group, a leading international business in the building and infrastructure materials industry, became the rst cement major to license Ecocem’s ACT technology.
The licensing agreement will see Titan and Ecocem co-develop and deliver a bespoke, general-purpose cement version of ACT, initially for Titan’s Greek domestic market.
Ecocem has also welcomed the December 2025 publication of the new European Assessment Document (EAD) on blended cements.
The EAD provides regulatory clarity, con rming that Ecocem’s breakthrough ACT technology meets recognised technical requirements for the European construction market.
This enables Ecocem and other providers of low-carbon cement technologies to pursue the European Technical Assessment (ETA) route and obtain CE marking, thereby bringing these innovative technologies to market.
Developed by the European Organisation for Technical Assessment (EOTA), the EAD is a harmonised technical speci cation that formally de nes the rules, methods, and criteria for assessing the performance of blended cements in Europe.
This EAD 150080-00-301 on blended cements with high ller content, ground granulated blast-furnace slag, pozzolanic material, or both, and clinker has been cited in the Of cial Journal of the European Union.
Ecocem obtained ETA 23-0877, issued by Cerema in December 2023, which allows the company to submit its CE marking application to bring its ACT technology to market.
“The publication of this EAD is a milestone for Ecocem, our ACT technology and for the wider cement and construction industries. It means the performance, durability and safety criteria for this technology are now formally de ned under a recognised European regulatory route,” O’Riain said.
“We are accelerating the commercial rollout of ACT in Europe and forging the pathway for global deployment, including in developing countries where low-carbon cement solutions are urgently required.” AB
1. Ecocem’s headquarters is in Dublin, Ireland.
2. Ecocem’s Donal O’Riain and Marcel Cobuz (centre right), chairman of the Titan Group executive committee, mark the start of the ACT technology licensing agreement.
McLanahan’s crushing, washing and screening solutions support all phases of the concrete recycling process.
Crushing support for concrete recycling
E cient and modern crushers can provide vital support for the recycling of concrete from construction and demolition waste streams.
Concrete remains the world’s most widely used construction material and, unsurprisingly, one of the largest contributors to construction and demolition (C&D) waste streams. Across Europe, ageing infrastructure, urban renewal and redevelopment mean that demolition residues, once considered waste, are increasingly regarded as valuable raw materials.
Crushing and screening plant manufacturer McLanahan has said that recycling concrete is no longer a fringe activity. With land ll capacity constrained, growing environmental regulation, and increasing demand for sustainable materials, concrete recycling is rapidly becoming a core component of modern construction logistics. The process not only reduces environmental impact but also provides high-quality recycled aggregates that can be reused, closing the loop on material supply.
Each year, Europe generates roughly 450-500 million tonnes of C&D waste, with at least one third of this being concrete, according to the European Circular Economy Stakeholder Platform. This demonstrates both the scale of the challenge, and the opportunity presented by effective recycling.
McLanahan showcased that recycling concrete can effectively be used as recycled concrete aggregate (RCA), involving a multistage process outlined in its blog posting, titled “C&D Recycling – Breaking Down Concrete”:
1. Collection and sorting – concrete elements collected from demolition or renovation sites. Embedded metals (rebar, mesh), plastics and unsuitable materials removed.
2. Primary crushing – large concrete pieces are broken down using crushers (jaw, impact, or hammermill types).
3. Secondary crushing and screening –material is further reduced and screened to the required particle sizes.
4. Washing and classi cation – optional but recommended to remove nes, dust, and contaminants, producing cleaner, more consistent RCA.
5. Stockpiling and grading – material is separated into de ned gradations for different uses (eg road base, drainage, back- ll).
McLanahan’s equipment supports all these phases. From heavy-duty crushers to modular wash plants and classi cation screens, it can supply end-to-end systems tailored for large and small-scale C&D recycling operations alike.
McLanahan said the business case for recycling concrete pays. By recycling on–site or near-site, projects cut haulage and disposal costs, often substantially when virgin aggregate or land ll tipping fees apply.
In regions with high aggregate-levies or land ll taxes, using RCA signi cantly reduces operating costs and enhances pro t margins. This is one reason recycled aggregates uptake is growing in the UK, according to analysis by Future Market Insights on the recycled concrete aggregates market.
Using RCA reduces demand for quarried rock, sand and gravel – preserving nite natural resources and extending the life of quarry reserves.
It avoids energy-intensive mining, crushing and transport of virgin aggregates.
Shorter transport distances and re–use of local demolition material cut carbon emissions considerably, supporting European carbon–reduction targets under climate and sustainability policies.
While the upside of concrete recycling is considerable, McLanahan said that there are practical and regulatory challenges.
Quality and consistency of RCA must be controlled carefully. Proper crushing, washing and screening is essential to meet speci cations for structural or drainage uses.
Regulatory and standard compliance is a key consideration. Not all recycled materials are acceptable for high-spec applications, standards like EN 206 for concrete mixes or EN 13242 for aggregates must be satis ed.
Data tracking and traceability of demolition, processing and reuse, especially in larger countries or across regional jurisdictions, is needed to avoid “hidden waste”. The lack of consistent, transparent data remains a complaint across the European sector.
quality recycled aggregate, with the same performance, wherever they are in Europe or around the world.
Market acceptance and perception is a challenge as some contractors still prefer “virgin” aggregates for structural projects, seeing RCA as inferior. Modern processing methods are actively shifting this assumption.
“At McLanahan, we believe concrete recycling is central to Europe’s sustainable construction future. By providing robust and exible crushing, washing and screening solutions, we help unlock the true value of demolition material, reducing waste, cutting costs, and delivering a circular supply of aggregate,” McLanahan business line director David Hunter said.
McLanahan has said that its role is to give contractors and recyclers the tools they need to process concrete waste into
Crushing and screening plant manufacturer McLanahan says that recycling concrete is no longer a fringe activity.
The European Union’s C&D waste statistics and circularity analysis explain how, as Europe embraces circular economy policies, concrete recycling stands as a pillar of resource ef ciency. With potentially 150–170 million tonnes per year (assuming one third of C&D waste is concrete) available for recycling, the aggregate potential is vast.
McLanahan has said that concrete recycling is no longer a niche or optional activity. For contractors, recyclers and infrastructure customers across Europe, recycled concrete aggregate offers a viable, scalable and cost-effective alternative to virgin materials.
Excelling in Finland
Metso crushing and screening equipment is helping southern Finland-based Pärhä produce high-quality concrete aggregates. Pärhä uses Metso’s Lokotrack solutions to ensure ef ciency and superior end-product quality.
Metso’s two-stage crushing process, combined with electric-driven screens, delivers signi cant fuel savings and improves the cubicity of the nal product.
The Lokotrack LT330GPSE provides power not only for its own crusher and screens but also for a separate ST4.10 mobile screen.
“The Lokotrack secondary crusher is a true powerhouse. Its robust diesel engine drives a generator that supplies power to the unit’s own equipment: the pre-screen, the cone crusher, and a large two-deck screen. Thanks to a connecting cable, surplus power also runs a separate large three-deck screen for nal product separation,” Pärhä owner Jari Pärhä said.
He said that he is more than satis ed with the cost-ef ciency of Metso’s two-stage plant and mobile screen.
The primary crushing is handled by the diesel-electric Lokotrack LT120E jaw crusher, followed by the electrically powered LT330GPSE cone crusher-screen unit, and precise nal classi cation is done by the e-Power Lokotrack ST4.10E three-deck screen.
“We calculated that all Metso crushing and screening units powered by diesel-generated
Entrepreneur Jari Pärhä at the Pennala quarry with Metso’s diesel-electric Lokotrack LT330GPSE cone crusher-screen plant in the background.
Images: McLanahan
electricity, plus two-wheel loaders on site, consume about 0.7 litres of fuel per produced tonne of aggregate – which is quite a modest gure,” Pärhä said.
Pärhä’s partnership with Lokotrack began in 2013 with the purchase of an LT106 jaw crusher. Four years later, capacity was increased with the diesel-electric LT120E jaw crusher and LT330GPSE cone-screen plant. In 2024, the primary unit was upgraded to a new model based on excellent performance.
Automation has also advanced signi cantly, making operators’ work easier. Additional features such as Remote IC remote control improve equipment management and enhance safety. Pärhä applies a method familiar from Norway and Sweden, where the LT120E jaw crusher operates separately, about 20 meters away from the secondary crushing and screening units. A wheeled loader picks up the primary crushed rock and feeds it into the LT330GPSE via a feed hopper.
The secondary crusher differs from mainstream set-ups: material passes through a pre-screen before entering the cone crusher, allowing nes and selected fractions to be removed when needed.
“For concrete aggregates, quality is more important than quantity. With the feed hopper and pre-screen combination, we ensure a steady, continuous feed to the secondary crusher, which stays consistently full. This improves cubicity and extends the wear life of parts,” Pärhä said.
“The LT120E is also powerful enough that in separate operation, we don’t need to run it at full capacity all day.”
Based in Heinämaa, Orimattila, Pärhä Oy is recognised as a specialist in concrete aggregates. The family-owned company operates six quarries in the Päijät-Häme region, producing mainly crushed aggregates for concrete plants.
In March 2025, Metso’s two-stage plant and mobile screen were completing a 35,000tonne contract at the Pennala quarry south of Lahti. In addition to 6–12mm and 12–16mm aggregate sizes, the process produces stone dust and 3–6mm grit for winter sanding.
The reddish rock is crushed in two shifts, including necessary maintenance work.
“We produce about 3000 tonnes of smaller concrete aggregates per day. For larger sizes, the output would be even higher. Finished aggregates are delivered within a radius of about 100km,” Pärhä said.
What will Lokotrack and other quarry equipment look like in 40 years?
“Rocks will still be reduced in jaw and cone crushers. Automation will make work even easier, lowering the threshold for new people to join the industry. Remote operation will become more common, and quarry equipment will be controlled more from monitoring rooms than from machine cabins,” Pärhä said.
In separate news, Metso is expanding its screening portfolio with Grande Series screens to maximise productivity and exibility for customers.
The launch of the Grande Series by Metso marks a major advancement for customers,
delivering high-performance screening solutions speci cally engineered to maximise productivity and ef ciency in mining and aggregates operations, and to meet the most demanding screening requirements.
Covering three new stationary screen types – GLH, GMF and GFF – the new series is designed to help customers handle even the most challenging, high-capacity applications. The larger screen sizes within the Grande Series enable customers to take advantage of enhanced capacity, reduced downtime, and greater operational exibility to support their business targets.
“It’s all about helping our customers succeed with the right tools for their unique needs. With the newly launched Grande Series, customers gain more exibility, easier screen replacements, and access to solutions for even the most demanding screening tasks,” Metso screening business line vice president Jouni Mähönen said.
The GLH Series horizontal screens are engineered for, among other things, heavyduty slurry and water handling in demanding mining environments.
The GMF Series multi-slope banana screens offer high-capacity screening of both ne- and near-size particles.
These new additions bring exible engineered-to-order (ETO) con gurations and very large-screen designs to Metso’s portfolio.
The GFF Series, featuring ip- ow technology, enables ef cient screening of challenging materials and ne separation.
The Grande Series also includes Trellex screening media compatibility, ensuring customers bene t from a complete solution that integrates seamlessly with Metso’s broader offering.
Top tips
Wire-based screening media manufacturer Major has provided three tips for effective maintenance of screen media.
Do not slack on installation
It’s not uncommon for an operation to send a new crew member to complete the undesirable job of screen media change-outs, but the task bene ts from more experience. The best screen media in the world will not do any good if it’s installed incorrectly. This could mean improper tensioning or even installing it the wrong way around. The resulting issues can include accelerated wear, panels broken too soon and just overall inef cient screening.
In addition to a bi-power Metso Lokotrack ST4.10 mobile screen, Finnish concrete producer Pärhä operates two Lokotrack ST2.8 direct-feed screens, one equipped with e-Power.
While speci cs vary, there are a few best practices for screen media installation. To start, clean and check the condition of components that touch the screen, ensure the screen panel matches what was ordered, and install the screen based on instructions from the manufacturer. During installation, make sure each support bar touches the screen and the tension matches manufacturer recommendations.
Consider looking into installation and maintenance training to prolong screen life. Manufacturers often offer the service via site visits or a nearby dealer. The bene t will be a crew with shared knowledge of proper installation that could prevent downtime.
Keep an eye on the screen
Once installed correctly, it’s still best to check screen media at least weekly to make sure tensioning is proper, and the panels are not showing unusual signs of wear. A little bit of extra time during routine preventative maintenance can have a noticeably positive effect on pro ts.
While checking tension, also look at the clamp bars themselves. Check for wear, corrosion or cracks and examine the rail for straightness, which is necessary for even tension. Examine all nuts and bolts and replace any that are worn, stripped or corroded. Shaker bolt threads with excess build-up can be cleaned by running them across a wire wheel. Also, replace clamp bars that are thin or caving in to greatly improve screen media wear life and be sure to choose original equipment manufacturer versions.
Utilise diagnostic tools
Diagnostics systems can help prolong media life and improve screening by checking and monitoring a machine’s health. Use a vibration analysis system to inspect the machine for balance and excessive vibration, which can lead to screen media failure or unintended machine wear.
Vibration analysis systems are becoming easier to use. Some only require a single, wireless sensor and allow access to results via a smartphone or tablet. AB
Image: Metso
New-generation loading
Production rate and lower fuel consumption are the name of the game following the latest updates from loading equipment manufacturers in the quarrying and aggregates sector.
As the quarrying and aggregates sector seeks to increase production rates and lower production costs, including fuel consumption, manufacturers are shaping their equipment to meet these demands.
Volvo Construction Equipment (Volvo CE) has unveiled a short-swing excavator model, the Volvo ECR255 short-swing crawler excavator, as part of its CONEXPO-CON/AGG 2026 showcase.
According to Volvo CE, the new model prioritises high production rates and lower fuel consumption in operation, with a seven per cent increase in lifting capacity and a 10 per cent reduction in fuel consumption compared to previous models. Available in the North America, Europe, Oceania, Turkey, Korea, and Japan markets, the 25-tonne excavator replaces the previous generation’s ECR235E as an option for contractors working in con ned-space applications and needing compact equipment. The ECR255 joins the large ECR355, mid-size ECR145 and compact ECR90 excavators in Volvo CE’s short-swing excavator models.
“This launch means Volvo now offers a comprehensive range of short-swing models in our new generation of excavators, giving customers the exibility to choose the right machine for their application without compromise,” Volvo CE chief project manager Jaesu Kim said.
“It’s designed to help customers do more in con ned spaces thanks to its reduced tail swing, increased lifting capability, lower fuel consumption and industry-leading operator environment.”
With features including auto-idling, automatic engine shutdown, customisable work modes, and an advanced electrohydraulic control system, the ECR255 provides a smoother, more fuel-ef cient operation. The ECR255 features a redesigned structure and a heavier counterweight, increasing its lifting capacity. Combined with advanced features such as Volvo Active Control, the operator can automate boom and bucket movements, enabling precise digging and grading. Due to the operator’s ability to set boundary limits, the ECR255 excels in con ned-site applications.
CONEXPO-CON/AGG attendees can see the ECR255 in-person at Volvo CE’s booth (F24029) at the Festival Grounds.
Building in the US
Develon has started construction of a new training centre for construction equipment, which will play a key role in supporting its customers with training and education.
Located in Tucson, Arizona, the HD Construction Equipment (HDCE) Real Operation Centre (ROC) replaces the previous facility and will host customer training sessions across the current and new Develon heavy and compact equipment range, as well as dealer and customer events.
“For the past 15 years at our former facility, we hosted thousands of construction equipment owners, operators and dealer representatives for hands-on training, product testing and special events,” Develon senior director of dealer development and marketing Morgan Stallings said.
“The new facility will build upon its success and support our North American dealers.
The generation 8 crawler excavators were launched in 2019.
Signi cant developments
Liebherr has unveiled a series of “signi cant” developments for its eighth-generation crawler excavators, including new settings and greater availability of assistance systems.
“It will have acres of open operation area where visitors can come year-round to see and feel what makes Develon machines different from other brands.”
Develon broke ground on the facility in October 2025, with plans to build a permanent facility that includes service bays for dealer training and maintenance. Attendees can learn from Develon’s team of experts on how to use key Develon features, including the transparent bucket and aroundview monitor camera system.
“The training facility plays a key role in what we do. It helps our sales team get hands-on equipment experience and gives us a place to test machines and gather real data,” Best Line Equipment vice president of sales Armand Cencetti said.
“And it lets us bring in customers to see and demo Develon equipment in person, building stronger, long-standing relationships along the way.”
The new settings are available across Liebherr’s R 922 to R 945 G8 crawler excavators. Liebherr has said the new updates are designed to meet customers’ demands for performance, energy ef ciency and ease of use.
A key upgrade is the Liebherr Power Ef ciency (LPE) mode - Liebherr’s patented system for energy management - which has been integrated as standard on R 922 to R 945 G8 models. According to the manufacturer, the LPE optimises the excavator’s hydraulics and diesel engine to reduce fuel consumption by 10 per cent while maintaining high production levels.
Liebherr has also made the Leica 2D control system standard across the R 922 to R 945 G8 crawler excavators.
The system, integrated into the main display, provides operators with clear, colourcoded visuals for levelling and earthmoving tasks. The 2D system can be expanded via “3D ready” options from Leica, including passive 3D or semi-automated 3D functions for greater precision.
The Liebherr generation 8 crawler excavators have become relied upon in many applications since their global launch in 2019.
“From the R 922 to the R 945, the generation 8 range combines outstanding performance with reduced fuel consumption, supported by a comfortable operator environment and simpli ed, safe maintenance access,” Liebherr said in its release.
“Proven in diverse applications worldwide, this generation continues to evolve, driven by Liebherr’s commitment to providing customers with the highest possible performance and long-term reliability.” AB
Develon is investing in a new training centre for its North American customers.
The ECR255 excels in confined-space applications.
Liebherr has announced several updates for its generation 8 crawler excavators.
Image:
Liebherr
A Rokbak RA40 hauling overburden in Alberta, Canada.
Strong ADT demand
Conditions are challenging, but hauling manufacturers say markets such as the UK, Africa and Italy o er major opportunities going forward.
Articulated dump truck (ADT) manufacturer Rokbak has said that demand for its articulated haulers remained strong in 2025 despite the challenging market conditions seen in the construction equipment industry.
The Scotland-based company celebrated milestones, new dealers and lots of Rokbak trucks out working for customers on demanding job sites around the world. Rokbak has said the total global articulated hauler market was expected to close at over 9000 units for 2025, which is down on the previous year when 10,300 trucks were sold across all brands. Some markets have declined, such as North America, which is by far the biggest market for articulated haulers, while others, such as the UK, Africa and Italy, increased. Despite the global reduction, 2025 was still a good year for Rokbak with customers choosing the company’s ADTs for their reliability, durability and low fuel consumption.
There were sizable orders – such as 25 RA30s sold to an infrastructure contractor in the US – and expansion into new markets thanks to new dealer partnerships. During 2025, Rokbak continued to strengthen its European dealer network in line with its expansion plans.
Rokbak partnered with DIR International Trading in Spain and Portugal and Idromac in Italy, where demand for ADTs has risen steadily since 2021, increasing by around 10 per cent annually. The expectation for Italy was that, by the end of 2025, more than 100 units across all brands would have been sold nationwide.
Rokbak said the appointment of Idromac as its of cial dealer in Italy means it is ready to meet rising ADT demand across the country with proven, dependable articulated haulers and strong aftersales support.
Idromac previously toured Rokbak’s Motherwell factory in preparation for the heavy equipment dealer to bring Rokbak articulated haulers to its Italian customers.
Idromac chief executive of cer and founder Francesco Casillo recognised that Italy’s changing job site requirements created a clear need to introduce a premium articulated hauler brand to its offering.
The company has long specialised in heavy equipment, and adding proven ADTs to its portfolio represented a natural step.
“Construction transport in Italy is changing rapidly,” Casillo said.
“Dump trucks are no longer con ned to quarries, they are playing a decisive role in roadwork and earthmoving operations across the country.
“To keep pace with this market evolution, we needed a proven, reliable articulated hauler brand that aligned with our values and ambitions. Rokbak matched our vision perfectly.”
In the US, similar comments were made about three RA30s working on a residential development where the trucks were praised for their reliability, low fuel consumption and uptime.
Another highlight in 2025 for Rokbak in Europe was the expansion of its dealer in Northern Ireland, Sleator Plant, which now covers the entire Irish market with the establishment of a specially designed €1.2m
depot in north Dublin, built to enhance accessibility and support for customers throughout Ireland.
While at a quarry in Northern Ireland, an RA30 has been called out for its ef ciency and productivity, helping to support continued business success.
“As quarry manager, I know rst-hand that you have to get the right plant for the job,” Loughran Rock quarry manager Colin Loughran said. “You want something reliable – the less downtime the better. The RA30 has been nothing but reliable, with minimal maintenance requirements and prompt support from the dealer, Sleator Plant, when needed.”
In 2025, Rokbak marked 75 years of manufacturing at its Motherwell facility. The company also recently won the Made in Scotland award for its outstanding contribution to manufacturing. From this, Rokbak was shortlisted for the Made in Britain awards.
A slightly different application that showcases the versatility of the Rokbak RA30 and RA40 is the Hydex adaptation of the ADTs into high-capacity water trucks to meet the growing demand for dust suppression across North America. The venture between Hydex and Rokbak dealer Hills Machinery sees the trucks up tted with highperformance water tanks for deployment across quarries, mines and infrastructure projects under the Hydex banner.
“This is about using a proven platform to meet a pressing and growing need,” Rokbak director of sales for the Americas Robert Franklin said.
Images: Rokbak
“The RA30 and RA40 give contractors the power, manoeuvrability and durability they need in a base machine – and now, with this adaptation, we’re showing just how far that platform can go.”
Other highlights from Rokbak’s year included meeting customers and dealers at shows, where visitors could see the trucks up close and talk to the Rokbak team.
At Nigeria Mining Week, Rokbak and its West Africa dealer HMD presented the RA40, which attracted substantial interest. The Scottish-made haulers are fast proving to be popular in the African mining, quarrying and infrastructure sectors thanks to the trucks’ reliability and durability. Earlier in 2025, Rokbak and HMD also met with customers at Mining Indaba in Cape Town, South Africa.
“We see a lot of opportunities in West Africa with the mining, quarrying and construction industries performing well,” Rokbak global sales director Guy Wilson said.
“It has been a strong market for us this year, and we expect to see this continue next year.”
The RA30 was also at Le Dig Tour in Lyon, highlighting Rokbak's ongoing commitment to the French market, and the Balmoral Show, Northern Ireland’s largest agricultural and machinery event.
One of the rst events in Rokbak’s calendar for 2026 is AED in the US, where the company will meet with its North American dealers and potential new dealer partners.
Welcome delivery
Stevens Equipment Rental (SER), based in Cumbria in north-west England, has added
11 new Liebherr TA 230 Litronic ADTs to its eet following customer feedback.
The delivery was SER’s third major eet enhancement in 2025, meaning it’s now the largest ever in the company’s 50-year history, with further expansion planned for 2026.
It follows other recent additions from Volvo Construction Equipment and Caterpillar, designed to ensure high machine availability and support for SER’s growing national customer base.
By working with multiple original equipment manufacturers and their dealers, SER sales manager for the North and Scotland Mark Neeld said it can ensure timely deployment and provide reliable, responsive service.
“Our customers’ projects are our top priority. When demand is as high as it is now, being agile is crucial,” he said.
“Our multi-brand approach means we have the exibility to secure the best equipment to meet our customers’ schedules. It’s about ensuring we can say ‘yes’ and deliver a high-quality, reliable machine that’s well supported with parts and service, no matter where the site is in the UK.”
The decision to invest in further Liebherr ADTs was based on the performance of the rst TA 230 Litronic units, introduced to SER’s eet in 2023. These initial machines underwent a two-year real-world evaluation with customers.
“The feedback from the customers who ran the rst Liebherr trucks was extremely positive, particularly on their high uptime and low fuel consumption,” SER sales manager for the South Ben Beard said.
"That experience, combined with the fantastic back-up support we’ve received from Liebherr so far, gave us the con dence to add further units. The TA 230 Litronic has proven to be a great product and is a perfect example of our dedication to nding solutions that work for our customers.” AB
Rokbak managing director Paul Douglas and Idromac CEO and founder Francesco Casillo.
A Liebherr TA 230 Litronic ADT from the SER fleet.
E cient by design
Conveyors are the backbone of material handling operations, including in the quarrying sector. Manufacturers are preparing to showcase their latest innovations for 2026.
Martin Engineering president emeritus Todd Swinderman shares key tips and practices to make conveyor belts last longer.
State of play
Most conveyor belts in quarries are considered to be operating in “severe duty” and typically don’t just wear out.
They are exposed to raw materials and punishing weather conditions, so they're more often subject to a shortened life from catastrophic events, whether it’s a signi cant impact, splice failure, or piercing damage. Or they suffer from chronic issues such as mistracking or frozen idlers.
In addition to correcting such problems to extend belt life, a concern for many bulk material handling operations is damage from loading, belt wear from cleaning devices, and the dif culty of cleaning damaged belts.
Properly positioned and tensioned primary and secondary cleaners mitigate belt wear issues commonly associated with cleaners.
Belt wear from loading
Since the belt is a major cost element in the process of conveying bulk materials, much attention is focused on reducing wear and damage.
In general, loading wear occurs over a long period of time from the discharge of material onto the belt and from contact with conveyor components such as idlers and belt cleaners. Belt wear from loading includes both impact damage and frictional wear.
Damage to the belt can be a single event, such as that from tramp metals or oversized lumps in the material ow stream.
Such sudden damage can result in catastrophic failure that requires immediate attention, demanding a system shutdown.
The negative effects of long-term wear are less dramatic, and replacement can generally be scheduled for planned outages to avoid affecting conveyor availability.
One key to understanding belt wear from loading is the chute. The development of discrete element modelling (DEM) as applied to conveyor loading chutes has given the industry a valuable tool for verifying chute designs and predicting conveyor belt wear. A survey of the literature yields evidence indicating belt life improvements of 40–300 per cent from using DEM to optimise chute designs.
The primary objectives of chute design are to direct an uninterrupted ow of the bulk solid from the chute to the receiving belt, centred in the direction of belt travel and as close as possible to the speed of the receiving belt.
While the interaction between the belt and the bulk material is complex, in general, troubleshooting belt wear caused by chute design can take advantage of some simple relationships. The rst is the general relationship between material impact angles and the wear rate of rubber. Figure 1 shows that as the impact angle increases, the wear generally decreases.
The second fundamental principle that can be applied to chute design to minimise belt wear is the speed of the bulk material stream, which is affected by friction and acceleration due to gravity as the load falls onto the belt. The coef cients of friction between the bulk material, chute and belt are important parameters that are utilised in DEM programs to optimise the shape of the chute, producing the desired exit velocity and direction of the discharged bulk material.
Common chute con gurations include rock boxes, inclined at chutes and curved chutes, as shown in Figure 2. Ve is the exit velocity of the bulk material stream from the chute, and Vb is the belt speed.
Other factors to consider when designing the optimum chute for a given application include drop height and preferred liner materials, but in general, belt wear from the choice of chute design is greatest with rock boxes, which do little to slow the material’s velocity and introduce a large amount of disruption as the load cascades from one shelf to the next, then lands on the moving belt at a near-perpendicular angle.
Flat inclined chutes help shift the load in the general direction of the receiving belt’s travel but can involve even greater impacts than a rock box, depending on the drop height. The violent landing takes a constant toll on the belt, often creating signi cant amounts of fugitive material in the form of dust and spillage.
Belt wear from loading impact is generally minimised when using curved chute designs, as the bulk material stream’s velocity can be most closely matched to that of the belt with curved chutes.
ABOVE: Figure 1 shows the general wear of rubber based on impact angle.
RIGHT: Figure 2 shows a comparison of loading velocities and vertical components.
Figure 3 shows the relative differences in loading velocity vectors. Vey is the bulk material stream velocity perpendicular to the belt and is the primary factor in belt wear. The wear of the belt is proportional to the magnitude of Vey, so minimising this component through chute design is a focus of a DEM analysis.
Figure 2 is a generalisation, but it shows that the exit velocity of a curved chute is the lowest of the three design choices. This is due in part to the force resulting from the curved chute, which tends to reduce the impact velocity (Vey) relative to a at chute, even if the basic discharge angles are similar. Rock boxes may reduce chute liner wear, but can create signi cant belt wear due to the relatively high vertical velocity and the resulting shearing action between the bulk material and the belt as the load gets up to belt speed. While belt wear is the main concern, a signi cant amount of attention should be paid to the selection of liners to prolong chute life. Given the relative cost of the belt compared to the chute in most applications, the wear liners should be considered sacri cial components, and attention would be better spent on improving chute design, selecting lower-friction liners, and making the liners easier and quicker to change. Some manufacturers have engineered new designs for liners that can be serviced from outside the chute, for example, eliminating the need for con ned space entry and drastically reducing replacement time.
Cleaning damaged belts
Cleaning ef ciency is related to the material properties extracted from the mine, the number of belt cleaners, the mechanics of a particular belt cleaner design and the belt surface, among a host of other variables.
It’s common to expect a conveyor belt to be cleaned with an ef ciency approaching 100 per cent, but even a brand-new belt has macro and micro defects that make achieving 100 per cent practically impossible.
These imperfections can result in as much as 60g/m2 of carryback passing a belt cleaner station with a new belt.
When the belt surface is damaged, the amount of carryback that can be shielded
from belt cleaning in scratches and gouges can be even more signi cant, on the order of 100–200g/m2. The US Mine Safety and Health Administration (MSHA) estimates that 85 per cent of all conveyor problems, including wear, come from fugitive materials.
Fugitive materials are those that escape the conveyor other than at the discharge, including spillage, dust and carryback.
Since carryback is a signi cant source of fugitive materials, which in turn contribute to belt and component wear, it makes sense to focus on adequate belt cleaning.
Cleaning damaged belts is best done with water and mechanical scrapers.
In severe cases, brush cleaners are effective at removing material from damage such as skirtboard grooves, but they require more frequent adjustment and replacement than mechanical scrapers.
With a belt in good condition and professional maintenance, a belt cleaning station can usually control carryback to within 10–100g/m2.
The Conveyor Equipment Manufacturers Association (CEMA), in its seventh edition of Belt Conveyors for Bulk Materials, has established a system for rating the dif culty of the belt cleaning application and for desired levels of carryback exiting a cleaning station to aid users in specifying belt cleaning performance, rather than making decisions based on brand preference or price alone.
Three di erent chute design approaches.
Take aways
•Curved chutes are effective in minimising belt wear from loading.
•Belt cleaners do wear the belt, but at a much lower rate than loading.
•Rather than focusing on extending the life of sacri cial wear materials, making the service of wear materials easier and faster should be the goal of design and maintenance engineers.
More
uptime,
less disruption
Smiley Monroe has over 45 years of experience in belt conveying, supplying major equipment manufacturers and supporting sites across varied material-handling applications. Their team regularly sees the same core issues across industries: spillage, carryback, belt damage, and the pressure to get lines up and running again quickly after a failure. While rips, breakages, and blockages can occur in any operation over a belt’s lifespan, their frequency increases wherever materials are abrasive, heavy, ne, wet, oily, sharp-edged, or inconsistent in size.
Across fast-paced industrial environments, conveying equipment is the backbone of consistent output. Whether you’re handling aggregates, waste, grain, or compost, unexpected conveyor issues can rapidly turn into lost time and lost revenue. With throughput targets rising and
downtime becoming increasingly costly, proactive maintenance and smart spares strategies are essential to keeping operations
running smoothly.
Below are some practical steps to reduce these risks and maximise machinery uptime.
Tackle material spillage
Material spillage is a widespread problem in bulk handling and processing environments, and it’s one of the biggest contributors to downtime. Spillage can cause belt mistracking, accelerated wear, blocked rollers, extra clean-up, and even safety hazards. A strong rst defence is conveyor skirting. Well- tted skirting prevents material escaping at load zones and transfer points, exactly where spillage is most likely to start.
Skirting rubber should be installed so it lightly contacts the belt surface: tight enough to contain material, but not so tight as to increase friction or damage the belt cover.
A key rule of thumb is to choose skirting with a lower shore hardness than the belt cover. That way, the skirting wears rst, protecting the belt and extending its working life.
Keep conveyor belts clean
Carryback, material sticking to the belt after discharge, is another common issue across industries. It leads to buildup on return rollers and structures, increases spillage, and can create secondary blockages that unexpectedly bring everything to a halt.
Installing belt cleaners is a simple preventative measure that removes carryback while the conveyor is running. Cleaners can be speci ed for different belt types, including at and chevron patterns, and matched to your material characteristics.
For applications involving oily, sticky, or chemically aggressive materials, choosing the right belt cover grade also matters. Oil-resistant belts, for example, help slow down degradation when belts are exposed to oil-based products (synthetic or natural), reducing premature replacement.
Ready-to- t replacement
Even with excellent maintenance, failures can still happen—and the speed of recovery often makes the biggest difference to total downtime.
One of the most effective uptime strategies is keeping a mechanically fastened replacement belt on-site, ready to install immediately.
Smiley Monroe’s Zip Clip replacement conveyor belt is designed for rapid, safe belt changes without specialist tools or a vulcanising crew. Because it’s ready-to- t, teams can quickly swap belts on site and get machinery back into service.
Zip Clip can typically be tted from ground level in around an hour or less, helping sites avoid the extended downtime associated with traditional vulcanised splicing. This also removes common installation bottlenecks, like waiting for specialist vulcanising teams, managing lifts or scaffolding, and coordinating shutdown windows.
Keeping a spare belt in stock works much like a spare tyre: if a belt fails, you t the spare and restart production, then reorder another spare to restore your contingency.
It reduces operational stress and gives teams con dence that a breakdown will not turn into an all-day shutdown.
Book a site survey
Every conveying application is slightly different. Material type, loading method, belt speed, environment, and output demand all affect wear patterns and failure risk.
Smiley Monroe works closely with customers to understand these variables and ensure the belt speci cation and components are matched precisely to your application.
A site survey helps identify weak points before they become stoppages, whether that’s a skirting set-up, belt cleaner choice, splice type or belt grade.
With the right combination of belt and conveyor components, sites can improve reliability, reduce unplanned downtime, and extend service intervals. AB
Industrial.
Smiley Monroe has developed a wide range of solutions for conveyor belt systems after more than four decades in the industry.
Zip Clip is a popular solution from Smiley Monroe.
Image: Smiley Monroe
Rebuild revolution
Remanufacturing and rebuilding is becoming increasingly prominent in the quarrying and aggregates sector as customers look to cut down on expenditure.
Metso’s Lokotrack is one of the leading mobile crusher brands, renowned for its robust design and features. A great example of this is a 20-year-old Lokotrack LT110 jaw crusher, which the Norwegian crushing contractor Tverås Maskin gave a new life to through a total overhaul at Metso's repair facility.
This sturdy, 2005-manufactured Lokotrack jaw crusher has broken hard Norwegian stone for around two decades. During this period, approximately four million tonnes of rock have gone through the sturdy Nordberg C110 jaw crusher cavity. Like most Norwegian crushing contractors, Tverås Maskin has primarily used its LT110 jaw crusher as a standalone primary crusher, with feeding done by an excavator.
One of the main locations during this Lokotrack’s career has been Balhald quarry in Stjørdal, near Trondheim in central Norway.
One of the leading crushing contractors in Norway, Tverås Maskin had kept good care of its 20-year-old Lokotrack. All inspections and servicing were carried out on time, supported by the Metso Norway maintenance crew.
In late-2024, the company faced two options: either to purchase a new primary crusher or to have Metso maintenance specialists perform a complete overhaul at the company’s Tampere repair shop in Finland.
“After considering the options available and discussing with Metso experts in Norway and Finland, the decision was quite simple – we wanted to keep our old, trusted Lokotrack,” Tverås Maskin
crushing operations manager Vidar Bjerkås said. “In fact, I believe this old Lokotrack LT110 to be the best jaw crusher that Metso has ever built.
“We took care of refurbishing the feeder section ourselves, and Metso Finland's repair workshop took care of the thorough overhaul of the rest of the Lokotrack.”
Bjerkås said the lifetime of LT110 will be extended by another 10–15 years with the complete overhaul. After the major renovation, the crusher was successfully restarted in August at Balhald quarry.
Fed by an excavator, the average capacity is 400 tonnes per hour.
It’s always a matter of discussion whether a 20-year-old crusher is worth overhauling.
To make the decision easier, Metso’s Tampere repair shop experts paid a visit
Remanufacturing is becoming increasingly in demand with quarrying customers.
to the Norwegian quarry site to see the Lokotrack LT110 jaw crusher in operation.
“After inspecting the unit, the decision was clear. This LT110 has been kept very well-reserved, serviced in a timely manner, and clearly a good case for a total overhaul,” Metso repair shop manager Petteri Piirainen said.
In early 2025, the Lokotrack was transported from Norway to Metso’s Tampere workshop, which features approximately 3400 square metres of premises, state-of-theart machinery, and skilled personnel.
The workshop can accommodate six Lokotrack crushers for simultaneous servicing. After disassembling all Lokotrack parts to achieve a skeleton-looking frame for sandblasting, the main focus was on rebuilding the robust C110 jaw crusher, the heart of the Lokotrack.
“We rebuilt the jaw crusher by replacing all the necessary worn parts of the jaw, like side plates, pitman bearings, clamping bolts, belt guards and other wear parts,” Piirainen said.
“During the renovation, we could utilise the old crusher end plates, pitman and bearing housings that we welded and machined in new condition.
“Thanks to the professional work, this over 20-year-old jaw was rebuilt as good as a brand new crusher, ready to carry on crushing tasks ef ciently and safely.”
The rebuild also included the renovation of the main electrical switchboard and the renewal of all cables. Regarding hydraulics, all hoses were replaced, and the hydraulic tanks and coolers were cleaned.
The original Cat C12 diesel motor and gearbox were completely overhauled.
As the nal touch, the jaw crusher got fresh, original beige paint. Just after midsummer 2025, the new-looking Lokotrack LT110 was transported by truck back to Norway.
From the customer side, Vidar Bjerkås of Tverås Maskin was happy with the outcome of the demanding achievement.
“Our co-operation with Metso Norway and Finland worked well. We always received the necessary information on how the renovation was proceeding,” Bjerkås said.
Rebuilt and better
During an Aggregates Business visit to Finning UK & Ireland’s Leeds facility in November 2025, Finning UK & Ireland product manager for aftermarket Mark Tudball said there rise in customers working in industries such as quarrying who are opting for certi ed FinningCat machine rebuilds. Tudball said that machine rebuilds can support customers on their ‘sustainability journey’. Rebuild options offer exible scopes of work to suit customer needs, and certi ed Caterpillar three- to ve-year warranties are available. Machine upgrades include part numbers and the latest upgrades. Furthermore, Caterpillar remanufactured parts help customers reduce carbon emissions by reducing raw material use. Rebuilds also deliver greater costeffectiveness than buying new.
In late June 2025, the fully overhauled Lokotrack was transported by a truck back to Norway.
The professional team from the Metso Tampere workshop oversaw the complete overhaul of the over 20-year-old Lokotrack LT110 jaw crusher.
“We have had more Cat D6 dozer customers who previously opted for only component rebuilds now taking the certi ed powertrain and hydraulics option after dealer feedback led Caterpillar to set a price point at which we could offer it, along with an undercarriage rebuild and a ve-year, 8000hour warranty. It’s a promotional offer that equates to a customer spending 55 per cent or less on a new machine,” Tudball said.
“We aim to achieve the ‘55 per cent or below of the cost of a new machine’ on most rebuild models, but it’s not possible for all. The ‘55 per cent or below’ gure is based on new machine sales.
“Together, with our partners Caterpillar, we worked towards a customer-focused solution and offered the rst CHR [Certi ed Hydraulic Rebuild] completed on a wheeled loader.”
This ensured the asset gained a second life, with the hydraulic system rebuilt and the powertrain scope reduced, adding value through the certi ed equipment protection plans.
Tudball said that Finning UK & Ireland typically orders parts from Caterpillar ahead of each scheduled rebuild, with Finning's response repair and rebuild facilities (RRR) targeting a 12-week rebuild-to-return-tocustomer time for each machine.
Tudball said that more than 43,000 machines, powertrains and components have been rebuilt by Caterpillar and Cat dealers since 1985.
He said that Finning UK & Ireland’s rebuild program can improve parts sustainability by reducing carbon emissions, energy use, and raw material consumption. He does this by charting a part’s journey from its installation, through performance, owner maintenance, maturation, replacement, return to Caterpillar, disassembly and cleaning, inspection and salvage, remanufacture and assembly, testing, and, nally, re-entry into the supply chain.
“Rebuilds are a great way of maintaining the residual value of the machine,” Finning UK & Ireland marketing manager Tracey Earp said.
“The way we got to all the rebuild options is that Mark [Tudball] and his team got lots of feedback from customers as to what they wanted for their business.”
Finning UK & Ireland’s Leeds site opened on 5 June 1958 as a major eld service and repair workshop for the northeast of the UK. The branch was extended with the opening of the component rebuild centres rebuild workshop in January 1979. The site’s uid analysis lab was moved off-site in 2013 due to capacity and capability constraints, and to support growth plans. Currently, there are 135 staff and engineers based at the Leeds facility, including employees in the sales and service of ce.
On an Aggregates Business tour of the rebuild workshop, two Caterpillar trucks, a 772 and a 775, owned by a leading UK building materials supplier, were nearing completion of their rebuilds.
At the Finning UK & Ireland Leeds workshop, customer service manager Mike Sanderson led the workshop tour and also showcased a recently rebuilt Cat D6 dozer, which was about to be returned to its owner.
“Everything from a Cat 775 down will pretty much t in one [workshop] bay,” he said.
“We had a Cat 992 [large wheeled loader] last week. Anything that comes through the Leeds workshop is largely a complete rebuild. We get the odd repair to do via a eld service team member who has to bring a machine in, and we’ll create a space for it, like that [Cat] D6 [dozer] over there, which is having an undercarriage repair.
“We get machines from all over the country, such as the [Cat] 992 that was here last week, which came up from Somerset. It’s partly about nding a [Finning UK & Ireland RRR] facility that can take the machine, but customers aren't always open to that. They want the machine to go to their most local site, which we’ll accommodate where possible. We nd that customers like the xed price they’re quoted.
“We are looking to recon gure the workshop to create what we call ‘super bays’. It will mean pretty much getting rid of the current walkways and having four super bays. You’d still have a central area to walk around the workshop, and it will enable us to have more working space and accommodate a higher volume of machines.”
Reborn in Malaysia
A Volvo L220G wheeled loader in Malaysia has been restored through the Volvo Certi ed Rebuild Program, undergoing a signi cant overhaul from the engine to the cab using only genuine Volvo remanufactured parts.
The rebuild delivers near-new performance, extended machine life, and substantial cost and sustainability bene ts.
A Volvo L220G wheeled loader in Malaysia has undergone a full transformation through the Volvo Certi ed Rebuild Program. Volvo said the project demonstrated a way customers can access cost ef ciency, technical expertise and support sustainability.
Mark Tudball is pictured next to a rebuilt Cat C27 engine for a Cat 775 truck Images: Prime Global Publishing
rebuilt, and tested to ensure it performs exactly like a brand-new component.
Every panel was cleaned, repaired, repainted, and resealed with fresh decals to protect against the elements.
Inside the cab, the operator’s environment was restored to a like-new state – clean, comfortable, and ready for long shifts, with all controls and displays functioning as intended.
Finally, the rebuilt L220G underwent a rigorous pre-delivery inspection and testing phase to con rm it met Volvo CE’s exacting standards for quality and performance.
Only once it had passed every check was it returned to the customer, ready to deliver many more years of productive service.
“Central to Volvo CE’s sustainability strategy is a strong emphasis on resources, adopting a ‘reuse, reduce, remanufacture, and recycle’ methodology,” Volvo CE Malaysia head of aftermarket Yee Kam Hoong said.
The Volvo Certi ed Rebuild Program is designed for customers who want to extend the working life of their machines without compromising on performance or reliability. By restoring a machine to meet original factory speci cations, using only genuine Volvo CE parts, the program delivers the productivity of a new machine at a fraction of the cost.
The transformation of the L220G began, as every Volvo certi ed rebuild does, with a comprehensive inspection.
This in-depth assessment, conducted by experienced Volvo-certi ed technicians, evaluates the machine’s overall condition and determines the optimal level of refurbishment to deliver the best results for the customer.
Every major system and component is thoroughly checked, from the engine to the hydraulics, allowing customers to choose from a range of rebuild options, including targeted component repairs and a full machine overhaul.
For the L220G, the decision was made to go all in. After 10 years in service and over 25,000 operating hours, this heavyduty wheeled loader remained a reliable workhorse but was ready for a second life. The plan called for a signi cant rebuild, restoring every aspect of the machine to meet original Volvo CE factory speci cations.
The process began with the careful disassembly of key systems. The original Volvo D13H six-cylinder turbo diesel engine was removed, cleaned, and completely rebuilt. Critical parts such as pistons, liners, turbocharger, and fuel injectors were either replaced with new genuine Volvo components or remanufactured to as-new condition. All seals, gaskets, and lters were replaced, while the cooling system was pressure-tested to ensure optimal performance under heavy loads.
The transmission, one of the most vital components in any wheeled loader, was replaced with a fully remanufactured Volvo unit. Far more than a simple repair, a remanufactured transmission is stripped down to its core, meticulously cleaned,
This guarantees smooth shifting, strong power delivery, and maximum reliability.
The drive shaft was disassembled, balanced, tted with new universal joints, and realigned to prevent vibration and premature wear.
The axles, wheel hubs, and brake systems were overhauled to ensure safety and control, critical for handling heavy loads in demanding quarrying and materialhandling applications. While the mechanical work was underway, the exterior received equal attention.
“The Volvo Certi ed Rebuild Program and our genuine Volvo reman parts allow customers to maximise machine life, reduce costs, and minimise environmental impact, all while maintaining the quality, reliability, and performance Volvo machines are known for.” AB
Rebuilding a Cat 775 truck.
The Finning UK & Ireland Leeds RRR facility
Image: Finning UK & Ireland
Exploring new frontiers
Manufacturers continue to modernise their screening bucket and bucket attachment ranges as quarry operators seek versatile options.
When Simex looked at the common pain points its customers were facing, selective separation and on-site screening kept coming up.
The twin issues were not con ned to a single sector. The quarrying and aggregates sector was increasingly looking to screen waste materials, including construction and demolition waste. Earthmoving operations sought to clean and reclaim topsoil from debris, especially as green-space restoration projects became increasingly popular.
Through its market research, Simex understood that the more customers could screen materials on-site, the greater savings they would make over time. Especially as recovering all valuable materials from waste aggregates reduces disposal costs and increases the amount of “sellable” material available for operations.
Following the extensive research, Simex designed a solution to solve these pain points: the VSE Tornado screening buckets. The VSE Tornado range can separate different materials on-site, including damp materials that contain moisture. Due to its three-shaft con guration with star-shaped attachments, processing is faster, supporting overall ef ciency.
“Simex has been investing in screening buckets for years, though the focus has traditionally been on recovering heavy
aggregate materials from demolition and crushing,” Simex research and development project engineer Nicola Sisti said.
“In recent years, however, the market has increasingly expressed the need for on-site soil cleaning and recovery. I’m referring to urban green maintenance, compost aeration, gardening, and small private worksites. The goal is to clean the soil from stones and debris, avoiding total disposal in land lls and reusing directly on-site.”
The VSE Tornado range is suited to mini and midi excavators ranging from 1.5–10 tonnes. It excels in applications involving debris, stones, and gravel, as well as for compost aeration. The standard output particle size is 0–20mm, however, by adjusting the spacers, it can be reduced to 0–10mm or increased to 0–30mm.
The VSE Tornado Buckets feature a quickchange system, which means the whole shaft or individual screening elements can be replaced. This minimises downtime and ensures greater uptime on-site. The buckets can also be equipped with polyurethane tools when dealing with wet or sandy applications as well as steel tools when working with heavy-duty or abrasive materials.
New quick coupler
Steelwrist has expanded its SQ technology range with the launch of the SQ40 automatic coupler for compact excavators.
Steelwrist has designed the SQ40 so it can be quickly changed using high- ow-powered work tools. SQ technology means hydraulics and electrical signals can be connected in a single movement, and operators can change the tool without leaving the cabin.
It follows Steelwrist's 2017 launch of the SQ auto connection system for quick couplers and tiltrotators. Since launching the technology, Steelwrist has expanded the SQ range to include eight models, from the SQ40 to the SQ90, covering excavators from 2–70 tonnes. The SQ40 is speci cally designed for compact excavators from 2–7 tonnes.
“Since we introduced SQ40 at bauma there has been a lot of interest for the product from many customers, and with the introduction of the SQ40 quick coupler we can also offer a sandwich tiltrotator installation. This is bene cial when you want to easily disconnect the tiltrotator to use for example a breaker,” Steelwrist chief executive of cer Stefan Stockhaus said.
“For the past two years, I have been running the SQ40 size on my own excavator, and once you get used to not having to leave the cab when changing hydraulic-powered work tools, you never want to go back.”
According to Steelwrist, the SQ40 coupler is optimised to achieve a ow of 70 litres per minute with Steelwrist’s coupling providing 40 per cent more ow area compared to
Simex has launched the VSE Tornado.
Images: Simex
a standard 3/8” coupling. Alongside the SQ40, Steelwrist has also introduced the H6 electrical connector as an upgrade on the Open-S V14 electrical connector.
The H6 is a six-pin electrical connector that is fully integrated into the SQ40 locking wedge and has a moulded design. It features large contact surfaces and strong springloaded pins ensuring reliable electrical transmission and high current capabilities.
More organisations join Open-S
The Open-S alliance has welcomed three new members: attachment manufacturers Epiroc and Genesis Attachments, and equipment rental company Kanamoto.
The alliance now has 23 members after welcoming nine members in 2025 including companies from the Asia Paci c, Europe and North America, who support creating an open industry standard for automatic couplers and work tools. It would mean that customers are not restricted by proprietary solutions when choosing work tools and attachments for their excavators.
Epiroc’s con rmation is a major boost for the Open-S Alliance and comes after Epiroc acquired ACB+ with Epiroc/ACB+ now an associate member of the alliance.
“By joining the Open-S Alliance, we reinforce our commitment to delivering open, compatible solutions that empower customer freedom of choice,” Epiroc vice president for the hydraulic attachment tools business line Predrag Petrovic said.
“This shared standard is not just about technology, it’s about building a more ef cient, connected, and sustainable industry.”
Genesis Attachments has also joined the Open-S Alliance as an associate member. The US-based manufacturer specialises in designing and manufacturing hydraulic mobile shears, grapples, concrete processors and specialty attachments for scrap processing, demolition, material handling and offshore decommissioning applications.
“The standards set forth by
The VSE Tornado was designed in response to customer feedback.
Open-S are a foundation to maintain the best interests of the owners and operators, which perfectly coincide with Genesis’ focus,” Genesis Attachments director of engineering Roger Johnson said.
“The information shared through Open-S will ensure that Genesis can continue to offer advanced attachment solutions that seamlessly integrate with supplementary equipment in the eld.”
Kanamoto has joined the Open-S Alliance as a supporting member, committed to promoting the alliance’s principles through its construction equipment rental business, with a presence in Japan, Southeast Asia, and the Oceania region.
“Kanamoto places great importance on improving the compatibility of hydraulic excavator attachments used at construction sites.
“By joining the Open-S Alliance, we expect to create an environment where attachments can be used regardless of model or manufacturer, thereby enhancing user convenience,” Kanamoto board of directors member Jun Watanabe said.
Stockhaus, who also serves as the Open-S Alliance chairman as well as CEO of Steelwrist, welcomed the three appointments.
“We are thrilled to welcome Epiroc and Genesis, both well-known brands and benchmarks for quality, as members of the organisation and supporters of our vision for an open industry standard,” he said.
“It is a true pleasure and an honour to welcome them on board, and I am convinced their participation will help propel the next phase of our growth.
“With Kanamoto, the Open-S Alliance welcomes yet another member in Japan, a testament to the international expansion of our ambition to create a global standard.” AB
The VSE Tornado enables on-site screening.
Steelwrist has debuted the SQ40 automatic coupler.
Opportunities emerge in new markets
O -the-road tyre manufacturers are targeting new frontiers, with key trends including increased infrastructure development, mining, and construction projects in emerging economies.
Global off-highway tyre manufacturer BKT (Balkrishna Industries) has further extended its original equipment (OE) division by appointing two new specialist gures for South America and one for France.
BKT has said the appointments mark a further step towards its long-term objectives outlined in the company’s 2030 growth vision and strategic roadmap.
The BKT announcements come as a new report from consulting company MarketGenics said the global off-the-road (OTR) tyre market is likely to grow from $US3.3 billion in 2025 to $US4.5 billion in 2035. This will be driven by an increase in infrastructure development, mining, and construction projects in emerging economies and developed economies.
The growing urbanisation and industrialisation, especially in Latin America and the Asia Paci c, are creating the need for heavy machinery that uses strong OTR tyres.
As part of BKT’s global OE deployment and to scale operations in the key business region of South America, BKT has announced the arrival of two senior professionals for South America.
The rst is Cadu Accica, who has been appointed as head of original equipment manufacturing (OEM) for South America and brings 19 years of experience in the specialty tyre industry, with a proven record in business development, marketing, and sales. At BKT, Accica will lead OE partnerships, delivering value through customer proximity and long-term collaboration.
The second appointment is Lincoln Sugimoto, who joins BKT as OEM technical manager for South America. With a strong background in engineering and project management and 15 years of experience, including key roles in the specialty tyre and material handling industries, Sugimoto will ensure that OEMs in South America receive best-in-class technical support, fostering innovation and operational excellence in every partnership.
France-based Rémi Morin has been appointed as brand speci cation manager.
Morin brings in over 12 years of experience with a major global OEM and a decade of international leadership across smart farming, mobility, and innovation to this role.
BKT has said the move re ects its commitment to aligning product development even more closely with the needs of OEMs, dealers, and end-users - ensuring innovation is driven by the real-world demands of the eld.
OTR tyre manufacturer BKT has made two new appointments in the expanding South American market.
Following recent strategic additions to the OE teams across Europe, Africa, and the Middle East, BKT said it is now in a uniquely strong position to scale its OE business across all segments – OTR, agriculture and industrial - unlocking new growth opportunities, reinforcing its global vision, and fully in line with its ambitious 2030 strategic plan.
In a separate move, BKT Europe has announced a revision of the organisational structure within the global OEM sales organisation of the India-headquartered off-road tyre manufacturer.
Under the new model, the various regions will report directly to BKT Europe managing director Lucia Salmaso to simplify decision-making ows and streamline commercial governance.
Transparent solution
Retreading and sustainable tyre solutions provider Marangoni has said it is now one of the rst manufacturers in the industry to make CO2 emissions data available for its complete Ringtread product portfolio.
With this initiative, Marangoni said that it provides customers, partners, and eet operators with a reliable tool to quantify the environmental bene ts of retreading and to integrate this knowledge into their sustainability strategies.
The disclosure of CO2 emissions values is a key element of Marangoni’s long-term sustainability commitment.
Compared to new tyres, retreaded tyres signi cantly reduce raw material and energy consumption, while contributing to a circular economy, according to Marangoni.
“Transparency is the key to trust and sustainable progress,” Marangoni director of sales and marketing Ronny Dietsch said.
“By openly sharing the carbon footprint of our Ringtread products, we empower our customers to base their choices on solid data and together accelerate the transition towards a lower-emission future.”
Marangoni said the CO2 emissions data for its Ringtread product line is based on calculation methods aligned with international standards so customers can con dently conduct their environmental, social and government reporting.
New appointment
Triangle Tyre has appointed Vaculug as distributor for its OTR tyre segment in the UK after-market, succeeding RH Claydon.
Vaculug will focus its sales of Triangle Tyre’s product range on key OTR sectors, including quarrying, mining, port operations, materials handling, and heavy industrial applications.
“We are truly excited by the opportunity to enter the market with an agreement with such a leading brand,” Vaculug managing director Jorge Crespo said
“We are looking forward to building a strong relationship with Triangle and serving both our current customers as well as new ones with quality products.”
Established in 1950, Vaculug produces high-quality OTR and truck retread tyres for eets across the UK, while offering effective and practical eet management solutions to its customers.
Since the beginning of its European operations in 2017, Triangle Tyre has focused heavily on re ning its distribution model across Europe and appointed distributors in key segments, including the OTR, passenger car radial, and truck, bus and radial segments.
Triangle Tyre Europe OTR director Luca Mai welcomed the announcement.
“Vaculug’s professionalism, infrastructure, and customer-driven approach make them the ideal partner for Triangle in the UK,” he said.
“We thank R.H. Claydon for their successful collaboration over the past years and look forward to building the next chapter of growth with Vaculug.” AB
BKT has a global presence in the tyre sector.
BKT has appointed Cadu Accica as head OEM South America.
Entering a digital age
Digital technology solutions are fast becoming a trusted part of site management in the global quarrying and aggregates sector.
The aggregates, asphalt, and readymix concrete sectors are entering a period of rapid transformation driven by arti cial intelligence (AI) and intensifying pressure to deliver materials in an ef cient and sustainable way.
For decades, dispatching was dominated by manual processes and legacy software. But today’s operating environment, marked by complex delivery constraints and regulatory demands, requires a fundamentally new approach.
AI business software provider INFORM showcases how operators who modernise
stand to gain operational, nancial, and environmental advantages.
Legacy dispatching
It is essential to understand the limitations of the systems still used by many producers. Legacy dispatching tools, often based on spreadsheets or basic heuristics, were not built for the complexity modern planners face. Balancing truck capacities, driver availability, haul distances, loading times, customer windows, and unpredictable traf c requires evaluating millions of scenarios in real time. Legacy tools cannot do this.
As a result, dispatchers are forced to rely on reactive, manual planning.
When conditions change, and they always do, schedulers must recalculate routes, shift orders, and update timelines by hand. This reactive posture leads to inef ciencies, including low truck utilisation, oversized eets, and inconsistent service quality.
These hidden costs accumulate daily; meanwhile, companies that adopt AI-powered scheduling often see double-digit improvements in loads per truck, on-time performance, and logistics unit cost.
Simulation studies comparing legacy plans with AI-generated ones routinely reveal striking differences in eet ef ciency and cost per tonne delivered. Many organisations hesitate because they fear disruption or underestimate the nancial upside. But the biggest risk is the cost of staying with systems that can no longer keep up.
Fortunately, modernising is far simpler than many expect. AI-based planning tools integrate smoothly with existing enterprise resource planning (ERP), scale, telematics, and weighbridge systems. Implementation can be phased and simulation studies allow producers to quantify the bene ts before committing. INFORM has said, for most organisations, the business case quickly becomes undeniable.
Planning
Once organisations move beyond legacy tools, the true value of AI becomes clear. Unlike generic AI models, INFORM’s
advanced transport optimisation for aggregates logistics is built on operations research, machine learning, and mathematical algorithms engineered speci cally for multi-constraint planning. These systems analyse countless permutations of eet, order, and routing data long before the rst truck leaves the yard. They automate the most intensive aspects of planning while giving dispatchers full visibility and control. Instead of spending the day re ghting, dispatch teams focus on communication, service quality, exception management, and continuous improvement.
According to INFORM, one European producer, producing 580,000m³ of ready-mix concrete annually, achieved nearly 25 per cent productivity gains and saved €2.2 million annually after implementing INFORM’s AI-based dispatch software. That’s nearly a 23 per cent drop in logistics costs. Gains of this magnitude are no longer the exception, according to INFORM.
AI also improves upstream processes. When order takers have real-time visibility into feasible delivery slots, they avoid overpromising and reduce unnecessary strain on the eet. Rather than replacing planners, AI augments their capabilities, handling computation while humans apply judgment. This combination of mathematical rigour and human expertise produces resilient transport plans that withstand real-world volatility.
The driver shortage
Driver scarcity continues to threaten delivery reliability across Europe and beyond. The issue is not limited to licensing numbers. Many licensed drivers have left the profession due to dif cult working
INFORM’s solutions can support planning activities in a quarry set-up.
conditions, unbalanced hours, and compensation that is misaligned with the demands of the job. As experienced drivers retire, younger generations are not entering the profession in suf cient numbers.
While autonomous trucks fuel speculation about long-term solutions, they remain years away from widespread use in open-road construction materials logistics.
However, limited autonomy is gaining traction in controlled environments such as mines and quarries, where repetitive haul cycles and de ned routes create ideal conditions for automated haulage.
In the near term, the most realistic and impactful tool for mitigating the driver shortage is AI-powered optimisation.
By improving utilisation and reducing empty mileage, AI helps producers deliver the same, or greater, transport volume with fewer active vehicles. Fewer trucks needed means fewer drivers required. This ef ciency relieves pressure on the workforce without compromising service reliability.
Importantly, AI also strengthens dispatcher–driver collaboration.
Planning automation frees dispatchers to focus on supporting drivers, thereby improving communication, streamlining operations, and ensuring safer deliveries.
Electri cation
Alongside AI, electri cation is reshaping the future of aggregates logistics. With the European Union’s strengthened CO2 reduction targets, eet decarbonisation is shifting from optional to inevitable. Early pilot programs
Images: INFORM
have demonstrated the viability of batteryelectric trucks for short-haul aggregate and ready-mix deliveries, especially in urban zones where diesel restrictions are expanding.
Yet electri cation introduces a new layer of planning complexity. Unlike diesel trucks, electric vehicles (EVs) require dispatchers to consider:
• Battery range and charging time
• Charger availability and depot grid capacity
• Weather impacts on energy consumption
• Route elevation and load weight
• Time-of-day energy pricing
These factors directly in uence truck selection, scheduling, and routing.
Traditional systems cannot incorporate these variables dynamically, making AI indispensable for managing mixed diesel EV eets. AI can optimise where EVs should be deployed, when trucks should charge, how many chargers each depot requires, and how charging aligns with delivery cycles.
These insights help producers avoid bottlenecks, minimise energy costs, and plan charging infrastructure strategically.
With electri cation accelerating, dispatching will only become more complex. AI is emerging as the critical tool for ensuring sustainability goals can be met without sacri cing pro tability or service reliability.
A path forward
Aggregates supply chains are becoming more dynamic and data-driven each year.
INFORM has said AI-powered transport planning, paired with electri cation readiness and enhanced human-machine collaboration, offers the most practical and pro table path to navigating this transition.
For producers still relying on outdated dispatching systems, the message is clear: modernisation is no longer a luxury. It is operationally essential.
According to INFORM, the companies that act now will lead the industry into a new era of ef ciency, sustainability, and competitive advantage. Those who wait may discover that the greatest risk is standing still.
Enhanced capabilities
CheckProof has launched its new risk assessment capability through its platform and app. According to the Swedish SaaS company, the integrated addition simpli es and strengthens safety management. The tool enables organisations to replace manual, disconnected safety processes with a fully digital, traceable, mobile- rst solution, allowing teams to proactively identify, mitigate, and monitor risks across their operations.
“Many teams still rely on annual paperbased risk assessments. Our platform allows everything, from large-scale project risk assessments to quick ‘Take 5’ checks, to be managed seamlessly in one place,” CheckProof chief executive of cer Håkan Holmgren said.
Holmgren said this addition will give teams a faster, more consistent way to identify risks, document controls, and take action before issues escalate.
Key bene ts of CheckProof’s risk assessment feature include:
• Mobile- rst assessments – eld teams can quickly identify hazards, assess probability and consequence, and log actions directly from their devices.
• Action and accountability – assign responsibilities, set deadlines, and monitor mitigation measures in real-time.
• Residual risk evaluation – verify the effectiveness of safety actions with follow-up assessments, ensuring risks are reduced, and progress is fully traceable.
• Elevated compliance and documentation – all assessments, actions, and results are digitised, stored, and fully traceable, creating a historical record and enabling quicker responses to high-level risks.
CheckProof said the tool is designed for daily use yet robust enough for complex projects. The feature supports pre-work risk assessments, dynamic risk checks, generic risk assessments, and brief safety moments such as Take 5 or Take 1.
This ensures frontline teams and management have full visibility, enabling proactive safety, compliance, and operational ef ciency. AB
INFORM is a trusted partner for quarries looking to upgrade to digital site management solutions.
PNG
Fuelling demand
Renewable fuels are likely to play an increasing role in the quarrying and aggregates sector now and into the future.
The construction and quarrying sectors are major consumers of fossil fuels. Diesel-powered machines, including excavators, loaders, and dump trucks, are prevalent on construction sites worldwide. Environmental concerns over greenhouse gas emissions and air pollution are prompting site owners and managers to adopt greener practices. Renewable fuels produced from sustainable resources offer a quick and straightforward solution to begin the path towards a zero-emissions future.
The bene ts of adopting hydrotreated vegetable oil (HVO) include strong greenhouse gas (GHG) emission reductions when using waste-based feedstocks. As a drop-in fuel, renewable diesel requires no engine modi cations and can be blended easily, offering a pragmatic path to decarbonisation. They will also extend the life of the current proven engine technology for some years to come.
Shell views renewable diesel, alongside sustainable aviation fuel (SAF), bioethanol, and renewable natural gas, as crucial tools for reducing emissions in hard-to-decarbonise sectors such as aviation and commercial transport. These fuels are valued for their ability to blend seamlessly into existing fuel infrastructures with minimal adjustments.
Shell decided late in 2021 to build a major biofuels facility at its Rotterdam Energy and Chemicals Park, intended to produce up to 820,000 tonnes per year of SAF and renewable diesel. This would be enough to avoid 2.8 million tonnes of CO2 emissions annually.
This plant was also connected with carbon capture infrastructure to store emissions offshore. In July 2024, Shell temporarily paused construction of the Rotterdam biofuels plant due to technical issues, higher costs and a weaker renewable fuel market. This enables Shell to review the project’s commercial viability and assess future risk. Even with this move, Shell reaf rms its commitment to achieving net-zero emissions by 2050 and considers low-carbon fuels, including renewable diesel, as a key part of its strategy. Falling mandates and regulatory delays in Europe have weakened demand and depressed margins for renewable fuels. This is evident in Shell’s pause and re ected in its leadership priority changes, trimming investments in some renewables while bolstering oil, gas, and LNG assets to improve pro tability.
So what are Shell’s competitors doing about renewable diesel?
As of early 2025, As of early 2025, BP has scaled back its investment in renewable energy, reducing annual green transition spending from approximately $US5 billion to $US1.5–2 billion. Oil and gas investment has increased to $US10 billion per year. Its Cherry Point, US, facility has undergone a $US50 million upgrade to enable the processing of approximately 7000 barrels per day of renewable diesel, resulting in a reduction of CO2 emissions by 600,000 tonnes annually. In 2022, BP acquired a 30 per cent stake in Green Biofuels Ltd, the UK’s largest HVO provider. Their fuel, HVO Gd+, offers up to 85 per cent reductions in particulates and up to 30 per cent lower NOx emissions while delivering lifecycle GHG savings of around 87 per cent, and it’s engine-drop-in ready.
BP remains engaged with renewable diesel through targeted investments.
There is increasing customer demand for biofuels.
However, its broader strategy appears to be shifting back toward its traditional oil and gas operations. Net zero by 2050 remains a stated goal, but with a more cautious approach to low-carbon spending. They look to be scaling back overall, with targeted cautious investments in projects like Cherry Point and HVO partnerships.
Neste remains one of the world’s largest and most advanced producers of renewable diesel, with facilities in Finland, Singapore, and Rotterdam, as well as a joint operation in Martinez, California. Total nameplate production reaches 5.5 million tonnes per year. They stand out as a frontrunner in renewable diesel, are deeply committed, highly capable, and technically advanced. Processed with its proprietary NEXBTL technology, Neste MY Renewable Diesel can reduce greenhouse gas emissions by up to 90 per cent* or by up to 75 per cent** when emissions over the fuel’s life cycle are compared to fossil diesel.
Neste’s fuel has excellent cold properties and is fully compatible with current diesel engines and energy infrastructure, so quarries do not need to make any investments or modi cations to their vehicles or equipment. Neste’s renewable diesel can be used neat or blended with fossil diesel at any ratio. More than 90 per cent of their feedstock is waste and residue oils and fats, such as used cooking oil and animal fat waste. They also research emerging sources like novel vegetable oils produced with regenerative agricultural practices, lignocellulose, and even lique ed waste plastics. To meet the global demand for renewable diesel, Neste has invested over the past several years to increase its production capacity. For example, the expansion of its Singapore re nery, completed in 2023; the joint operation with Marathon Petroleum in Martinez, California, in 2022; and the ongoing expansion of the Rotterdam re nery, which will increase annual nameplate capacity to 6.8 million tonnes in 2027.
As one of the renewable diesel leaders in the US, Valero operates, through its Diamond Green Diesel (DGD) joint venture, two Gulf Coast plants with a combined annual production capacity of approximately 1.2 billion gallons. In October 2024, Valero completed a SAF project at Port Arthur, producing 235 million gallons per year of SAF, which cuts GHG emissions by 74–84 per cent compared to conventional jet fuel. Major airlines, such as Southwest and JetBlue, are already on board. Valero is a signi cant North American player in renewable fuels, particularly in renewable diesel and SAF, and is rapidly expanding its operations.
Enerkem (Canada) is collaborating with Shell and others to construct a new biofuel facility in Varennes, Quebec. This plant will convert 200,000 tonnes of residual biomass into 125,000 tonnes of biofuels annually starting in 2025.
BP, along with Johnson Matthey, is backing the Louisiana Green Fuels project, which aims to produce renewable diesel from forestry waste using advanced FischerTropsch technology, targeting carbon-negative fuel outputs.
Biodiesel is an area of increasing innovation by manufacturers.
For all suppliers, the primary limitation on growth in renewable diesel production is feedstock constraints. The availability of truly low-carbon feedstocks, such as used cooking oil, is limited. Rapid scale-up risks shifting toward virgin vegetable oils, which may lead to deforestation and biodiversity loss, potentially negating GHG bene ts. Shell and BP are maintaining a presence, but broader shifts in strategy and shareholder pressure around pro tability have dampened their momentum. Neste and Valero are rapidly scaling. Neste is demonstrating strong emissions reductions through its advanced feedstock strategy and expertise in drop-in fuels.
Enerkem and its allied rms are innovating in feedstocks and process technology.
Making the transition to HVO
Enerkem and partners are advancing innovative biofuel technology via joint ventures and plants like Varennes and Louisiana to produce sustainable diesel from waste or feedstock. Valero is producing large volumes of renewable diesel and SAF in the US, serving airlines and eet markets.
So a quarry’s transition from standard fossil diesel to renewable diesel does not have to wait on Shell, BP or the majors.
Many eet operators in the construction, mining, and aggregates industries are already taking advantage of this independently to reduce their carbon emissions and bene t their businesses. It also provides consistency to these businesses, enabling them to utilise their valuable assets for many years to come. AB
Many eet operators across the construction, mining, and aggregates sectors are already transitioning from standard fossil diesel to renewable diesel (HVO100).
How should a quarry make the move?
1 Check the technical feasibility
Renewable diesel (HVO100) is a drop-in fuel approved by most original equipment manufacturers (OEM), including Caterpillar, Volvo CE, Komatsu, Liebherr, Scania, and others. No retro tting is needed; just a check against the required fuel speci cations.
Once con rmed, the machines can run on 100 per cent HVO or on blends with HVO and standard diesel. They can also switch between them without mechanical risk. Therefore, no equipment modi cations are required; only validation is needed, following OEM guidelines and warranty conditions. The results are cleaner combustion and potentially less maintenance.
Manage the fuel supply
Arrange with local distributors who can source from major companies, such as Shell and BP, or from independent suppliers, such as Neste, Greenergy, Preem, World Fuel Services, or regional biofuel distributors. Supply options should align with the current diesel supply, either through bulk deliveries into onsite tanks or direct supply via mobile bowsers. Feedstock shortages and policy volatility can impact fuel prices and availability, so a quarry should consider locking into supply contracts where possible.
*) In Europe and Asia-Pacific, the calculation method EU RED III (revised RED EU/2018/2001)
**) In the US, the calculation method for the US California LCFS GHG emission reductions vary depending on region-specific legislation that provides the calculation methodology, as well as the raw material mix used to manufacture the product in each market.
Taking centre stage
Some of the biggest quarrying and aggregates events are coming up and provide a perfect opportunity to engage with other industry professionals.
MARCH
3–7
ConExpo-Con/Agg
Show producer: Association of Equipment Manufacturers
Show owners: Association of Equipment Manufacturers, National Stone, Sand and Gravel Association (NSSGA) and National Ready Mixed Concrete Association
Tel: +1-(866) 236-0442
1–4
NSSGA Annual Convention 2026
Organiser: National Stone, Sand and Gravel Association (NSSGA)
Tel: (703) 525-8788
MAY
6–9
SaMoTer 2026
Organiser: Veronafiere
Telephone: +39 045 11176091
JUNE 23–25
Hillhead 2026
Organiser: The QMJ Group
Tel: +44 (0)115 945 4367
JULY 1–2
PNG Expo
Organiser: Prime Creative Media
Tel: +61 03 9690 8766
OCTOBER 6–8
IQA National Conference
Organiser: Institute of Quarrying Australia
Tel: +61 (02) 9484 0577
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