ABE May-Jun 2022

MAY/JUNE 2022 | VOL.16 ISSUE NO3 | www.AggBusiness.com

Lightening the load

PONSI BLY

RE

R

•

INTERVIEW Nigel Jackson: Strong & effective industry advocacy p08

F OO T P R

ON RB

PR TO

A

•

QUARRY PROFILE New premium C&D recycling plant for Malcolm Construction p42

T

RES

IN

ED

I N T E D & PO S

T

Volvo CE maps out better load zone navigation p23

DUCE OU

HILLHEAD PREVIEW Party time! 40 years of Hillhead p61

C

WHO’S THE BEST OPERATOR IN THE ENTIRE WORLD? There’s only one way to find out.

Watch the Cat® Global Operator Challenge 2022/23.

Already, over 10,000 contestants from more than 30 countries are competing in local competitions.

The winners go on to the regional finals, and the winners of those fly to Las Vegas for the grand final, and a chance to become Cat Global Operator Challenge Champion 2022/23.

And you can watch every minute, for free, by registering at https://www.cat.com/operatorchallenge today.

What are you waiting for? © 2022 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow,” the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

COMMENT

© Bambulla | Dreamstime.com

HEAD OFFICE EDITOR: Guy Woodford ASSISTANT EDITOR: Liam McLoughlin CONTRIBUTING EDITORS: Patrick Smith, Dan Gilkes EQUIPMENT EDITOR: Mike Woof DESIGNERS: Simon Ward, Andy Taylder PRODUCTION MANAGER: Nick Bond OFFICE MANAGER: Kelly Thompson CIRCULATION & DATABASE MANAGER: Charmaine Douglas INTERNET, IT & DATA SERVICES DIRECTOR: James Howard WEB ADMINISTRATORS: Sarah Biswell, Tatyana Mechkarova MANAGING DIRECTOR: Andrew Barriball PUBLISHER: Geoff Hadwick CHAIRMAN: Roger Adshead ADDRESS Route One Publishing Ltd, Second Floor, West Hill House, West Hill, Dartford, Kent, DA1 2EU, UK TEL: +44 (0) 1322 612055 FAX: +44 (0) 1322 788063 EMAIL: [initialsurname]@ropl.com (psmith@ropl.com)

EDITOR

ADVERTISEMENT SALES SALES DIRECTOR:

Philip Woodgate TEL: +44 (0) 1322 612067 EMAIL: pwoodgate@ropl.com Dan Emmerson TEL: +44 (0) 1322 612068 EMAIL: demmerson@ropl.com Graeme McQueen TEL: +44 (0) 1322 612069 EMAIL: gmcqueen@ropl.com SUBSCRIPTION / READER ENQUIRY SERVICE Aggregates Business is available on subscription at the rate of: £85 / US$145 / €111 per annum.

Single copies £20 / US$35 / €26 Email subs@ropl.com for further details.

Subscription records are maintained at Route One Publishing Ltd. SUBSCRIPTION / READER ENQUIRIES TO:

Data, Route One Publishing Ltd, Second Floor, West Hill House, West Hill, Dartford, Kent, DA1 2EU, UK TEL: +44 (0) 1322 612061 FAX: +44 (0) 1322 788063 EMAIL: data@ropl.com

No part of this publication may be reproduced in any form whatsoever without the express written permission of the publisher. Contributors are encouraged to express their personal and professional opinions in this publication, and accordingly views expressed herein are not necessarily the views of Route One Publishing Ltd. From time to time statements and claims are made by the manufacturers and their representatives in respect of their products and services. Whilst reasonable steps are taken to check their accuracy at the time of going to press, the publisher cannot be held liable for their validity and accuracy.

PUBLISHED BY

© Route One Publishing Ltd 2022 AGGREGATES BUSINESS USPS:

is published six times a year. Airfreight and mailing in the USA by agent named World Container Inc, 150-15, 183rd Street, Jamaica, NY 11413, USA. PERIODICALS POSTAGE PAID AT BROOKLYN, NY 11256 US POSTMASTER: Send address changes to

Aggregates Business, World Container Inc, 150-15, 183rd Street, Jamaica, NY 11413, USA. Air Business Ltd is acting as our mailing agent PRINT: ISSN 2051-5766 ONLINE: ISSN 2057-3405 PRINTED BY: Warners (Midlands) PLC Facebook @AggBusiness

LinkedIn Aggregates Business Magazine Twitter @Agg_Business

Instagram @aggbusiness_magazine

www.AggBusiness.com

Top quarry tech first-hand & future-proofing sand supply

W

hatever we do in life, there are few people who will say they are not interested in being more productive and efficient at it. Just ask Schwinger Granit’s Kristian Daub.Standing on the edge of a haul road high up in his company’s impressive granite quarry in Nittenau, Bavaria, Daub enthusiastically demonstrates on his smartphone how his use of Cat Productivity technology has had a hugely positive impact on the site’s loading and hauling productivity and efficiency.

“Using the technology is saving us €150,000€200,000 a year,” says Schwinger Granit’s director, citing how decisions based on the “facts” generated by Cat Productivity data analytics had enabled him and his site team to implement operational change. This has led to many gains, including a significant reduction in fuel use through less machine idling and in the number of haul truck passes required when processing post-blast material.

Schwinger Granit’s Nittenau site processes 4,000 tonnes of granite materials a day during 11-hour shifts, Monday to Friday. “We used to work six-day weeks, but with the help of Cat Productivity we can reach our required production volumes in five days,” explains Daub. “I use the Quiply [employee] app to send data generated by Cat Productivity to either a group in our team or individual machine operators when they have done a task well.

They really appreciate the real-time feedback.”

A full Quarry Profile feature on Schwinger Granit’s use of Cat Productivity technology will appear in a forthcoming edition of Aggregates Business Europe.

A new UN study recognising the strategic importance of sand resources to global economic development makes very interesting reading.

Welcomed by the UK’s Mineral Products Association (MPA), which contributed to its preparation, the UN Environment Programme (UNEP) Sand and Sustainability report acknowledges that sand resources – encompassing all primary aggregates, including sand, gravel and crushed rock

– are essential for built development and infrastructure and that their supply cannot be presumed.

The report cites the UK as a model of good practice where aggregate extraction is tightly regulated and well managed, with restoration schemes that deliver biodiversity improvement once quarrying is complete.

That’s in stark contrast to the way sand resources are extracted in many developing countries, where sand, in particular, is removed from active geological systems like rivers and beaches.

The report also calls for greater use of secondary aggregates, which are by-products of other industrial processes, and recycled aggregates made from construction, demolition and excavation waste. That’s another area in which the UK is a global leader, with almost 30% of UK aggregates demand being met from secondary or recycled sources.

Responding to the report’s publication, Mark Russell, the MPA’s executive director for Planning & Mineral Resources, said that one of its key recommendations, of particular relevance to the UK, is the need for major infrastructure schemes to factor in the sourcing of raw materials before construction begins – developers need to carry out a resources and materials supply audit, rather than assuming the materials will turn up when they are needed. “The supply of essential mineral resources like sand and gravel must be planned for, monitored and managed to ensure needs can be met,” Russell stressed.

I am writing this Comment piece while receiving a stack of press releases from original quarrying equipment manufacturers highlighting their lineups for the keenly anticipated Hillhead 2022 exhibition at Hillhead Quarry near Buxton, in Derbyshire, England. I will be there and am really looking forward to some quality face-to-face time with a wide variety of quarry operators and equipment manufacturers. It should be one hell of a show! GW © AGGREGATES BUSINESS EUROPE May/June 2022

03

CONTENTS

MARKET REPORT

“Demand for mineral products and quarrying and construction equipment remains healthy in the UK and Ireland, but a perfect storm could hit sales” p37

MAY/JUNE 2022 | VOL.16 ISSUE NO3 | www.AggBusiness.com

Vol.16 ISSUE No.3 May/June 2022

Lightening the load

Regulars

Features

03 COMMENT

19 CRUSHING & SCREENING

Ritchie Bros. scraps Euro Auctions acquisition; Holcim completes PRB Group acquisition

Excavator sector hit by fall in Chinese demand

INTERVIEW Nigel Jackson: Strong & effective industry advocacy p08

TO

R

IN

•

T

PONSI BLY

F OO T P R

ON DUCE OU

C

HILLHEAD PREVIEW Party time! 40 years of Hillhead p61

ABEMJ2022_NEW.indd 1

26/05/2022 17:33:06

COVER STORY: A Volvo EC550E crawler excavator at work in a quarry

The evolution of quarrying-suited engines

18 LEGAL UPDATE

RES

RE

•

QUARRY PROFILE New premium C&D recycling plant for Malcolm Construction p42

26 ENGINES – 1 16 ASSOCIATION NEWS

ED

PR

23 LOADING

RB

06 NEWS

I N T E D & PO S

T

Achieving practical crushing & screening excellence A

Top quarry tech first-hand & futureproofing sand supply

Volvo CE maps out better load zone navigation p23

30 RECYCLING – 1

How to ethically defend employment claims

72 EQUIPMENT UPDATE

The aggregates recycling ascendancy

32 WEAR PARTS

Global OEMs’ new equipment launches & applications

74 EVENTS

Quality aggregates production is the sum of its premium wear parts

35 PORTABLE POWER – 1

All the key events in the quarrying & aggregates world

Increasing productivity with advanced energy storage

Specials 08 INTERVIEW MPA chief executive Nigel Jackson on the importance of strong & effective industry advocacy

37 MARKET REPORT

19

Healthy UK & Ireland mineral products demand amid headwinds

42 QUARRY PROFILE CDE aids Malcolm Construction’s welcome aversion to landfill

55 THE FUTURE OF A COMBINED IQ-NSC Future-proofing the IQ & NSC with a worthier site for proud eyes

61 HILLHEAD 2022 PREVIEW

26 04

AGGREGATES BUSINESS EUROPE May/June 2022

All the key OEMs; all the key launches & plant showcases

www.AggBusiness.com

POWER T DO MORE FOR YOU.

Resilient product. Global support.

Engines that have the power to do more for you.

The Cummins B6.7 Performance Series engine is proven in a wide range of industrial applications. Power increases to 326 hp / 243 kW enabling replacement of engines with higher displacement with no impact on productivity. cummins.tech/aggbusiness-dec21

©2021 Cummins Inc. Box 3005, Columbus, IN 47202-3005 U.S.A.

NEWS

HOLCIM COMPLETES PURCHASE OF PRB GROUP Holcim has completed the acquisition of PRB Group, France’s biggest independent manufacturer of specialty building solutions, with 2022-estimated net sales of €340m.

PRB Group offers a broad range of high-performance building solutions, from coatings and insulation to adhesives and flooring systems with advanced energy efficiency and renovation solutions.

Advancing Holcim’s strategic goal to reach 30% of group net sales in Solutions & Products by 2025, PRB expands Holcim’s portfolio of specialty building solutions in Europe, adding to PTBCompaktuna in Belgium.

PRB Group’s HQ in Les Achards, western France.

Pic: PRB Group Miljan Gutovic, region head EMEA [Europe, Middle East, Africa], said: “I warmly welcome all members of the PRB Group into the Holcim family. I’m excited about the outstanding expertise and passion they bring to our team in France. This is another exciting step in the expansion of Solutions & Products in the highly attractive repair and refurbishment market. We look forward to unleashing our next era of growth together to make cities greener with more energyefficient and long-lasting buildings.”

Founded in 1975, PRB Group has grown to become France’s largest independent manufacturer of specialty building solutions. Holcim says PRB’s products and solutions complement its own and expand its reach in the high-growth repair and refurbishment market.

06

Ritchie Bros scraps Euro Auctions acquisition O ff-highway equipment auctioneer Ritchie Bros has abandoned plans to buy its Northern Ireland-based rival Euro Auctions over concerns the sale would not be approved by UK regulators.

The announcement puts an end to the major proposed US$775m merger, which the two companies entered into an agreement for in August 2021.

Canada-based Ritchie Bros says its decision follows the referral of the proposed acquisition to a Phase 2 review by the UK Competition and Markets Authority (CMA).

It added in a statement: “Amongst other things, completion of the agreement is conditional on receipt of clearance from the CMA on terms satisfactory to the RB Purchaser, but after extensive

consideration the RB Purchaser does not believe there is any realistic prospect for approval by the CMA on such terms given the significant concerns raised by the CMA to date.”

Ritchie Bros CEO Ann Fandozzi said the company was disappointed by the decision taken by the CMA to refer the proposed acquisition to a Phase 2 review and respectfully disagrees with its views.

She added: “While we believe the proposed acquisition would have accelerated our strategy, we remain committed to forging ahead in our transformational journey to become the trusted global marketplace for insights, services and transaction solutions. We will continue to seek out and execute on organic investments and key acquisitions to accelerate our pace in achieving our ultimate vision.”

Metso Outotec increases Q1 sales but highlights Ukraine crisis uncertainty

Metso Outotec is developing the new Lokotrack range of crushers and screens Metso Outotec grew its sales by 26% to €1,164m in Q1 2022 while increasing its received orders by 29% to €1,424m in the same period.

Further good news for the Finnish quarrying and mining plant giant came via operating profits rising in the quarter to €139m. The company’s adjusted EBITA rose to €157m, or 13.5% of sales.

Despite the good trading results, the company notes increased market uncertainty caused by the situation in Ukraine.

© AGGREGATES BUSINESS EUROPE May/June 2022

Metso Outotec president and CEO Pekka Vauramo said: “Our performance during the first quarter was good, despite the uncertainty caused by Russia’s military offensive against Ukraine and the ensuing overall volatility in the market environment.

“We announced a temporary suspension of deliveries to Russia as of late February and we have not taken new orders for deliveries to Russia. However, we continue to have a backlog to Russian custom-

ers, and while fully complying with the applicable sanction regimes, we will wind down these contracts in a controlled way considering our stakeholders.

“Our markets elsewhere continue to be very strong. If anything, the demand for minerals has increased, and we expect that the market will enable us to compensate for Russian orders.”

Vauramo said Metso Outotec’s 26% quarterly sales increase resulted from higher equipment deliveries from the backlog and double-digit growth in the company’s services business. “While we saw cost increases from raw materials, components, freights and energy during the quarter, we were able to better mitigate those pressures compared to the second half of 2021, and those actions will continue going forward.”

After the reporting period in April, Metso Outotec announced a project to develop a new, complete range of electrically driven track-mounted Lokotrack crushers and screens.

www.AggBusiness.com

NEWS

The FAM HQ in Magdeburg, Germany Pic: Beumer Group

CEMEX AND COOLBROOK ELECTRIFY CEMENT PRODUCTION

Beumer Group acquires FAM Beumer Group has acquired FAM, a German-based supplier of conveying and loading technology.

Beckum, Germanyheadquartered Beumer Group, a global manufacturer of premium tech-led quarrying, cement and mining conveying and loading solutions, says the deal significantly strengthens its market position in

the large equipment sector.

FAM is one of the world’s leading full-range suppliers of bulk materials handling and processing plants. FAM successfully plans, designs, and manufactures turnkey plants and systems for mining, conveying, loading, and storing minerals, raw materials, and goods.

The FAM Group employs

approximately 750 people at its headquarters and subsidiaries in Brazil, Chile, China, Canada and India, and representatives worldwide.

With more than 4,500 employees in over 70 countries, the Beumer Group is long established in the bulk materials technology market.

DEUTZ reports rise in revenue and earnings O ff-highway diesel engine maker DEUTZ says it can look back on a successful 2021, with revenue and earnings both significantly up on the previous year. The German company achieved its guidance, which it had most recently raised in September 2021. At €2,012.6m in 2021, DEUTZ’s new orders were up by 52.2% compared with 2020, which had been heavily affected by coronavirus.

It says this growth can be explained by customers being very willing to invest, reflected in double-digit percentage increases across all application segments and regions. DEUTZ adds that the exceptionally strong rise was also attributable to one-off effects of spending brought forward in June and September, which amounted to more than €100m.

www.AggBusiness.com

As at December 31, 2021, orders on hand stood at €676.7m (December 31, 2020: €269.0m), which indicates continued growth.

The proportion of orders on hand attributable to the service business stood at €35.7m (December 31, 2020: €24.4m).

With a total of 201,283 engines sold, the DEUTZ Group registered an increase in unit sales of 33.4% in the reporting period. The number of DEUTZ engines sold rose by 32.9% to 160,882.

CEO Dr. Sebastian C. Schulte said DEUTZ increased its revenue by almost 25% to €1.62bn and improved its EBIT (earnings before interest and taxes) margin before exceptional items by around 8 percentage points to 2.3%.

He added that the company has made substantial progress with transforming its business to focus

more on alternative, green drive systems.

“Our hydrogen engine is just one example of how DEUTZ is positioning itself in the field of off-highway drive technologies for a sustainable future,” said Schulte.

Commenting on the current year, he added: “The supply situation remains difficult, and we anticipate that the supply chain will continue to contribute to the pressure on margins. Moreover, nobody can predict the economic impact of the war between Russia and Ukraine. We are therefore preparing for a challenging year.”

To report more transparently on its transformation, DEUTZ says it introduced a new Green segment on January 1, 2022 that covers all activities connected with the development and production of new non-diesel drives.

CEMEX says it expects to work with Dutch-Finnish company Coolbrook to test their patented technology, which uses electricity in place of fossil fuels in the heating process of cement production.

Fossil fuels used to heat the kilns account for approximately 45% of the carbon emissions in cement production. The companies have reached a memorandum of understanding to combine their expertise to develop optimal electric process heating solutions that can be applied in the cement manufacturing process.

Coolbrook’s Roto Dynamic Heater (RDH) technology aims to revolutionize cement production by replacing fossil fuels traditionally used to heat the kilns with electricity.

The breakthrough of the RDH technology is that it is able, using only electricity, to heat the kiln at a high enough temperature, around 1,700 degrees Celsius, necessary to produce cement with state-of-the-art materials.

When powered by electricity from renewable sources, the technology eliminates CO2 emissions from the fuels used in process heating and is an important development in the eventual decarbonisation of the industry.

“The electrification of the heating and calcination process of cement production is an important step towards decarbonising our cement operations,” said Roberto Ponguta, CEMEX vice president of global operations, technical and energy.

Ilpo Kuokkanen, executive chairman of Coolbrook, said: “Together with CEMEX, we can bring the technology to cement production and achieve significant emission reductions in one of the most energy and CO2-intensive industrial processes.”

Coolbrook’s RDH technology

© AGGREGATES BUSINESS EUROPE May/June 2022

07

INTERVIEW

Strong & effective industry advocacy After 13 years as the Mineral Products Association’s (MPA) chief executive, Nigel Jackson is just as passionate and committed to the industry. Guy Woodford caught up with him at the MPA’s Westminster, London-based HQ for a straight-talking and wide-ranging discussion about the key challenges facing the UK mineral products sector, including the crucial role government can play in helping the industry deliver the mineral products to future-proof Britain’s prosperity

08

© AGGREGATES BUSINESS EUROPE May/June 2022

www.AggBusiness.com

INTERVIEW

A

mixture of pride and frustration is a constant theme during any industry-based conversation with Nigel Jackson. Pride is evident when the MPA’s chief executive notes the British Government’s official recognition during the COVID-19 pandemic of the essential role the UK mineral products sector has in securing national prosperity, with MPA members producing 400 million tonnes of resources and products for UK construction and manufacturing each year.

Recognition has followed tireless campaigning by the MPA, including the 2018 publication of the first industry-led UK Minerals Strategy designed to help the country meet the demand for minerals for the next 25 years sustainably. The strategy, prepared by the MPA and the CBI Minerals Group, has been recognised by the Government, NGOs (non-governmental organisations) and professional bodies, including RICS (Royal Institute of Chartered Surveyors) and the Royal Town Planning Institute.

Frustration is apparent when Jackson refers to the lack of a level playing field for the mineral products industry compared to other UK industries, such as agriculture. On 1 April 2022, mineral products companies lost their right to use lower-tax red diesel, effectively costing the industry at least £100 million a year.

“We have consistently said over ten years that the rebate should be maintained until such time as the industry has an alternative to diesel. We understand the link with decarbonisation, and there’s no principled objection from our side. It’s about the timing of this. What the Government needs to do is incentivise the development of commercially viable alternatives like electric power, so our industry gets them faster. Nothing irritates

me more about Government measures than where they are inconsistent, disproportionate and unreasonable, and this issue ticks every box.

“Agriculture is another primary industry; if you can’t grow it, you’ve got to dig it. I would say they have parity with us strategically, yet the agriculture industry will retain the [red diesel] rebate. We don’t understand the disparity. Our colleagues in the construction industry are equally anxious about this. We were disappointed with the UK Chancellor’s Spring Statement, as it was an opportunity for the Government to say that they’d listened and would keep the rebate for a year or two.

We know that alternatives are coming in. For instance, JCB, an MPA member, is bringing in more and more electrical plant as are other manufacturers. Government pragmatism on this would help build industry goodwill, and it would make companies want to lean in more and transition to non-diesel fuels in a practical and profitable way.”

Asked whether the ending of the red diesel rebate would lead to smaller mineral product producers going out of business, Jackson replied: “Mineral products companies are very resilient. This will increase costs that they may or may not be able to pass on [to customers], so it could cut into their profitability. If that profitability turns into a loss, it is harder to go to the bank and get funding to invest and innovate on alternative fuels and carbon reduction and other aspects of their business. With the general increase in

UK energy costs, this issue has really hit home and become more business-critical.”

Jackson is also frustrated with aspects of the Aggregates Levy, introduced in 2002

by Tony Blair’s Labour Government as an environmental tax aiming to encourage more efficient extraction and use of aggregates and encourage alternatives to virgin aggregates.

The MPA welcomed the Chancellor’s autumn 2021 budget announcement that the levy would continue to remain at £2 per tonne of aggregates used in construction, its level since April 2009, but would like to see this extended beyond April 2023.

“The Aggregates Levy was a bad tax conceptually from the outset, which remains the case. We’ve never been convinced about its environmental justification. We see it as an outright tax. I could take it more seriously if all producing industries were being taxed like this. At the same time, the mineral products industry has significantly improved its environmental performance, for which it has received no credit. We also lost the one good aspect of the levy, which was the sustainability fund which helped reinvesting into local communities. The industry is responsible and already had proud environmental credentials before the Aggregates Levy came in. We have now got one of the best [mineral products] recycling stories you will find, probably globally.

“The cumulative burden of the Aggregates Levy and other green taxes that the mineral products industry is facing is well in excess

“A lot of our member companies are fourth-generation family businesses; they know that when the sun is shining, you put the money away for a rainy day”

Government recognition of the essential role the UK mineral products sector has in securing national prosperity has followed tireless campaigning by the MPA. Pic: MPA

www.AggBusiness.com

© AGGREGATES BUSINESS EUROPE May/June 2022

09

Change starts with electromobility In a world where sustainability requirements are constantly increasing, electric machines can lower emissions and give you a competitive advantage.

Read more at volvoce.com/changestartshere

Volvo Construction Equipment

INTERVIEW

of half a billion pounds each year. Other industries are not subjected to this. The withdrawal of the red diesel rebate, costing at least another £100 million, is another kick in the teeth for our industry at a bad time.”

Does Jackson believe the Aggregates Levy is here to stay? “Yes – and that’s always been our view. Regarding the future structure of taxation, you have to ask yourself, ‘Is it more or less likely that environmental taxes will increase or decrease?’ In a world that’s chasing net zero [carbon] and nature recovery, the strong likelihood is that these taxes will proliferate and widen. Politically, it’s too easy and too attractive not to do it, quite frankly. If you were to lose, for example, up to £400 million a year in Aggregates Levy taxation, you’d have to tax something else.”

A highly respected and valued industry figure, Jackson has worked for over 45 years in senior management and board-level positions in the mining, quarrying, waste and construction industries. He has been chief executive of the MPA since its founding in June 2009, following the merger of the Quarry Products Association, the British Cement Association and The Concrete Centre. As well as his work as the MPA’s chief executive, he is chair of the Confederation of British Industry (CBI) Minerals Group, an officer of the Construction Products Association, vice president of UEPG (the European Aggregates Association) and a founding member and co-convenor of the UK Minerals Forum.

The MPA is the trade association for

After 13 years as MPA chief executive, Nigel Jackson is just as passionate and committed to the UK mineral products industry. Pic: MPA

the aggregates, asphalt, cement, concrete, dimension stone, lime, mortar and silica sand industries. It is the sectoral voice for mineral products. With the merger of British Precast, and the affiliation of the British Association of Reinforcement (BAR), Eurobitume, MPA Northern Ireland, MPA Scotland, the British Calcium Carbonate Federation, and most recently CONSTRUCT, it has a growing membership of over 530 companies.

MPA membership includes the vast majority of independent SME (small and medium enterprise) quarrying companies throughout the UK and ten major international players. It covers 100% of UK cement and lime production, 90% of GB aggregates production, 95% of asphalt and over 70% of ready-mixed concrete and precast concrete production. Mineral products industry production represents the largest materials flow in the UK economy and is also one of the largest manufacturing sectors. In 2018, the industry supplied £16 billion-worth of materials and services and was the largest supplier to the construction industry, which had annual output valued at £172 billion.

Like all commerce, the UK mineral products industry is emerging from a prolonged period of disruption due to the global COVID-19 pandemic. The Ukraine crisis has pushed energy prices up even higher, eating further into companies’ margins as they look to get back to a more normal trading environment, last seen in 2019.

“The big thing for all business, including

our members, is recovering and sustaining profitability so you can finance your engagement with key issues, like climate change,” says Jackson. “If you don’t have a viable business, responding to climate change becomes academic. We need Government to create conditions that give business confidence to invest to secure growth.

Anything we put to Government is linked to building business confidence.

“No one wants to operate with any more uncertainty than is necessary. There is a point you can reach where the loss of confidence is corrosive. We’re picking it up in businesses’ carbon and energy costs and serious inflation.

It is making it very difficult for businesses to price ahead. A [supply chain] client’s going to say, ‘I can’t pick up the risk on that’, and that gets to the commissioning client who says, ‘There’s too much risk and uncertainty here, I might just hold off on the development’. BEIS (Department for Business, Energy & Industrial Strategy) has picked up on this, too. You have to make sure that doesn’t lead to a domino effect that seriously undermines growth prospects.

“2021 was a solid year for the mineral products industry. Numbers were up, and we want to keep it that way. Our members are busy but anxious, like much of the British economy. We are a heck of a lot closer as an industry to where we were in 2019. You do, however, need to take pent-up demand out of that.

“If I had to pick one word to describe MPA members, it would be ‘resilient’. In the [global] financial crash [of 2008-2009], none of our members went bust, despite the shocking behaviour of the banks. They got through it. A lot of our member companies are fourth-generation family businesses; they know that when the sun is shining, you put the money away for a rainy day. They will cut their cloth accordingly and will have reset their cost base so, when the rebound comes, the hits they may have taken when things were not so good can be earnt back.”

“Nobody should ever forget the value of a bridge, a tunnel, a sewer, the foundations of a building. Without those things, we become, essentially, fragmented, poorer and uncivilised”

www.AggBusiness.com

© AGGREGATES BUSINESS EUROPE May/June 2022

11

MPA membership includes the vast majority of independent SME (small and medium enterprise) quarrying companies throughout the UK and ten major international players. Pictured is Broadway stone quarry in the Cotswolds, Worcestershire, England Jackson is pleased with the great progress the UK mineral products industry has made in the last five years on health and safety, the MPA’s top priority. Its Vision Zero – Safe & Well Everyday strategy is the foundation for the association’s reinvigorated health and safety plan until 2025. It includes several ambitious targets in this area, including achieving an industry-wide Lost Time Incident Frequency Rate below 1.5 days by 2025 – equivalent to a 50% reduction on 2020; to achieve zero reportable incidents (fatalities and serious injuries) attributable to ‘The Fatal 6’ causes by 2025; with far greater attention to leading indicators.

‘The Fatal 6’ refers to the fact that 94% of historic fatalities in the mineral products industry fall within six common themes: Contact with moving machinery and isolation; Workplace transport and pedestrian interface; Work at height; Workplace RCS; Struck by moving or falling object; and road traffic accidents.

The MPA also stages a well-attended annual Health & Safety Awards event in London, showcasing and sharing members’ best practices, available on safequarry.com.

“In 2017 the industry incurred a lot of fatalities, but it was the catalyst to reset the approach to health and safety,” says Jackson.

“In terms of employees and contractors, we’ve since had the longest period fatality-free ever. There have been three third-party fatalities, which is still completely unacceptable, but it shows what can be done when you get a collective commitment. It’s no coincidence that the MPA’s development of Vision Zero and the adoption of the ‘The Fatal 6’ has preceded a time of no fatalities among industry employees and contractors.

“In terms of the larger-scale issues: climate change, access to mineral resources, and resource use - we’ve been saying for many years now that this is the agenda of the future. If you want to earn your licence to operate, you have to demonstrate that you understand what your carbon footprint is, decarbonise and get to net zero, by 2050 in the UK’s case.”

Jackson notes that most of the mineral products industry’s carbon emissions come from manufacturing cement to go into the “world’s most sought-after man-made

12

© AGGREGATES BUSINESS EUROPE May/June 2022

material”, concrete.

“Our members have identified how they’ll not only get to net zero by 2050 but go beyond that. It’s a non-negotiable mission. But what we need to do increasingly is communicate the progress being made on that ambition and actual delivery. We are doing that through our campaigning vehicle, UK Concrete, to explain why we need concrete and the value it brings to the world. It’s not a downside balance sheet as some green activists suggest; it’s a positive balance sheet in terms of civilising the infrastructure and built environment at minimised environmental cost.

“The formative thinking on all of this was done years ago. It’s not because of COP26 in Glasgow; it’s because the people in our industry understand that the climate is changing, that there’s a footprint that the industry creates, and there’s a moral and ethical necessity to respond to that. Young people coming into our industry don’t want to work in an industry that is unresponsive to these issues. I pay a lot of credit to them for bringing in modern thinking to augment the experience of the industry.”

A recent MPA report depicted Britain’s success story on the recovery of construction waste to produce recycled aggregates. Based

© Davidmartyn | Dreamstime.com

INTERVIEW

on 2020 data, the association estimates that nearly 30% of aggregates for construction come from recycled and secondary sources – some 62 million tonnes in 2020. The MPA says this means the UK mineral products industry recycles more than any other sector by volume and places Britain among the leading recyclers of construction materials in Europe.

“The conclusion is that if demand for aggregates is going to stay at or around the same level we’ve experienced in recent years, and recycled materials represent the first element of supply, the rest has to come from quarries,” says Jackson. “You can’t recycle away the need for quarries. You do get people still evangelising recycling as if it’s a new nirvana concept that no one has thought of; it is an ‘old-news’ story for our industry.

“The challenge has been pushing the material up the value chain, but there is a limit to how far it can go. The important thing is that this is by far the best recycling story this country has got to tell, which DEFRA (Department for Environment, Food & Rural Affairs) do not understand or recognise.”

Jackson explains that the UK mineral products sector’s biodiversity record is another cracking success story that the

Nigel Jackson says the big thing for all business, including MPA members, is recovering from the COVID pandemic and sustaining profitability, to enable firms to finance their engagement with key issues, like climate change. Pictured is Longcliffe Quarries’ Brassington Moor Quarry, near Matlock, Derbyshire. Pic: Longcliffe Quarries

www.AggBusiness.com

Zaxis-7

Create your vision n You’re in control of your safety with the new range of Hitachi large excavators. Exceptional visibility from the cab and a 270-degree view from the Aerial Angle camera system helps you to work safely and efficiently. Make your vision a reality with Zaxis-7.

Learn more at www.hitachicm.eu

3 at Z s nd t u ta si s Vi ad he ill H

You’re in control

INTERVIEW

MPA CEO Nigel Jackson stresses that the Government’s recognition of the essentiality of the mineral products sector is “something said that can now never be unwritten or unsaid”. Pic: MPA industry needs to tell even more clearly than ever. “Conscious nature habitat creation resulting from quarry restoration is an industry success story going back at least 50 years. In the early years, it was more likely to be by default than design. But in the last 20-25 years, it’s been far more by design. I see quarries as oases for nature recovery.

We’ve evidenced that and documented it well.

There’s no other sector in the country that’s delivered and continuing to deliver what we’re doing. I hear an awful lot of greenwash from other industries, like agriculture and water, that talk a good game but are doing little or nothing that makes any difference compared to the harm they are doing to soil, water, hedgerows and biodiversity.

“We have created priority habitat already the equivalent in size to Nottingham, and a further area the size of Liverpool is already planned and in the pipeline. You would have thought that someone at DEFRA might have shown an interest in this story as an example of how industry is also delivering for nature as it delivers materials for the UK. We are still trying to get through to them, but thankfully Natural England and leading NGOs like the RSPB and Wildlife Trusts get it and are interested.”

Commenting on the ongoing expansion of the MPA’s team of experts, Jackson says: “The world is uncertain and changing, and you’ve got to resource well to respond to that.

We decided pre-pandemic that we wanted to invest in certain areas, including public affairs, economic affairs, communications, carbon energy, and, critically, with the formation of MPA UK Concrete, how we tell the story of concrete to non-technical audiences.

“We need to push back on the ignorance and misperception that exists in the non-technical sphere of people who think that timber is the answer [in construction]. Timber is not the answer to the world’s construction or manufacturing needs, whether that’s renewable energy infrastructure or climate

14

© AGGREGATES BUSINESS EUROPE May/June 2022

adaptation systems. I’m not anti-timber; I’m simply anti using timber when better alternatives exist. The understanding of the benefits of concrete compared to other products needs explaining. When we explain, we see that people understand the wholelife cost advantages of concrete a whole lot better. You are going to have to use billions of tonnes of aggregates and cement every year if you want to have a sustainable, civilised world, and there are no serious alternatives at scale to replace that reality.

“Further, the UK is the only country in Europe where we’ve got nearly all the key products in one industry association, and we are building a fighting force to protect and promote the industry for the vast majority of companies that work in it.”

As we near the end of our conversation, Jackson again refers to the huge significance

The cover of the 2020 MPA Biodiversity Strategy.

Pic: MPA

of the Government’s recognition of the essential role of the mineral products industry: “It helped keep businesses going and weather the disruption of COVID. Essentiality of the sector is something said that can now never be unwritten or unsaid.

The [mineral products] industry is fortunate, unlike retail and hospitality, to still have its capability and capacity, but like all sectors, we need to build in a way that is even more sustainable. We should be thankful that we have a well-run and essential industry that is critical to the fortunes of our economy and our quality of life.

“Nobody should ever forget the value of a bridge, a tunnel, a sewer, the foundations of a building. Without those things, we become, essentially, fragmented, poorer and uncivilised. Mineral products are critical parts of the glue that shape our civilisation. Everyone in the mineral products industry should be as super proud as I am to be involved in it as our end product is non-negotiable, and it will get better over time. We also represent the largest remaining heavy-side industry in the country.”

So, what does Jackson think his biggest achievements have been as MPA chief executive? “Building unity and retaining it.

Without unity, there is no influence. That goes not just for the members we serve but the building and retention of our team. We have a stable, solid and world-class team that does a great job. I feel passionately that without industry unity, you cannot compete for attention, and you will not have influence with Government and key stakeholders.

“We are in a far more complicated working environment than in 2009 when the MPA was founded. We are dealing with more issues, and more interconnected and complex issues. You cannot map and respond to that unless you have a coherent team of experts within member companies and the association working together to broker solutions. That is where our future lies.” AB

www.AggBusiness.com

MEET THE ROCK-SOLID HAULER V IS I T U S AT H I L L H E A D U K Stand N14

rokbak.com

ASSOCIATION NEWS

Sustainable Finance – are we in?

H

ave you heard about sustainable finance? One year ago, only insiders and experts would have answered ‘yes’. Since France has pushed Brussels to consider nuclear energy as sustainable (with German reluctance as Berlin is phasing out nuclear power), almost everyone talks about it.

Few, however, know about the work of the EU Platform on Sustainable Finance (PSF) and the taxonomy regulation and even fewer have detailed knowledge of the reports which frequently start with a scary statement: “This is a long report. Please think before printing.”

It was back in summer 2020, when UEPG (the European Aggregates Association), and more than 500 other highly qualified individuals, applied for a seat on the PSF. None of the non-energy extractive industry association (NEEIP) representatives were selected.

A distinguished club of 57 members and 11 observers on the platform and in subgroups were asked to determine technical criteria on what could be described and qualified as a ‘significant contribution’ to sustainable development. A tricky task to judge on the wide range of statistical NACE code-based activities including “mining and quarrying” without having the experts on quarrying!

16

© AGGREGATES BUSINESS EUROPE May/June 2022

UEPG closely followed the work of the Sector Team 2 “mining and quarrying”, where representatives from authorities, (environmental) NGOs, academia and industry were debating the potential contribution to the six environmental objectives of the EU taxonomy regulation, namely: climate-change mitigation, climate-change adaptation, sustainable use and protection of water and marine resources, transition to a circular economy, pollution prevention and control and the protection and restoration of biodiversity and ecosystems. The challenge: demonstrate a significant contribution while excluding significant harm to any of the environmental objectives. The result: eligible or not. The question: what is significant and how to prove its significance?

These questions will be answered by an ad-hoc UEPG working group which will develop biodiversity indicators showing the contribution of our sector. While this will take some time, the industry will continue to provide good-practice examples on ecosystem restoration, biodiversity in quarries, and temporary and dynamic nature.

The two-year mandate of current members of the PSF will come to an end in September 2022 but could be renewed.

More work remains to be done. The 30

March 2022 report on technical screening criteria for the four remaining environmental objectives identified quarry restoration as a potential activity eligible for sustainable finance. UEPG is explaining to experts involved in PSF that quarry restoration is an integral part of aggregates extraction and not a separate economic activity. The fact that aggregates also have an enabling role in ensuring the expansion of renewable energy and are needed for climate-change adaptation shows what UEPG keeps saying: Aggregates, we are part of the solution! AB

A pair of hobbies successfully bred in Tarmac’s 400-hectare Panshanger Park. The former UK sand and gravel quarry in Hertfordshire, England, attracted rare birds of prey during works to restore it to a country park and nature reserve. Pic: Ian Ward

www.AggBusiness.com

A powerful partnership Sheer power. That’s Volvo Penta. Robust, energy efficient industrial engines that keep running even in the toughest conditions. Easy to install, operate and maintain. A powerful partnership you can trust all the way from the drawing board throughout the operational life of your application. Quick access to off-the-shelf parts wherever you are.

Easy contacts for service and support across the world.

www.volvopenta.com

LEGAL UPDATE

EMPLOYMENT CLAIMS – HOW TO DEFEND THEM ETHICALLY The way you handle employment claims can have a big impact on your business. Joe Nicholls, a partner in the Employment team at Stephens Scown LLP, shares some tips on how to approach the situation ethically

N

o employer wants to have to defend legal action brought by their employee. The cost to the business can be significant. The time spent providing information and instructions to legal representatives, searching for documentation, and in preparing and giving witness evidence, is something that every business could do without. It can be particularly disappointing where managers and HR teams have diligently followed internal procedures and exhausted alternatives to dismissal or addressed allegations of discrimination or whistleblowing objectively and fairly.

It is also a commercial reality of employing people that disputes will arise and yet an organisation does not need to abandon its values simply because a decision has been challenged externally.

Why take an ethical approach to employment claims?

Many businesses invest so much into harnessing a supportive, progressive and inclusive culture as they strive to be a good employer. It is counter-productive to undermine that by dealing with disputes with hostility and aggression. It also makes sense to do the right thing.

Ongoing relations Claims can be brought by existing employees; deductions from wages and discrimination are amongst the most common, but whistleblowing detriments, victimisation and harassment claims can be pursued by employees who remain employed.

There are ongoing express and implied contractual duties to all employees, which include health and wellbeing. Dealing with their claims in the wrong way can lead to further legal action and barriers to their return to work.

and the general public. A business can demonstrate that no matter how acrimonious the dispute, they are a business that treats people fairly and justly.

Responsibility Even former employees are potential customers or members of the communities a business might serve. To alienate them through a destructive litigation strategy is illogical.

It is not uncommon for claimants to be adversely affected by ongoing litigation, to the extent that it severely disrupts their lives and their health. Ensuring this isn’t aggravated by the unreasonable way in which proceedings are conducted is universally positive.

Achieving a resolution Co-operating and listening to an opponent makes resolution far more likely. Explaining why claims are misconceived or are unlikely to succeed and by giving them the chance to withdraw without feeling defeated is rarely achieved through force.

How to approach settlement terms for employment claims Sometimes people bring claims because they feel wronged and want to be heard.

Mediation is a way to resolve a dispute that gives them this chance. Offering them an alternative, to be able to walk away with a level of dignity through a resolution, is healing for the individual.

•

•

Reputation All judgments in the employment tribunal are published and the conduct of employers can be scrutinised by tribunals, other employees

18

© AGGREGATES BUSINESS EUROPE May/June 2022

The approach – it can be tailored in a way which gives people a resolution and a feeling that justice is possible without needing to part with large sums of money or offering admissions and apologies. It starts by understanding what the claimant wants to achieve.

The terms – settlements which don’t impose unreasonable and unnecessary confidentiality clauses or other restrictions demonstrate integrity and allow people to explain their employment history.

•

Advice and time – encouraging claimants to seek independent legal advice and giving them reasonable time to consider their options demonstrates genuine confidence in a businesses’ ability to defend claims.

•

Their departure – allowing people to say goodbye to colleagues if they leave under a settlement, perhaps through an agreed statement, is often just as important for the morale of the staff you’re keeping.

Too often, people are rushed out the door without any explanation and while sometimes this is necessary and beneficial to all involved, it isn’t always the case for the bigger picture.

The risks and rewards of defending employment claims Public hearings create risks for all involved, as do published judgments. It is worth recognising that defending the claim doesn’t necessarily mean a business escapes criticism. The witnesses called by the business (and even potentially other employees) can read the comments from the judge and take a view on the way a claim was defended.

Doing the right thing as a hallmark of a business’ values isn’t limited to the good times. It’s easy to portray a strong, cultural core in positive circumstances. Overcoming challenges and supporting staff when they leave, even acrimoniously, is something of which to be proud. AB

CONTACT Joe Nicholls specialises in employment disputes, as well as negotiating exits for employees. With more than 70 years’ experience representing mining and minerals clients, Stephens Scown’s specialist team is recognised by the Legal 500 and Chambers.

For more information, visit www.stephens-scown.co.uk

www.AggBusiness.com

CRUSHING & SCREENING

Practical crushing & screening excellence A new Kleemann MOBISCREEN has been excelling in its first practical quarry site application, while other new crushing and screening plant and their linked technology are catching industry attention. Guy Woodford reports

T

he first practical quarry site application for Kleemann's new MOBISCREEN MSS 802i EVO has been taking place over recent months at Ernst Krebs & Co.'s gravel quarry in Neumünster, Germany.

Owned and run by Caren Krebs and her son André, Ernst Krebs & Co. operates several gravel quarries between Hamburg and Kiel in northern Germany. The company portfolio includes demolition and recycling, earthwork, roadbuilding and a transport and logistics section.

Last year, André was in the market for a flexible new screening plant that could comfortably switch from processing sand and fine-grained material in a gravel quarry to handling particularly cohesive topsoil and recycling rubble and rail ballast at the company's recycling site.

André took his request to his contact partner at Wirtgen Germany, Henning Lüdtke, who he had worked with for many

years. After hearing how Ernst Krebs & Co. wanted to use their new plant, it was clear to Henning Lüdtke that the new Kleemann screen for coarse elements, the MOBISCREEN MSS 802i EVO, was an ideal fit.

At the time, the machine was not yet available on the German market. So, Henning Lüdtke found an unconventional solution.

He offered André a pilot series model of the plant, which André happily accepted. "Even though it was a bit like buying a pig in a poke.

There were hardly any documents on the product", said the business operator, smiling.

Given that Ernst Krebs & Co. had been long-term Kleemann customers, André knew that taking the pilot screen was not really a gamble. "In our gravel quarries and our recycling, we have been using Kleemann machines for a long time. I was, therefore, fully confident that this machine would also do a good job and based on the description from Henning, I knew that this was exactly the machine we needed here.

"It's obvious that with this new MOBISCREEN, Kleemann has once again looked at what makes work more effective in practice. Everything is so much quicker: set-up times are shorter, and output is higher.

All in all, it pays off."

The flexibility begins with the MOBISCREEN MSS 802i EVO's large feed hopper. The hopper rear wall and the filling aids can be folded variably so that loading from different heights, from both sides and the rear, can proceed optimally. The screen surface change is comparatively easy even in the lower deck because the screen casing can be completely horizontal. The screening parameters can be adjusted precisely, and even conversion, for example, from three to two final grain sizes, is uncomplicated.

Transport from one work site to another is also fast: the discharge conveyors can be folded in without disassembling parts.

Thanks to the stepless driving control, the plant can also be moved and placed precisely.

The MOBISCREEN MSS 802i EVO plant at Ernst Krebs & Co.'s gravel quarry in Neumünster

“The numerous wellthought-out details all make the plant userfriendly and thus safer”

www.AggBusiness.com

© AGGREGATES BUSINESS May/June 2022

19

CRUSHING & SCREENING

The MOBISCREEN MSS 802i EVO has impressed André Krebs with its ability to handle a challenging material processing brief

Ernst Krebs & Co. places a high emphasis on jobsite safety. André believes that the company is in the best of hands with Kleemann, with all relevant functions of the MOBISCREEN MSS 802i EVO operable from a safe distance. "Everything is set up practically and logically. For example, the display can be plugged in at different points on the machine.

The user is always near the function currently being executed – a real advantage." With the new MOBISCREEN model, the blind operation of levers arranged remotely from the component to be folded is a thing of the past. Apart from the increased safety, this also simplifies operation during set-up and service. The numerous well-thought-out details all make the plant user-friendly and thus safer.

During a few months of practical testing, the MOBISCREEN MSS 802i EVO demonstrated its qualities. André continues: "One of the real challenges for us is, for example, gravel extraction. We have to deal with a lot of sand with a relatively small proportion of stone. This means that the fine-grain side discharge conveyor has a real tough job. Other screening plants would soon reach their limits. This is no problem for the new plant."

A further positive surprise for Ernst Krebs & Co. has been that the new MOBISCREEN's casing can be set over 20% steeper than many other screens for coarse elements.

This guarantees a great cutting effect for separating fine material such as sand, and significantly higher output.

André is completely satisfied with the new acquisition, and he has already ordered another plant.

Metso Outotec has launched an upgraded

20

© AGGREGATES BUSINESS May/June 2022

version of Metrics, an innovative cloud-based tool for real-time monitoring of aggregates customers' Lokotrack mobile crushers and screens.

The new remote-monitoring solution will significantly improve connectivity and optimisation benefits to aggregate customers' crushing processes. The solution has been developed with distributors and customers and offers several state-of-the-art features supporting customers to achieve their sustainability and operational targets.

The new Metrics features include C02 tracking for sustainability benefits, 24/7 access to real-time data, a maintenance module, critical dashboards for utilisation, and geolocation. Furthermore, the new

Metrics allows remote troubleshooting, and the user interface can be tailored to address different customer needs. New features and functions can be also updated remotely.

By combining the new Metrics with its global service footprint, Metso Outotec and its distributor partners can support customers in making data-driven decisions that impact their crushing and screening operations.

"We wanted to develop a next-generation solution that will bring quantifiable value and deliver more production hours and tons to our customers. The key to building sustainable operational efficiency is having the correct information to make decisions and select the right combination of services to lift the bar. Metso Outotec Metrics for aggregates connects mobile crushers and screens, providing increased real-time data visibility and analytics to improve availability, performance, reliability, and profitability," says Merja Tyyni, vice president, Standard Crushers, Metso Outotec.

The Metrics solution is part of Metso Outotec's Planet Positive portfolio.

In addition to the improved data transmission speed, new features will continually be developed. One currently in development is integrated mass flow

Sandvik's QA452 plant in action

www.AggBusiness.com

ABP HRT ASPHALT MIXING PLANT

June 23

SUSTAINABLE AND EFFICIENT CUSTOM-MADE RECYCLING SOLUTIONS

S TA

us isit

21-

v

2022

ND N7

The use of reclaimed asphalt, or recycling, is an absolute necessity of today. Ammann offers you custom-made solutions for using recycled products.

At the forefront of RA use is the Ammann ABP HRT asphalt mixing plant (High Recycling Technology). The HRT concept incorporates a high degree of technology and innovation, in particular the counter-current drying method of the RAH100 recycling drum.

LOW EMISSIONS

HIGH EFFICIENCY

• Indirect heating

• Low exhaust gas

• Homogenous heat distribution • Recycling rates of up to 100% possible

temperature • High RA temperature

• Recipes are more flexible as there is no need to overheat the minerals

Additional information about our products and services can be found on our website: www.ammann.com PMP-2383-01-EN | © Ammann Group

GENTLE BITUMEN PROCESSING • No radiation heat • Gentle heating of the RA material

CRUSHING & SCREENING

measurement for tracking production and waste to help customers quantify their production performance.

Metso Outotec Metrics for aggregates generates a strong link between customer operations, product management, and product development.

"The new Metrics will enable us to take equipment features and customer experience to a new level by improving our customers' equipment's performance and increasing both uptime and the overall machine lifecycle," says Kimmo Anttila, vice president, Lokotrack solutions, Aggregates business area, Metso Outotec.

While newer Lokotrack machines come equipped with Metso Outotec Metrics, legacy equipment can, in most cases, be modernised and integrate digital connectivity equipment with a Retrofit Kit. In the initial launch phase, the Retrofit Kit is available for certain Lokotrack crushers and screens.

Sandvik Mobile Crushers & Screens (Sandvik) says its new QA452 mobile plant is the latest evolution of its QA Series products and three-deck Doublescreen technology.

Doublescreen technology is said to typically outperform traditional screens by up to 30%, offering a tailored rock-processing solution for the quarrying, recycling & mining industries.

Featuring a host of innovations, Sandvik's new QA452 solution offers independent

screen angle adjustment and hydraulic screen separation. The model also features two triple-deck inline screen boxes with equal-sized screen decks, each providing 9m³ of screening area.

Screen enhancements on the QA452 include an 11% longer bottom screen deck to extract more fines. Featuring independent screen angle adjustment, the primary screen can be independently adjusted from the secondary screen, allowing operators to optimise their throughput, screening efficiency, and product gradations. The primary screen performs as a fines extractor, while the secondary screen performs as a grader. Two processes on one plant, offering exceptional flexibility, excellent separation, accurate grading and massive throughput.

Sandvik offers a hybrid 'e' drive with electric plug-in, which means you can choose the most economical and efficient energy source for your materials-processing plant.

The QA452 provides a lower environmental impact due to reduced fuel consumption, and the latest powerpack onboard offers less operating noise and low emissions.

In addition, the hydraulic system has been enhanced to reduce energy wastage. Its hydraulic oil change intervals have been extended from 2000 to 4000 hours, meaning up to 50% less hydraulic oil is said to be consumed over 10,000 hours of machine usage (subject to oil sampling).

The QA452's primary screen can also be hydraulically separated to gain better access for maintenance and screen media changes.

The addition of a new oversize cross conveyor means greater oversize material extraction. This cross conveyor can also be reversed to allow the plant to function like a two-deck screen with oversize and mid overs discharged together.

Each screen deck features end-tension screen media using Sandvik's unique mesh tensioning system. This means faster screen mesh tensioning and removal when you need uptime.

Sandvik's new range of WX rubber media combines the high accuracy of wire screens but with the durability of rubber, said to offer up to 10x longer wear life and up to 50% faster installation time than wire mesh. Having equal-sized panels also means the screen media is interchangeable between decks.

The QA452 comes with Sandvik's My Fleet telemetry system and seven-year data subscription as standard. This offers 24/7 fleet management, geo-fencing and remote support.

Sandvik says safety is its top priority, and the QA452 has several features as standard to improve operator and onsite protection.

Dust-suppression spray bars, onboard water pump, safety pull cords and lighting mast are now fitted for extra peace of mind. AB

LIPP-MUS TEST Lippmann has entered the UK crushing and screening market.

The American company has teamed up with two distributors renowned for their high customerservice support levels. Stewart Plant Sales (SPS) and Aggregates Processing & Recycling Ltd (Agg Pro) will now be providing quality crushing and screening systems to aggregates suppliers throughout Scotland, England, and Wales.

With a legacy covering nearly 100 years in North America, commencing operations in Milwaukee, Wisconsin, USA, in 1923, Lippmann began with heavy-duty jaw crushers that have become world-renowned. Continuous development and innovation have seen the company grow into a premier aggregates-processing equipment manufacturer.

In recent years, Lippmann has seen opportunities for growth beyond its primary markets in the United States and Canada. The hard-rock processing requirements across the UK region are said to be well-suited to Lippmann crushing systems.

"Taking this first step into the UK is an exciting time for Lippmann,"

22

© AGGREGATES BUSINESS May/June 2022

Lippmann's 1200j-e tracked jaw crusher being showcased at ScotPlant 2022

says Kevin Kiesgen, vice-president Lippmann. "We look forward to the next 100 years in this region and know that we have partnered with two strong and well-respected specialist distributors."

With the two new distributors, SPS & Agg Pro, Lippmann equipment sales and support will be efficiently covered throughout the entire UK region. Exclusive in each of their respective territories, SPS will be responsible for Scotland and Northern England (including

Lancashire and North Yorkshire). At the same time, Agg Pro will cover all remaining English counties in the South and Wales.

"Agg Pro's history of putting customers first and its extensive service department made it a clear choice as a dealer for Lippmann.

Along with over 25 years in the crushing business, it has an extensive knowledge base for establishing products and brands in the UK. "Meanwhile, SPS has a long and

rich history in the heavy-equipment market in Scotland and Northern England, trading for over 50 years with over 17 locations," continues Kiesgen. "We are confident it will be a smooth and successful transition, bringing Lippmann crushing and screening equipment into their portfolio and to their customers."

The SPS booth at the ScotPlant tradeshow on 22-23 April in Edinburgh, Scotland, proudly presented a Lippmann jaw crusher for the first time in the UK. "It truly is a momentous day for Lippmann," said Kiesgen. "To see our growth solidified with a brand-new Lippmann 1200j-e tracked jaw crusher and its new UK distribution partners in place is amazing."

Lippmann's new 1200j-e is a heavy-duty, mobile jaw crusher that can be powered via an electric line or onboard diesel generator. Its double-deck prescreen feeds the 48" x 34" high-inertia, single-toggle jaw and, at 75" deep, is suitable for the hardest rock applications. The 12" DSE control panel manages numerous built-in safety features as standard and, together with 365SiteConnex telematics, ensures maximum productivity and efficiency from any location.

www.AggBusiness.com

LOADING

Reduced demand in China for machines such as excavators has impacted Volvo CE’s results for Q1 2022

Excavator sector hit by fall in Chinese demand Sales of excavators in Europe, Africa and the Americas have been healthy in early 2022, but China’s huge market has been hit by price pressures and renewed COVID lockdowns across the country. Liam McLoughlin reports

E

xcavator and loader manufacturer Volvo CE says that net sales of its equipment in the European market grew by 13% in the first two months of 2022, influenced by a large number of investments in infrastructure and housing, while North America increased by 20% thanks to the high levels of housing construction and manufacturing in the region. Due to the strong demand for commodities, Volvo CE says South America has continued its robust rise in market demand with a 45% increase on the same quarter last year.

The manufacturer adds, however, that all of this has been affected by a 33% decline in China (the world’s largest market), primarily due to a spike in COVID-19 cases that has led to restrictions and lockdowns across the country, but also due to a price pressure that remains primarily on excavators. Asia, outside of China, has also been negatively impacted by price increases on machines in India, related to new emission regulations, and has reported an 8% fall.

Volvo CE says it is “demonstrating a solid performance during challenging times, while also continuing its evolution as a sustainable leader, not just for the company but for the industry and society as a whole”. It adds that Q1 has seen the successful launch of its first fully electric machine in the Asian market

www.AggBusiness.com

– the ECR25 Electric compact excavator – now available for customers to buy in South Korea and the introduction of a tailored CO2 Reduction Program aimed at helping customers realise their own unique goals towards carbon neutrality.

Volvo CE has recently unveiled its Connected Map solution, a positioning service which provides a visualised site overview for all machines - also non-Volvo machines - and vehicles on a site, accessible by personnel in the machines (via Volvo Co-Pilot or Android/iOS device) and in the office (via the Office Portal web platform).

Connected Map will visualise a host of typical jobsite features and landmarks, including roads to assist operators in navigating around the site, load zones, dump zones, speed zones as well as restricted zones. Points of interest such as offices, workshops and fuel stations can also be visualized, especially helpful for new or temporary operators. Single lane (narrow road) sections can be defined, notifying the operator if another machine is approaching within a single lane section helping to avoid traffic congestion.

Azadeh Fazl Mashhadi, service offer owner site solutions at Volvo CE, commented: “With Connected Map, users benefit from complete jobsite visibility. It gives them a visual overview in real time of

the position of every machine, every vehicle and every visitor on a site connected to the App, helping to make their operation more efficient and more productive.”

Elsewhere in the excavator and loader sector, Hyundai is adding to its A-series range by introducing a further two compliant crawler excavators, the 16-tonne HX160A L and 18-tonne HX180A L. The mid-weight machines are powered by the latest Cummins diesel engines, achieving Stage V emissions standards without the need for exhaust gas recirculation (EGR).

Hyundai says the excavators offer improved fuel consumption, deliver improved operating speed and performance, in addition to increased visibility and safety.

Features include the Cummins EU Stage V B4.5 diesel engine that delivers a 13% increase in power and 27% more torque than previous models.

There is an up to 5% improvement in fuel consumption in levelling and truck-loading operations in P mode, plus particulate matter (PM) reduction of 60% with no requirement for EGR. The new Lifting Mode improves fine hydraulic control, using engine rpm reduction, power boost action and pump flow control, while upgraded Electric Pump Independent Control (EPIC) optimises © AGGREGATES BUSINESS May/June 2022

23

LOADING

hydraulic pump flow rate and power to match the machine’s working conditions.

Hyundai says the HX A Series excavators benefit from a range of state-of-the-art digital connectivity technologies. This includes the proven standard Hi-MATE remotemanagement system, that delivers high levels of service connectivity and remote diagnostic ability. The Mobile Fleet App has been updated to allow fleet owners easy access to machine operating data, including economical usage, utilisation and fault code recognition.

That Wi-Fi connectivity, using Miracast, allows the operator to use many of the functions of their smartphone, directly through the machine’s 8” infotainment screen. Drivers can operate their phones hands-free, listen to music directly from their smartphone and use a number of internetbased applications through the Miracast system.

Optional Engine Connect Diagnostics (ECD), which is an integrated resource between Cummins and Hyundai, allows technicians and dealers to support customers with diagnostic reports and engine performance data. HCE-DT Air also allows the customer to connect wirelessly through a smartphone or laptop on site.

Hitachi has unveiled the largest model in its new Zaxis-7 wheeled excavator range, the ZX220W-7.

It features the HIOS III hydraulic system which is said to achieve higher levels of productivity with better fuel consumption than previous models, reducing running costs. Operators can also control the fuel efficiency and costs with the all-new ECO gauge, which is clearly visible on the large LCD monitor.

Owners can further boost their profits by working on a wider variety of projects thanks to the excellent versatility of the Zaxis-7 wheeled excavator. It can be used with a broad range of Hitachi attachments, such as tilt rotators and buckets, breakers and sorting grabs, to suit the application.

Volvo CE’s Connected Map solution provides a visualised site overview for all machines

24

© AGGREGATES BUSINESS May/June 2022

Hyundai’s new HX180A L excavator These are easily changed using the enhanced attachment support system and can be conveniently transported using the optional trailer support package. The new model can also be fine-tuned to suit the operator’s preference and jobsite requirements – for optimum productivity, while reducing fuel consumption.

The redesigned Zaxis-7 cab is designed to be ultra-spacious and comfortable, offering low noise levels and less vibration than the previous generation.

Hitachi says that operators will feel less tired at the end of their shift thanks to the synchronised motion of the seat and console. Easy operation also comes from: the new ergonomic design of the console and switches; convenient access to the controls; and features such as cruise control, automatic transmission and the optional ride control system that suppresses vibrations from the front attachment.

Added functionality to the easy-to-view screen and joysticks, and the auto working brake, has also been incorporated into the cab. The cab also offers a superior view of the jobsite to protect operators and the machine from potential hazards. Visibility is boosted by a 270-degree bird’s-eye view with the Aerial Angle camera system. Operators can choose from six image options on the

monitor to view the immediate environment.

Their vision through the cab’s front window is also improved by the slim steering column (with wider adjustment angle) and smaller steering wheel.

Hitachi says that, to enable operators to work more confidently and productively, even in challenging conditions, the Zaxis-7 wheeled excavators are fitted with new features such as LED work lights, a windscreen wiper with an increased sweeping area, and larger mirrors. Heated mirrors are also available as an option. For additional safety, the upper structure and front attachment will lock in place when the machine is in the correct position, for driving on public roads.

A new innovation continuously monitors the quality of engine and hydraulic oil, 24/7. Data is transmitted daily via two oil sensors to Global e-Service. These detect if the oil quality has deteriorated, due to contamination or low viscosity. It reduces maintenance and unscheduled downtime, and gives owners peace of mind thanks to scheduled servicing and a higher resale value.

HCME excavator product manager Wilbert Blom commented on the new ZX220W-7: “It offers outstanding versatility for a wide range of applications when used with Hitachi attachments, and delivers an exceptional performance – allowing our customers to create their vision.”

Swedish manufacturer engcon is adding two new products to its range. The company is introducing a third-generation tiltrotator system for excavators, featuring technology based on a newly developed type of valve in combination with smart software that collaborates with the excavator's loadsensing hydraulic system. This optimises both the tiltrotator's functions and the excavator's movements, which engcon says leads to smoother digging with higher precision. At the same time, the excavator's wear and need for maintenance also decreases.

"To meet increased demands for electrification, digitalisation, security and sustainability, we have developed a solution adapted for the future of digging," says Stig Enöström, founder and owner of engcon and the leader of the company's product development. “Our new tiltrotator system

www.AggBusiness.com

LOADING

shows that engcon is at the forefront of innovative solutions that drive the development forward to reduce dependence on fossil fuels and thus the climate impact of excavators.”

With an app, the third-generation tiltrotator system also enables a higher degree of individual customisation in the form of improved possibilities for, amongst other things, connected remote diagnostics and mobile support.

In addition to the energy-efficient technology, the new series EC-Oil, the automatic quick-hitch system can easily and smoothly connect the tiltrotator and hydraulic gear automatically, without the driver having to leave the cab. engcon is also launching a newly developed compactor plate for 12-24-tonne excavators, that it says is a further step forward in making the excavator an effective tool carrier. The company adds that the new PC6000 compactor plate has been adapted for use under a tiltrotator, increasing the excavator's efficiency whilst reducing risk of personal injury. engcon says that combining a compactor plate with an excavator is becoming more common for soil compaction, reducing the number of machines or tools required for the task. Personal safety has also been increased by removing the need to have a person with a hand-operator compactor in a shaft

engcon is introducing a third-generation tiltrotator system for excavators with the risk of walls collapsing because of vibrations or a chain or strap breaking whilst lifting equipment. engcon says that all of this significantly increases workplace safety and, in addition, the working area becomes larger as it is possible to rotate and angle the compactor plate so that it follows the lines of the ground.

Johan Johansson, engcon designer and project manager for the new compactor plate, says that it has increased the flexibility of the excavators so that the excavator operator can tilt and rotate the compactor plate. “Among other things it’s possible to compress around slopes and wells, without constantly having to change the position of the machine. This means that the excavator can perform more types of work,” he adds.

A production run of the PC6000 compactor plate is planned for autumn 2022.

An L975F wheeled loader from Chinese manufacturer SDLG is showing its efficiency

in demanding conditions at a gravel quarry in the Oman desert.

High temperatures and dust make the working conditions in the area extremely tough. However, Volvo-owned SDLG says the harsh working environment is the best test ground to verify the performance of its equipment. The loader is mainly used for ore handling, site preparation, civil engineering and aggregate loading at the quarry, and has earned a good reputation for its overall performance, productivity and fuel efficiency.

The owner of the unnamed quarry said: "The SDLG machine works 14-15 hours a day.

Its loading efficiency is pretty high. It saves me a lot of time, compared with other brands I used before.”

The owner adds that the L975F’s centralised lubrication system has been impressive, making it very convenient to perform maintenance.

SDLG says the efficiency of the L975F stems from its reliable configurations. It features a Volvo box-type chassis with 5.5m³ bucket capacity as standard, and is powered by a Weichai WP10 engine with a maximum traction force that reaches 229kN. The loader has a HT200 heavy-duty automatic transmission, and the lifetime can reach more than 15,000 hours. Its 3550mm wheelbase is claimed to be longer than that of most competitors and makes the machine more stable. AB

An SDLG L975F wheeled loader is excelling at a gravel quarry in the Oman desert

HCME STRIKES UKRAINE DEAL WITH MHM Hitachi Construction Machinery (Europe) has appointed Mobile Heavy Machinery Ltd (MHM) – part of the Alwark Group – as its authorised dealer in Ukraine.

Based in the port city of Odessa on the Black Sea in the south of the country, MHM will offer a wide range of Hitachi machinery to the market.

The new Ukrainian Hitachi (HCME) dealer will be authorised to sell medium (from the ZX70LC-5 to ZX400LCH-5), large (ZX470LC-5 to ZX870H-3) and wheeled (ZX170W-5 to the ZX210W-5) excavators, and

www.AggBusiness.com

medium (ZW180-5 to the ZW310-5) wheeled loaders.

As a consequence of the Russian invasion of Ukraine in February, the construction and related markets changed overnight and this has naturally had a huge impact on MHM’s strategy for the country.

Before the conflict, the construction industry had registered an annual growth of 23.9% in 2019 and 5.2% in 2020, and despite the pandemic this figure was also expected to increase in 2021 and beyond. This was scheduled to be supported by the government’s

investment in the development of transport infrastructure, energy and utilities, and industrial construction projects (due to be completed by 2030) with additional financial assistance from the EU. MHM’s regional director Ukraine, Raivis Veckagans, says: “It is of course currently difficult to make any forecast on the future of the market, but we remain as optimistic as possible despite the war. There has been incredible damage to Ukraine’s infrastructure and one day there will be a huge requirement to rebuild it with the

supply and support of Hitachi construction machinery.”

Furthermore, MHM says it will embrace HCME’s value chain strategy to become the country’s first-choice solutions provider and help to build a better future.

This will be achieved by providing the Ukrainian market with access to the Hitachi Premium Rental and Premium Used programmes, as well as remanufactured parts and the wide range of connective technologies available under the ConSite and Solutions Linkage banner. © AGGREGATES BUSINESS May/June 2022

25

ENGINES – PART 1

The quarrying-suited engine evolution Cutting-edge engines and linked technology well suited to powering aggregates production plant offer big financial and ecological returns for quarrying businesses globally.

Guy Woodford reports

C

ummins has been at the cutting edge of developing power solutions for over a hundred years and is continuing this leadership by developing a diverse range of sustainable drivetrains – from clean diesel to natural gas to battery and hydrogen power solutions. At the start of 2022, Cummins announced the expansion of its industryleading power portfolio with the launch of fuel-agnostic internal combustion powertrain solutions.

This is an industry first. These are the first engine platforms to be intentionally designed with commonality in mind for both the engine footprint and components across diesel, natural gas and hydrogen fuels.

This new approach will be applied across Cummins’ B, L, and X-Series engine portfolios, initially in on-road applications but with off-highway use coming soon.

For Cummins, this fuel-agnostic development, alongside its hydrogen fuel production activity, is crucial to achieving the company’s Destination Zero by 2050 commitments. This Cummins pledge will reduce emissions in duty cycles across markets via a range of solutions, as there is no one solution that will work for all application types or all end users and OEMs (original equipment manufacturers).

Creating a diverse power portfolio that can operate using different fuels, with minimal adjustments to engine architecture, enables greater flexibility to OEMs and therefore encourages the use of lower emission fuels.

The agnostic-fuel powertrain solutions will feature a series of engine versions that are derived from a common internal combustion engine, with up to 80% commonality compared to diesel engine counterparts. Below the head gasket of each engine will be largely similar components, and above these head gaskets will be different components matched for different fuel types. Each version will operate using a different, single fuel.

The fuel-agnostic platforms are designed and built following extensive trial and error research, resulting in Cummins' development

26

© AGGREGATES BUSINESS May/June 2022

of millions of diesel and natural gas engines that are currently in use. By designing the three new engine platforms with inherent fuel-agnostic capabilities from the outset, Cummins can avoid performance limitations and efficiency compromise, problems that are often associated with converting existing engine designs.

Fuel-agnostic engine platforms offer a unique combination of benefits to OEMs and fleet owners interested in reducing vehicle emissions. The immediate reduction in carbon emissions, economic viability, and reliability are three of the most critical benefits of fuel-agnostic engines.

The choice between reliability and reduced emissions is not a trade-off.

Using a fuel-agnostic engine with internal combustion engines offers a balance of reliability and reduced carbon emissions.

In addition, technicians’ existing familiarity with the fuel-agnostic platforms strengthens the day-to-day reliability of these engines, as repairs do not have added layers of complexities from unfamiliar technologies.

Enabling internal combustion engines

to become fuel-agnostic brings important advantages for OEMs and fleets: • Minimal vehicle redesign: Engines within a fuel-agnostic platform have a common product architecture. For OEMs, there is less need to alter vehicle design to accommodate different versions of the same engine family • Limited manufacturing process changes: The need to re-tool production lines and create manufacturing processes to accommodate engines that are a part of a fuel-agnostic platform is lower than adopting a completely new power technology • Reduced incremental technician training: Engines within a fuel-agnostic platform look and feel like the products technicians are already familiar with Annually, Cummins spends US$1 billion on research and technology to help its customers decarbonise. This research and development, supported with a string of acquisitions has identified a diverse range of solutions to decarbonise the power sector. A key focus of this recent Cummins activity and

www.AggBusiness.com

ENGINES – PART 1

the development of the fuel-agnostic engine platform has been supporting the future of hydrogen in the power sector.

There are three key areas when focusing on hydrogen: • Production of green hydrogen • Management and transportation of hydrogen • Application of hydrogen in engines and fuel cells As a fuel source, hydrogen is lightweight, easy to store, and capable of providing high energy per unit mass, with no CO2 emissions at the point of use. For hydrogen to be truly emission free, the production of the fuel needs to be “green” i.e., without direct emissions of air pollutants or greenhouse gases. Without hydrogen being green, it cannot be a meaningful part of the solution as we move toward carbon neutrality.

Green hydrogen is produced using electrolysis to turn sustainable power sources (wind, solar, hydro) into hydrogen with zero carbon dioxide emissions.

Companies like Cummins are investing in research to advance electrolyser technology so green hydrogen can be made in a more cost-effective manner, with reduced environmental impact. An example of this can be seen in the partnership between Cummins and Air Liquide to construct the world’s largest proton exchange membrane electrolyser, which is producing up to 8.2 tons per day of low-carbon hydrogen in Québec, Canada.

The use of hydrogen engines will be gradual over the next 10 to 20 years, as it becomes operationally and economically viable for OEMs and operators to transition power solutions. However, current generation diesel technology and other alternative fuel technologies can support this journey.

As a company committed to meeting the world’s sustainability challenges, Cummins continues to deliver a broad portfolio of power solutions that can support OEMs and customers transition to zero-carbon solutions. The firm is at the forefront of driving innovation in the areas of advanced fuel cells, alternative fuels and advanced energy solutions. Cummins continues to develop integrated engine system technologies and controls and is working with partners to integrate its products and services in the autonomous vehicles of the future.

Volvo Penta’s extensive quarryingsuited industrial engines’ portfolio ranges from five-to 16-litre solutions. Speaking to Aggregates Business, Riccardo Sardelli, the company’s industrial sales manager for UK & Ireland, says business is “extraordinarily busy” as the market continues to recover from prolonged COVID-19-induced disruption.

“There is big demand not just in Europe but globally,” he notes. “We are seeing particularly strong interest in our five- and eight-litre engines, and the generator

[engine] side of the industrial engines business is up 22-25% on last year. Demand is driven by emissions compliance - moving away from Stage IIIA engines to Stage V solutions is an 83% reduction in NOx [nitrogen oxides], [diesel] particulate and carbon.”

Sardelli says the biggest challenges faced by Volvo Penta and other off-highway machine engine manufacturers are the lack of semiconductor availability and shortages of raw material, such as copper. “A lot of raw material is processed in Russia, and [given the Russia-Ukraine crisis] new supply lines involving different countries are taking time to set up. A lot of shipping containers were also mothballed during the coronavirus pandemic and are in the process of being set back up.”

Commenting on key global regional market differences, Sardelli says smaller eight- and 11-litre engine-powered crushers tend to be preferred in the US quarrying market, with many European customers favouring larger crushers powered by 13- and 16-litre engines. Sardelli explains that these larger engines offer “significantly longer” life cycles.

He adds: “All our engines offer a highpower density for their cubic capacity. The 5-litre unit, for example, is a real torque animal. You don’t need to run it at a higher speed and are in the optimum area for lower fuel consumption.

“We have a dedicated industrial servicing network, so quarry customers are calling out top-tier Grade 3 and 4 technicians that

Volvo Penta’s Stage V 8-litre engine

www.AggBusiness.com

© AGGREGATES BUSINESS May/June 2022

27

ENGINES – PART 1

KOHLER TO USE HVO IN ALL EUROPE DIESEL ENGINES

FRONT RIGHT TO LEFT: Sam Thirlaway, application engineer; Tim Barclay, head of service market industrial UK and Ireland; Riccardo Sardelli, head of industrial sales UK and Ireland; David Sherry, technical support engineer; and Nick Styles, OEM account manager VE BACK ROW RIGHT TO LEFT: Wendi Goodman, OEM account manager GE; Jonathan Taylor, business development manager; Chris Slevin, service engineer

know all about Volvo Penta products and how to diagnose them. That’s important with maintaining machine uptime.”

Sardelli highlights that Volvo Penta is part of the Volvo Group’s engine remanufacturing scheme where customer engines, along with transmissions and axles, can be rebuilt at a dedicated facility in Limoges, France. “A lot of regeneration work is carried out from reman injectors to carbon recovery from DPFs (diesel particulate filters) at the facility, with a lot of carbon recovered from the DPFs and sold back to the plastics industry for processing all kinds of polymers for use by the household appliance and automotive industries.”

Sardelli forecasts more hybridisation in quarrying machine engines, with a combustion engine combined with an electrical system. Furthermore, greater demand for energy-storage systems will allow for fully electric quarry machine operation. “You must be careful with crushing and screening applications as there can be huge plant vibrations, so electric components need to have great resilience. Large battery packs do not like shaking.”

Sardelli says Volvo Penta is working “very diligently” on its net-zero programme. “We are heavily focused on developing renewable technologies for the northern hemisphere, and we cannot ignore demands for the southern hemisphere with lower emission products.”

He notes the continued success of the Electric Quarry project involving Volvo Construction Equipment and Skanska that began five years ago. “Around 17 large, mostly 18-litre diesel engine-powered, rigid dump trucks, and other diesel enginepowered machines were replaced by fully

28

© AGGREGATES BUSINESS May/June 2022

electric or hybrid-powered units powered by two generators. The wheeled loader, for example, was hybrid-powered with a small five-litre engine, and the crushers were electrically driven. The site also ran completely autonomous dump trucks, like skips on wheels. Environmentally, the carbon reduction was huge.”

Sardelli stresses how much he enjoys working as part of a “small, dynamic team” based in the UK. “We have Wendi Goodman looking after generators; Nick Styles working on variable speed; and Sam Thirlaway is our application engineer. We feed into our Service Market Team headed by Tim Barclay, who is supported by Chris Slevin, David Sherry and Jonathan Taylor. This group is very knowledgeable on hybridisation, electrical systems, and hydrogen-powered engines.”

Remaining with Volvo Penta, Morgan Blomgren, director Strategy & Business Development, and Prabhakaran Sundaramurthi, vice president - Product Management Industrial, have spoken to Aggregates Business in more detail about the company’s quarrying-suited industrial engine research and development work.

“In the short-term, the focus is still very much on diesel-powered engines. In this part of the business, we see continued strong demand for diesel engines, and we will continue our development in diesel moving forward, at least past a Stage VI regulation.

However, we also see a rising interest in alternative fuels. Besides our engines being able to run on HVO and biodiesel already today, we are also looking into using both CNG, biogas and hydrogen as energy carriers for internal combustion engines.”

Asked about the challenges posed in

Kohler Engines has approved the use of EN15940-compliant hydrotreated vegetable oils (HVOs) for all its diesel engines in Europe.

The manufacturer says the use of HVOs, either pure or as a blend with conventional diesel, is part of its commitment to lessen the environmental impact of its engines. The approval came after intensive laboratory and on-the-field testing by Kohler’s engineering team.

The group says its diesel engines do not require any kind of modification or specific upgrade to use HVO. However, use of exhaust gas after-treatment systems will still be necessary where already required.

HVO is a renewable paraffinic fuel, also known under the names 'synthetic diesel' and 'renewable diesel'. It is produced with plant or animal oils derived from the residues of the meat and fish industries.

Since it is obtained from organic material, HVO – unlike biodiesel – does not use agricultural resources or contribute to deforestation. It can be used wherever diesel fuel is used today.

Kohler says a reduction in overall CO2 emissions of up to 90% can be obtained depending on the raw material employed in HVO production. It adds that, compared to most conventional diesel fuels, HVO has an exceptionally low sulphur content and its use leads to lower vehicle exhaust emissions.

Synthetic diesel is widely available in service stations across northern Europe and Kohler says it is taking hold as the next-generation fuel. It is 100% fossil-fuel free and 100% recycled. HVO fuel can be distributed, handled, and stored just like any conventional fuel.

ensuring sustainability when engineering new off-highway engine solutions, the pair say: “Of course, new technologies always bring some challenges when it comes to engineering. But what we are seeing now is also a challenge in keeping on top of the different regulations when it comes to batteries and new types of fuel. A lot is happening across the globe when it comes to this and it’s extremely important to make sure that the solutions we put on the market are compliant with the various regulations.

On the engineering side, we would say that some of the main challenges are to generate enough power to replace one of our bigger diesel engines today and still limit the size and weight of the solution, and also to reach a similar or better total cost of ownership.”

So, when can quarrying customers expect to see new Volvo Penta engines for

www.AggBusiness.com

ENGINES – PART 1

their machines? “The second part of this decade is when the market can expect new solutions from Volvo Penta in this specific part of the business. We have already started our journey towards zero emissions within the battery-electric area. But we are, in parallel, looking at a wide range of solutions to support our full range of customers.

This includes internal combustion engines powered by alternative fuel and hybridisation.

These are most likely the transitioning solutions before reaching zero-emission solutions for this segment of the business.”

Commenting on how new quarryingsuited Volvo Penta industrial engines will stand out in a highly competitive marketplace, Blomgren and Sundaramurthi say the company always aims to give customers a solution they can rely on to perform. “To strengthen this even further we will soon provide several different services that maximise uptime and support efficient usage of the engine. This reduces fuel consumption even further.

“We have a solid foundation to stand on with our current diesel offering and together with the rest of the Volvo Group we are sure that we will continue to have strong customer testimonials moving into offerings beyond diesel as well.”

Asked about the feasibility of many future quarry sites being entirely powered by electric, hydrogen and other non-dieselpowered crushers, screeners, loaders and

John Deere Power Systems’ JD18 engine

www.AggBusiness.com

haulers, Blomgren and Sundaramurthi add: “With a combination of the different alternatives mentioned it is quite feasible to see production sites like this in the future, but it will take a combination to achieve it.

Electrification has its limits and so have other solutions but bringing them together in a site like this can offer a viable solution with less or even zero emissions.

“The big question is when it will be realistic to reach zero emissions. And that is most likely the million-dollar question here. One of the keys to making it happen is of course the availability of alternative fuels, like hydrogen, HVO, and biogas.

This in combination with the electricity supply is what will determine the speed of transformation in the industry. There are ambitious plans for this across Europe and in other areas of the globe, but we are looking at the 2030 timeframe to reach sufficient levels of supply. Reaching a high enough supply is also a key to reaching a price level for the fuel that makes it a realistic option in a fuel-consuming business like this [quarrying].”

John Deere Power Systems (Deere) is constantly innovating ways to meet both market and customer demands to deliver new levels of reliability, durability, flexibility, and serviceability. The result is a comprehensive engine lineup for a wide array of heavy-duty applications. The newest addition to the next-generation Deere

industrial engines is the 18-litre JD18 engine.

Featuring uptime-focused controls that offer improved diagnostic capabilities, users are able to quickly target the source of a performance issue and get back to work. The JD18 features a bedplate design, providing structural benefits for extreme durability, with the ability to be re-built two times. The engine also has Hydraulic Lash Adjustment (HLAs), which offers a maintenance-free valvetrain, eliminating the need to reset the lash.

New combustion technology means John Deere can offer an engine in the 522 – 676kW power range without aftertreatment, so users have one less fluid to manage. The highpressure common-rail fuel system in the JD18 allows the engine to deliver optimised fluid consumption. Plus, the DiamondLike Coating (DLC) improves bio-diesel compatibility and system robustness.

With the addition of the JD18, users can put John Deere power and performance into their entire line-up of equipment from 36kW to 676kW. OEMs are encouraged to contact their local John Deere engine distributor or dealer for more information on the JD18.

Building on its experience in integrating smart and sustainable technology innovations into powertrain systems, Deere has made strategic investments in two companies that are leveraging unique technologies for alternative fuel and electrification solutions.

In late 2021, Deere made an equity investment in ClearFlame Engine Technologies, a growing start-up dedicated to the development of clean engine technology. ClearFlame’s solution enables low-carbon fuels like ethanol to be easily integrated into compression ignition engines, offering a more sustainable solution without compromising engine performance.

In early 2022, Deere also acquired majority ownership in Kreisel Electric, Inc. (Kreisel), a battery-technology provider based in Rainbach im Mühlkreis, Austria.

Kreisel develops high-density, highdurability electric-battery modules and packs. Additionally, Kreisel has developed a charging-infrastructure platform (CHIMERO) that utilises this patented battery technology.

This investment in Kreisel provides optimal integration for Deere to efficiently design vehicles and powertrains around superior immersion-cooled, high-density battery technology. Kreisel’s in-market experience combined with the global footprint of Deere is a powerful combination that will leave both companies better equipped to meet the growing demand for electrification.

Deere intends to continue to invest in and develop technologies to innovate, deliver value to customers, and work towards a future with zero-emissions propulsion systems.

Deere’s UK distributor, EP BARRUS, is due to showcase the company’s current Stage V engine range on stand G15 at Hillhead 2022 (21-23 June) near Buxton, England. AB © AGGREGATES BUSINESS May/June 2022

29

RECYCLING - 1

Crushing it in recycling Companies are stepping up their recycling and sustainability efforts across a range of sectors including crushing & screening and off-road tyre retreading. Liam McLoughlin reports

G

erman building materials recycling group Erdtrans has invested in a Kleemann MOBICONE MCO 90i EVO2 mobile cone crusher to enable cost-effective recycling and the production of high-quality ballast chips and high-grade flint.

Since summer 2021, the first plant of this type to be deployed worldwide has been recycling mainly railway ballast. Downstream of the cone crusher is a MOBISCREEN MS 953 EVO screening plant.

The MOBICONE MCO 90i EVO2 features the Kleemann continuous feed system (CFS) which uses ultrasonic probes to monitor the crusher level and other parameters. This optimises the utilisation of the crusher.

To guarantee fast and safe train travel, the ballast bed under railway tracks has to be regularly repaired. High demands are placed on the material because, in a high-quality ballast bed, the stones dig into one another with their sharp edges to form a stable base.

Furthermore, only suitable material gives the track system the required elasticity and ensures the unrestricted downward flow of rainwater.

German Railways (DB) uses licences for the railway ballast suppliers to ensure that the material used meets the requirements.

Erdtrans, which has offices in Zossen and

30

© AGGREGATES BUSINESS May/June 2022

Trebbin near Berlin, has had corresponding DB product qualification for years because "we recycle or process everything that's under the rails," explains company MD Michael Schwarzer.

Schwarzer adds that he is highly satisfied with the new Kleemann plant after its first six months in operation. Now he worries even more than before the purchase that "not enough recycling materials are used in ballast beds. The use of new material simply no longer meets contemporary standards. The

new crusher shows clearly that we can easily use modern machine technology to produce railway ballast and other high-quality products from recycling material."

Northern Ireland-based compact crushing and screening brand EvoQuip has launched the ‘Think Green, Think EvoQuip’ campaign to illustrate its commitment to developing increasingly sustainable equipment as part of global sustainability efforts.

Barry O'Hare, business line director for EvoQuip, says that sustainability is a strategic

EvoQuip says the ‘Think Green, Think EvoQuip’ campaign shows its commitment to developing sustainable equipment

www.AggBusiness.com

RECYCLING - 1

priority for the company and consistently at the top of its agenda. “We see it as our responsibility to do what we can to be as sustainable a company as possible and to help to build a world that puts sustainability at the forefront of everything we do," O’Hare adds.

Terex-owned EvoQuip has also posted a sustainability responsibility statement on its website stating four key commitments.

These are: production of sustainable equipment that is as kind to the environment as possible whilst still being effective and eco-friendly in its use. This is both in the design stage of the products and in the physical processing of material; the use of sustainable materials where possible in the production of all equipment, parts, and packaging to help to ensure the products are sustainable from design to the finished product to operation; offering the best solution to customers to ensure their operation is as efficient and environmentally friendly as possible. They promise to comply with all legislation and health and safety requirements.

Recycling is an important industry for EvoQuip, with over 40% of equipment out in the field working in a recycling application.

It is possible to process many types of waste, which can then be reused as product on site or sold. The entire EvoQuip range provides the ideal solution for generating profit from waste.

EvoQuip says it will be increasing its hybrid/electric offerings over time as part of the ‘Think Green, Think EvoQuip’ campaign.

Fuel consumption monitoring, assessing and reducing carbon footprint and reducing waste

to landfill will also help EvoQuip live up to the name of its campaign.

The campaign's economic contribution comes from reducing machine running costs, turning waste into profit and having a more measured approach to research and development. EvoQuip is also ensuring its training to operators is constantly and consistently updated to ensure that operators know the most economical way to operate

Marangoni has won four categories at the Recircle Awards, one through its TRM subsidiary

and service the machines.

Off-road tyre retread specialist Marangoni has won four categories at the Recircle Awards. The Italian company says this is a record for the awards event, which is dedicated to the circular economy in the tyre retreading and recycling sectors.

Marangoni made it to the highest podium in the Best Tread Rubber Supplier, Circular Economy Award, Best Tyre Retreader (for the second consecutive year), and Best Retreading Equipment Supplier (through its TRM subsidiary) categories.

Marangoni COO Matthias Leppert commented on the success: "We are extremely honoured by the recognition given to Marangoni: not by the excellent result itself, but rather by our customers, who with their votes have expressed their trust in the quality of our products and services.

"The categories in which our customers placed us on the podium, confirm how Marangoni supports in the finest way the retreader partners with a 360 degrees offering, ranging from machinery to retreading materials, and the fleets – especially in Italy – thanks to the retreaded tyre.”

Leppert concluded: “This result was achieved thanks to the extraordinary participation of our customers, partners and collaborators, which is an encouragement to renew Marangoni's commitment to further consolidate its leadership in the sector."

The Recircle Awards’ winners were announced at the ceremony broadcast online on 25 April. The trophies were delivered during The Tire (in Cologne, Germany, on 24 May) and Autopromotec (in Bologna, Italy, on 26 May) industry events. AB

Erdtrans is using a Kleemann cone crusher to recycle railway ballast

www.AggBusiness.com

© AGGREGATES BUSINESS May/June 2022

31

WEAR PARTS

Nordic Bulk is taking care of the servicing and after-sales of a CDE waste recycling plant at Norwegian crushed stone, asphalt and concrete producer Velde

Enhancing after-sales service Aggregates equipment manufacturers are putting more engineers on the ground to improve their after-sales service, and stressing the importance of using original OEM wear parts to ensure optimum performance. Liam McLoughlin reports

N

orthern Ireland-based wet processing company CDE has joined forces with Norwegian firm Nordic Bulk to maximise customers’ productivity and minimise waste.

Nordic Bulk is a supplier of bulk material processing plants operating in the mining and aggregates industry in Nordic countries with 30 years of operational experience. It designs and delivers turnkey projects utilising advanced technology. The company supports its customers with a full warehouse of all needed parts and a service department with dedicated staff.

CDE and Nordic Bulk have worked together before on a number of projects in Iceland and Norway, resulting in a drive to enhance the after-sales care offered to new and potential customers across the Nordic region.

With the increased demand across Scandinavia, CDE says it recognises the requirement for more engineers on the ground and local holding of spare parts, to ensure a more timely delivery and reliable after-sales service. Having already established a good working relationship, CDE adds that it is confident in Nordic Bulk’s ability to deliver a high standard of aftercare on their behalf and thus the partnership was formed.

CDE’s CustomCare team supports customers in achieving and maintaining optimum efficiency in the running of their

32

© AGGREGATES BUSINESS May/June 2022

plants and working collaboratively with customers to ensure maximum plant efficiency and uptime. CDE has worked alongside Nordic Bulk providing extensive and ongoing training to immerse them in CDE’s method of service and help the team gain a deeper understanding of the products, ensuring consistent aftercare for customers in Nordic markets.

Customers in Nordic markets can now expect a faster service turnaround and quicker delivery of plant equipment, as and when required. Part of this partnership sees Nordic Bulk taking care of servicing and after-sales of CDE’s largest waste recycling plant for Velde in Norway, operating at up to 300tph. CDE has integrated a new 220tph natural processing plant for Velde, which integrates feeding, screening, sand and aggregate washing and stockpiling on a single chassis and allows Velde to extract more fraction from its feed and produce a high-quality saleable aggregate. Nordic Bulk’s expertise and after-sales care will ensure the plant continues to work efficiently to ensure maximum profitability.

Martin Jackson, head of CustomCare at CDE, says the partnership will improve the service for Nordic customers.

“The collaboration with Nordic Bulk will not only benefit existing customers, but it will give reassurance to potential customers in the Nordic markets that we are dedicated to delivering first-class after-sales service in a timely manner,” Jackson adds.

Eunan Kelly, CDE head of business development for North West Europe, says: “For us, this partnership was a no brainer.

We’ve been working on projects with Nordic Bulk over the years and really admire how dedicated they have been to our customers and equally in their own rights. Over the years we have built a lot of trust with Nordic Bulk, and this partnership was a natural progression in our relationship.

“We recently hosted an event at Nordic Bulk’s headquarters to explain our new venture to our customers, which was followed by a tour at one of our flagship project sites, Velde, to showcase the positive outcomes of our working relationship.”

Nordic Bulk’s CEO Peder Egeland says that CDE is a key partner for his company to exceed its customers’ expectations delivering advanced and effective washing processing plants.

“Together we maximise customers’ resource yield and minimise waste,” Egeland adds. “CDE have provided us with comprehensive and detailed training into their products and also their delivery of service so that we can provide customers with top quality after-sales service. We have seen the support that CDE provide to their customers and their dedication in producing quality material, making it a straightforward decision to partner with them, and we are excited to work together to enhance the after-sales service.”

www.AggBusiness.com

WEAR PARTS

CDE and Nordic Bulk staff visit Velde’s CDE recycling plant

As well as the CustomCare partnership, CDE and Nordic Bulk state that they will continue to deliver projects across Nordic markets, which will include the installation of a new major waste recycling plant in Norway.

Weir Minerals has highlighted how buying original equipment manufacturer spare parts improves the performance of its Warman range of slurry pumps.

Simon Jones, pumps product manager at Weir Minerals Europe, comments: “When you buy genuine spares for Warman slurry pumps, you get so much more than just a volute liner, impeller or side liner. You’re

making an investment in a product that will receive expert lifetime support, achieve higher pump performance, last longer and reduce your process’ risk profile.”

He adds that Warman slurry pumps are designed to operate under demanding conditions that place every component in the pump under a significant amount of stress.

“Ensuring components meet such a challenge is an enormous task, requiring the highest quality construction materials, lengthy and precise design processes, stringent quality control in manufacturing and extensive safety testing,” Jones says.

Jones adds that replicators cut corners in design, manufacturing and transport, use inferior wear-resistant materials and do not supply safe lifting methods, which introduces significant risk to pump operations.

“Even tiny gaps between imperfectly replicated components can lead to leakage, vibration or excessive stress concentration which causes dangerous and unpredictable cracks in components - a problem that OEM parts don't have thanks to our strict quality control,” he says.

Jones says that failure of critical components can lead to high-pressure slurry spray, which is often toxic, corrosive or heated to very high temperatures. It can also cause high-energy brittle fracture projectiles which can travel dozens of metres. The risk of hitting other equipment or personnel is high in such situations.

He adds that a major advantage of buying genuine Warman spare parts is that the purchaser receives Weir Minerals’ cuttingedge wear-resistant materials.

“The products of our unique, advanced materials technology group are vital to achieving the legendary wear life of Warman pumps in harsh, abrasive and corrosive mining conditions,” says Jones.

“For most situations, nothing compares with Ultrachrome A05, our near eutectic highchromium white-iron alloy that provides a great balance of hardness and toughness, without sacrificing corrosion resistance.”

A LONG WAY

TOGETHER

For info: europe@bkt-tires.com

www.AggBusiness.com

© AGGREGATES BUSINESS May/June 2022

33

WEAR PARTS

Weir says buying original OEM wear parts improves equipment performance

He says that Weir Minerals does not rely on one alloy for every situation, and that its ever-expanding range of Ultrachrome and Hyperchrome chromium carbide alloys allow the company’s engineers to specify the optimum wear solution to fit the needs of the application.

According to Jones, the inferior alloys found in replicated Warman pumps are not only prone to failure, their lower, unpredictable lifespans also make it extremely challenging to efficiently align the pump’s maintenance needs to overall campaigns.

He adds that the complex manufacturing processes involved in producing its OEM parts are difficult to reverse engineer and are different for every size and component.

“Our cast alloy components require specific heat treatment, together with a variety of proprietary moulding, methoding and pouring techniques to achieve a high-quality casting with all the required mechanical properties,” he states.

Jones says that parts supplied by replicators either: produce a structurally inferior and possibly defective product, prone to cracking in the high-pressure environment of a Warman slurry pump; or modify the geometry component to suit their manufacturing process, which won’t achieve the fit required due to their poor tolerancing.

“Without the appropriate tolerances, replicated spares can fail to perform in any number of ways, ranging from high localised wear caused by gaps between liners, excessive vibration during operation, and fitment interference leading to an inability to thread the impeller or close the pump without cracking the volute liner,” he adds.

Aside from the rapid wear these issues

34

© AGGREGATES BUSINESS May/June 2022

cause, any geometrical divergences from the OEM design will naturally interrupt the intended hydraulic performance of the pump, reducing throughput, total head and efficiency.

Aggregates and mining equipment does not last forever under the tremendous strain it is subjected to, and Jones says this is why the support that operators receive from their supplier is almost as important as the part itself.

“Genuine spare parts for Warman slurry pumps are backed up by our unique global support network, which includes dedicated service centres within 200km of almost all of the world’s major mining regions,” adds Jones. “That means Weir Minerals engineers, with decades of experience complemented by our unique skills working with mines across the world, are there to support you every step of the way, from installation to replacement or even decommissioning and disposal.”

Off-highway hydraulic component manufacturer Danfoss Power Solutions has restarted its business activities in Ukraine.

The Denmark-based multinational halted trading in the country after its war with Russia began, following the latter's invasion.

Danfoss's resumed business in Ukraine will focus on restoring critical infrastructure in damaged cities and towns.

Adam Jedrzejczak, president of Danfoss East Europe region, said: "It is key for us to continue supporting our customers in Ukraine. It is not only the right thing to do, but our products are also key components for the critical infrastructure which needs to be rebuilt. Thanks to Danfoss's products, residents in some of the most badly damaged areas of Ukraine will again have access to heating and hot domestic water."

Most Ukrainian employees decided to stay in Ukraine, but families were evacuated in February by the Danfoss crisis team. As safety levels in most parts of Ukraine are improving, employees are starting to move back. Currently, 40 Ukrainians – including eight Danfoss employees – are in Poland.

Other colleagues and family members have been safely moved elsewhere. Currently, there are 16 Ukrainians in Germany, six in Denmark, four in Spain, three in Slovakia and two in Austria. All evacuated employees and their families are relatively well, and Danfoss continues to be in close contact with all families, both the evacuated families and those remaining in Ukraine.

Danfoss, a manufacturer whose varied industries' product portfolio includes hydraulic components for off-highway machinery such as excavators and bulldozers, says Ukraine remains an important Eastern European market for the firm.

According to The Kyiv School of Economics, the cost of direct damage to Ukraine's infrastructure has already reached the level of US$63bn. Therefore, solutions such as those provided by Danfoss are critical as they positively impact the rebuilding of district energy infrastructure, commercial and residential buildings, and water and wastewater treatment utilities.

A company spokesperson said the safety and security of the Danfoss team remain its key priority. Despite uncertainties, it has been key for Danfoss to resume business activities in the country as quickly as possible. For now, Ukrainian customers can pick up their products at a so-called crossdocking warehouse that the company has established in Lviv.

General manager in Danfoss Ukraine Andriy Berestyan, working out of Lviv, said: "Our team in Ukraine is eager to come back to their work. They want to play their part in rebuilding their home country. They are extremely motivated, and Danfoss's products are important to help rebuild our country's infrastructure." AB

www.AggBusiness.com

PORTABLE POWER - 1

Increasing productivity with advanced energy storage systems Diesel generators have traditionally provided power sources for quarry sites, but lithium-ion battery energy storage systems (ESS) are now addressing the need for more environmentally friendly and sustainable equipment. Liam McLoughlin reports

P

roductivity on a quarry site is vital to completing a project within budget. This is especially important in today’s economic climate where quarrying companies are also under increased pressure to operate as cost-effectively as possible.

The ability to work efficiently and finish a project on – or even ahead of – schedule can ultimately help improve the bottom line.

A critical component of any site, and one that has a significant effect on productivity, is power. Without a good, reliable source of power, quarry workers risk unwanted downtime which can set their project back.

Traditionally, diesel generators have been the power source. However, in recent years, lithium-ion battery energy storage systems (ESS) have been developed to address the need for more environmentally friendly and sustainable equipment.

Barbara Gregorio of Atlas Copco Power and Flow says these energy storage systems can play a pivotal role in helping sites to increase productivity. They can assist rental companies increase their profitability, and quarry operators to make cost savings, while contributing to a lower total cost of ownership (TCO).

“Noise is a major environmental problem and as such there are regulations that stipulate maximum noise levels” Barbara Gregorio, Atlas Copco Power and Flow

“One factor that has a significant impact on productivity is the noise levels of the equipment, says Gregorio, who is divisional product marketing manager Innovative Energies and Digital Solutions at Atlas Copco’s power and flow division. “Noise is a major environmental problem and as such there are regulations that stipulate maximum noise levels to address the effect on the hearing and general well-being of employees and visitors of a site, and the environmental noise that may affect people living in the vicinity of a quarry and other adjacent potentially noise-sensitive properties and areas outside a site.”

Generator-powered solutions with engines inherently make some noise and there is no way of eliminating this entirely.

In contrast, batteries operate silently, and so energy storage systems are noise-free.

Gregorio says this has major benefits, helping operators to comply with regulations and enabling them to extend their working day.

Atlas Copco’s ZenergiZe energy storage systems provide energy backup for 24/7 industries that cannot afford blackouts

www.AggBusiness.com

© AGGREGATES BUSINESS EUROPE May/June 2022

35

PORTABLE POWER - 1

Energy storage systems can also be used to increase productivity on remote sites or applications where grid installations are not stable as there is no need for refill generators. Atlas Copco says its lithium-ion ZenergiZe range of energy storage systems is an ideal solution as a source of energy backup to ensure continuous production for industries running 24/7 that cannot afford the consequences of blackouts.

“Energy storage systems can help operators to increase productivity during electricity peaks,” Gregorio states. “They can be used in parallel with diesel generators (in a hybrid mode) in this case, so there is no need for sites to reduce activity to avoid exceeding the grid limits. As the energy storage solution provides a separate energy source to the grid, it enables smart load management, and work can continue even during peak electrical demand.”

She adds that there are further benefits of hybrid setups. By operating an energy storage system in combination with a generator means operators can use a smaller-sized generator, and downsizing the generator means maintenance can be kept to a minimum and ensures the generator works at its optimal point.

Productivity can also be increased by a reduction in maintenance. If equipment needs regular servicing, this downtime can lead to unwanted and costly stoppages.

“That’s where lithium-ion battery energy storage systems can have a significant positive effect,” says Gregorio. “For example, in normal operating conditions, these batteries have a lifespan of 40,000 hours and an overload capability of 200 percent.

Atlas Copco energy storage systems have also been specifically designed to operate in high and low ambient temperatures, from -15C to +50C. Their heating, ventilation and air conditioning systems help minimize maintenance needs during the battery energy storage systems’ lifecycle, helping operators achieve optimal uptime.”

In addition to improved productivity, Gregorio says there are financial benefits to both rental companies and end users in terms of cost savings to be made, profits and return on investment.

Offering an efficient hybrid alternative to using a large generator for variable loads is the combination of Atlas Copco’s Energy Storage Systems (ZBP and ZBC models) and the company’s latest QAS+ generators.

Compared with a generator of 650 kVA,

working as a standalone solution, Gregorio says that a ZBC250-575 with a QAS+ 325 in hybrid mode can reduce daily fuel consumption by up to 80%. It is equivalent to approximately 200 tons of CO2 during their working life. “This has a significant impact on productivity, boosting it by 50% and keeping the solutions’ total cost of ownership to an absolute minimum,” she says.

Atlas Copco’s energy storage systems are designed to optimise the generator’s performance, extending its lifespan by up to 15% and cutting in half any maintenance and overhaul requirements.

Atlas Copco says the introduction of lithium-ion energy storage systems such as its own range is having a real, positive impact on business for both rental companies and end users alike, enabling them to improve productivity. Additionally, users can benefit from minimising environmental impact with low cost of ownership.

“These novel energy systems are delivering zero CO2 emissions, zero NOx pollution, zero noise, with virtually zero maintenance, supplying reliable energy without compromise,” says Gregorio. AB

CATERPILLAR LAUNCHES XQP310 GENSET Caterpillar is introducing the 310 kVA Cat XQP310 generator set, the company’s latest mobile power solution meeting European Union (EU) Stage V emission standards for engines used in non-road mobile machinery.

Available now through the global Cat dealer network, the Cat XQP310 follows the launch of the 200 kVA Cat XQP200 mobile generator set in 2021.

Cat says the new generator set shows its ability to meet the 90% reduction in nitrogen oxides when compared with the Stage IIIA standard, as well as other changes specified by Stage V standards.

With 12% more power than its predecessor, the Cat XQP310 is engineered for flexibility by switching between 50 and 60 Hz and across a range of voltages.

This allows one machine to satisfy varying load requirements in diverse regions and applications, such as quarrying, mining, manufacturing, oil and gas, and construction.

Caterpillar says the XQP310 uses proven technology to enable simple, reliable operation. It is equipped with Cat Connect technology to remotely track and manage the generator set and improve operational efficiency. Through a subscription,

36

© AGGREGATES BUSINESS EUROPE May/June 2022

the telematics send real-time information on fuel level, AdBlue/ diesel exhaust fluid (DEF) level, battery voltage, and run status.

Connected assets support peak operation with timely insights that help customers better control costs, improve performance and reduce risks.

“As construction and mining activities rebound worldwide, the Cat XQP310 demonstrates how we are expanding our portfolio of mobile power solutions to deliver the performance and reliability customers need while helping them support their sustainability initiatives and address evolving emission standards,” said Tom Caldwell, global general manager for electric power rental solutions at Caterpillar.

Cat mobile generator sets meeting EU Stage V emission standards offer numerous features that make them ideal for rental applications. They are equipped with the EMCP 4.2B digital control panel, which provides all generator set controls and system indicators in a single, easy-toaccess interface. Programmable logic controller (PLC) functionality is designed to improve reliability and flexibility for accommodating changes in processes or application requirements.

They are designed with a dual-wall fuel tank with an open bund that helps to protect the environment by containing spills, while coastal ingress protection (CIP) enables operation in harsh conditions.

Their wide, impact-absorbing base frames, customer connections isolated from circuit breakers, and optional CEE sockets are designed to facilitate transportation, set-up and use. Forklift pockets, dragging

points, and a lifting arch help to simplify loading, unloading, and placement around the worksite.

Cat mobile generator sets meeting EU Stage V emission standards can use up to 100% hydrotreated vegetable oil (HVO), a renewable diesel fuel that can further reduce the carbon footprint of the engine and the environmental footprint of users.

All Cat mobile generator sets are available through the manufacturer’s worldwide dealer network.

Caterpillar’s new XQP310 mobile generator set

www.AggBusiness.com

MARKET REPORT

A Liebherr L 580 wheeled loader loading a Liebherr TA 230 ADT at a British quarry

Healthy demand amid headwinds Demand for mineral products and quarrying and construction equipment remains healthy in the UK and Ireland, but material shortages, rising energy costs, and the April 2022 ending of the red diesel rebate for off-road equipment used in the construction and mineral products industries threaten growth and commercial prosperity. Guy Woodford reports

T

o use an industry-related metaphor, the mineral product stockpile was in good shape at the start of 2022.

However, there was much concern over whether a perfect storm of external factors would harm the smooth flow of material off the conveyor belt.

In Britain, demand for mineral products, such as aggregates, concrete, asphalt and mortar, recorded double-digit growth during 2021, a sharp recovery from the COVID-19pandemic-induced slowdown a year earlier.

A comprehensive industry survey by the Mineral Products Association (MPA) showed that volumes of primary aggregates increased by 15.7% on an annual basis in 2021, 14.1% for ready-mixed concrete, 12.5% for asphalt and 24.4% for mortar.

These materials are the essential elements of the construction supply chain, forming the foundations and structures of building projects and infrastructure schemes, with MPA members supplying 90% of total market demand in Great Britain. Compared to the previous quarter, sales volumes of aggregates and ready-mixed concrete grew by 3.8% and 5.9%, respectively, in Q4 2021.

Asphalt and mortar sales recorded small

www.AggBusiness.com

quarterly declines, but total demand in volume remains elevated. Survey results also showed that construction demand remained strong in the final quarter of the year, despite unprecedented supply bottlenecks impacting progress on construction sites, cost increases and higher uncertainty due to Omicron.

Overall, the recovery in mineral products demand last year was faster than expected and imbalanced. For instance, aggregates and asphalt sales in 2021 exceeded pre-pandemic levels in 2019, but ready-mixed concrete and mortar sales remain weaker. Asphalt and aggregates demand was supported by an acceleration in infrastructure work, including roads and major infrastructure projects such as High Speed 2 (HS2). Asphalt sales have maintained a historically high activity level for the past 18 months, with producers working hard to meet pent-up demand from delayed road projects due to the pandemic.

That’s in addition to the demand stemming from the Government’s Road Investment Strategy 2 and an increase in demand from local authorities for repair and maintenance work.

After a healthy first quarter of 2022 for UK producers of mineral products, the

MPA believes the outlook for the rest of this year will be influenced by rising costs, lower growth prospects and international uncertainties.

MPA figures show that markets for essential materials like aggregates, concrete, asphalt and mortar continued where they left off at the end of 2021, with sales volumes increasing on a quarterly basis in Q1 2022.

This reflects firm construction demand at the start of 2022 despite the bad weather that hit parts of Great Britain during February, and some easing in reported supply chain constraints, including for HGV drivers - albeit at a cost.

The latest MPA industry survey shows that asphalt sales volumes in Great Britain rose by 1% compared to the previous quarter, sand & gravel by 2.1%, ready-mixed concrete by 3.2% and mortar by 5.5%. Only crushed rock volumes saw a marginal decline on a quarterly basis (-0.4%) but remain at an elevated historical level.

After hitting their highest peak since 2008 last year, asphalt volumes continue to be supported by pent-up demand from delayed road projects due to the pandemic, in addition to demand stemming from National © AGGREGATES BUSINESS EUROPE May/June 2022

37

MARKET REPORT

Highway’s Road Investment Strategy (RIS2) and an increase in demand from local authorities’ repair and maintenance work.

The bulk of the logistical and haulage issues reported by asphalt producers last year appear to have eased, but the cost of labour, energy and raw materials including bitumen, are all escalating. The big concern is the impact this may have on planned National Highways schemes and already stretched-out local authorities’ repair and maintenance budgets.

Ready-mixed concrete sales were hit hard during the onset of the pandemic, and in the year ending March 2022 were still 6% below the pre-pandemic (2019) levels.

Both London and the Southeast, which make up just over 30% of the total share of volumes across Great Britain, have endured a sustained period of weakness which can be traced back to comparatively slow recovery in commercial construction projects, particularly for new office towers and retail space. Overall demand is nonetheless supported by major infrastructure projects, including HS2 and Hinckley Point C, as well as a healthy pipeline of industrial warehouse projects.

Simultaneously, a pickup in new housing starts since last summer is also fuelling increases in mortar demand. On a quarterly basis, mortar sales reversed the two backto-back quarterly declines in the second half of 2021, with a 5.5% increase in 2022 Q1.

Sales volumes returned to their highest level since 2019 Q3. However, while the current year has begun strongly, the uncertainties facing housebuilding have increased amid rising costs of materials and labour. The wider macroeconomic conditions are also being closely watched, particularly as the increasing cost of living has sparked a

“Construction forecasters have already reduced their growth expectations for this year and there are signs that the pressures are continuing to pile up” Aurelie Delannoy, MPA director of Economic Affairs

decline in confidence among UK households and nudged the Bank of England to increase interest rates four times in less than five months, pushing up mortgage costs.

In the aggregates market, crushed rock sales remain comfortably above the pre-pandemic level, benefitting from demand from highways schemes and the manufacture of asphalt, and as fill materials on major infrastructure projects. Sand & gravel sales

have been more muted, albeit this is linked to weaknesses in some areas of ready-mixed concrete demand.

The bulk of the momentum in mineral products demand recorded at the start of the year should carry over into Q2, but thereafter, Aurelie Delannoy, MPA director of economic affairs, warns that steep cost increases and broadening risks facing the UK economy could make for a more challenging environment over the second half of the year and into next year.

“Current construction activity levels and mineral products demand remain high. The short-term pipeline is also robust. However, with material cost inflation running at 25% on an annual basis in April, the supply environment is a challenge. There are concerns over the impact of passing these costs onto customers and the commercial viability of future projects.”

“We expect that large infrastructure projects will continue to drive further growth in demand, but this cannot be at the expense of the ‘bread and butter’ activity level fuelled by the private sector, particularly consumerfacing private new housing, private housing repair and maintenance and commercial retail sectors. Construction forecasters have already reduced their growth expectations for this year and there are signs that the pressures are continuing to pile up. This means that mineral products companies are facing a tough combination of rising costs, dwindling growth prospects and international uncertainties.

“Confidence to invest in future capacity to deliver on Government’s increased

An excavator handling large rocks at a UK quarry

38

© AGGREGATES BUSINESS EUROPE May/June 2022

www.AggBusiness.com

MARKET REPORT

Table 1. MPA sales volumes in GB: change on the previous period (seasonally adjusted)

ASPHALT

READY-MIXED CONCRETE*

CRUSHED ROCK

SAND & GRAVEL

MORTAR

2019

-0.8%

-3.9%

-0.7%

-5.4%

-2.3%

2020

-8.6%

-18.2%

-9.6%

-12.4%

-23.5%

2021

12.5%

14.1%

16.7%

13.3%

24.4%

2021 Q2

4.5%

1.2%

-0.9%

0.9%

21.2%

2021 Q3

-4.2%

-6.4%

-4.6%

-10.4%

-3.8%

2021 Q4

-0.3%

5.5%

3.2%

4.5%

-0.7%

2022 Q1

1.0%

3.2%

-0.4%

2.1%

5.5%

4 quarters to 2022Q1 vs. 2019

2.9%

-5.9%

4.8%

-1.7%

-0.1%

* Ready-mixed concrete sales volumes at GB level cover sales from both fixed and site (mobile) plants.

Source: MPA, ONS. infrastructure and housing ambitions relies on better delivery of planned projects than has been evident in recent years. Meanwhile, two energy-intensive mineral products industries - cement and lime – have been excluded from Government’s compensation scheme for climate change costs on the basis of technicalities. Clearly, a more consistent and strategic approach to Government’s objectives and policy delivery is still lacking.”

The Construction Equipment Association (CEA) said UK Chancellor of the Exchequer Rishi Sunak’s Spring Budget Statement to parliament on 23 March 2022 was a “missed opportunity" to help manufacturing.

Suneeta Johal, CEO of the CEA, said that the measures set out by the Chancellor had ignored industry pleas for a delay to red diesel and biofuels rebate reform.

“This mini-budget was an opportunity for Rishi Sunak to take significant action to help businesses to minimise the impact of rising inflation, which is at a 30-year high and continues to rise," she added. "This Spring Fiscal Statement comes at a critical time for manufacturing in the UK – and as expected it did not deliver and was very much an exercise of smoke and mirrors.

"Petrol and diesel prices have soared in recent weeks hitting an all-time high – whilst the announcement of a fuel-duty freeze and the temporary cut of 5p per litre is welcome, in reality, it will do very little in the way of easing the burden on the construction sector, where despite extensive lobbying, Government has ignored pleas for a delay of the reform of the red diesel and biofuels rebate.”

Johal added that spiralling energy costs are crippling the construction equipment

www.AggBusiness.com

sector and the situation has worsened due to the Russian war on Ukraine. She said that the lack of support for businesses is "deeply disappointing".

"The VAT cut on energy-saving devices, such as solar panels, has marginal benefits,"

"It was immediate help our sector needed - and once again Government failed to deliver"

said Johal.

She added that investment in alternative sources of power was overlooked and is an opportunity missed.

"It was immediate help our sector needed - and once again Government failed to deliver," she commented.

The MPA also welcomed the 5p-a-litre reduction in fuel duty announced by Chancellor Sunak, but, like the CEA, said it was disappointed not to see a change of mind on the red diesel rebate, with fuel costs skyrocketing at a time of high inflation.

Suneeta Johal, CEO of the CEA

© AGGREGATES BUSINESS EUROPE May/June 2022

39

MARKET REPORT

CRH CEO Albert Manifold has praised the Irish building materials giant's resilience during a challenging trading period

CEO Nigel Jackson said: "Taken in the round the statement does little to ease the worsening cost burden on industry, particularly energy and carbon costs, nor does it boost demand and give the confidence to invest in the short term or more strategically for the longer term."

The MPA, whose members produce 400 million tonnes of materials for UK building and manufacturing each year, had written to the Chancellor earlier in March to request a delay in the removal of the red diesel rebate, as well as calling for urgent action on soaring energy costs and transparency on delivery of the Government's infrastructure plans.

UK construction market output was valued at £286.99 (US$350.4bn) in 2020 and was forecast to record growth of more than 10% in 2021, according to analysis

by GlobalData, a leading business market intelligence consultancy.

The UK construction industry is projected to register an annual average growth of more than 3% between 2022-2025, says Global Data, adding: “The industry’s output over the forecast period will be supported by investments in the transport, renewable energy, housing, automotive and manufacturing sectors.”

GlobalData expects Britain’s construction sector to return to pre-pandemic levels in 2022. However, the same source states that project delivery will continue to be hampered by high materials prices and shortages.

“The industry’s output over the long term will be supported by a strong pipeline of construction projects,” continues GlobalData.

“In September 2021, the UK government published its National Infrastructure and Construction Pipeline, which outlines £611.4bn (€720.6bn) investment in infrastructure projects over the next 10 years. The largest share of the investment plan has been earmarked for the transport sector, which includes flagship projects such as HS2 and the Lower Thames Crossing road tunnel. The energy and utilities sector will receive £56.1 billion (€66.1bn) between

40

© AGGREGATES BUSINESS EUROPE May/June 2022

2021 and 2025, the second-largest share of the investment package and includes major projects such as the Hinkley Point C nuclear power plant.”

Irish building materials giant CRH says its UK & Ireland Q1 2022 sales were well ahead of the same period of 2021, reflecting good underlying demand and milder winter conditions. A group statement released on 20 April 2022 said: “In the UK, price increases were implemented across all products with volume improvements also positively impacting sales. Our businesses in Ireland had a positive start to the year with volume increases in all key products against a prior year comparative impacted by COVID-19 restrictions.”

CRH’s good Q1 in UK & Ireland follows on from chief executive Albert Manifold hailing the "outstanding commitment and resilience" of the group’s workforce after CRH posted a 12% year-on-year global sales rise in 2021.

GlobalData, states that the construction market in Ireland was valued at £24.6 billion (€28.9bn) in 2021. The market is projected to grow by the same source at an annual average growth rate [AAGR] of more than 4% during the period 2023-2026. The Ireland construction market growth in 2022 will, says GlobalData, be supported by investments in healthcare and housing initiatives under the 2022 Budget, which was announced in October 2021. GlobalData says the implementation of projects under the Nation Development Plan (NDP) 2021-2030 will also provide support, but there are downside risks in the form of supply chain disruptions and high prices for construction materials and energy.

Gerry Farrell, CEO of the Irish Concrete Federation, says that after a strong 2021 and first quarter of 2022, headwinds like those facing the UK mineral products industry may be experienced in Ireland.

“In general, there is a lot of concern at the potential impact of inflation and supply chain disruption on manufacturing and building costs. All our quarry and concrete manufacturing members up to now [mid-May 2022] are still relatively busy but there are some signs that the unprecedented increases in the price of building materials could lead to a slowing down of activity later this year and into next year.

“The Irish government is still predicting 5% economic growth this year, but inflation is a big factor, and it’s predicted to rise to 6.5% for 2022. There is a good pipeline of government public work to 2030, but the Construction Industry Federation has highlighted that materials and other cost inflation is pushing up the cost of building, which hits builders hard as they’re tied into fixed-price projects.

Recently Government has indicated that they will look at introducing some kind of price valuation clause in public contracts to allow works to continue.

“Rising energy costs is another massive concern for our members, both directly and indirectly. Obviously, the key raw material of concrete is cement, which is highly

energy-intensive to manufacture, making it particularly vulnerable to the massive increases in electricity costs in recent times.

There has also been a major increase in the cost of fuel, thereby adding to transport and delivery costs and the cost of carbon credits arising from the EU Emissions Trading Scheme is starting to bite.”

On a more positive note, Farrell says that the Irish construction and building materials industries are buoyed by the Irish government’s Housing for All policy, which quantifies the need for the construction of an average of 33,000 houses per year until 2030. In 2021 there were only 21,500 houses completed so there is an urgent need for a major increase in new house construction from current levels. The question is, will this happen given rising building costs?

Farrell says the Irish building materials industry has not changed much in its large and small to medium-sized (SME) makeup in recent years. “The biggest new player here is Breedon, after its purchase of the Lagan Group.”

Speaking about the Irish Concrete Federation’s new projects, Farrell says: “We are setting up a sustainability resource within the federation as there is an ever-increasing need to communicate better that our members’ activities are absolutely essential for society and our materials are sustainable.

We are also launching a policy document on the future availability of authorised aggregates reserves. Our members are concerned about the lack of authorised aggregates reserves in certain parts of Ireland, and we have identified reform of the quarry planning system as crucial in protecting the future supply of locally available and sustainable aggregates. Other areas we want to do more on is upskilling our employees through effective training and developing initiatives to attract new people into our industry.” AB

“In general, there is a lot of concern at the potential impact of inflation and supply chain disruption on manufacturing and building costs” Gerry Farrell, Irish Concrete Federation CEO

www.AggBusiness.com

CAVEX®

WARMAN®

I S O G A T E

TRIO®

E

N

D

U

R

O

N

®

LINATEX®

ENDURON®

Visit us at Hillhead 2022 Stand A4

Think about your entire circuit; we have.

Consider an end-to-end solution from Weir Minerals. Our product range covers everything you need. With best-in-class products from Cavex®, Enduron®, Isogate®, Linatex®, Trio® and Warman®, your circuit will work in perfect harmony. Whether it’s a pump or an entire circuit, every Weir product comes with a lifetime of support from Weir Minerals’ extensive global service network. That’s what makes our market leading product range, market leading, from end-to-end.

To get more from your quarry, visit www.global.weir today.

www.global.weir

Copyright © 2018 Weir Minerals Europe Ltd. All rights reserved. WARMAN, CAVEX, ISOGATE, LINATEX, ENDURON and WEIR LOGO are trade marks and/or registered trade marks of The Weir Group PLC and/or its subsidiaries. Certain features of the technology featured in this publication may be protected by pending and granted patents and designs in the name of The Weir Group PLC and/or its subsidiaries.

QUARRY PROFILE

Malcolm Construction’s Loanhead Quarry now features a new CDE construction and demolition (C&D) waste recycling facility

CDE AIDS A WELCOME AVERSION TO LANDFILL Malcolm Construction is on target to divert over 500,000 tonnes from landfill yearly with its second state-of-the-art CDE plant. Guy Woodford reports

F

rom its early days as a familyowned business in the 1920s, The Malcolm Group has become one of the leading providers of logistics, construction and maintenance services in the UK. Malcolm Construction, a division of The Malcolm Group, has embarked upon a second project with wet processing industry experts CDE to install a 150 tonnes per hour construction and demolition (C&D) waste recycling facility at its Beith site. The move is an example of the Scottish business’s commitment to developing sustainable business solutions.

With its head office in Glasgow and additional facilities in Scotland’s southwest at Irvine (Shewalton Quarry) and Beith (Loanhead Quarry), Malcolm Construction provides comprehensive civil engineering and groundwork services and has earned an enviable reputation for quality service and problem-solving. Projects are delivered either on a standalone basis or as part of a larger package for major contractors, local authorities and engineers.

Its construction and demolition waste treatment, transfer and recycling business is an asset within its service. Its three facilities are dedicated to sorting recyclable materials to provide high-quality recycled

42

© AGGREGATES BUSINESS EUROPE May/June 2022

aggregates, topsoil, and subsoil. Waste is sorted and sent to specialist reprocessors for further processing at the sites. These procedures minimise waste sent to landfill, increase recycling rates and reduce Malcolm Construction’s environmental impact.

At its Beith facility, Malcolm Construction identified that landfill space for waste products it could not treat and repurpose was becoming exhausted. Therefore, the company set an objective to divert over 500,000 tonnes of material a year from

Malcolm Construction’s three facilities are dedicated to sorting recyclable materials to provide high-quality recycled aggregates, topsoil, and subsoil

www.AggBusiness.com

O AREA

ND DEM

ALL C6 A

U IN H KOMATS

Komatsu WA480-8

The 224 kW / 300 HP Komatsu WA480-8 wheel loader offers an outstanding combination of stability, breakout power and tractive effort. Very versatile, its high efficiency bucket and the E-light work mode combine to greatly increase operating comfort, boost productivity and reduce fuel consumption.

Komatsu Europe International N.V. · Mechelsesteenweg 586 · B-1800 Vilvoorde · Belgium · All rights reserved

Komatsu_WA480-8_210x297en.indd 1

komatsu.eu 23.05.2022 10:18:40

QUARRY PROFILE

A new premium CDE plant is helping Malcolm Construction fulfil its target to divert over 500,000 tonnes from landfill yearly

“Our investment was a very considered one and based on intensive research done over a number of years” Graeme Lindsay, Waste transfer & recycling operations manager

landfill. In addition, as a forward-thinking organisation, the company sought to develop marketable and innovative solutions with a broad range of applications in the construction sector.

Ten years ago, the company worked with CDE to install a 70 tonnes per hour recycling wash plant at its Shewalton Quarry. The plant continues to operate to the company’s great benefit and has diverted over one and a half million tonnes from landfill to date. However, it could no longer meet growing demand alone as a small capacity plant.

Therefore, the team at Malcolm Construction spent five years carefully researching all options for developing a new wash plant at the Loanhead site. This included considering several brands on the market and visiting a range of CDE reference sites across the UK to observe different plant set-up options. The company concluded with certainty that CDE could offer them the best solution to meet their production requirements and decided to invest.

As the site is an existing hard rock quarry, which produces a wide range of aggregates, the solution developed by CDE can conserve their natural reserve and save tipping space.

Graeme Lindsay, waste transfer & recycling operations manager, explained: “Our investment was a very considered one and based on intensive research done over

44

© AGGREGATES BUSINESS EUROPE May/June 2022

Graeme Lindsay & David Kinloch at Loanhead Quarry a number of years. We have had a ten-year relationship with CDE and greatly value its ‘Customer for Life’ model; we have had nothing but positive experiences. In addition, we felt that this investment was our best approach to delivering on our sustainability goals by saving void capacity, extending the life of hard rock reserves, developing

resources from waste and aligning with further long-term business goals.”

CDE’s C&D waste recycling facility consists of an R4500 primary feeding and screening system, AggMax 252R logwasher, EvoWash sand washing fine material classification plant, AquaCycle A600 thickener and Filter Press sludge dewatering system that increases water recycling to more than 95%.

Proven solutions from CDE provide maximum recycling potential and full water treatment, which considerably reduce wasteto-landfill volumes. Indeed, the plant was set to process waste at 150 tonnes per hour but has been overachieving design capacity since commissioning at the Beith site.

Walter Malcolm, managing director of the Malcolm Group Construction Service division, said: “We overcame any issues in the installation process together with CDE – which were to be expected with a project of this scale – and we also had to deal with COVID risking holding us back. I think it has been extraordinary that we managed to get the plant finished in the time we did and up and running as quickly as we did as well.”

The plant is already proving its effectiveness and delivering high-quality in-spec products for Malcolm Construction, including 0-2mm soft sand and 0-4mm concrete sand. The products will be used for concrete production, pipe bedding, and

www.AggBusiness.com

QUARRY PROFILE

backfilling utility tracks, amongst other applications.

David Kinloch, director of business development UK & Ireland at CDE, said: “We have been long-term partners with Malcolm Construction and have always had a great working relationship, so we were pleased when they confirmed they wanted to re-invest with CDE to install a new plant at a second company location.

“The waste recycling solution we have installed is already providing new products for the company, to the benefit of its business objectives in terms of return on investment and sustainability goals. We look forward to continuing our partnership with Malcolm Construction and witnessing the effectiveness of this new plant.”

Walter Malcolm added: “CDE, as they know, were not the cheapest option.

However, we decided to go for the most cost-effective option for ourselves and for our customers as well, that provides the best return on investment.

“We knew the support we get from CDE, and we also know the quality and material we are going to produce. That, for us, made it quite a straightforward decision to partner with CDE again. It’s been a first-class experience, and the build quality is excellent.

He concluded: “Sustainability is very important for us at Malcolm Construction.

We’ve been operating here as a family business for nearly 100 years. We’d like to be here for another 100 years and value the contribution of CDE technology to making that ambition a reality.” AB

Some of Malcolm Construction’s 0-2mm concrete sand

A Malcolm Construction lorry being loaded with processed material

The CDE AquaCycle at Loanhead Quarry

Inspecting CDE R4500 primary scalping

46

© AGGREGATES BUSINESS EUROPE May/June 2022

www.AggBusiness.com

THE

ROCK

WIRTGEN GROUP The Magazine for Materials Processing

Special Issue Welcome to the print edition of our new digital magazine for the materials processing industry. Always up-to-date at: THEROCK.wirtgen-group.com

2

THE ROCK INNOVATION

Content INNOVATION

Page 2: EVO2 – the new generation of crushing plants PASSION

Page 3: The MOBICAT MC 110i EVO2 in action at the Brenner Tunnel NEWS

Page 4: From a chocolate crusher to the German Design Award INNOVATION

Page 5: The new MOBISCREEN MSS 802(i) EVO mobile coarse screening plant PASSION

Page 6–7: From Bavaria to Trinidad – PRO machine combinations in action

THE EVO2 GENERATION

Mobile Crushing Plants with Added Value Kleemann proudly presents the MOBICAT MC 110(i) EVO2 jaw crusher and the MOBICONE MCO 90(i) EVO2 cone crusher. Thanks to innovative features, the machines now ZRUN HYHQ PRUH HĩFLHQWO\ $ VWURQJ WHDP IRU WKH ĥUVW DQG second crushing stages.

W

hen it comes to fast readiness, eĩFLHQW FUXVKLQJ DQG ĦH[LELOLW\ LQ DOO DSSOLFDWLRQV the new mobile crushing plants from .OHHPDQQ OHDG WKH ĥHOG 7KH QHZ (92 generation of jaw and cone crushers have been developed for applications in the medium output segment in quarries or for use by recycling companies and contractors. When coupled, they work together as a particularly strong team: matched performance and innovative line coupling enable a smooth DQG FRQWLQXRXV ĦRZ RI PDWHULDO WKURXJK the two plants. The technology behind this is the so-called Continuous Feed System, which uses ultrasonic sensors to monitor various crusher parameters and simultaneously optimizes the performance of both plants.

The digital app SPECTIVE CONNECT enables the display of all relevant process information and reports on a smartphone.

twelve-inch touch panel, SPECTIVE provides a clearly laid-out display of all important plant information and settings and proactively prevents operating errors.

The innovative overload systems of the machines sustainably increase the operational readiness of the plant by DVVXULQJ PD[LPXP FRQWLQXLW\ RI WKH crushing process and protecting the machines against damage.

Intuitive Operating System

LEGAL INFORMATION

.OHHPDQQ KDV VLJQLĥFDQWO\ VLPSOLĥHG plant operation with the intuitively structured SPECTIVE operating system. On its

THE ROCK

WIRTGEN GROUP Online Magazine for Materials Processing

Publisher

WIRTGEN GROUP, Branch of John Deere GmbH & Co. KG, Reinhard-Wirtgen-Strasse 2, 53578 Windhagen, Germany E-mail: magazine@wirtgen-group.com, www.wirtgen-group.com Mannheim District Court, HRA 704371, VAT ID No.: DE 283 504 884 General Partner John Deere GmbH, limited liability company, Registered in Luxembourg, Commercial Registry No. R.C.S. Luxembourg B 161281 General Managers Dr. Volker Knickel, Markwart von Pentz, Dr. Thomas Peuntner, Domenic G. Ruccolo, Alejandro Sayago Editorial Team Wirtgen Group Corporate Communications Production muehlhausmoers corporate communications gmbh, Cologne

The improved diesel-direct drive concept ensures more economical operations.

Discover more online

THE ROCK PASSION

7+( 02%,&$7 0&Ю i EVO2 IN THE REAL WORLD

In Action at the Brenner Tunnel

T

3

The new plant HDVLO\ IXOĥOOV WKH tight deadlines set on the construction site and assures that everything goes to plan.

In the course of the construction of the Brenner Base Tunnel, the new MOBICAT MC 110i EVO2 mobile jaw crusher simply crunches its way WKURXJK WKH %UL[HQ JUDQLWH LQ 1RUWKHUQ ,WDO\ 7KH SDUWLFXODU FKDOOHQJH IDFHG here is the density of the solid rock.

hese days, the careful handling and conservation of natural resources is an integral part of the planning of every large-scale construction project. A series of environmental reconciliation works are being carried out to minimize environmental impact in the construction of the 230 tunnel kilometers of the Brenner Base Tunnel, one of which is a catchment basin for water from natural springs. Lined completely with natural stone, the water catchment basin with a total holding capacity of 18,500 cubic meters is scheduled for construction beside the connecting road by the Eisack river in Spinges.

A Highly-Productive Crusher The challenges faced by lead contractor NordBau Peskoller from Kiens don’t stop

DW WKH H[WUHPH JUDGLHQWV DERYH DOO WKH SURMHFW WHDP KDV WR FRQtend with the density of the solid granite. Around 55,000 cubic meters of the hard and dense material has to be crushed and UHGXFHG WR ĥYH GLĪHUHQW JUDLQ VL]HV ZLWKLQ D SURMHFW WLPHIUDPH of only one year. This challenging remit demands a plant with H[WUHPHO\ KLJK SURGXFWLYLW\ DQG FRQVWDQW YROXPH UHGXFWLRQ The contractor chose the new MOBICAT MC 110i EVO2, ZLWK D PD[LPXP IHHG FDSDFLW\ RI XS WR WRQV SHU KRXU ,Q FRPSDULVRQ WKH FUXVKHU 1RUG%DX KDG XVHG XS XQWLO WKHQ RĪHUHG QRW HYHQ KDOI WKH SURGXFWLYLW\ ZDV VLJQLĥFDQWO\ ORXGHU DQG KDG considerably higher fuel consumption.

Equipped with the intuitive SPECTIVE operating concept, all settings and adjustments of the plant can be made easily, quickly, and without errors. What’s more, thanks to the Discover more SPECTIVE CONNECT app, the plant operator can even remote- online ly access all process-relevant information on a smartphone. The NordBau crew is impressed by the choice made by their boss, Franz Peskoller: “This new jaw crusher scores with astoundingly high performance,” reports NordBau Peskoller manager $OH[DQGHU +LQWQHU

4

THE ROCK NEWS

News

Rock Crusher and Padfoot Roller in One

QuickChange Artist Conveyor belts play an essential role in assuring optimum performance of crushing and screening plants. Users should always choose a model that matches the planned application. Belts DUH VXEMHFWHG WR H[WUHPH VWUHVVHV caused by the rock being processed. .OHHPDQQ RĪHUV WKUHH GLĪHUHQW FRQYH\RU EHOW V\VWHPV IRU GLĪHUHQW UHTXLUHPHQWV WKDW HVVHQWLDOO\ GLĪHU LQ WKH ZD\V they are assembled and disassembled, EXW DOO IXOĥOO WKH VDPH UHTXLUHPHQW PD[LPXP VHUYLFH OLIH Ŀ,W LV QRW DOZD\V

Chocolate Crusher

possible to avoid damage to belts. And this is why we came up with ZIP CLIP spare belts – to ensure that you can get \RXU SODQW ZRUNLQJ ZLWK PD[LPXP SURGXFWLYLW\ DJDLQ DV TXLFNO\ DV SRVVLEOH Ю your own crew can change the belt on-site in no time at all and your machine is soon up and running again,” H[SODLQV DSSOLFDWLRQV H[SHUW ,RDQQLV Karademiroglou.

The trainees Tim Schwarz and Tim Grabe were so inspired by Kleemann products that they decided to build a model of an impact crusher – and even programmed the control software themselves. Constructed from 2,700 plastic bricks, their model replicates the original in every detail – and not just its looks! Inside the model, a rotating rotor and an opening hopper work just like the real thing. The programming of the model impact crusher was carried out with the aid of the physical computing platform “Arduino”, which enables independent, interactive control of objects. The two trainees spent a lot of time on their project in the Kleemann training workshop. As can be seen, not a minute of it was wasted: apart from trueWR OLIH SDQHOLQJ WKH PRGHO LV ĥQLVKHG DQG works as it should. The performance of the model the two built corresponds to its size – it does a great job of crushing chocolate lentils instead of real rocks.

Congratulations to the two of you for your fantastic work.

Discover more online

Discover more online

In the construction of an embankment in Bad Fredeburg, Sauerland, two Hamm H 25i VC compactors simultaneously crushed and compacted the local slate with their special crusher drums.

The original intention was to use several jaw crushers, dump trucks, dozers, and compactors on the project. As it WXUQHG RXW WKH VLPSOHU DQG PRUH Hĩcient alternative was the use of two VC compactors. “We were immediately won over by the roller’s design,“ reports construction manager Michael Tillmann from Strassen- und Tiefbau GmbH. In the end, the quality of the crushed slate and the compaction of the embankment layers also gave cause for praise.

“By decoupling the process steps, we were able to handle around 4,500 cubic meters of material per day. That’s almost twice as much as originally set out in the planning schedule.” The simple operating concept, the comfortable cab, and the ease of changing tools also left a lasting impression on the users.

Multiple Award Winners Kleemann has received the German Design Award and the Good Design Award for its new EVO2 generation of mobile jaw and cone crushers. These awards once again underline the recognition of Kleemann’s outstanding powers of innovation. The concept of the new MOBICAT MC 110(i) EVO2 and MOBICONE MCO

L (92 FUXVKHUV UHĦHFWV D FRPPLWment to economic, ergonomic, and ecological standards that, together with consistent design, has proved to be an award-winning combination. With the German Design Award in gold, the MOBICAT MC 110(i) EVO2 won the highest possible recognition, while the

MOBICONE MCO 90(i) EVO2 earned the coveted “Special Mention” as a seal of quality. The US-American Good Design Award in the category Industrial Design FRQĥUPV WKDW WKH SURGXFWV QRW RQO\ IXOĥOO H[WUDRUGLQDU\ GHVLJQ FULWHULD EXW DOVR UDQN highly in the areas of innovate strengths, IXQFWLRQDOLW\ DQG HQHUJ\ HĩFLHQF\

THE ROCK INNOVATION

02%,6&5((1 066 i) EVO

Screen Star!

With its new mobile coarse screening plant, Kleemann demonstrates the enormous potential of the latest generation of screening plants for natural stone and recycling applications.

T

KH 02%,6&5((1 066 L (92 LV PRELOH H[WUHPHO\ SRZHUIXO FRVW HĩFLHQW DQG VSHFLDOO\ GHVLJQHG WR PHHW the constantly changing challenges of a wide range of project situations.

The technology of the screening plant is also very simple and safe for users. Its ergonomic design, optimized operating, and user-friendly maintenance concept are just as impressive as the technical highlights it brings to the processing chain.

Performance Meets Flexibility Like all other belt conveyors, its wide main discharge conveyor RĪHUV FRQWLQXRXVO\ YDULDEOH VSHHG DGMXVWPHQW ZKLOH WKH SDUWLFularly large material transfer system on the screening deck guarantees optimal utilization of the available screening areas.

Foldaway components of the plant and the ability to easily modify screening parameters ensure shorter setup times, JUHDWHU ĦH[LELOLW\ DQG YHUVDWLOLW\ LQ D ZLGH UDQJH RI SURGXFWLRQ scenarios. The conversion from 3- to 2-way grit is also a quick DQG HDV\ SURFHVV 7KH ĦH[LELOLW\ RI WKH FRQFHSW LV QLFHO\ URXQGHG RĪ E\ D SURSRUWLRQDOO\ FRQWUROOHG XQGHUFDUULDJH WKDW HQDEOHV quick relocation of the coarse screening plant. A line coupling option makes it easy to realize process coupling with the MSS 802(i) EVO and all other EVO and PRO crushing plants.

0RELOH DQG ĦH[LEOH VPDUW SODQW GHVLJQ DQG ĦH[LEOH conversion options guaranWHH KLJK PDWHULDO ĦRZ UDWHV

APPLICATION HIGHLIGHTS

> Intuitive and safe plant control with automatic start/stop function > Minimization of maintenance-related down times > Easy access and smart cleaning > Ideal lighting for excellent vision and visibility > Spacious working platforms

Discover more online

5

6

THE ROCK PASSION

A PRO PLANT TRAIN EATS GRANITE

Granite to Grit in Two Crushing Steps

The desired grit is produced in only two FUXVKLQJ VWDJHV 7KH team from Berger is PRUH WKDQ VDWLVĥHG with the stable performance and outVWDQGLQJ HĩFLHQF\ of the equipment.

%HUJHU 5RKVWRĪH *PE+ KDV EHHQ FUXVKLQJ JUDQLWH WR SURGXFH URDG VWRQH and grits in various fractions at the quarry in the heart of the Bavarian Forest since 2020. A PRO plant train from Kleemann at the production site delivers impressively high productivity.

I

n the Bavarian Forest region of Germany, the conversion of a factory quarry into a large-scale quarrying operation demanded considerable clearing work in many places. Transport routes had to be made as short as possible to guarantee FRVW HĩFLHQW TXDUU\LQJ RSHUDWLRQV $V LWV WHFKQRORJ\ IXOĥOOHG DOO UHTXLUHPHQWV LQ terms of suitability and productivity, the quarry operator chose a PRO plant train from Kleemann to take on the job. The core of the train comprises a MOBICAT MC 120 Zi PRO mobile jaw crusher and a MOBICONE MCO 11i PRO mobile cone crusher, supplemented by MOBISCREEN MS 952i and MS 953i EVO mobile screening plants and a MOBIBELT MBT 20 stockpile conveyor.

“These crushers are rugged and built to last,” says Markus Penz, operating engineer in charge of the plant. As granite LV DQ H[WUHPHO\ DEUDVLYH PDWHULDO DQ LPportant factor for Berger was the protection of the plant against wear. In view of

this, the jaw crusher features an independent double-deck preVFUHHQ WKDW UHOLHYHV WKH ORDG DQG SUHYHQWV H[FHVVLYH ZHDU 7KH team from Berger is also particularly impressed by the fact that the granite fed to the plant is transformed into the desired grit in only two crushing stages. “Normally, that’s almost impossible.“ H[SODLQV $QGUHDV :DJQHU VSHFLDOLVW FRQVXOWDQW IRU .OHHPDQQ SURGXFWV IURP :LUWJHQ *HUPDQ\ 0DUNXV 3HQ] LV H[WUHPHO\ VDWLVĥHG ZLWK WKH UHVXOWV Ŀ7KLV SODQW HQDEOHV XV WR HDVLO\ IXOĥOO DOO WKH targets we set, because it’s even better than we thought.”

Process Stability and Sustainability Although each machine essentially works on its own, line coupling enables the individual machines to pass signals to the upstream and downstream machines in the plant train in WKH HYHQW RI PDOIXQFWLRQV RU RYHUĥOOLQJ $W WKH VDPH WLPH WKH Continuous Feed System guarantees optimum utilization of the crushers. The line coupling of all machines in the train also ensures safety, as the concept prevents damage or overloading situations.

Berger also ordered all components of the train with a IDFWRU\ ĥWWHG H[WHUQDO SRZHU VXSSO\ RSWLRQ 3DUWLDO XWLOL]DWLRQ RI WKH SXUHO\ HOHFWULF RSWLRQ UHGXFHV KDUPIXO H[KDXVW JDV DQG QRLVH emissions. The Kleemann plants therefore represent an important milestone on the road to sustainable stone production.

Discover more online

7

Output Doubled A PRO PLANT TRAIN WITH AN APPETITE FOR LIMESTONE

A PRO plant train from Kleemann has been in operation for Jusamco Ltd since October 2020 on the island nation of Trinidad & Tobago in the south Caribbean. The plant train LPSUHVVHV ZLWK KLJK SURGXFWLYLW\ DQG HFRQRP\ DQG SURGXFHV ĥQDO SURGXFWV IRU WKH production of asphalt.

A

side from its own infrastructure projects on the island of Trinidad – the largest island of the nation – Jusamco places a strong focus RQ WKH H[SRUW RI DJJUHJDWHV WR Guyana, where there is currently enormous demand for processed stone products for use in ongoing large-scale infrastructure projects. In their choice of plant technology, the decision-makers at Jusamco were so impressed by the KLJK SURGXFWLYLW\ H[FHOOHQW quality of the end product, and the simple linking of the machines, that they opted for a PRO plant train from Kleemann.

Smart Processes and Optimized Performance At the heart of the plant train, a MOBICAT MC 120 Z PRO jaw crusher and a MOBICONE MCO 11 PRO cone crusher crush the stone and then pass it on to a MOBISCREEN MS 953 EVO mobile screening plant. “The simple linking of the machines and the perfectly coordinated automatic processes of the individual plants made our operations much easier. Thanks to line coupling, an automatic control stabilizes the entire process. At the same time, the Continuous Feed System guarantees optimum utilization of the crushers. This coordination reduces operator-workload, harmonizes the proFHVV ZKLOH VLPXOWDQHRXVO\ SUHYHQWLQJ H[FHVVLYH ZHDU GDPDJH or overload situations. The high productivity of the plant train FDQ DOVR EH TXDQWLĥHG WKH RXWSXW KDV EHHQ DEOH WR EH GRXEOHG against that of the plants previously used in the quarry. As Kyle 3DUVRQV UHSRUWV Ŀ0RUH HĪHFWLYHQHVV LV KDUGO\ SRVVLEOH ŀ After delivery of the new plants in September 2020, the project faced an unusual challenge due to the lockdown during

by COVID-19 pandemic: the commissioning of the plant train

The crushing and screening plants are easily accessible and can be LGHDOO\ FRQĥJXUHG IRU HDFK VSHFLĥF application.

had to be carried out online. Despite all the hindrances and initial concerns, the plant worked very well, without any major problems or noticeable wear.

Intuitive plant operation with SPECTIVE also played a role, as the visual presentation and simple user guidance make errors almost impossible. Maintenance and care of the plants are easy tasks for the crew on-site, minor replacements and conversions being carried out quickly and professionally with the assistance and advice of Kleemann specialists.

Discover more online

A JOHN DEERE COMPANY

Now online!

CLOSE TO OUR CUSTOMERS

STAY UP TO DATE. 5HDG DOO DERXW IDVFLQDWLQJ SURMHFWV LQ WKH DJJUHJDWHV EXVLQHVV ƓQG WLSV IRU XVHUV IURP WKH Kleemann experts, get the latest news about our innovative crushing and screening equipment, and see what goes on behind the scenes. The new Wirtgen Group digital magazine for materials processing is now online. With fascinating stories from the world of the Wirtgen Group.

THEROCK.wirtgen-group.com

FEATURE: IQ-NSC

A worthier site for proud eyes The Institute of Quarrying (IQ) is moving its headquarters to the National Stone Centre (NSC) in Wirksworth, near Matlock, Derbyshire, over the next few months as part of an ambitious merger aimed at future-proofing mutual long-term goals. Guy Woodford visited the NSC to speak to some of the merger’s key figures about the vision for the industrial-heritage-rich site

T

he architect renderings of how a revamped NSC and new home for the IQ may look are striking, befitting a minerals extraction industry that builds Britain, generating 400 million tonnes of resources and products for UK construction and manufacturing each year.

Aggregates Business has been given exclusive access to architect Babenko Associates’ (Babenko) vision for the NSC-IQ project. The renderings, the result of Wirksworth-based Babenko’s close consultation with NSC trustees and IQ management, are an eye-catching initial step in an industry, local authority and public consultation process ahead of a detailed NSC-IQ planning application to Derbyshire Dales District Council early next year. The application will bid to turn the NSC’s 42-acre site into a state-of-the-art visitor attraction, where cutting-edge technology immerses visitors in the UK stone industry’s fascinating story.

Currently run by a small group of volunteers and set within six former limestone quarries in the heart of the Derbyshire Dales, on the edge of the Peak District National Park, and close to the Derwent Valley Mills World Heritage Site, the NSC encourages people to engage with the origin, industry and history of stone. The site, created in 1990 after funding was secured via the Landfill Tax, is open to the public free of charge every day except Christmas. It currently offers outdoor fossil trails, a visitor centre with a shop, a café and the Building Britain exhibition, geological walks, picnic areas, and a children’s play area.

An aerial sketch view of how the National Stone Centre could look after a state-of-the-art revamp

A Site of Special Scientific Interest (SSSI) for its geological formations, the NSC also runs a very popular introductory course on dry stone walling and a stone carving course led by Mark Eaton, a highly experienced stonemason and master craftsman.

Viv Russell, the IQ’s chairman and former managing director of Derbyshire-based

Longcliffe Quarries, says an initial up-to£600,000 IQ investment will increase the NSC’s exhibition space and allow the Institute to relocate over the next few months from its current offices in Chilwell, Nottinghamshire.

Crucially, Russell says the new base will also enable the IQ to increase its support to members and play an enhanced role in

A sketch of the side elevation of Babenko Associates’ vision for a revamped NSC

www.AggBusiness.com

© AGGREGATES BUSINESS EUROPE May/June 2022

55

FEATURE: IQ-NSC

A view from the south-east of how a revamped NSC may look communicating the quarrying industry’s immense value to a wider audience.

“The National Stone Centre is in a superb location. There’s already a café here and a certain number of resources, but one of the things we’ve recognised at the IQ is that for many years we’ve tended as an industry to hide away and not broadcast the great things that we do. This makes the merger with the National Stone Centre a great opportunity.

We are two charities with very similar values,

and we will create a new base where the industry meets the general public.

“We aim to create a new state-of-the-art NSC visitor centre which will be visitoreconomy-focused from May to September, and then skills and education-focused from October to April. The skills- and education focus will allow us to engage more closely with the public and show them the great career opportunities in our industry.

“The new build we are proposing will use

modern low-carbon facilities and provide fantastic communal facilities in an area that is the heartland for the UK quarrying industry.

Part of our plan is also to run public visits from here to various quarrying sites. This will allow us as an industry to dispel a lot of the myths about it that have been created due to lack of knowledge.”

Russell says the revamped NSC will embody the “past, present and future” of the quarrying industry. “We want to make the

Babenko Associates’ site plan for a revamped NSC

56

© AGGREGATES BUSINESS EUROPE May/June 2022

www.AggBusiness.com

FEATURE: IQ-NSC

BUILDING ON A 30-YEAR LEGACY Ian Thomas, the founder and director of the National Stone Centre, is enthused about how the NSC-IQ merger can build on the NSC’s proud first three decades.

“The aim of the NSC is to be a centre of excellence at national, regional and local scales, in all aspects relating to learning about stone and allied matters in the United Kingdom. The IQ aims to advance the science and practice of quarrying internationally in the interests of the public at large.

By merging each organisation, one can support the other in delivering on its respective ambitions.

“This is very much about building upon the 30-year legacy of the NSC. It’s about securing a bright and impactful future for the organisation, bringing lasting benefits in personal development, awareness-raising, memorable experiences, and local revenue growth. Plus, with support from the extractives sector, the NSC will move into a new era of success, driving forward the vision of its founders. I’m personally delighted that the Institute of Quarrying is now able to call the NSC its permanent home.”

new build here the home of the industry’s archive. A lot of fantastic archive material has been lost during company takeovers and when people retire. But we’ve received some wonderful donated material from companies, such as Tarmac at Tunstead Quarry, who have donated over 26,000 digital images going back over 120 years. This allows us to make and refresh exhibitions.

“Overall, though, we want to inspire a visiting six-year-old as much as their grandad, who will enjoy spending time in an exhibition looking at pictures of the industry’s past.”

The IQ, whose team has begun moving into the Institute’s new NSC home, is currently exploring seminar opportunities and looking to expand its member education programmes. “We’ve got a biodiversity course at the NSC in June, and course attendees will be able to walk just a quarter of a mile down the road to see a restored quarry site,” highlights Russell.

Giving his perspective on what a revitalised NSC can offer, IQ chief executive James Thorne adds: “We want to create an industry centre of excellence. It isn’t just about one element. We want people to come here and get an idea of how the industry operates and where it is going, including on decarbonisation, sustainability, and use of technology. That creates awareness, and then we can tackle the long-term issue of getting more people into the industry. While core aspects of geology and mineral processing might be the same, the skill sets of quarry managers and equipment operators might

www.AggBusiness.com

ABOVE: Viv Russell (left), IQ chair, and James Thorne, IQ CEO, at The National Stone Centre BELOW: The Millennium Wall at the NSC

The exterior of the National Stone Centre’s current visitor centre, shop and café

© AGGREGATES BUSINESS EUROPE May/June 2022

57

FEATURE: IQ-NSC

need to be different in 15 to 20 years.

“In the short term, we will be bringing a temporary set of offices here next to the main National Stone Centre building. This will create a statement that we are doing new things here, while in the background, we’ll be engaging with industry figures and the public to get their ideas on what they want from a modern National Stone Centre and how they want the building to look. We have some great initial concept drawings. We need to build on that over the next three to four years and create a collaborative approach to this project.”

Thorne says moving the IQ to the NSC will better connect members “physically and digitally” to IQ services and education programmes. “It creates a focal point where IQ branches can come and visit and host events, giving us the space to run seminars and conferences. We can reach out from here and be in touch with the industry, which is, in some cases, just minutes away.

“Basing the IQ here will allow us to better convey to our members the industry challenges they need to face, helping them do their job better while also encouraging people coming into the industry and developing their skills and competencies.”

Russell says that because the IQ-NSC merger comes with a strong visitor-economy development focus, there are many potential funding streams to help deliver the longterm plan of a revamped NSC. “There’s the Government’s Levelling Up agenda, the

The NSC offers outdoor fossil trails, a visitor centre with a shop, a café and the Building Britain exhibition, geological walks, picnic areas, and a children’s play area. Pictured is an artist’s installation

National Lottery Heritage Fund, private businesses, and industry stakeholders we can look to engage. For instance, it is a fantastic opportunity for the industry to highlight its low-carbon products.

“We’ve already got local exhibitions booked for this summer at the NSC. One of them is a joint venture with the Natural History Museum.”

Giving an example of how new investment could lead to new job creation at the NSC and within the IQ, Thorne says: “We have said to the NSC that a key part of this project is expanding its activities. School visits, for instance, are largely volunteerled. If you are going to increase their scale, given such visits are a key part of showing why stones and other minerals matter, you are looking at recruiting paid employees. If we are delivering more courses and industry events, we will have more people coming in to support that.

“Part of creating an industry centre of excellence will also hopefully lead to industry secondments, where someone with expertise in an area, like innovation, can come in for six months or a year to build up what we can offer at the NSC.” Russell cites the Peak District-based Mount Cook Adventure Centre and the Derbyshire Eco Centre, a Derbyshire County Council-funded sustainability learning hub within the grounds of the NSC site, as other potential collaboration partners.

“If you look at what younger people

LOCAL APPROACH KEY TO MAKING A STONE-BASED DREAM REALITY Gabriel Babenko was “delighted” when his team at Wirksworth-based Babenko Associates had their hand-drawn vision for a revamped NSC chosen by the IQ board and NSC trustees.

The stunning renderings of how a newly merged NSC could look will be used by both the NSC and the IQ as part of their wide-ranging industry, public and local authority consultations over the coming months. The NSC-IQ is looking to secure funding and planning approval to deliver a cuttingedge industry centre of excellence, with a state-of-the-art exhibition space at its heart.

“We all live within a few hundred metres of the NSC. I measured it on Google Maps, and my house is just under 500 metres away,” said Babenko. “Babenko Associates is a multidisciplinary team of architects and engineers, and we’ve been established for six years. From speaking to our clients [NSCIQ], I understand that they are very keen to make this a very local project.

“I use the National Stone Centre café, and I’ve visited the Centre many times with my children in the 12 years we’ve lived in Wirksworth. We have often sat eating ice creams on the café steps, and the kids love to go gem panning.

“I like to get involved in the local community. I used to be on the board of the local community-owned swimming pool, and I’m on the board of the local music centre for kids.”

Babenko says that the Babenko Associates’ team have put a lot of thought and time into developing the concept-design ideas and drawings for the new NSC. “If the vision is realised, it will be a building that we will be extremely proud of, particularly as the site and its setting is such a special place for us.”

58

© AGGREGATES BUSINESS EUROPE May/June 2022

Gabriel Babenko of Babenko Associates

www.AggBusiness.com

FEATURE: IQ-NSC

joining our industry are demanding, it’s variety. You could potentially second someone out for six months as an industrycareer ambassador. Once young people realise the fantastic diversity of jobs within our industry, they are keen to try them. We are talking about a minerals production industry that offers skilled and well-paid work.”

Thorne continues: “You can raise some industry awareness from viewing platforms, but where we are now will allow us to involve industry partners and get quarry sites to bring pieces of equipment and machines here. We can then have dedicated sessions to show how the machines and their associated technology work. It will be a safe space, relieving some health and safety concerns, but as the NSC is on former quarries, it still looks and feels authentic and should excite people.

“We’re in a Hillhead year. We’d love to have livestream broadcasts from the showground to NSC-visiting schoolchildren, so they can see exactly what industry attendees are seeing.”

Russell adds: “At the NSC, we will have mobile plant simulators. You’ll be able to have a go at driving an articulated dump truck and learning how plant operators learn. The initial part of this project gives us the space to do that, virtually from day one.” AB

The NSC is currently run by a small group of volunteers and set within six former limestone quarries in the heart of the Derbyshire Dales

“Once young people realise the fantastic diversity of jobs within our industry, they are keen to try them.”

Viv Russell, IQ chair

ENGINEERED FOR ZERO WASTE Our relentless drive to transform waste into valuable resources has made us the leading provider of wet processing solutions.

DA Mattsson AB of Sweden counted on us to help transform their C&D waste into high quality profitable resources. Together, we created a wet processing solution that diverts 100% waste, while producing high quality aggregates and specialist sands.

“Our recycled products are now the same quality as natural products,” says plant manager Tommie Thuresson.

We turn waste into value for your business. More information at cdegroup.com

October 24-30, 2022

Meet us at stand 528, Hall B2.

Scan me

www.AggBusiness.com

© AGGREGATES BUSINESS EUROPE May/June 2022

59

FEATURE: IQ-NSC

MINING MUSEUM EXPLORING OPPORTUNITY TO RELOCATE TO NSC

Children enjoying a visit to the Peak District Mining Museum

A popular museum detailing the story of the Derbyshire mining and quarrying industry is exploring opportunities to relocate its valuable historical collection to the NSC. The opportunity for the Peak District Mining Museum to move to a new home has arisen following the 2021 merger of the NSC with the Institute of Quarrying (IQ).

Viv Russell, IQ’s chair, said: “Derbyshire has a long history of quarrying and mining, which has shaped the area’s natural environment that many people enjoy today. When we announced the merger of the IQ and NSC last summer and outlined our plans to redevelop the NSC, it got us noticed by the directors of the Peak District Mining Museum. They approached us for further exploratory conversations about a possible move. It’s still early days, but there’s a real energy and enthusiasm for this to work.”

Clare Herbert, museum manager at the Peak District Mining Museum, said: “We are quite literally just down the road from the National Stone Centre, so a move to the IQ’s proposed ‘centre of excellence’ for quarrying and mineral products would be a perfect fit for us. It would also enable us to realise the ambition we have for the museum and collection whilst remaining embedded in the Derbyshire mining communities from which we draw our inspiration.”

RM NEXT LEVEL 30 years experience – the best is just the start

VISIT US AT HILLHEAD! - J7

TAKE RESPONSIBILITY. PROTECT THE CLIMATE. CREATE FLEXIBILITY. EXPAND BUSINESS OPPORTUNITIES. REDUCE COSTS. INCREASE EFFICIENCY.

RUBBLE MASTER HMH GmbH | Im Südpark 196 | A-4030 Linz | +43 732 73 71 17 | sales@rubblemaster.com

60

© AGGREGATES BUSINESS EUROPE May/June 2022

RUBBLEMASTER.COM

www.AggBusiness.com

HILLHEAD 2022 PREVIEW

Hillhead turns 40 Hillhead, the UK's largest quarrying, construction & recycling exhibition, will take place once again Tuesday, 21 June to Thursday, 23 June 2022, at Hillhead Quarry, near Buxton, in Derbyshire, England. In its 40th year, the packed showpiece event will see three days of live demonstrations and over 600 exhibitors and thousands of products on display. Guy Woodford looks at what some of the leading industry brand names will have on show

H

illhead is renowned for its equipment launches and firsttime industry show exhibits, and McLanahan (Stand T1) will continue this trend by displaying the UltraWASH 6206 for the first time in Europe. The UltraWASH 6206 can be configured to produce up to three clean aggregates and two washed sand products and is part of McLanahan's complete line of modular systems.

For years, McLanahan has designed and manufactured wash plants such as

www.AggBusiness.com

the UltraWASH 6206 and now provides them in a modular design that can be sized and selected to meet a standard range of processing requirements. These plants are energy-efficient and include patent-pending maintenance features that make performing maintenance safer and simpler. They can also be supplied with a state-of-the-art control system that allows remote monitoring and adjustments.

McLanahan's latest tailings management solution, a Decanter Centrifuge, will also be on show. This machine provides an

alternative to filter and belt presses while improving tailings handling, helping to eliminate settlings ponds, improving water recovery and meeting environmental regulations. Already successfully used in the aggregates industry in Europe, McLanahan's Decanter Centrifuge separates waste material to create a liquid that can be reused as process water and a solids cake that is suitable for mechanical handling.

On the SMT GB stand (Y5), visitors will have the opportunity to see a host of new Volvo excavators displayed for the first time © AGGREGATES BUSINESS EUROPE May/June 2022

61

NEW FOR 2020

Aggregates Business' state-of-the-art website www.aggbusiness.com

The Aggregates Business website brings you the very latest in website functionality, with the most up-to-date content available relating to the quarrying and aggregates industry.

The site is fully optimised for desktop, tablet and mobile and has a growing social media audience.

The website is constantly being updated, with the Aggregates Business' editorial team posting 4-5 new items every day.

HILLHEAD 2022 PREVIEW

in Great Britain. These include the EWR130E wheeled excavator, the EW200E material handler, EC530E excavator and EC300E Hybrid excavator.

The multipurpose Volvo EWR130E wheeled excavator is said to set a new standard for powerful machine performance in a compact package. Ideally suited for working in tight urban spaces, its wheeled drive means it can quickly move through infrastructure projects with ease.

Designed especially for waste and recycling, the all-new Volvo EW200E material handler is built on the success of the larger EW240E MH and is said to deliver outstanding results in waste and recycling applications.

The Volvo EC530E crawler excavator, launched along with the EC550E in 2020, will also be shown on the SMT GB stand.

Designed for heavy-duty digging, mass excavation and large-site preparation, the EC350E and EC550E are said to boast superb operator comfort and a new generation of electro-hydraulics.

Another star of the show will be the new Volvo EC300E Hybrid crawler excavator.

This machine delivers the same levels of controllability and performance as an equivalent conventional excavator but with an up to 17% potential fuel-efficiency improvement, making it the environmentally respectful choice for powerful performance in built-up areas.

Due to be shown for the first time in the UK, the Volvo EC950F crawler excavator will be working in the demonstration area directly behind the SMT GB stand. The 95-tonne EC950F is the largest Volvo excavator to date and delivers maximum productivity in heavy rock or muck-shifting applications thanks to its perfect mix of power, stability and breakout force.

Wirtgen Group's Hillhead stand will be focusing on sustainable and cost-effective solutions for earthworks, road construction and materials processing.

The Kleemann MOBICAT MC 110i EVO2 jaw crusher, the MOBICONE MCO 90i EVO2 cone crusher and the MOBISCREEN MSS 802i EVO screening plant for coarse elements will be celebrating their UK show premiere. The event will also see the world premiere of the W 100 Fi one-metre-class milling machine from Wirtgen's new range of compact milling machines. The company group's quintet of machine premieres will be rounded off by the John Deere 672 GP motor grader.

In addition to the premieres, industry visitors can look forward to getting a first-hand impression of market and application-specific solutions for soil and asphalt compaction from Hamm and the WR 240i wheeled soil stabiliser and recycler from Wirtgen. Benninghoven will be showing the EVO JET burner from its range of combustion equipment for asphalt mixing plants. Meanwhile, two asphalt pavers from the Vögele Mini and Universal classes will represent the company's broad range of asphalt-paving product solutions.

www.AggBusiness.com

McLanahan UltraWASH 6206 modular wash plant

Volvo EC950F crawler excavator

Kleemann MOBICAT MC 110 EVO2 jaw crusher, MOBICONE MCO 90(i) EVO2 cone crusher & MOBISCREEN MSS 802(i) EVO screening plant

© AGGREGATES BUSINESS EUROPE May/June 2022

63

HILLHEAD 2022 PREVIEW

MB Crusher MB-R800 drum cutter on a Cat 320 excavator cutting chalk in a Mexico quarry

Rubble Master RM 100GO! hybrid in a dolomite crushing application in Latvia

LiebherrTA 230 Litronic ADT and a R 976-E electric crawler excavator

64

© AGGREGATES BUSINESS EUROPE May/June 2022

MB Crusher is making its Hillhead debut (Y1), with the Italian manufacturer bringing its full range of heavy-equipment attachments, including rotary screening buckets, grapples, and drum cutters.

Company consultants will be on-hand to answer questions about, for example, the twin-drive system of MB drum cutters. MB Crusher will also be demonstrating some of its product range.

Rubble Master Group's UK sales partners, Red Knight 6 and Taylor & Braithwaite will be demonstrating and explaining the RM 100GO! hybrid. Rubble Master says that if you combine a hybrid crusher with a hybrid screen, you can achieve fuel savings of up to 30%. A combination will be on display at RM Group's stand: the RM 120X crusher and the RM MSC8500e hybrid screen.

Also being showcased is Rubble Master's RM XSMART, the digital assistant allowing you to use your smartphone, tablet or computer to monitor plant fuel consumption, maintenance intervals, throughput, operating hours, or pinpointing the location of your Rubble Master equipment. The fleet management tool uses real-time machine data to simplify the everyday work of your machines.

"We don't want our customers to waste time doing paperwork for their machines.

We want our customers to make the highest profit, and we want to provide them with the best service. That's also why we are focusing on digitalisation," said Rubble Master CEO Gerald Hanisch.

On the Liebherr stand, the TA 230 Litronic articulated dump truck is making its Hillhead debut but has already made its mark with UK customers via several significant sales across the country. Carrying a 28-tonne payload, the driver views the working environment through panoramic windows and over a short, inclined bonnet for the best outlook of the driving, working and articulated joint area. There is an array of assistance systems such as hill start, speed retention and automatic traction control, while speed-dependent steering gives precise manoeuvring at low speeds and sensitive control at higher speeds.

Liebherr's will also be showcasing its XPower wheeled loaders. Power-split transmission as standard manages the interaction of the hydrostatic drive and mechanical drive, continuously adapting the mixing ratio of the two drive paths without noticeable switching and without interrupting traction.

That means the power adapts to the operation's specific requirements to achieve maximum productivity.

Several Liebherr excavators at Hillhead will illustrate the manufacturer's huge choice of machine variations in the 20-104-tonne range. All units arrive work-ready with a boxing ring, LEDs, a re-fuelling pump, and an auto lube. Fuel tanks are said by Liebherr to be larger than those on competitors' machines which means less downtime for refilling.

www.AggBusiness.com

INTERNATIONAL

MARCH/APRIL 2022 | VOL.16 ISSUE NO2 | www.AggBusiness.com

A FREE SUBSCRIPTION TO AGGREGATES BUSINESS EUROPE AND AGGREGATES BUSINESS INTERNATIONAL MAGAZINES GIVES YOU THE AGG BUSINESS eNEWSLETTER EVERY TWO WEEKS

MARCH/APRIL 2022 | VOL.10 ISSUE No.2 | www.AggBusiness.com

Rock-solid growth South Korea’s red-tape-busting aggregates advance p12

A new Geneva washing convention

19/04/2022 12:24:25

R

•

F OO T P R

PR

•

INTERVIEW Les Lothian: Unpacking Kemach’s journey to total solutions provider p08

ABI MA2022 Cover.indd 1

CRUSHING & SCREENING New-generation crushing & screening p19

T

PONSI BLY

IN

T

RES

RE

I N T E D & PO S

F OO T P R ON

•

ABEMA2022.indd 1

TO

C

MARKET REPORT Collaboration key to tackling Turkish aggregates challenges p43

ED

ON

•

A

DUCE OU

RB

R

PR

INTERVIEW Takaharu Ikeda: Why HCME is ready for the boom time p08

TO

A

PONSI BLY

RB

QUARRY PROFILE Maximising limestone quality in the land of grey and pink p15

T

RES

RE

IN

ED

I N T E D & PO S

T

State-of-the-art TWS plant for Swiss customer p39

DUCE OU

C

INDIAN CEMENT Creating a bigger, smarter Indian cement sector p43

19/04/2022 12:27:36

Get all the latest news, products and developments with unlimited access to aggbusiness.com, two eNewsletters every month, six printed issues a year of each edition and specialised supplements

SUBSCRIBE FOR FREE AT ROPLREG.COM

FOLLOW US ON Facebook @AggBusiness

LinkedIn Aggregates Business Magazine

Twitter @Agg_Business

Instagram @aggbusiness_magazine

HILLHEAD 2022 PREVIEW

Liebherr has been developing its expertise in electric crawler excavators for many years, and recent development has seen the introduction of the zero-emission R 976-E and R 980 SME-E models to replace the ER 974 B for quarry extraction.

Powerscreen will have a strong crushing and screening plant lineup at Hillhead. Sean Loughran, Powerscreen business line director & general manager, said: "To say that we are excited to be back doing what we do best at Hillhead would be an understatement. It has certainly been a challenging couple of years - but the team at the factory have been working extremely hard behind the scenes, and we are looking forward to sharing the results of this work with those who will be attending Hillhead 2022."

Powerscreen's static machine lineup (L4) includes the 'game-changing' Chieftain 1700X 3 Deck, the latest addition to the highly successful Chieftain range, a highproduction HLF75 Orbital Conveyor and the new Titan 2300, flagship of the new Titan secondary scalping screen range.

On the technology side, there will be a showcase of innovative digital solutions and insight into alternative powering offerings, which will play an important role in preserving the planet.

In the showground demo area, Powerscreen will be operating a Premiertrak PT450 jaw crusher, a Trakpactor TP480SR impact crusher, and a Chieftain CH2100XE mobile incline screen.

Neil Robinson, Powerscreen product and applications manager, said: "Pretty much everything on display at Hillhead 2022 is the result of a collaborative effort between our team members, dealers and customers."

Hyundai Construction Equipment Europe will showcase its comprehensive range of heavy-line equipment that has been purposebuilt for the quarrying sector.

Headlining is the HX480AL 48-tonne crawler excavator which makes its first UK public appearance and will be at work in the Hillhead demonstration area.

Powered by a fuel-efficient Stage V Cummins engine, the new machine is claimed to have the highest engine power and hydraulic flow on the market in its class. Its increased pump size enables the machine to work at lower rpm for greater fuel efficiency, and there is no EGR valve requirement. Four-way proportional piping is available with hydraulic pressure and flow customisable on the cluster, while the HX480AL's stacked cooling system delivers improved cooling capacity. A reversible fan for automatic cleaning further boosts performance in a demanding quarrying environment.

Showcased on the stand will be a series of other products from Hyundai Construction Equipment Europe's heavy-duty wheeled loader, wheeled excavator and crawler excavator ranges – including the latest A-Series models.

Rokbak will have its RA30 and RA40 articulated haulers on display. The RA40 will

66

© AGGREGATES BUSINESS EUROPE May/June 2022

Powerscreen Chieftain 1700X hybrid screen

Hyundai HX480AL 48-tonne crawler excavator

www.AggBusiness.com

HILLHEAD 2022 PREVIEW

Rokbak RA40 ADT

Hitachi ZX690-7 crawler excavator

www.AggBusiness.com

be on Rokbak's stand (N14), while the RA30 will be presented at the Molson Group's stand (J3). There will also be a Rokbak articulated hauler in the working demonstration area.

"The Rokbak RA30 and RA40 articulated haulers set new benchmarks in durability, productivity and fuel economy – so we're proud to be able to show the crowds at Hillhead what these machines are capable of," says Paul Douglas, managing director of Rokbak. "We are looking forward to meeting existing and future customers alongside our trusted partner, the Molson Group. The Molson Group is a very experienced dealer, and I'm pleased to have them by our side."

Rokbak articulated haulers are known for being robust, reliable, easy to operate and easy to maintain. The 38-tonne RA40 is a heavy-duty articulated hauler that makes light work of large-scale quarry, mine and construction jobs. Said to offer high capacity and performance, the RA40 delivers cost-effective productivity in the toughest conditions. The high-performance engine balances controlled power with maximum fuel efficiency. The modulating transmission retarder is coupled with an efficient exhaust brake and fully enclosed oil-cooled multidisc brakes for total control – even on steep inclines.

The 28-tonne RA30 articulated hauler is made for the toughest jobs and roughest sites, from quarries and infrastructure developments to commercial construction projects. With true independent front suspension as standard, it offers more control and comfort for operators. The RA30's new transmission and high-performance engine are said to improve fuel efficiency and operator comfort while delivering power when you need it.

Both machines feature the latest EU Stage V emissions-compliant engine for the European market, said to offer an up to 7% improvement in fuel efficiency compared to older EU Stage IV engines.

Visitors (Z3) will see Hitachi Construction Machinery UK 9 (HCMUK) showcasing the latest Zaxis-7 models and the groundbreaking equipment and recent innovations from HCMUK's Hitachi Connected Technology department, including the new mixed-fleet telematics system, CTFleet Link.

HCMUK will also have some of its larger excavators and wheeled loaders at work in the demo area.

For almost 40 years, SBM Mineral Processing (SBM) has consistently relied on diesel-electric drives. The Austrian company says it is the only manufacturer to offer an all-electric plug-in hybrid drive for trackmounted jaw and impact crushers from under 30 to around 150 tonnes operating weight.

All JAWMAX and REMAX models are said to be positioned at the forefront of their respective machine classes in terms of crusher size and production capacity. They offer low fuel consumption in diesel-electric operation and existing mains power for maximum savings. © AGGREGATES BUSINESS EUROPE May/June 2022

67

HILLHEAD 2022 PREVIEW

At Hillhead (Z7), SBM will be focusing on the popular 40-tonne class plant, including the compact JAWMAX 400 with a maximum operating weight of 37 tonnes. The claimed class-leading 1100x700mm jaw crusher produces up to 400 tonnes per hour, making it a flexible and highly economical solution even for short-term operations in recycling or quarrying.

SBM will also be highlighting its shortterm plans in the UK and mainland Europe markets, including further expansion of a UK-wide sales and service network and stronger cooperation with rental organisations to promote its technologies.

Over its 30-year history, CDE has been engineered for zero waste, with its wet processing solutions at the forefront of the evolution of sustainability across both natural processing and waste recycling.

Alongside its Hillhead product showcase (A9), CDE professionals will be joined by representatives from customers Peel NRE, part of Peel L&P. Peel NRE is at the heart of the UK's activity around clean growth and the circular economy – helping the nation achieve net zero by 2050 and supporting regions in their actions to achieve climate emergency targets.

The company is currently working with CDE to embark upon a new venture called NRE Aggregates, a vertical integration within their current business. During the show, the Peel NRE team will share more about the upcoming C&D waste recycling project at Port Salford in Greater Manchester and plans for creating sustainable aggregates.

Equipment on display will include CDE's R-Series primary scalping unit (R4500), AggMax logwasher and counter flow classification unit (CFCU).

CDE's R4500 was created to handle the most troublesome materials, including

SBM Mineral Processing JAWMAX 450 hybrid electrical jaw crusher

heavily clay-bound mineral and waste materials, offering a high-energy screening of material and oversize removal before entering the AggMax logwasher for scrubbing and classification.

The AggMax technology is engineered to operate in the toughest conditions to maximise product yield from the most abrasive and clay contaminated feedstocks.

Combining feeding, scrubbing, screening, and sizing on one chassis, the AggMax is suitable for various material streams such as sand and aggregates, overburden, scalpings, C,D&E (construction, demolition & excavation) waste, soils utility arisings, muck away and trommel fines.

Transforming the most difficult feedstock and waste streams into high-quality

concrete-specification sand, the CFCU provides an effective system for removing lightweight contamination from fine material fraction. Its unique features offer sand classification by mass and density where water is used to suspend particles at the cut point. The CFCU also provides the added benefit of tailoring the final sand gradation specific to its end-use. Visitors will have the opportunity to see the plant up close as CDE experts guide them around the equipment that will be installed at sites across the UK to customers Ace Liftaway (CFCU), Peel Group (R4500) and Scott Bros (AggMax).

McCloskey International's new C2C is the latest entry into McCloskey's cone crusher line, and its powerful MC200 cone will be on display (L1).

CDE wet processing recycling plant at Breedon's North Cave Quarry, near Hull, UK

68

© AGGREGATES BUSINESS EUROPE May/June 2022

www.AggBusiness.com

HILLHEAD 2022 PREVIEW

McCloskey C2C cone crusher material flow

The C2C brings the power of a 200HP cone to a compact footprint offering high manoeuvrability with an exciting lineup of features aimed at boosting productivity.

Standard features include a full-size MC200 cone, premium-quality components, unrivalled ground-level access, powerful engine, efficient conveyor design, and continuous load and material monitoring.

UP & RUNNING WITHIN 1 HOUR

The C2C is said to deliver high production from material feed to end product stockpile due to its innovative material flow features. A low feed height, large 6.2m³ capacity Hardox lined hopper allows for stop function, while the unrestricted feed opening improves intake capability and reduces the risk of blockage.

As the material enters the cone chamber,

SAFE & EASY TO INSTALL

SMILEY MONROE HQ, LISBURN, N.IRELAND | +44 (0) 28 9267 3777 SMILEYMONROE.COM | hello@smileymonroe.com

www.AggBusiness.com

features including a long stroke and high speed contribute to the high productivity while ensuring the highest quality of end product with variable speed. Multi-layer crushing delivers great capacity, better reduction and shape combined with less liner wear.

As the material moves to the classleading heavy-duty 48-inch-wide conveyor, the gap between the crusher discharge and main conveyor feeder enhances material flow. Stockpiles are formed up to 3.3m, and with ground-level access, the belt is easy to maintain and service.

Power is built into the C2C, with a robust 280kW engine on board and high-capacity fuel and hydraulic tanks to reduce the number of re-fuelling intervals.

The crushers are suited particularly to aggregates, construction and demolition recycling.

Astec has taken its sixteen industrycelebrated brands such as KPI-JCI, Astec Mobile Screens, Osborn, BTI and Telsmith in the crushing, screening and aggregate processing markets and Carlson, Roadtec, Rexcon, Con-E-Co and BMH in the concrete and asphalt sectors and recently assimilated the product range under the Astec brand name. The U.S.-headquartered company has also invested time and money into its European facility to help support its customers and distribution network globally in sales, service, support and spare parts.

MAXIMISES MACHINE UPTIME

VISIT US AT STAND E5

© AGGREGATES BUSINESS EUROPE May/June 2022

69

HILLHEAD 2022 PREVIEW

At Hillhead (J1), Astec will be highlighting some of its multi-brand equipment range as it looks to build its UK and wider European market presence.

Group VP, sales & marketing for Astec, Ron Earl, said: "We have manufacturing bases and regional offices in North America, Latin America, Canada, Africa and Ireland with additional regional offices in the Middle East, Asia, China and Australia to help serve customers locally. We are currently recruiting additional dealers to help represent us.

Hillhead will provide a great opportunity for everyone to meet the team, hear about our investment and discuss the strategic expansion of one of the most notable names in the industry."

Telestack will be showcasing how the Omagh, Northern Ireland-based manufacturer of bulk material handling solutions, is using its experience to spearhead the move from traditional track-mounted diesel-hydraulic equipment to solutions that promote environmental responsibility through the use of zero-emission technology.

Telestack's international sales manager, Padraig McDermott, said: "Europe is the main driver on electric units, in-line with regulated engines getting more complicated. We've offered electric conveyors for almost 30 years, and they have proven very effective. Many countries are now offering sizeable rebates on their capital expenditure for green technology, so we see the shift in all sectors." AB

Astec FT 300 mobile cone crusher and GT 205 mobile incline screen

The TC621 tracked conveyor from the Telestack Zero range

Actionable Insights See us at

Hillhead, Stand RC5

InsightHQ provides real-time operations visibility to improve performance and productivity. See target vs. actual production, delays, downtime and more, so you KDYH WKH FRQ‫ٴ‬GHQFH WR PDNH PRUH LQIRUPHG GHFLVLRQV <RXU ORFDO VSHFLDOLVWV R‫ٳ‬HU RQERDUG VFDOHV DQG UHSRUWLQJ IRU PL[HG ‫ٵ‬HHWV WKURXJKRXW WKH 8. :H R‫ٳ‬HU Ź Superior customer service Ź Specialist installers and trainers ACTIONABLE INSIGHTS | DASHBOARDS | NOTIFICATIONS

Ź Wide range of product options to suit your budget

To learn more visit Halomec.com, scan the QR code or call 01453 766444

70

© AGGREGATES BUSINESS EUROPE May/June 2022

www.AggBusiness.com

Facebook @AggBusiness

LinkedIn Aggregates Business Magazine

Twitter @Agg_Business

Instagram @aggbusiness_magazine

EQUIPMENT UPDATE

CDE unveils AquaCycle A2500 CDE has revealed its new AquaCycle A2500 thickener, the latest addition to its top-of-theline water management and recycling systems.

With a capacity of 2500m³/ hour, the new A2500 is CDE’s largest and most advanced water management system to date.

It has been developed in response to calls from materials processors operating in high tonnage markets for water management solutions equipped to supply their operations with sufficient water supplies while ensuring optimal production efficiency, minimum loss of fines and maximum water recycling.

Darren Eastwood, CDE strategic development director, says: “It is increasingly important for materials processors to invest in an effective water management system that ensures a steady supply of clean water to their plants through cost-effective means.

“The continued advancement of our pioneering wet processing solutions and leading-edge water management systems is supporting operators working in the natural processing and waste recycling sectors worldwide to overcome the challenges of washing in water-pressured or water-scarce areas today.”

Where CDE bridged the gap in 2018 with the launch of its A900 and A1500, providing a median alternative to its 600m³/hour and 1500m³/hour models, the new A2500 expands the range with a 2500m³/hour option to fit the requirements of sites processing

A bird’s-eye view of CDE’s AquaCycle A2500 thickener high tonnages. The increased capacity also provides a lower rise rate, enabling operators to process challenging, harder-tosettle materials.

Designed for easy use and safe access for efficient maintenance, it boasts the first lattice bridge structure on any CDE thickener. An integrated monorail also provides unrivalled access to the motorised rake, gearbox and motor.

With a sludge capacity of 125 tonnes/hour, the A2500 includes an adjustable rake-lifting mechanism. Featuring passive torque control, the automatic raise-andstart sequence is designed to protect rakes from surge pressure from dense sludges. The rake itself has also been reimag-

ined, with optimally spaced and redesigned blades for improved sludge conditioning.

Powered by the motorised rake arm, the introduction of a new floating scum scraper, which is independent of the rake’s height, allows for the easy removal of unwanted foam, oil and lightweight trash. And, creating even radial flow to all regions of the A2500, a redesigned volute feedwell optimises the incoming flow for improved flocculant performance.

Another key feature of the new A2500 is its feed height.

Sitting at almost 6.7 metres (6690mm), it simplifies upstream plant design complexity as it eliminates the need for expensive civils, helping to expedite

the commissioning process of entire plant solutions.

With a tank diameter of 20 metres and a weight of 88 tonnes when empty and 1,150 tonnes when full, the A2500 features a small footprint whilst packing a punchy 2500m³/hour and a solids capacity of 125 tonnes/hour.

An alternative to water extraction from natural sources and the costly process of pumping water to the plant, CDE’s A2500, like the full AquaCycle range, significantly reduces costly water consumption by ensuring up to 90% of process water is recycled for immediate recirculation.

Eastwood says the development of the new A2500 delivers all the benefits of CDE’s existing AquaCycle range on a much larger scale.

“It responds directly to the needs of materials processors operating in high tonnage markets. These operations, primarily in the areas of C&D waste, specialist sands and heavily clay-bound aggregates, require higher volumes of water resources; they need flexible water management systems with the capacity to supply their operations without compromising on footprint; and they need a system that can deliver this in a way that improves efficiency, driving down operational costs to maximise profitability and enable fast return on investment.

These are the guiding principles that underscore the design and development of the new A2500.”

www.cde.com

Hidromek K4 backhoe wins two big awards Hidromek’s new K4 Series backhoe loader has won two top off-highway machine design awards.

The new machine from the Turkish manufacturer picked up a ‘Winner’ award within the Red Dot Design Award 2022 event, and a ‘Product Design’ award in the 2022 staging of the IF Design Award.

With the new awards, HİDROMEK’s total number of international design awards for its machine range has reached 29.

Hidromek design studio manager Hakan Telışık said: “We

72

© AGGREGATES BUSINESS EUROPE May/June 2022

are happy and proud that our new K4 Series, which was designed in two-and-a-half years with a completely user-oriented design process approach, won two such valuable awards.”

Figures produced by İMDER (The Construction Equipment Distributors & Manufacturers Association of Turkey) show that Hidromek has been the biggest seller of backhoe loaders in Turkey for 11 years. The manufacturer has also been Turkey’s biggest-selling excavator manufacturer for eight years.

www.hidromek.com.tr

www.AggBusiness.com

NEW FOR 2020

Aggregates Business' state-of-the-art website www.aggbusiness.com

The Aggregates Business website brings you the very latest in website functionality, with the most up-to-date content available relating to the quarrying and aggregates industry.

The site is fully optimised for desktop, tablet and mobile and has a growing social media audience.

The website is constantly being updated, with the Aggregates Business' editorial team posting 4-5 new items every day.

EVENTS | FOR A FULL LIST OF EVENTS VISIT WWW.AGGBUSINESS.COM/DIARY

2022 JUNE 21-23: Hillhead Hillhead Quarry, Buxton, Derbyshire, England Organiser: The QMJ Group Tel: +44 (0)115 945 4377 Email: Harvey.sugden@qmj.co.uk www.hillhead.com

JULY 06-09: EIG 2022 Exeter, UK Organiser: EIG Conferences Email: marcus.dorey@hanson.biz https://www.eigconferences.com/ future-conferences 30 July-02 August: M&T Expo 2022 São Paulo, Brazil Organiser: Messe Munchen Tel: +55 11 3868-6340 Email: info@mtexpo.com.br https://www.mtexpo.com.br/en/

OCTOBER 19-21: SIM 2022 Marseille, France Tel: +33 (0)1 60 94 22 21 https://www.expositionsim.com

24-30: bauma Munich, Germany Organiser: Messe München Tel: +49 89 949-11348 Email: info@bauma.de https://www.bauma.de/en/

NOVEMBER 07-09: Trimble Dimensions Las Vegas, NV Organiser: Trimble https://dimensions.trimble. com/live 24th - ABMEC Conference and Exhibition 2022 Forest Pines, North Lincolnshire Organiser: ABMEC Tel: +44 (0)1924 860 258 Email: enquiries@abmec.org.uk https://abmec.org.uk/abmec_ events/abmec-conference-2022/

2023 JANUARY 19-20: CECE Congress 2023 Chamonix, France Organiser: CECE Tel: +32 2 706 82 26 Email: info@cece.eu https://www.cece.eu/

Stuck for a solution?

Don’t get bogged down on site.

Tsurumi’s pumps can transport almost anything to keep your project moving.

+49 211 417 9373 | SALES@TSURUMI.EU | WWW.TSURUMI.EU

74

AGGREGATES BUSINESS EUROPE May/June 2022

31 January-03 February: bauma Conexpo India 2023 Greater Noida, India Organisers: AEM and Messe München Tel: +49 89 949-20251 Email: info@bcindia.com https://www.bcindia.com/

MEET THE TEAM Aggregates Business travels the globe attending conferences, events and equipment shows, keeping you informed of the latest offerings. Come and join us for a chat at any of the events below.

MARCH 03-07: SaMoTer 2023 Verona, Italy Organiser: Veronafiere S.p.A. Tel: +39 045 8298561 Email: customercare@samoter.com www.samoter.it/en 14-18: CONEXPO-CON/AGG Las Vegas, NV Organiser: AEM Tel: +1 (800) 867 6060 https://www.conexpoconagg.com/

JUNE 2022 21-23: Hillhead 2022 Hillhead Quarry, Buxton, Derbyshire, England OCTOBER 2022 24-30: bauma Munich, Germany

AUGUST 23-26: steinexpo 2023 Homberg/Nieder-Ofleiden, Germany Organiser: Geoplan GMBH Tel: +49 7229 606-30 Email: info@geoplangmbh.de https://www.steinexpo.eu/

These dates were correct at the time of going to press, but please note that the COVID-19 pandemic means some events may be rescheduled with little advance notice

ADVERTISERS INDEX Advertisers in AGGREGATES BUSINESS can now be contacted via their websites - for instant links to all the websites listed below, by category, go to: www.AggBusiness.com COMPANY

PAGE NO

WEBSITE

Ammann

p21

www.ammann.com

BKT

p33

www.bkt-tires.com

CAT

IFC

www.cat.com

CDE

p59

www.cdegroup.com

ConExpo

IBC

www.conexpoconagg.com

Cummins

p5

www.cummins.com

Hitachi

P13

www.hitachicm.eu

Komatsu

p43

www.komatsu.eu

McLanahan

p45

www.mclanahan.com

Rubble Master

p60

www.rubblemaster.com

SBM

p71

www.sbm-mp.at

Smiley Monroe

p69

www.smileymonroe.com

Trimble Agg

p70

www.goloadrite.com

Tsurumi

p74

www.tsurumi.eu

Volvo

p10

www.volvoce.com

Volvo CE

p15

www.rokbak.com

Volvo Penta

p17

www.volvopenta.com

Weir

p41

www.global.weir

Wirtgen

OBC

www.wirtgen-group.com

www.AggBusiness.com

TAKING CONSTRUCTION

TO THE NEXT LEVEL.

250,000sqm of exhibits / 130,000 attendees / 1,800 exhibitors / 150 education sessions

MARCH 14-18 / 2023 / LAS VEGAS / NEVADA

No matter what sector of construction you’re in, you’ll leave CONEXPO-CON/AGG with new ideas, new relationships, and new opportunities to grow your business, and your place within the industry.

This isn’t just North America’s largest construction trade show, it’s taking construction to the next level.

LEARN MORE AT CONEXPOCONAGG.COM

2020 Attendee Britton Lawson, Veit and Company, Inc.

!,$3/8B94B-98B74&:89B()8.+3B$3(B)=9)38-;)B7$3+)B4*B8'7))3B0-3-3+8 B9,)B

B B " B '$3B)$8-0>B$($69B94B',$3+-3+B04'$9-438B$3(B3)<B46)7$9-3+B'43(.9-438B 2$/-3+B.9B.()$0B*47B$B<-()B;$7-)9>B4*B$660.'$?

9.438 B!,)B'4$78)B8'7))3-3+B60$39B*)$9:7)8B$3B-39:.9-;)B8>89)2B'439740B9,$9B7)(:')8B9,)B7.8/B4*B46)7$9.3+B)7747 B 3(B$00B 7)1);$39B*:3'9.438B'$3B&)B46)7$9)(B*742B$B8$*)B(-89$3')B*47B-3'7)$8)(B<47/B8$*)9> B!,)B B B B " B 9,)B,)$;> (:9> B;)78$9-1)B840:9.43B.3B3$9:7$0B8943)B$3(B7)'>'1-3+ B

AB $3*7)( #573)7 97 B B@B B %66.3+B)3BAB! B B B B B

B B