ABE Sept-Oct 2024

SEPTEMBER/OCTOBER 2024 | VOL.18 ISSUE NO5 | www.AggBusiness.com

Born to rock Feiring Bruk’s Tanja Gjerde is

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NEWS Jim Mintern is next CRH CEO p06

MARKET REPORT Poland & Romania are Eastern Europe rock stars p10

QUARRY PROFILE A crushing Metso victory for Bröderna Björklund Grus AB p14

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living her geology best life p20

DUCE OU

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OF EFFICIENCY

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CONTENTS

SEPTEMBER/OCTOBER 2024 | VOL.18 ISSUE NO5 | www.AggBusiness.com

THE ELECTRIC SHOWROOM

“LiuGong hosted ‘The BEV Experience: BEVs, Batteries, and Beyond’ at its new regional hub in Stalowa Wola, Poland” p33

Born to rock Feiring Bruk’s Tanja Gjerde is living her geology best life p20

Vol.18 ISSUE No.5 September/October 2024

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33 THE ELECTRIC SHOWROOM

A European perspective for the US

A bevy of electric possibilities

06 NEWS

37 WATER RECYCLING, FILTRATION & MANAGEMENT

CRH announces Jim Mintern as new CEO; Holcim makes Sublime investment; Heidelberg Materials’ pioneering CCS in the Mediterranean; Circular construction with ECOCycle

NEWS Jim Mintern is next CRH CEO p06

Admirable water saving & other pressing matters

40 DRILL RIGS, HAMMERS & BREAKERS – 2

09 ASSOCIATION NEWS REACH & recovered aggregates: A comprehensive overview

51 EVENTS All the key events in the quarrying & aggregates world

Features

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MARKET REPORT Poland & Romania are Eastern Europe rock stars p10

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Regulars DUCE OU

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QUARRY PROFILE A crushing Metso victory for Bröderna Björklund Grus AB p14

COVER STORY: Tanja Gjerde has a big geology and planning role, spanning 13 quarry sites operated in eastern Norway by Feiring Bruk

Electrifying the hammers and breakers sector

Specials

44 TYRES – 2

10 MARKET REPORT

Big acquisition amid strong tyre sustainability focus

Poland & Romania are positive standouts in the Eastern European aggregates sector

48 BLASTING & ALTERNATIVES

14 QUARRY PROFILE

Increasingly sophisticated blasting analysis

A crushing Metso victory in Sweden for Bröderna Björklund

20 INTERVIEW

16 WIRTGEN GROUP

Why Feiring Bruk’s Tanje Gjerde is ‘born to rock’

New cutting-edge machines from Kleemann and Hamm

25 CRUSHING & SCREENING Crushing and screening solutions making tracks in Africa and America

29 HAULING Searching for a more productive & efficient haul

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COMMENT

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EDITOR A European perspective for the US

I

t was good to draw on a number of European best-practice examples of digitalisation and the use of artificial intelligence (AI) in aggregate production during the recent AggNexus Digital Innovation Conference at the University of Texas at Austin. Attended by nearly 100 industry professionals, the event, held and sponsored

by SEMCO Publishing, the parent company of Rock Products magazine, in collaboration with Price Bee and On The Rocks Digital, engaged representatives of technologysavvy multinational or independent cement, aggregate, concrete and asphalt producers, plus allied software developers or service providers.

Aggregates Business was supporting the event as an international trade media partner, and I was delighted to moderate three senior executive panel discussions following the first conference day’s vendor and attendee meetings, a ‘speed-dating’ event and a cocktail dinner.

Titled Buying or creating your software?, Challenges and opportunities in digtalisation for the aggregates industry, and How and when will AI transform our industry, the panels featured insightful commentary from vendor participants Burgex Mining Consultants/ Mineralogy Aggregates, Concrete.ai, EveryPoint/ Stockpile Reports, Inform Software, Cobotiq and TAC Insight/Fast-Weigh. Rounding out vendor participants were CheckProof of Sweden, Eltirus of Australia, and GoBuild360 of South Africa.

The panels also included leading figures within current or prospective technology partners, including Big Town Concrete, Luck Stone, New Enterprise Stone & Lime (NESL), and Knife River.

Among European examples I could draw on during the panel sessions was Holcim’s July 2024 announcement that it will be scaling up the use of AI in manufacturing across more than 100 plants worldwide over the next four years.

This will allow the Swiss building materials giant to use AI platform software provider C3 AI’s state-of-the-art predictive maintenance solution while also piloting generative AI to enhance its capabilities. I also noted that Tarmac, a CRH company, and London tech company Converge would be offering Tarmac customers advanced AI-enhanced digital sensors to optimise concrete mixes via the brand of the British building materials major’s

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new CEVO low-carbon concrete alternatives. I also used the example of a tech-savvy German quarry operator in Bavaria, who I visited with Caterpillar, using WhatsApp to communicate key performance data, feedback and company news to quarry machine operators in response to an AggNexus attendee question on how it was possible to achieve ‘easy wins’ in the industry via increased digitalisation.

Among key takeaways from the panel discussions were how difficulties finding good software developers, shorter programming schedules, and overall programming costs favour construction materials producers turning to specialised off-the-shelf or market solutions.

Producers with the right team and committed leadership can develop software in-house and realise a unique strategic advantage. Also, developers and programmers must understand what construction materials producers’ customers need.

AggNexus attendees heard that first movers in new software offerings enjoy a competitive advantage, although often for a limited window.

They can also contribute to a knowledge base or artificial intelligence model that benefits peers and competitors. Users must target fundamental, clean data from all existing and new platforms.

AI has different uses and adoption timelines in cement, aggregates and concrete production.

Cement companies are leading the way with AI-enabled predictive maintenance programs, which hold great potential given their plants’ complexity.

AI developers for aggregate operators need to embrace the process-driven nature of crushed stone, sand and gravel production.

AI applications in concrete production are emerging for quality control, mix design optimisation, plant equipment monitoring and fleet dispatching. Crucially, several panellists noted that AI models are of limited value without tight controls around data.

In my AggNexus wrap-up session remarks, I quoted Mo Gawdat, Google X’s former chief business officer, who said AI is an “inevitability”, and it is all about “how we shape it”. I see AI and digitalisation as supporting, not supplanting, our aggregates industry’s brilliant people. GW © AGGREGATES BUSINESS EUROPE September/October 2024

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NEWS

HOLCIM MAKES SUBLIME INVESTMENT Holcim has invested in Sublime Systems, a leading low-carbon cement technology startup, to expand its range of highly engineered solutions to decarbonise building at scale. The partnership will advance Sublime’s first commercial manufacturing facility in Massachusetts, USA, giving Swiss building materials giant Holcim a large share of Sublime Cement produced there through a binding offtake reservation. The two partners have established a dedicated project team to co-develop further facilities to scale up and commercialise Sublime Systems’ technology for swift market deployment.

Nollaig Forrest, chief sustainability officer at Holcim, said: “The Sublime Systems team has developed a unique technology to decarbonise cement, cutting across the entire production process from the use of clean electricity to carbonfree raw materials. We are excited about this technology’s potential and are delighted to be partnering to bring it to market at scale. This investment advances our strategy to decarbonise construction by scaling up the most innovative technologies across our operations.”

Dr. Leah Ellis, CEO and co-founder of Sublime Systems, said: “In the cement industry, scale is everything. We are proud to collaborate with Holcim who supports our mission of swift and massive impact. By pairing Sublime’s technology with Holcim’s advanced global operations from manufacturing and logistics to commercial distribution, we can scale up our impact together.”

Nollaig Forrest, Holcim chief sustainability officer. Pic: Holcim

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CRH announces Jim Mintern as new CEO B

uilding materials provider CRH has appointed Jim Mintern as its next chief executive officer, succeeding Albert Manifold, who retires at the end of 2024.

Mintern is currently CRH’s chief financial officer and has been a director of its board since June 2021. He has more than 30 years of experience in the building materials industry and 22 years with CRH, serving in various senior leadership roles.

CRH says Mintern has deep industry knowledge, has led various operational businesses, and is an accomplished developer of teams and people.

He also has extensive portfolio management and expertise in financial and capital markets.

Most recently, Mintern led the strategic transition of CRH’s primary listing to the New York Stock Exchange.

Since joining CRH in 1998, Manifold has held varied responsibilities. He was appointed CEO in January 2014 and will step down from the board and relinquish his executive responsibilities on

Jim Mintern (right) will be CRH’s next chief executive officer, succeeding Albert Manifold (left) Image: CRH December 31, 2024. He will continue as an advisor to CRH for another 12 months.

Announcing the appointment, CRH chairman Richie Boucher said: “The board has a significant focus on succession planning throughout CRH. With the support of independent advisors, we have followed best practices, including a review of external candidates, and we have carefully monitored the development plans for potential internal candidates.

“Over recent years, we have closely observed Jim’s character, qualities and abilities, as well as his significant influence on the evolution of CRH. We are very pleased to have a successor of such calibre. We are confident that Jim is best positioned to lead the CRH team, building the company’s future for our investors, customers, colleagues and communities.

“Jim will become the chief executive officer of a highperforming company in robust strategic and financial health after 11 years of exceptional leadership from Albert.

“CRH has made enormous progress thanks to Albert’s clear vision and leadership of a talented, hard-working team.

CRH is a very focused, highperforming group recognised by its customers as the industry’s leading innovative building materials solutions provider.

Under Albert’s leadership, CRH has delivered superior growth and performance while consistently improving profitability, cash generation, and returns.”

Metso enhances digitalisation footprint Metso is continuing its investments in digitalisation by opening a Digital Design and Development Studio in Krakow, Poland.

Metso’s digital strategy builds on the company’s core competencies in equipment excellence, processing, and metallurgical and material expertise combined with technical and field-services support and enriched with leading-edge digital capabilities.

The studio plays an important role in the development and implementation of digital solutions to enable customer value creation and to meet the needs of the industry.

“Opening of the Digital Design and Development Studio marks the next phase in our digital offering development journey. This new digital

Metso is opening a Digital Design & Development Studio in Krakow, Poland. Pic: Metso capabilities and knowledge hub centers around the competences related to software development, design, data, UX design and AI required to serve our customers’ increasing appetite for advanced digital solutions,” says Olivier Guyot, senior vice

president for Minerals Digital at Metso. Metso has approximately 50 digital experts working in the Krakow office, and the number is expected to increase significantly within the next months. Overall, Metso has some 250 people working on its rich portfolio of digital solutions.

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NEWS

Heidelberg Materials’ pioneering CCS H eidelberg Materials has started a feasibility study for a decarbonisation project at its Rezzato Mazzano cement plant in the province of Brescia, which could become the first plant in Italy to produce carbon-captured net-zero cement and concrete.

With expertise from its broad range of launched CCUS projects and an ambitious net-zero roadmap, Heidelberg Materials is well-positioned to participate in the development of the CCS sector in Italy.

An important development in CO2 storage opportunities is the start of phase 1 of the Ravenna CCS project, carried out by a joint venture between Italian integrated energy company Eni and energy infrastructure operator Snam. This milestone opens up possible scenarios for Heidelberg Materials’ CCS project at the Rezzato-Mazzano plant, which could participate in the future allocation processes of CO2 transport and storage

Heidelberg Materials has started a feasibility study for a decarbonisation project at its Rezzato Mazzano cement plant. Pic: Heidelberg Materials

capacities in the depleted gas fields off the coast of Ravenna.

“We are excited to explore the economic feasibility of a carbon-capture initiative in the Mediterranean”, said Dr Dominik von Achten, chairman of the managing board of Heidelberg Materials.

“Our ambition at Heidelberg Materials is not only to implement a decarbonisation initiative that is highly efficient in terms of resources and

energy but also to provide an important impetus for developing a regional CCS cluster.”

As part of the initiative, Heidelberg Materials will evaluate the feasibility of capturing CO2 from cement production and transporting it via pipeline to the Ravenna CCS storage hub under the Adriatic Sea. In this regard, Heidelberg Materials has started technical discussions with Eni and Snam for a preliminary technical

Circular construction path boosted with the introduction of ECOCycle Aggregate Industries, part of Holcim, has demonstrated its clear commitment to making construction more circular with the introduction of ECOCycle to the UK. ECOCycle, being rolled out globally by the Holcim network, categorises products manufactured with at least 10% construction demolition materials (CDM), ensuring nothing is wasted. With its unique mark, the circular approach is applied to products that contain at least 10% CDM content following independent verification to ensure they comply with the applicable clauses of ISO 14021:2016.

Products with an ECOCycle inside can contain 10 to 100% recycled materials. This can also be applied to plants that can process recycled materials.

The move is part of the

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ECOCycle utilisation and the London skyline.

Pic: Aggregate Industries company’s drive to scale up circular construction, reduce its use of natural resources, and build new from old. It is being introduced in the UK in a phased approach across the five divisions that make up the business. It will be applied first to its asphalt and surfacing product lines, including solutions such as its Foamix product, which contains 92% recycled

content. Thirty-one of its asphalt plants have been certified to manufacture products with ECOCycle inside.

It will also be applied to part of its aggregates portfolio, which is focused on the materials produced through its Sivyer recycling hubs in London and across five of its ready-mix concrete plants in London and the Midlands.

evaluation. Jon Morrish, member of the managing board of Heidelberg Materials and responsible for Europe, said: “With an aspired capture rate of more than 95% of our plant’s emissions, this initiative aims to explore options for industrialscale CCS in Italy. This would enable us to supply locally produced, carbon-captured net-zero cement under our evoZero brand to regional customers.”

As announced by Eni and Snam, the Ravenna CCS project aims to leverage Eni’s depleted gas fields in the Adriatic Sea, which would be converted for exclusive use as permanent geological CO2 storage sites. The total storage capacity of these fields is estimated at more than 500 million tonnes, making this project the reference CCS hub in the Mediterranean. Snam is committed to developing a pipeline network to transport CO2 from emitters to the Ravenna CCS hub.

SigmaRoc Polish lime deal SigmaRoc, the Northern European lime and minerals group, has acquired CRH’s Polish lime operations.

This concludes the third and final acquisition, as described in the announcement on 23 November 2023 (the first and second relating to Germany—and UK-based assets). The full divestment of CRH’s European limestone operations is valued at US$1.1 billion.

The new acquisition includes CRH’s Polish lime and limestone flour production, associated distribution network, and Polish assets. Founded in 1910, Irish building materials giant CRH has two lime production sites in Kujawy and Sitkowka.

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ASSOCIATION NEWS

REACH & recovered aggregates: A comprehensive overview

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he European aggregates industry is committed to circularity and environmental sustainability.

Key to this commitment is the use of recovered aggregates, which are recycled aggregates sourced from construction and demolition waste (CDW) and, to a much smaller extent, manufactured aggregates which originate from another industrial process, such as incinerated bottom ash or furnace slag.

CDW represents the largest waste stream generated in the EU and has an average recovery rate of 88%1.

Recovered aggregates refer to materials processed from waste products, most commonly from C&D activities. By repurposing waste materials, recovered aggregates contribute to resource conservation and reduce landfill use.

Recovered aggregates support sustainability goals and circularity by reducing waste and recycling materials in line with the EU Green Deal and the Circular Economy Action Plan.

Since 2010, recovered aggregates have been classified as articles under the REACH regulation2. REACH (Registration, Evaluation, Authorisation, and Restriction of Chemicals) is a comprehensive regulation implemented by the European Union in 2007. It aims to safeguard human health and the environment by ensuring that chemicals

produced, imported, or used in the EU are registered and assessed for safety. REACH is responsible for evaluating and managing chemical risks on manufacturers, importers, and downstream users.

Under REACH, article status, unlike substance status, means that the product is exempt from registration and the associated administrative costs. However, in 2024, ECHA, the European Chemicals Agency, changed its interpretation of recovered aggregates, considering that they should be identified as substances or mixtures rather than articles.

This reclassification could seriously harm the circular economy. Aggregates Europe – UEPG, together with an extensive coalition of European manufacturers of recovered aggregates3, has submitted a legal opinion and a position paper to the European Commission and the CARACAL4 authorities on 4 September 2024. This follows the Commission’s call to study the current implementation of the legislation and the feasibility of potential exemption solutions suggested by Articles 2(7) (b) and (d) of the REACH Regulation.

The coalition position is that recovered aggregates meet the definition of articles under REACH because their shape, surface, and design are crucial to their function, more so than their chemical composition.

EU case law, SiA Guidance, ECHA Guidance, and EN standards support this classification. Additionally, exemptions under Articles 2(7)(b) and (d) are impractical and disproportionately burdensome. The current REACH classification better supports environmental and circular economy objectives than a mandatory registration approach in line with the European Green Deal and Circular Economy goals. Therefore, REACH registration could undermine these goals by making production costly and complicated, discouraging the production of recovered aggregates, increasing reliance on primary raw materials and negating environmental benefits. Finally, classifying recovered aggregates as articles under REACH is consistent with their role and use.

The European Commission and CARACAL authorities are considering the most appropriate approach to updating ECHA’s guidance and are inviting member states to provide input. No final decision is expected at this stage. The topic is intended to be further discussed in the next CARACAL meeting in November 2024, where Aggregates Europe— UEPG has been invited to present the legal memo and position. AB

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https://www.statista.com/statistics/1316268/recovery-rate-of-construction-and-demolition-waste-eu-by-country/ recovery rate in 2020.

ECHA Guidance on recovered substances and waste (2010), 3 Concrete Europe, EAPA, EURIC, FEAD and FIR. 4 Competent Authorities for Registration, Evaluation, Authorisation and restriction of CHemicals (REACH) and Classification, Labelling and Packaging (CLP).

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© AGGREGATES BUSINESS EUROPE September/October 2024

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MARKET REPORT

A Caterpillar CAT 772 hauler and CAT 988K/988KXE loader in operation at a limestone quarry in south-eastern Poland.

Image: Bergerat Monnoyeur (Poland)

Poland and Romania stand out in mixed conditions The highly-stable Polish market remains a mainstay in the East European aggregates sector, while the less-developed Romania offers strong potential from infrastructure upgrades and construction projects. Liam McLoughlin reports

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here is a mixed picture overall in terms of aggregates-sector market conditions and future prospects in the Eastern Europe region, according to experts who spoke with Aggregates Business Europe.

Revenue in the construction market in the region is projected to reach US$809.2bn in 2024 and expected to grow at a compound annual growth rate (CAGR) of more than 3% in the period to 2028, according to research from GlobalData.

The research company states that the regional infrastructure-construction sector registered a double-digit, year-on-year growth rate in 2023, primarily supported by development works in Azerbaijan, Belarus, Kazakhstan, Romania, Slovenia and Ukraine. Among these, the highest YoY growth rate particularly in the infrastructure sector was recorded by Ukraine owing to the recovery efforts from the destruction caused due to the ongoing conflict with Russia.

Stefan Lind, commercial manager for Central/Eastern European markets at hauler, loader and excavator manufacturer Volvo CE, says the current market situation for aggregates producers varies significantly by country. Hungary faces the worst conditions, with a market slump due to the drying up of subsidies over the last two years. Recovery is expected by late 2025, driven either by new subsidies in the 2026 election year or by customers needing to replace ageing equipment.

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Lind adds: “Romania is in a complex situation, with subsidy programmes peaking in 2023 and new ones yet to start, creating uncertainty, though moderate growth of up to 10% is possible by 2025.

Slovakia has seen a sharp market decline.

Political instability poses risks, particularly regarding large infrastructure projects.

The Czech market is slightly declining in 2024, but recovery is expected before the 2025 elections, spurred by public investment and potentially increased machine demand following recent floods.

Lower interest rates may also stimulate investment.”

Lind says that Slovakia currently has the most robust and productive quarrying and aggregates sector in the region, with high mineral output. He adds, however, that many operations in the country are outdated, and the future is uncertain due to the complex and often publicly opposed process of opening new quarries or expanding existing ones.

“The Czech Republic faces similar challenges, with fewer quarries and lengthy environmental impact assessment (EIA) processes that can take over 15 years, often with uncertain outcomes,” says Lind. “Romania, while less developed in this sector, has significant potential due to its strong demand for infrastructure upgrades and construction.”

Kenny Price, regional sales manager EMEA at articulated dump trump manufacturer Rokbak, says that market

uncertainty and volatility alongside high interest rates is making businesses in Eastern Europe, including those in the quarrying sector, more cautious.

“Rising costs of operating machinery, while aspiring to make operations more sustainable, is a challenge but Rokbak’s focus on machine efficiencies such as reduced fuel consumption, extended service intervals, lowering the cost-pertonne-moved assists customers in this regard,” Price adds. “In the wider scheme of things, businesses need governments to commit to investing in long-term infrastructure projects and housing and industrial construction to allow the best forward planning and stability in the supply chain.”

A number of important current and planned infrastructure and construction projects in Eastern Europe are likely to influence demand for aggregates.

These include three major projects in Romania: the Metro underground rapidtransit system under construction in the northwestern city of Cluj-Napoca; the highway from Constanta to Arad at the Hungarian border; and the highway from the Romanian capital Bucharest to Belgrade in Serbia.

Lind says a lot of infrastructure projects in east Hungary are being supported by various Chinese investments.

Important infrastructure projects in the Czech Republic include new high-speed train links from the capital Prague to Brno

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MARKET REPORT

and Ostrava, and a nuclear plant extension in Dukovany.

Rokbak’s Price identifies opportunities for the aggregates sector from the Central Communication Port, which is a major project for the construction of a new US$9bn superhub airport in Poland. “It is not only an airport construction project serving the capital Warsaw but will include high-speed rail links to major cities across the country,” he adds.

Price says that the construction of the Rail Baltica high-speed railway across Latvia, Lithuania, and Estonia and a connection to Poland, is another major project amongst others on the continent aimed at improving rail connectivity. As well as being the largest aggregates producer in Eastern Europe – excluding Russia – Poland also has one of the most resilient and healthy quarrying sectors in the region.

Jaroslaw Wojtanowski, quarry and aggregates market manager at Bergerat Monnoyeur (Poland), Caterpillar’s Polish market dealer, says that the overall condition of Poland’s quarrying and aggregates market is currently “very stable”.

“Quarry and aggregate raw material production (excluding limestone and marl for lime and cement production) has been around the same level of 250 million tonnes per year since 2018,” Wojtanowski adds. “In the last year we observed a decrease in extraction for lime and marl but looking at this year the numbers are getting back to normal historical extraction levels.”

He adds that sand and gravel extraction in Poland totalled 167.08 million tonnes in 2023 (compared with 170.78 million tonnes in 2022), while extraction of aggregates and blocks in Poland was 79.6 million tonnes in 2023 (with blocks accounting for 3.5 million tonnes of this total) compared with 170.78 million tonnes in 2022.

“In the last two years we are seeing much lower exports of blocks to Western Europe.

In previous years that was about 30% of total exports,” says Wojtanowski. “Compared to the level in 2001, production has decreased by about one million tonnes.”

The situation looks slightly different in terms of limestone and marl production for the lime and cement industry with extraction in 2023 down to 45.5 million tonnes from 50.1 million tonnes in 2022. “Last year we observed for the first time in the last decade a decrease of over 9% of total volume of production in this segment of the industry,” says Wojtanowski. He adds that an optimistic projection is that in the first half of 2024, limestone and marl production will reach the same level as in the corresponding period in 2022.

In terms of the overall aggregates-market condition in Poland, Wojtanowski says: “We have very good results - 3rd or 4th place in the EU. The average profit for the aggregates market is 9%, and for cement and lime products it’s even higher.”

Wojtanowski says there is starting to be much more pressure and interest around

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Jaroslaw Wojtanowski of Bergerat Monnoyeur (Poland)

the material recycling segment in Poland.

“The market is starting to push harder for this approach and this could be related to decreasing production volume at some players on the market. This strategy is related to changes in the production and manpower structure, for example decreasing of working shifts and personnel numbers. Another very important factor is that the producers are starting to understand that our deposits are not renewable, and we will finish them in the future. The scale of this tendency is not large, but it will only increase year by year in future.”

He adds that there is currently a lot to do in this area in Poland with the current aggregates recycling level being 3% of total market volume, compared to an average of 6% in the EU and as much as 30% in the Netherlands.

The current political climate across the Eastern Europe region has undoubtedly impacted many markets negatively, according to Pat Brian, vice president at crushing and screening equipment manufacturer Terex MP Aggregates.

“With specific countries currently in an election cycle, local and government investment has slowed,” Brian says.

“However, we are observing an increase in opportunities in construction and demolition (C&D) recycling. As each region becomes more comfortable with using recycled aggregates, this sector is expected to grow.

“Our distributors can leverage the wide range of equipment available in the Terex line-up to meet the varying specifications

required in these projects. In particular, Terex Washing Systems is experiencing heightened demand for wet-processing solutions.”

Regarding current market conditions in Eastern Europe, Volvo CE’s Lind says that Slovakia has the most robust and productive quarrying and aggregates sector, with high mineral output. However, he adds that many operations in the country are outdated, and the future is uncertain due to the complex and often publicly opposed process of opening new quarries or expanding existing ones.

“The Czech Republic faces similar challenges, with fewer quarries and lengthy environmental impact assessment (EIA) processes that can take over 15 years, often with uncertain outcomes,” says Lind.

“Romania, while less developed in this sector, has significant potential due to its strong demand for infrastructure upgrades and construction.”

Notable recent aggregates-market developments in Eastern Europe include Heidelberg Materials commissioning an innovative recycling plant for selective separation at its production site near Katowice, Poland, in June this year.

The first‐of‐its‐kind facility features a proprietary crushing mechanism that enables sophisticated separation and sorting capabilities to fully recycle demolition concrete and substitute virgin materials in concrete production. With a capacity of up to 100 tonnes of concrete per hour, Heidelberg Materials says it is the first company in the industry to introduce high‐quality, selective concrete separation at this scale.

Nicola Kimm, chief sustainability officer at Heidelberg Materials said: “Thanks to our strong commitment to continuous innovation, we are now introducing a revolutionary and commercially viable technology combining circularity with decarbonisation on our path to net zero.

Innovations like these help to accelerate our

Metso has opened a Digital Design and Development Studio in Krakow, Poland. Pic: Metso

© AGGREGATES BUSINESS EUROPE September/October 2024

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MARKET REPORT

transformation and highlight our ambition to closing the loop offering circular alternatives for 50% of our concrete products by 2030.”

To further explore this technology, Heidelberg Materials is building an industrial pilot facility for enforced carbonation at its cement plant in Gorazde, Poland. The recycled concrete paste (RCP) obtained at the recycling plant near Katowice will be transported to the pilot facility in Gorazde, where it will be exposed to the exhaust gases from the kiln. Mechanical completion of the facility is expected by the end of 2024.

In September, mineral-processing technology provider Metso continued its investments in digitalisation by opening a Digital Design and Development Studio in Krakow, Poland.

Metso's digital strategy builds on the company's core competencies in equipment excellence, processing, and metallurgical and material expertise, combined with technical and field-services support and enriched with leading-edge digital capabilities. The studio plays an important role in the development and implementation of digital solutions to enable customer value creation and to meet the needs of the industry.

Currently, Metso has approximately 50 digital experts working in the Krakow office, and the number is expected to increase significantly within the next months. Overall, Metso has some 250 people working on its portfolio of digital solutions.

"Digital is a critical enabler for new sources of value because it helps our clients to optimise throughput and recoveries, increase equipment uptime and availability, and enable productivity while improving the sustainability of their operations. Digital solutions can also be the answer to reducing the knowledge gap and labour shortage in the industry," says Olivier Guyot, senior VP for minerals digital at Metso.

Also in September SigmaRoc, the Northern European lime and minerals group, completed the acquisition of CRH's Polish lime operations.This concludes the third and final acquisition, as described in the announcement on 23 November 2023 (first and second relating to Germany- and UK-based assets). The full divestment of CRH's European limestone operations is valued at US$1.1bn.

The new acquisition includes CRH's Polish lime and limestone flour production, associated distribution network, and Polish assets. Irish building-materials giant CRH has two Polish lime production sites in Kujawy and Sitkowka.

In June this year wheeled loader and excavator manufacturer Develon opened its new Uptime Center for Europe at the company’s regional headquarters in the centre of Prague in the Czech Republic.

The Prague branch is part of a global Develon Uptime Center (DUC) operation headquartered in Seoul in South Korea, with more branches around the world, including those in Dubai, Ghana, Brazil, North America and Indonesia.

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© AGGREGATES BUSINESS EUROPE September/October 2024

Stefan Lind of Volvo CE The focus of the DUC is to optimise machine uptime, ensuring that customers’ equipment operates efficiently and effectively.

With the DUC, Develon aims to enhance customer productivity by comprehensively utilising digital-based service technologies and by quickly resolving remote-support requests from customers and dealers/ distributors.

The facility provides a centralised hub for monitoring the health and availability of various digital assets. Aggregating data from diverse sources provides Develon with a comprehensive and visual overview of the critical systems and services of the machines.

This allows the company to gain insights into system performance, identify potential issues and to swiftly respond to any emerging problems.

In terms of the prospects going forward for the East European quarrying and aggregates sector, Wojtanowski says that in Poland the main drivers are always the same: the road construction business and concrete production.

“The biggest issue for the quarrying and aggregates market is that for 2024 the General Director of National Roads and Motorways (GDDKIA) did not open any new projects,” he adds. “Due to the typical lengths of these projects this will have an impact even up to 2026.”

Kenny Price of Rokbak Price of Rokbak says that across Eastern Europe there will be more of a move towards connected services on-site, and non-fossil fuel environments where suitable.

“In Eastern Europe as elsewhere, Rokbak is continuing to advance its connected services,” he adds. “Connected services is now at the heart of everything we do.

Rokbak’s Haul Track telematics system leverages GPS technology to deliver detailed, real-time machine location and tracking data, designed to simplify fleet monitoring, even for the largest hauler operations.”

From Volvo CE’s point of view, Lind says he expects to see growth in the Czech Republic market and strong growth in Romania. Brian of Terex MP Aggregates believes that legislation will significantly influence the industry's development in Eastern Europe. “In some regions, increasing restrictions on opening new quarries are limiting the availability of virgin materials,” he explains. “This shift is likely to drive the demand for recycled materials and washed products, and Terex is well-positioned to meet this emerging need.

“Additionally, there is a growing number of local crushing and screening contractors in the region. Due to fluctuating power prices and availability, these clients will continue to drive the demand for high-output mobile tracked equipment.” AB

The recycling facility at Heidelberg Materials’ production site near Katowice, Poland. Pic: Heidelberg Materials

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QUARRY PROFILE

A CRUSHING METSO VICTORY FOR BRÖDERNA BJÖRKLUND A robust and highly efficient Metso solution for a savvy Swedish crusher contractor. Guy Woodford reports

A

ny crushing contractor will find it challenging to successfully recycle the hardest rock material. Operating for over 100 years, Swedish company Bröderna Björklund Grus AB (Bröderna Björklund) found the right solution with Metso’s portable, wheelmounted NW130 crusher, equipped with a world-renowned jaw.

“After two years of usage, this portable crusher has proven itself to be just the right tool for us. It crushes even the hardest rock types at an average capacity of 300 tonnes per hour and includes all the features we need,” says Bröderna Björklund owner and managing director Peter Björklund.

“A wheel-mounted unit is perfect for us because we do not need to move the machine on-site. Electric drive is highly economical, while having a powerful generator readily available.

“Our portable plant is being moved between our different sites on a monthly basis. As a compact machine, NW130 can be transported during one full day,” he adds.

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On a rainy January day, the Bröderna Björklund team runs their NW130 jaw in a Bjärlöv quarry near Kristiansand, owned by Scandinavian Stone. Production and cutting of high-quality paving stones create a large amount of excess rock that can be recycled into different aggregate products.

This rock is extremely hard to crush, with a crushability index of 25% and abrasiveness of 1760g/t. The feed contains leftover blocks from floor and road pavement production, even abandoned tombstones.

The Björklund team hammers the granite blocks to 0-700mm size to suit the Nordberg C130 crusher cavity. Then, a Caterpillar 980 M wheeled loader feeds the crusher, operated at a 120mm closed-side setting.

Typical of Swedish and Norwegian quarries, primary crushing is carried out separately from secondary and tertiary crushing for better overall control. After going through the NW130, the materials are loaded into a nearby Jonsson crushing and screening plant for typical aggregate grades.

The entire process is powered by a Scania 450kVa generator, which consumes about 30 litres of diesel per hour. Because of the rock’s hardness, the NW130 jaw is equipped with a 200-kW electric motor.

Listing the main requirements of the primary crusher at the company’s jobs, Peter Björklund stresses the benefits of the C130 jaw crusher design:

Bröderna Björklund Grus AB (Bröderna Björklund) is going from strength to strength with Metso’s portable, wheel-mounted NW130 crusher. Pic: Metso

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QUARRY PROFILE

The average production rate of the Metso NW130 portable jaw operated for 10 hours per day by Bröderna Björklund, has been around 300 tonnes per hour. Pic: Metso

“This 40-tonne weighing crusher is sturdy and powerful enough to process even the extremely hard materials we recycle.

The long cavity is a must for us, and the increasing stroke in the bottom of the cavity ensures a good reduction ratio while keeping production high.

“Thanks to the large, 1.3 x one-metre feed opening, the crusher can process rather large stone blocks with less need for extra hammering.

“Feed with no fines, just the hard granite blocks, creates another challenge for the wear parts. We use two-piece quarry-profiled wear parts and turn them around to reach the full lifetime.”

After approximately one month of crushing, it’s time to move the NW130 jaw to

Managing director Peter Björklund represents the fourth family generation at Bröderna Björklund Pic: Metso

the next quarry in Skåne, southern Sweden.

“For transporting our 67-tonne portable jaw, we lift the feed hopper and feeder from the main chassis and move them on a low-bed trailer. The rest of the wheeled equipment goes smoothly attached to a truck via king pin.”

Bröderna Björklund has a compact genset for electricity and one container for tools and maintenance spares, which follows the equipment. Including all site preparations, moving NW130 from site to site takes one long working day.

Peter Börklund and his brother Thomas, who run the company together, represent the fourth generation in charge. Their grandfather Albin and his father started the company in 1922.

Bröderna Björklund and Metso work closely together to optimise the performance of the former’s NW130 portable jaw Pic: Metso “Our company started the crushing works already in 1925, and the first jaw crusher we bought was the Finnish Lokomo, the predecessor of Metso,” Peter Björklund states.

Today, Bröderna Björklund produces a million tonnes of natural and recycled aggregates annually. In addition to concrete and road grades, the firm produces materials at its six quarries for offshore and water-building purposes, exporting to Denmark and the Baltic countries.

One interesting and important end-product type is 55-130mm aggregate blocks, 60,000 tonnes of which are supplied to Hässelholm and Vilnius a year to produce mineral wool. AB

“The first jaw crusher we bought was the Finnish Lokomo, the predecessor of Metso” Bröderna Björklund feeds the crusher and cleans the pile under the conveyor with a Caterpillar 980 series wheeled loader Pic: Metso

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ADVERTORIAL

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In the Heart of Istanbul

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he MOBIREX MR 130i EVO2 from Kleemann is demonstrating its capabilities in Istanbul’s financial quarter. There, material for the concrete and road bed is being produced in combination with the MOBISCREEN MSS 802i EVO mobile scalper. Around a million tons of excavated material will be processed efficiently on the site over a period of about one and a half years. “We have to be especially flexible at this location,” explains Feyzullah Kahraman, managing director of construction

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© AGGREGATES BUSINESS EUROPE September/October 2024

contractor Safir Proje, “both regarding the unusual environment and the material.”

The contractor is impressed with the high performance, low fuel consumption, and easy handling of the Kleemann machines.

he NEO line is the new highperformance compact class from Kleemann. The MOBIREX MR 100(i) NEO mobile impact crusher is the first member of the new family and impresses with outstanding efficiency, performance, and versatility. Regardless of whether there is limited space on the project site or whether project sites frequently change – thanks to its compact dimensions and low transport weight, the machine can be quickly and easily moved from site to site and deployed in a wide range of situations. It is the ideal choice for uses ranging from the processing of concrete, mixed rubble, and asphalt, to the processing of soft to medium-hard natural stone. The new impact crusher is particularly sustainable in the version with E-DRIVE. This enables purely electric machine operation resulting in zero local emissions.

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SUSTAINABLE HANDLING OF PRIMARY RESOURCES AND CONSTRUCTION MATERIALS

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INTERVIEW

Born to rock Tanja Gjerde has quickly made her mark in the aggregates sector, holding an important and wide-ranging role in geology and planning covering the thirteen quarry sites operated in eastern Norway by Feiring Bruk. She told Liam McLoughlin that her desire to work in the sector dates back to childhood when she became fascinated by the importance of rocks.

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© AGGREGATES BUSINESS September/October 2024

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INTERVIEW

S

ome people are fortunate enough to know exactly what they want to do with their life from an early age, and that certainly applies to Tanja Gjerde who has been working as the mining engineer/ geologist at Norwegian quarrying group Feiring Bruk for three years.

She is the first person to hold this newlycreated role at the family-owned group, working across all of its thirteen sites in eastern Norway that extract and produce crushed stone, gravel, aggregates and asphalt.

Growing up in the small town of Tomrefjord on the northwest coast of Norway, her interest in all things mineral rapidly became apparent.

“We were surrounded by mountains, and my family has always been really curious when we’ve been out,” she says. “My mom is quite into the biology in nature and when I was first introduced to geology, I said to my parents that I’m going to be a geologist.

They weren’t surprised and I’ve never been in doubt since. I say to my friends and family that being a geologist isn’t work, it’s a lifestyle.”

Tanja’s main duties at Feiring Bruk revolve around quarry planning, including where to drill next, where to build a new road, where to blast, and also regulatory planning regarding contact with the government.

“I am in a lot of dialogues, both internally in the company about our plans, but also with the relevant government departments which is a big part of the job,” she adds.

Another important aspect of her work at the Feiring quarries is using drones to measure the stockpiles, and making the 3D models that the company uses for operational planning.

Tanja says the data gathered from the drone operations is important both for production and controlling how much is extracted from the quarry sites, how much is being sold and investigating the production mass balance so that the amount of waste material being produced is cut down.

“When I started flying drones, we had an idea of what they could be used for and then we just realised as time passed that, wow, we can use it to a lot more than we thought initially.

“We’re trying to use all this data so that when we’re planning, we can use the 3D

models for visualisations. We can also go back in time and see if there’s some things we don’t have full control of. We have documentation on how things were, what and where we extracted at a particular time.”

Her role is quite wide-ranging and also includes health and safety issues such as the documentation for fencing round the quarries.

“I do a lot of work around quality in terms of evaluating aggregates from secondary sources. For example, if you have a tunnel in Oslo or you’re building a garage in your garden and you have too much rock material, I will go and evaluate the quality of them and then say how we can reuse them in our production at Feiring.”

Tanja joined Feiring in 2021, and took up the newly-created position of mining engineer/geologist. What was the reason for the company introducing this role?

“Our production chief had to deal with a lot of the quarry regulatory aspects and we have 13 quarries, so that’s a lot of planning.

Combined with that, he had responsibilities for staff members and so it was partly to reduce his workload.”

In the period Tanja has been with Feiring the company has been putting an increasing amount of resources into its sustainability initiatives. Starting in 2020, it has been heading a four-year science project in this area, in cooperation with European research institute SINTEF, and she took over the leadership of the project in January this year.

The geological survey of Norway (NGU )

and a technology company Fremby are also taking part in the project.

“We’re in the end-phase of the project this autumn, and a lot of my work was directly into the sustainability science of it.”

Among other things, the project has looked at issues including the most effective and sustainable ways to handle different types of secondary rocks and looked at the whole value-chain of recycling mass streams from construction sites. One of its findings was that only 20% of the emissions related to asphalt at Feiring sites are due to transport, with 80% occurring in the production process.

Several data scientists have worked on the project and contributed their insights on transport and emissions.

The project has involved a lot of work with different businesses including contractors and entrepreneurs, and Tanja says they are very willing to try and cut down on their CO2 emissions but do not have the resources to handle the costs and risks alone.

Norway has a relatively low rate for recycled and secondary materials in total aggregates sales, and ranked 20th out of 21 countries in 2020, according to data from Aggregates Europe - UEPG and the UK Mineral Products Association. Tanja says this situation is now improving.

“At Feiring we’re taking in more and more recycled materials and that’s something that is being seen all over Norway with the amount of aggregates from secondary sources like tunnel projects and construction sites increasing.

Drone flying and stockpile measurement is an important part of Tanja’s duties at Feiring Bruk

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INTERVIEW

“Our excavation from the quarries will probably be going down in the coming years, which is great because then our prime rock can go into the best quality products and we can expand the lifetime of our quarries.”

In terms of what her main objectives are in her role as mining engineer/geologist at Feiring Bruk, Tanja says she wants to combine her interests in geology and sustainability.

“I love rocks, and I also love the earth we’re living on, so I want to extract the resources in a responsible, sustainable and safe way. A lot of the choices we take today affect not only us, but the next generation.

When I’m planning a quarry, the horizon I’m working in can be between 40 and 100 years, so it’s a big responsibility to do it in a sustainable and efficient way, with respect for the resources.”

Her educational background has been invaluable in her job at Feiring. Studying geology at high school where she went on field trips to Iceland, she then went on to take a bachelor degree in geology and geo-hazards at the Sogndal department of the Western Norway University of Applied Sciences in western Norway . The degree covered government regulations around rock extraction, in addition to basic geology such as the study of geohazards, glaciers, structural geology, hydrogeology and geophysics.

“There was a lot of field work, which I loved. I found I was distanced from the study of avalanches, and that I was more drawn to the in-depth study of rocks. I started my master’s thesis on bedrock and resource geology and that was when I studied mining engineering [at the Norwegian University of Science and Technology in Trondheim], because I think the whole extraction of rocks and how our society is so dependent on it is really fascinating.”

This background has provided her with a detailed understanding of the geological properties of rocks and how this is important in the planning of the quarries. She has the expertise to do a lot of structural geological measurements of the quarry cores at Feiring and work out the best way to blast rock, for example to optimise the fragmentation.

“Our site workers know how the different rock types behave, even though they don’t have the theory. I have the theory but not necessarily the practical insight, so it’s been fun having a lot of links between theory and practice.”

She is planning to become more involved in the production processes at Feiring’s quarry sites and is currently putting in the hours test-driving to get operating licences for dump trucks and wheeled loaders.

“This will enable me to be a part of the team outside,” she says. “I plan a lot of their work guidelines so I need to understand what their challenges are.”

In furtherance of its environmental efforts Feiring is planning to introduce a biogaspowered 28-tonne wheeled loader shortly.

The loader is an original diesel Hitachi

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ABOVE: Collecting sediments from the fjord outside a Feiring quarry RIGHT: Attending a meeting in Brussels held by European standardisation organisation CEN BELOW: Tanja is currently studying for licences to drive Feiring’s wheeled loaders and dump trucks

ZW310 that is being re-built at Nasta’s main office in Larvik and converted to biogas.

Another area of her expertise that has been useful at Feiring is in using Esri ArcGIS mapping software. One part of the software is called SiteScan, which is the tool that Tanja and her colleagues use for drone flying and measurement of the stockpiles. It can also be used for applications to the municipalities, or landowner calculations. “I did a lot of that in my studies and it’s a great tool that I use so much here.”

In terms of what she enjoys most about her job Tanja highlights two main things, the first being that it provides the opportunity to have both office and field days.

“I did not educate as a geologist to sit in an office all day, so I really love spending time outside in the quarries and the surrounding nature.”

She is generally outside more during the summer months but adds there is still plenty of tramping around in the snow in Norway’s cold winters.

She also enjoys being able to work in an interdisciplinary team where her competencies are relevant: “I have a lot to

contribute in the discussions, parallel to being surrounded by skilled people who can teach me a lot of new things.”

One of the main things she enjoys about working at Feiring Bruk is that it is a small and family-owned company, where the people all know each other and work as a team to reach their goals.

“It’s a really good environment in terms of that,” she says. “We cheer on each other and celebrate our achievements, as do our owners. They’re very innovative and let people follow their path if they’re passionate about something.”

She says that the company owners are also quite visible in the media and take their social responsibilities very seriously.

In terms of the technologies that are proving a big help to her work in quarrying, Tanja says improvements in machine data monitoring now provide greater details about their levels of efficiency and emissions.

She adds that this allows data users to be creative and have real and direct results when choosing to explore new methods in materials production.

“We can always improve and we’ve

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ROCK-SOLID RELIABILITY

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INTERVIEW

Tanja mountaineering where she grew up in northwest Norway

focused a lot on small things that we know from the machine data can reduce emissions by, for example, having good practices for maintenance on our roads.”

She says the quarry industry can do more to improve its sustainability levels and that may partly be due to it not being subject to the same levels of regulatory scrutiny that the asphalt, concrete and construction sectors are. “We are making improvements, but have not fully got there yet.”

She adds that there has been a change in the last couple of years with the increased focus on sustainability following the EU’s European Green Deal in 2020 and Critical Raw Materials Act introduced this year, which have seen politicians in Norway starting to talk more about the quarrying industry.

“We can’t just leave the responsibility with the politicians though. The quarry industry in Norway has traditionally preferred a low media profile, maybe because it’s seen as unattractive with a lot of noise and dust.

Now both the industry and the politicians are starting to talk about sustainability, and this is great because it means we can show a lot of the good things we are doing.”

In general, the quarry industry remains quite male-dominated, but Tanja says she has noticed a difference in recent years, at least in her own country.

“I’m not sure how Norway is compared to the rest of Europe, but in our company the CEO is female. We have females in all positions. We have machine operators, laboratory workers, some of the heads of

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© AGGREGATES BUSINESS September/October 2024

don’t have the same mechanical properties but they’re still good for some uses. We need to be able to allocate the correct quality rock to the correct purpose.”

Norway is the ninth-biggest aggregates producer in Europe according to data from European aggregates association UEPG – Aggregates Europe. It is also a major exporter, ranking second in the world for export value of pebbles, gravel, broken & crushed stone for aggregates with US$221m in 2022, behind the United Arab Emirates with US$295m (source: Observatory of Economic Complexity). The Mibau Stema Group in the west of Norway is a major exporter of aggregates to Europe.

Norway has a large number of extraction sites (1,121 in 2022, according to UEPG data), and Tanja says the quarries have historically generally served areas in the immediate vicinity within a 30km radius, with it not being cost-effective to transport them longer distances.

Tanja’s longstanding love of rocks is also reflected in her hobbies and interests outside her professional life.

“I really enjoy spending time in the mountains, so I do a lot of traditional climbing and also trail running. I’ve been running some 42km trail marathons in the mountains, and in the winters I spend as much time as possible skiing.” AB departments at the different quarries are women, and I think this does something with the culture, because for us young ones coming up in the industry, we now have some role models to look up to.”

“We have to look at the geology in the quarry and not think that everything is just the same, because it’s not and it has different qualities”

Regarding her professional ambitions in the quarrying industry going forward, Tanja says she would like to increase knowledge around the importance of the extraction sector and the best way to re-use and recycle resources.

In particular she stresses the importance of optimising rock usage for the best purpose, which she says still has plenty of room for improvement.

“We have to look at the geology in the quarry and not think that everything is just the same, because it’s not and it has different qualities. That way we can channel rocks that have great quality, rocks that are perfect to use in any kind of purpose that should go into asphalt and concrete, for example.

“Then we have many other rock types that

Tanja Gjerde has worked as the mining engineer/ geologist at quarry group Feiring Bruk since 2021

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CRUSHING & SCREENING

Crushing and screening solutions making tracks in Africa and America Recent launches and regional rollouts in the crushing and screening sector have included a high-pressure grinding roll crusher becoming available in southern Africa, a new range of longer-life vibrating screens, and a track-mounted screening solution making its debut in North America. Liam McLoughlin reports

H

aving made its global debut in 2018, the Metso HRC 8 highpressure grinding roll crusher is now available in southern Africa from equipment dealer Pilot Crushtec International. While the machine is primarily targeted for the manufactured sand market, there is an opportunity to deploy it in mining, principally in pre-milling applications as a pre-grinder to help improve mill efficiency.

Pilot Crushtec says the demand for economical and efficient ways to produce crushed sand is growing, as natural sand deposits located near growth centres are being depleted and environmental regulations are becoming stricter. As a result, manufactured sand is becoming a high-demand material. The arrival of the Metso HRC 8 ushers in a new era for manufactured sand-makers.

The machine uses a method of interparticle comminution by drawing in a bed of material between two rotating rollers. The rollers, one of which is in a fixed position and another one floating, generate an extremely high pressure, extruding the feed material down to the desired smaller grain sizes.

“The HRC 8 is the ultimate solution to produce excellent quality sand that can substitute natural sand from natural deposits such as rivers. The quality of sand can be adjusted and optimised, thus reducing the amount of cement and asphalt required in concrete mixes or asphalt. The machine produces a gradation according to customer needs and delivers a perfect cubical shape for concrete and asphalt sands,” explains Oldemar Meneses, product manager, HRC Technology at Metso.

In addition, the HRC 8 can convert quarry waste into sellable product. The

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machine can reprocess non-sellable waste materials to correct the gradation curve and particle shape, converting them into high-value sellable products. This not only addresses the cost factor, but also speaks to the manufactured sand market’s drive for sustainable operation.

The machine is suited for manufactured sand, and also for pre-milling applications across commodities such as chrome, lithium, gold, and copper, amongst others.

Both sand manufacturers and mines will benefit from the HRC 8’s increased throughput in a single pass, energy efficiency, reduced ultra fines and reduced operating costs as well as safety and ease of maintenance.

Southern Africa crushing and screening equipment dealer Pilot Crushtec International now offers the Metso HRC 8 high-pressure grinding roll crusher for producing manufactured sand. Pic: Pilot

The HRC 8 provides a notable increase in production efficiency. The flange design maximises the amount of material that is crushed by pulling the feed into the crushing zone. This method prevents the material passing the rollers and increases efficiency and throughput. The patented arch-frame, on the other hand, eliminates downtime caused by skewing.

“By reducing energy consumption and increasing wear life of components, the HRC 8 helps lower operational costs. Its efficient grinding mechanism also reduces the need for secondary crushing, further cutting down operational expenses,” says Francois Marais, sales and marketing director at Pilot Crushtec.

Weir has launched the all-new ENDURON Orbital range of vibrating screens, which features an all-bolted construction for longer life. Engineered for sand and aggregate, construction, and small-tonnage mining operations, the new screens are designed to meet the most demanding of applications.

The screens' all-bolted construction will significantly improve reliability by eliminating welding in high-stress areas, removing the leading mode of failure in vibrating screens. Locking bolts ensures structural integrity and durability, facilitating easy maintenance with quick replacement of individual components without extensive downtime.

“The team has worked hard for the past two years to bring our customers a product that is reliable with the lowest total cost of ownership,” says Corné Kleyn, global product manager for Vibrating Screens at Weir. “Our first screen has been successfully installed and commissioned at a large global customer, and we are gaining momentum with more units planned for both the © AGGREGATES BUSINESS September/October 2024

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CRUSHING & SCREENING

European and North America markets.”

The ENDURON Orbital range is available in two screen types: the E series: Elliptical Motion Horizontal Screens and the C series: Circular Motion Inclined Screens. Both screen types are designed with a commitment to innovation and quality, incorporating the latest technologies to deliver exceptional performance in a broad range of sand and aggregate and mining duties.

A wide operating window provides flexibility to adjust screen settings in line with changing applications or feed conditions without compromising the equipment’s structural integrity and minimising the risk of structural failure related to harmonic resonance.

The modular screen construction ensures that individual components can be easily replaced. Common interchangeable screen parts reduce inventory overflow and simplify maintenance. Both screens are digitally enabled, including the modular exciter technology, which senses and reports on the exciter's condition. The exciter itself features a bolt-on/bolt-off design, meaning it can be easily changed on-site and refurbished in a mechanical workshop.

EDGE Innovate’s first track scalper screen production model, the SCREENPRO S18 is making its North America debut.

The highly versatile EDGE SCREENPRO S18 signals EDGE Innovate’s emergence as a comprehensive screening-equipment solution provider for its global distributor network and individual operators in the mining, quarrying and recycling industries.

“The EDGE SCREENPRO Series represents a huge opportunity for EDGE Innovate and our partners in North America,” says Lee Williamson, EDGE Innovate’s North American distributor manager. “After years of lobbying from our distribution partners, especially in North America, for us to bring out a series of track-mounted screening solutions, we firmly believe this is now the right time.”

Finlay has named Klettur as its new Iceland dealer

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© AGGREGATES BUSINESS September/October 2024

ABOVE: Weir has launched the all-new ENDURON Orbital range of vibrating screens. Pic: Weir BELOW: The SCREENPRO S18 from EDGE Innovate is the first of a series of scalping screens to be revealed by the company in 2024

The EDGE SCREENPRO S18 is the first track-mounted, heavy-duty scalping screen to roll off the company’s production line which will also see a range of differentsized scalping screens set to be added to the SCREENPRO range in 2024 and 2025. The new range of SCREENPRO products will allow EDGE Innovate to satisfy differing customer requirements and budgets.

The new SCREENPRO S18 features a dynamic 15.4m x 1.75m two-deck screen with interchangeable flip flow and conventional scalper screens. This flexibility allows the EDGE SCREENPRO S18 to tackle screening applications that other conventional screens cannot, such as incinerator slag or wet, damp and sticky material. Other design features include a low-level feed hopper, two- or three-way split configuration, and hydraulic folding discharge conveyors to facilitate the quick transition from operation to transport and a fully integrated power unit with large service access.

Global mobile crushing, screening, and conveying equipment manufacturer Finlay has selected Klettur as its authorised distributor in Iceland.

Headquartered in Reykjavik, with a team of skilled professionals and a well-established branch network across the island, Klettur brings extensive experience and a deep understanding of the Icelandic market. With an existing population of Finlay equipment operating under the extreme climatic conditions encountered in Iceland year-

round, the strategic appointment of Klettur will strengthen Finlay's presence and provide enhanced service and support to customers in the region.

"We are thrilled to welcome Klettur as our authorised dealer in Iceland," said Adrian Millar, regional sales manager at Finlay.

"Klettur's reputation for excellence and their dedication to providing efficient and reliable service align perfectly with Finlay's values. Finlay machines thrive in the most demanding applications, including those operating in Iceland's extreme climate.”

Snorra Árnason, sales manager at Klettur, commented: "Over the years we have seen Finlay machines working effectively in quarries across Iceland during all four seasons. The Finlay range of equipment complements our existing portfolio of construction equipment, and we are committed to delivering the quality and reliability that Finlay is known for globally.”

Klettur will provide comprehensive sales, service, and support for Finlay products throughout Iceland.

Mobile crushing, screening, and conveying equipment manufacturer Powerscreen has carried out the successful installation and operation of equipment in Ladakh, Northern India - one of the world's most challenging environments.

A Powerscreen PT400X Jaw Crusher, 1000 Maxtrak Cone Crusher, and Chieftain 1700 Screen were commissioned to work on a Border Roads Organisation (BRO) project near Demchok, close to the China border, at Umling La, Leh Ladakh (UT). At an altitude of 19,024 feet, this project is at the world's highest motorable pass and aims to produce road-construction materials such as granular

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sub base (GSB), wet mix macadam (WMM), and aggregates (5mm, 10mm, 20mm).

The site’s high altitude presented significant challenges due to low oxygen levels and temperatures, which dropped to -°3°C during the project. Additionally, the terrain was hilly with sharp bends and no feasible roads, complicating the transportation and installation of the equipment onsite.

Powerscreen says its equipment is uniquely suited and reliable in extreme climatic conditions due to its robust engineering and advanced technology, reinforced by rigorous testing and quality materials to withstand harsh environments—including high-altitude conditions. Additionally, the innovative design of Powerscreen equipment allows for dismantling and reassembly, facilitating transportation and installation in rough, inaccessible terrains. To navigate the rough terrain, the service team expertly dismantled the Powerscreen equipment for transport and reassembled it on site.

Despite the extreme conditions, the service team completed the installation and commissioning in 15 days.

The Powerscreen PT400X Jaw Crusher has been set up as the primary crusher and takes large and variable-sized feed material to be fed into the 1000 Maxtrak Cone Crusher, which uses Automax crusher technology to provide high volumes of excellently shaped, consistent product. This material is then screened by the Chieftain 1700 Screen to separate the product into its various sizes.

The successful deployment of Powerscreen equipment at Umling La has enabled the BRO to produce the necessary materials for their road project, ensuring the continuation of vital infrastructure development in the region.

The infrastructure will improve access to remote villages, making it easier for residents to travel for medical care, education, and other essential services. The road will also facilitate the delivery of goods and services, contributing to the overall socio-economic development of the region.

ABOVE: The Kleemann MOBIREX MR 130i mobile impact crusher operated by construction-material recycler Feess BELOW: Powerscreen equipment working against the impressive backdrop of the Ladakh region, Northern India

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© AGGREGATES BUSINESS September/October 2024

“This project underscores Powerscreen's commitment to delivering high-performance solutions in the most challenging environments,” said Ranga Swamy, director – Customer and Product Support.

At its headquarters site in Kirchheim unter Teck, Baden-Württemberg, Germany, Feess, a family business, champions the benefits of construction-material recycling in the construction sector via its trading and in-house training centre, as well as its interaction with trade associations and politicians.

A key component in Feess’ overall recycling-process chain is the Kleemann MOBIREX PRO MR 130i mobile impact crusher. The company tested the plant at the end of the development phase and was so impressed that it decided to keep it. Upgraded to serial production standard, the plant now plays an important role in Feess' climatefriendly production.

Company CEO Walter Feess said: "Construction and demolition wastes are a huge factor in the overall volume of waste generated – they make up over 50% of the total waste produced in Germany! At present, high-quality mineral construction resources are dumped in landfill sites every day or are, at most, utilised as materials for sub-bases or filling. This is an incredible waste of valuable resources that we are making every effort to prevent. We return large amounts of construction materials to the cycle and use them, for example, to produce R concrete aggregate.

"With the MOBIREX MR 130i PRO mobile impact crusher, we process concrete demolition material and mixed rubble to produce materials such as mineral aggregates for R concrete. Around 40% of

recycled aggregates can be added to concrete without any disadvantages with respect to processing, appearance, haptics and strength.

Unfortunately, the material is currently rarely used by architects and civil engineers – simply because it is still relatively unknown.

Changing this situation is one of the points we focus on in our training centre: We want to make professional users aware of the quality of R concrete and the amazing opportunities it offers.”

Feess says his company was awarded the contract for the deconstruction of a district administration office in the region. On that project, Feess was able to return more than 90% of the materials to the construction cycle. More specifically, this meant that the aggregate for the R concrete for the new district administration office was produced from the construction materials reclaimed from the old building.

"In other words, we turned old into new!” he adds. “The largest proportion of the mineral construction materials was crushed directly on the construction site or at our recycling depots at a rate of up to 1,800 tonnes a day.”

Feess says the overall concept of the Kleemann MOBIREX MR 130i PRO plant appealed to him and his team right away.

“The low fuel consumption, the high output and the extremely efficient double-deck post screening unit. Space is at a premium here, and with this plant we get two machines in one. We used to use a crushing plant followed by a separate screening plant - now, thanks to the high performance and the ability to discharge two classified final products, the MR 130i PRO is just what we need. It also means that we now only have to operate, service and refuel one machine in our daily routine.” AB

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HAULING

Searching for a more productive & efficient haul A new driverless hauling development, an appraisal of a successful articulated haulier brand’s first three years, and new technology and the latest hauling products offer much for quarrying customers. Guy Woodford reports

S

eptember 2021 was a notable month. Cristiano Ronaldo became the all-time leading goal scorer for men’s national football teams, and SpaceX launched the first all-civilian spaceflight. But in Motherwell, Scotland, the celebrations were centred around something altogether more groundbreaking: the launch of the Rokbak brand.

Since rebranding three years ago, the Scottish articulated hauler manufacturer has carved out a unique identity based on robust and reliable products, an unwavering commitment to customers and an instantly recognisable brand.

“We had a solid product line at the time of launch, but introducing any new brand has an element of risk,” says Jacqueline Reid, Rokbak head of marketing, communications and product management. “However, we had great support from Volvo Group and a clear understanding of who we are and what we stand for, so we were able to create something that perfectly encapsulates our company, our people and our products. And since we launched our customer focus areas, we’ve been able to evolve that even further.”

Launching the Rokbak brand proved a huge success and led to five accolades at the Marketing Society Star Awards 2022. The company has gone on to become a leading name in articulated dump trucks in just three

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years, with its distinctive machines delivering productive and profitable performance to customers worldwide, in demanding applications such as construction, quarrying and mining.

“We set out to create something that not only we could be proud of but that others would be proud to represent,” adds Robert Franklin, director of Sales for the Americas.

“Three years later, we have a strong brand, a strong team and a growing dealer network, all with a positive outlook on the future.”

In fact, North America has been one of Rokbak's biggest success stories. In 2021, the company’s first machines were delivered here, with a pair of RA30s sold to earthmoving, utility, and clearing company Linco Construction of Houston, Texas, via Easton Sales and Rentals.

Since then, RA30 and RA40 models have provided excellent performance in all hauling conditions to customers worldwide.

From muddy terrain to slippery slopes, from scorching heat to sub-zero conditions, these trucks move earth and materials in the UK, Ireland, France, and Germany and on to Indonesia, Papua New Guinea, Australia, and New Zealand.

“We’re proud of the market image and enthusiasm generated by the Rokbak brand,” says Scott Pollock, senior product manager.

“Our team members and external partners

embraced the opportunities it presented, fostering stronger relationships and delivering a more solidified market presence.”

Rokbak's success is rooted in its commitment to customers. It emphasises close collaboration with dealers and personal partnerships with end users and owners. This strategy has been a cornerstone of Rokbak’s growth, with its dealer network expanding as the brand’s reputation grows and customer satisfaction increases.

“We’re fortunate to benefit from strong word-of-mouth referrals and have a wide range of customers and dealers who have a positive view of Rokbak,” says Franklin.

“We’ve had several third-party approaches to work with us due to this. We have a different approach to others, and customers have confidence that their dealer has solid support from the OEM.” Rokbak’s culture of openness extends to its Motherwell facility, which regularly welcomes dealers, customers, and operators to tour the factory, take training sessions, or catch up with colleagues.

Ambitious goals were set for Rokbak before its launch, which the company has not only met but exceeded, including in sustainability, as Reid explains: “Rokbak has introduced clearer communications and built a stronger dealer network. We’ve also improved our product sustainability through reduced fuel

TOP LEFT: Since its launch in September 2021, Rokbak articulated haulers have made their mark worldwide.

ABOVE: Jacqueline Reid, Rokbak head of marketing, communications & product management. Pic's: Rokbak © AGGREGATES BUSINESS September/October 2024

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HAULING

consumption and adapting to alternative fuels such as HVO. We’re increasing the time between maintenance intervals to keep uptime high and reduce material disposal to further reduce our impact on the environment.

“It’s amazing to think how far we’ve come in three years. We have the tools and the people to prepare us for future growth, too.

We’re always moving forward and already looking forward to the next three years.”

Pronto, a Silicon Valley-based autonomy pioneer, and Heidelberg Materials North America, a leading producer of construction materials, will deploy Pronto's autonomous haulage system (AHS) at Heidelberg Materials Lake Bridgeport quarry in Texas.

The announcement follows last year’s successful pilot of Pronto's technology at the same quarry, conducted in partnership with Komatsu North America. The next phase of this pilot will also be on a Komatsu platform.

It will include integrating Komatsu Smart Quarry technologies, enabling enhanced data collection and analysis and improved safety and productivity.

Pronto's AHS is the industry's most cost-effective solution for recruiting skilled operatives while increasing the utilisation of haul truck assets. Pronto's AHS leverages advanced sensors, cameras, and artificial intelligence to autonomously operate haul trucks in complex and dynamic environments.

Heidelberg Materials and Pronto are committed to leading the industry into a new era of efficiency, safety, and environmental responsibility by deploying this innovative technology.

UK-based Longcliffe Quarries has invested in a new Komatsu HD605-8 rigid dumper for quarrying operations.

The company says the move reinforces its commitment to continually invest in the future of its business.

With its reserves of high-purity calcium carbonate, the Derbyshire-based company produces over 100 critical mineral products, which are used in everyday essentials such as animal feeds, glass, and adhesives.

LEFT: Scott Pollock, Rokbak senior product manager. RIGHT: Robert Franklin, Rokbak director of sales for the Americas. Pic's: Rokbak The dumper benefits from the latest Komatsu technology and increased power.

Standout features include auto engine shut-off, auto speed control, a small turning circle, and wireless performance monitoring, designed to offer maximum productivity and low operation costs. With a 778 HP engine, body capacity of 40m³, and payload of 63 tonnes, this large dumper will be well used at the quarry!

Quarry manager Jon Murgatroyd said: “The dumpers can be the unsung heroes of our operation, but they play a vital role in the primary part of our process. With its capacity to carry up to 63 tonnes of rock, this machine will help keep our process running smoothly with a continued supply of stone for crushing and milling.

“The new machine will be operated by one of our very experienced team who can move around 8,000 tonnes of rock per week, keeping customers supplied and the business operating efficiently. Over its lifetime, it will carry up to 3.5 million tonnes of limestone.”

Adam Dennett from Marubeni-Komatsu Ltd (Komatsu) added: “It’s always a pleasure working with Longcliffe, and we are extremely excited to be able to add this new machine to their fleet. We look forward to supporting this investment with a comprehensive repair and maintenance package, ensuring Longcliffe benefits from the improved efficiency and productivity.”

For the operators, this new dumper truck offers a step up in comfort and safety with a bigger cab, 360-degree vision, and a night heater. Longcliffe’s dumper trucks can provide up to 2500 hours of service a year.

Jon concludes: “This investment forms part of our plan to continually upgrade equipment and ensure we maintain our efficiency, production levels and customer service.”

Independently owned Longcliffe operates two quarries—Brassington Moor and Ryder Point— and the Ryder Point Wind Energy sustainable energy sourcing operation.

Less than a year after launching its Bell Equipment Trusted Alternative (BETA) Parts offering, Bell Equipment has expanded its footprint in South Africa and Zambia to include the major articulated dump truck markets of the European and United States

Longcliffe quarry manager Jon Murgatroyd has welcomed the business’s investment in a new Komatsu HD605-8 rigid dumper. Pic: Longcliffe Group

Pronto's autonomous haulage system (AHS) will be deployed at Heidelberg Materials’ Lake Bridgeport quarry in Texas. Pic: Pronto

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© AGGREGATES BUSINESS September/October 2024

www.AggBusiness.com

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HAULING

dealer networks.

Meltus Badenhorst, Bell Equipment director of aftermarket and product support, said: “We introduced BETA Parts after identifying the need to give customers a convenient and competitive parts alternative, endorsed by Bell, for their more mature machines, or those looking for cost-effective solutions. We have been pleased with the interest shown by our African-based customers and their acceptance of the range and are now ready to offer BETA Parts in other regions. Our team is also constantly looking at opportunities to grow the range.

It has supplemented the pilot range of alternators and starters with turbos, V-belts and ground-engaging teeth for buckets.”

According to Meltus, BETA Parts bridges the gap between Original Bell Parts, the company’s premium-quality parts designed to OEM specifications and used in production, and Bell ReMan, major components remanufactured to meet OEM specifications.

Original Bell Parts and Bell ReMan have a one-year/unlimited-hour warranty, while BETA Parts carry a six-month/1000-hour warranty.

At the other end of the scale, Bell Used Parts, available in the South African dealer network, are also available but do not carry a warranty.

He says, “It’s about giving our customers choices so we can fully support their needs throughout their Bell ownership experience.

Our premium Original Bell Parts is our ‘alpha’ or leading parts brand, and BETA Parts is the next best alternative. These give customers more cost-effective parts with less risk than other cheaper parts because they are endorsed by Bell and covered by a Bell warranty.

“Choosing BETA Parts also simplifies the purchasing process, offering a one-stopshop experience that eliminates the need for customers to search and compare prices from multiple suppliers in their quest for savings."

By offering BETA Parts, Bell Equipment ensures that Bell ADT, Tractor, and

Hexagon has launched the newest generation of its advanced Hexagon Collision Avoidance System (CAS) for mining and quarrying customers. Pic: Hexagon

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© AGGREGATES BUSINESS September/October 2024

ABOVE: Bell Equipment has expanded its BETA Parts footprint in South Africa and Zambia to include the major ADT markets of the European and US dealer networks. LEFT: BETA Parts bridges the gap between Original Bell Parts, Bell Equipment’s premium-quality parts designed to OEM specifications and used in production, and Bell ReMan. Pic: Bell Equipment

Tri-Wheeler customers have a wider range of options to suit their needs. They also have the convenience and assurance of dealing directly with Bell Equipment’s extensive dealer network in regions where BETA Parts are available.

Hexagon, the global leader in digital reality solutions, has launched the newest generation of its advanced Hexagon Collision Avoidance System (CAS). Now supporting 4D radar technology, enhanced insights, and interoperability with the Hexagon Personal Alert tagging system, the significant upgrade positions Hexagon CAS as the most advanced collision prevention system on the market.

The upgraded CAS has already been installed in 15,000 vehicles around the globe.

Its standout feature includes advanced 4D radar technology, which enables vehicleto-object detection and vehicle-to-vehicle alarming in GNSS-denied areas. GNSS (Global Navigation Satellite System) depends on the use of satellites, and there are areas of mining and quarrying operations where satellite reception is inaccessible or unreliable. The

4D radar enablement in Hexagon CAS means the select customers who have installed the updated system as part of its initial release can now help prevent collisions in these challenging areas.

At the same time, Hexagon is introducing CAS Insights—a robust insights platform available for use with CAS—which offers customisable, filterable reports that pinpoint the unique collision-risk issues faced at the customer's site. CAS Insights provides timely information about device health and identifies high-risk event areas, enabling operations to make targeted interventions to refine their processes and infrastructure to avoid vehicle collisions.

Lastly, the upgraded Hexagon CAS now includes interoperability with the Hexagon Personal Alert system. Personal Alert uses ultra-wideband technology for vehicle-toperson protection. Together with CAS and the award-winning Hexagon Operator Alertness System (OAS), it provides a critical additional layer of safety.

The advanced Hexagon CAS system, already recognised for its simple installation and accurate alarming, retains its EMESRT Level 7- and 8-compliant vehicle-to-vehicle alarms while offering a scalable pathway for safety upgrades to Level 9 protection.

"Our commitment to creating a zeroharm mining environment is at the heart of everything we do because the most important thing to come out of any mine is the miner," says James Dampney, vice president of Resource Optimisation and Material Movement at Hexagon."

The enhanced CAS system and its interoperability with other Hexagon safety solutions will provide our customers with the monitoring, interventions, and actionable intelligence they need to ensure the protection of people working on their sites and the efficiency and sustainability of their operations. It represents another significant stride towards safer, smarter mining." AB

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THE ELECTRIC SHOWROOM

A bevy of electric possibilities An ambitious global off-highway machine manufacturer showcases its significant electric product range, and two UK building materials players make eye-catching electric equipment moves.

Meanwhile, another top construction and quarrying equipment name has rigorously tested its new electric wheeled loader for UAE customers before its market launch. Guy Woodford reports

L

iuGong hosted 'The BEV Experience: BEVs, Batteries, and Beyond' at its new regional hub in Stalowa Wola, Poland. Dealers and customers from 12 European countries explored the latest battery-electric equipment. They engaged in insightful conversations with BEV (Battery-Electric Vehicle) experts to see how LiuGong is going beyond expectations to give its customers a complete electric experience.

LiuGong demonstrated a range of four BEV machines along with their charging solutions, highlighting their market readiness and their aim to become a market leader in electric construction equipment. Guests participated in product demonstrations, hands-on sessions, and technical discussions to see how LiuGong is advancing its technology and market readiness infrastructure to make BEVs a fully viable option for all its customers.

"This event was a great opportunity to engage with our valued customers and dealers, discussing LiuGong's BEV machines and our expertise in electric technology," said Russell Hudson, product manager at LiuGong Europe. "Hosting the event at our new regional hub in Stalowa Wola allowed us to showcase LiuGong's cutting-edge

work and address any questions our guests had. Guests also had the opportunity to see dynamic demonstrations and participate in hands-on sessions, experiencing first-hand the capabilities of our wide range of LiuGong machines.

"We presented on a range of crucial topics, including charging solutions, machine control systems, safety and security, fleet management, ILINK, spare parts availability and advanced service and maintenance techniques. This comprehensive approach demonstrated LiuGong's commitment to providing robust support and solutions for all our customers."

Four cutting-edge BEV machines were at the forefront of LiuGong's display. The 9027FE mini excavator offers a compact and powerful solution, ideal for work in confined spaces, while the 922FE excavator combines muscle and high efficiency with the latest electric technology. In the wheeled loader category, LiuGong featured the 820TE and 856HE, each representing its dedication to sustainable solutions without sacrificing power and performance.

LiuGong also showcased its impressive line-up of ICE (Internal Combustion Engine) machines. LiuGong's versatile 375B Skid Steer Loader is robust and adaptable, suited

for various job site applications. In the mini excavator range, LiuGong presented the 9018F, 9027F, and 9057F, each designed to deliver efficiency and reliability. The excavator segment included the 915 FCR, 922F, 936F, and 952F, models that enhance productivity with advanced features. Additionally, LiuGong's wheeled loaders, such as the 856T Series, 877H, and 890H, are engineered to boost operational efficiency and performance.

The DRESSTA series includes highperformance dozers celebrated for their durability and strength. The TD-16N sets the benchmark for visibility and safety, while the TD-40, with its impressive 67 tonnes of performance, is engineered to handle the most demanding tasks with precision and power.

China leads the world in BEVs, and LiuGong is a leader in China. As a leader in China's booming BEV technology sector, LiuGong is at the forefront of driving a revolutionary wave in BEV R&D. The Liuzhou-headquartered manufacturer’s plans include launching over 40 BEV models by 2027, including new electric excavators, wheeled loaders, telehandlers and access equipment. LiuGong's pioneering efforts in electric machines are part of the company's

LiuGong hosted 'The BEV Experience: BEVs, Batteries, and Beyond' at its new regional hub in Stalowa Wola, Poland. Pic: LiuGong

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CLOCKWISE FROM ABOVE: LiuGong’s 820TE wheeled loader in action at ‘The BEV Experience’ event.

LiuGong demonstrated a range of four BEV machines and their charging solutions. LiuGong says its 922FE excavator combines muscle and high efficiency with the latest electric technology. Pics: LiuGong strategy to become Europe's No. 1 leader in BEV technology by 2027.

European product director Harry Mellor said: "At LiuGong's 'BEV Experience', guests saw first-hand our impressive range of BEV machines and the comprehensive strategies and solutions we offer. This event highlighted our commitment to sustainable technology, reinforcing our leadership in Europe's transition to electric construction equipment.

As a company, we are on a mission to create a more sustainable future in the construction equipment industry. Our continued investments in R&D, customer insights, and new facilities like the one in Stalowa Wola exemplify that commitment."

Attendees had the opportunity to interact with LiuGong's dedicated BEV team, comprising of experts from product management, service, parts, and sales departments. These professionals are committed to supporting LiuGong's BEV products and ensuring their optimal performance in the market.

Guests were given an exclusive tour of LiuGong's new regional hub in Stalowa Wola, demonstrating its commitment to market readiness and investment in Europe. This integrated facility includes an impressive dealer training centre where professionals gain hands-on experience with the latest machinery and technology.

Additionally, the hub features a sophisticated parts distribution centre equipped with advanced smart logistics and ordering systems, ensuring efficient and timely component delivery. The productproving grounds offer a practical environment for testing and showcasing the capabilities of LiuGong's equipment range. Furthermore, the service repair centre underscores LiuGong's dedication to exceptional maintenance and support services.

This comprehensive tour highlighted LiuGong's capabilities and strategic focus on enhancing customer satisfaction and operational excellence.

According to LiuGong Europe chairman Howard Dale: "We wanted to give our customers and dealers an unforgettable

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and informative journey through LiuGong's electric capabilities, and we did just that with the 'BEV Experience'. Our guests left with a deeper understanding of our impressive line-up of BEV machines and an appreciation of the hard work that the LiuGong team put in behind the scenes at facilities like this new regional hub in Stalowa Wola.

Through the 'BEV Experience', we have once again showcased our substantial market readiness and significant investments in our facilities and the European market. As a result, LiuGong continues to establish itself as a highly credible alternative to the old mainstream brands."

Signifying another step towards a net-zero future, Volvo Construction Equipment (Volvo CE) has successfully staged its first-ever electric construction equipment trials in the United Arab Emirates (UAE) by testing an L120H Electric wheeled loader in collaboration with dealer Al-Futtaim Auto & Machinery Company (FAMCO) and various customers including leading Abu Dhabi-based

concrete supplier ALAS Emirates Ready Mix. The L120H Electric is a 20-tonne wheeled loader that uses the market-recognised conventional machine as its base. It promises the same performance as the conventional machine but alongside the environmental advantage of being emission-free, with near-silent operation and a much more comfortable work environment. It is powered by 282kWh batteries for a runtime of eight hours in light and medium-duty applications, with the ability to work indoors and in noisesensitive areas.

Equipped with cutting-edge electric propulsion technology, the Volvo CE L120H Electric wheeled loader represents a leap forward in reducing carbon emissions and noise pollution associated with traditional diesel-powered construction machinery. By leveraging the power of electricity, the loader offers a cleaner, quieter, and more efficient solution for construction projects.

Plant and machinery specialist FAMCO conducted the trial of the Volvo L120H Electric

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THE ELECTRIC SHOWROOM

wheeled loader at the ALAS Emirates Ready Mix worksite in Abu Dhabi. The machine was tasked with loading from stockpiles to a feeder hopper for the ready mix.

"We've been privileged to experience firsthand the high-performance capabilities of the Volvo L120 Electric," says ALAS Emirates Ready Mix production manager Elie Touma.

"The wheeled loader is extremely impressive, reliable, and efficient, with quick response time. The low noise and vibration reduction has created a comfortable work environment for our operators, which has been reflected in a measured uptick in productivity."

Volvo CE developed a solution to convert the tried and trusted L120 wheeled loader to electric as part of an industry-leading ambition to advance its electromobility offering without detriment to speed and reliability. Volvo CE is continuing its longtime focus on environmental care and driving industry transformation and decarbonisation to combat climate change. The target of net-zero value chain greenhouse gas emissions by 2040 is a united commitment for Volvo Group across all business areas. It is set for ten years earlier than the Science Based Targets initiative as the industry advances the discovery of best practices for constructive environmental change.

"Zero carbon emissions is a big plus for us in helping us achieve our business goals," Touma adds. "Corporate and environmental responsibility significantly influence how we work and try to lead the industry, and we can see the Volvo Electric wheeled loaders as part of that path in our future projects."

The decision to test the L120H Electric wheeled loader in the UAE reflects Volvo CE's dedication to meeting the evolving needs of the construction industry in the region. With the UAE's growing focus on sustainability and green initiatives, introducing the electric loader underscores Volvo CE's commitment to supporting the nation's sustainability

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ABOVE: Volvo CE has successfully staged its first-ever electric construction equipment trials in the UAE by testing an L120H Electric wheeled loader in collaboration with dealer FAMCO and various customers. Pic: Volvo CE BELOW: Following a successful trial during the summer months, Aggregate Industries is set to deploy the first electric cement truck in Britain, with more to come.

Pic: Aggregate Industries goals and contributing to a greener future as the nation continues to prosper. The UAE construction market was valued at $98.3 billion in 2023.

During the testing phase, Volvo CE evaluated the performance, efficiency, and suitability of the L120H Electric wheeled loader for various applications in the UAE's unique climate and operating conditions.

The insights gained from this testing process ensure that the electric loader meets the rigorous standards expected by customers in the region.

"Bringing our L120H Electric wheeled

loader to the UAE for testing means seeing the machine working in one of the most dynamic and ambitious markets in the world," says Ilkay Fidan, commercial manager for Volvo CE in the Middle East. "This reflects our ongoing efforts to drive sustainability and innovation in the construction industry.

By working closely with our partners and customers in the UAE, we aim to deliver solutions that meet their operational needs and contribute to a cleaner and more sustainable future.

"The UAE emerged as the ideal location to pilot electric machines as a mature construction equipment market with strong potential for e-mobility. The L120H Electric has been tested extensively in applications including ready-mix concrete production and the results have been very encouraging, demonstrating strong performance while significantly reducing emissions. This success strengthens our confidence in a wider launch of these electric models in the UAE and around target areas of the Middle East. We believe this is a significant step forward for sustainable construction in the region, and we're excited to be at the forefront of this change."

Volvo CE remains committed to advancing the development and adoption of electrified construction equipment, paving the way for a more sustainable and environmentally conscious construction industry. As testing the L120H Electric wheeled loader concludes in the UAE, Volvo CE looks forward to its commercial launch in the key market.

Aggregate Industries has announced a groundbreaking step in its commitment to sustainability with the introduction of Volvo electric trucks to its cement fleet.

Following a successful trial during the summer months, the UK building materials major is set to deploy the first electric cement truck in Britain, with more to follow.

The new trucks will be based out of the company's Cauldon cement plant near Stoke, alongside its existing 60-strong fleet and several electric charging points.

These represent a significant leap towards environmental responsibility that will © AGGREGATES BUSINESS September/October 2024

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complement further low-emission vehicles within the fleet, including biofuel.

"Introducing electric trucks in our operations marks a pivotal shift towards efficiency and sustainability and is all part of our ongoing effort to decarbonise the business and contribute to our own Net Zero Strategy," says Steve Curley, managing director of Aggregate Industries' cement division.

"The clean and powerful performance of electric vehicles reduces our carbon footprint and enhances operational efficiency, ensuring a reliable and eco-friendly solution for transporting material. "By harnessing cuttingedge technology, we are not just modernising; we are optimising our processes to build a greener and more efficient future for our industry."

Electric cement trucks offer versatile performance due to their ability to deliver bulk and bagged cement. The new Breedon trucks also come with a powerful 600KW motor, offering a sustainable alternative for transporting cement.

Furthermore, as part of the move to electric, Aggregate Industries is partnering with Lomas Distribution, its strategic distribution ally and contracted haulier for the UK domestic market.

"We are excited to work together with Aggregate Industries in adopting sustainable practices," says Gareth Durnall, general manager at Lomas Distribution.

"This exciting step forward perfectly aligns with our joint commitment to environmental responsibility, reflecting a shared dedication to fostering a better and cleaner future."

Breedon Group, a leading vertically integrated construction materials group in Great Britain, Ireland and the United States, recently completed a three-month trial of a fully electric ready-mix concrete vehicle at the Raisby quarry in County Durham, northeast England.

The trial, launched in June 2024 in partnership with Putzmeister and Zenobê,

Breedon Group recently completed a three-month trial of a fully electric ready-mix concrete vehicle at the Raisby quarry in County Durham.

Pic: Breedon Group

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By working collaboratively with Putzmeister and Zenobē, Breedon is improving its understanding of BEVs and their role in industry decarbonisation. Pic: Breedon Group was a significant step for Breedon in Britain as it executes its ambitious net-zero strategy.

With approximately eight hours of running time in urban areas without a recharge, the iONTRON eMixer can support a full day's operations. Its electric motor significantly reduces noise emissions, further aiding its suitability for operations in densely populated urban environments. The 9m3 drum is comparable to conventional mixers, resulting in operational performance comparable to Breedon’s existing internal combustion engine-powered fleet.

The custom-built vehicle is 100% electrically powered and equipped with a substantial 350kWh battery provided by SANY, the parent company of Putzmeister.

Zenobê will monitor the vehicle's operational performance and provide the charging infrastructure: a 120kWh free-standing DS Series charging unit located at Breedon’s Raisby quarry.

By working collaboratively with Putzmeister and Zenobê, leading operators in the battery-electric vehicle and charging infrastructure ecosystem, Breedon is enhancing its understanding of BEVs and how introducing them can help the industry cut emissions.

Breedon is committed to achieving its ambitious carbon reduction targets, and the findings of this trial could pave the way for the widespread adoption of electric vehicles across the quarrying and construction sectors.

Mike Pearce, managing director of Breedon GB Materials, said: “We are very pleased to be part of this exciting development, which shows our commitment to helping our sector reduce carbon emissions. Our trial of the battery electric ready-mix vehicle is a major step forward in our decarbonisation journey and demonstrates our responsibility and ambition to embrace innovative solutions.

“Breedon is always looking for ways to evolve and utilise new technologies to reduce the impact of our products and services on the environment, communities and colleagues.

Over the next three months, we look forward to working closely with our partners on this trial and exploring how our findings can support greater change across the entire industry.”

Kevin Eichele, head of business development at SANY eTrucks, stated: “At SANY and Putzmeister, we’re not just building machines that reduce emissions; we’re building a cleaner future for people. Used in urban areas, our eMixer will outperform diesel mixers on noise levels and TCO, and we are very excited to bring this into action together with Breedon.”

Steven Meersman, co-founder and director of Zenobê, said: “We know that data and analysis are crucial for successful electrification – from planning through delivery and operation. This trial with Breedon Group, SANY and Putzmeister is another fantastic demonstration of the viability of heavy fleet electrification in the construction sector. Through collaboration, we will gain shared insights that will further the electrification of the sector at speed and scale.” AB

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WATER RECYCLING, FILTRATION & MANAGEMENT

Admirable water saving & other pressing matters A big UK wash plant installation, a filter-press first, and a five-year filter-press manufacturing anniversary. Guy Woodford reports

S

ustainability has become a key focus in the aggregate processing industry worldwide. Many producers strive to create as little waste as possible.

Preventing potentially usable products from entering landfills, settling ponds, or spoil tips not only cuts down on the amount of waste materials being produced but also allows for more profit for a producer by generating an additional saleable product.

Reclaiming process water for reuse can also increase production sustainability by reducing freshwater requirements.

Water is a limited resource that quarry operations must manage carefully and strategically. A tailings and water management programme can significantly enhance a site's ability to retain, recycle and reuse water. A well-developed tailings and water management plan can also create a potentially saleable product, minimise pond cleaning and maintenance, and generate clean, recyclable process water.

A secondary aggregate producer in the UK has partnered with McLanahan to implement a wash plant with water recycling capabilities to further add to its sustainability goals. Goonvean Aggregates, based in Saint Austell, Cornwall, southwest England, specialises in processing granite-based

secondary aggregates, which are byproducts from china clay processing. These secondary aggregates are used as alternatives to primary aggregates, promoting sustainable construction, supporting the circular economy and enhancing overall environmental sustainability.

Currently, Goonvean Aggregates sources its secondary aggregates from a supplier.

After processing, some of this material was being returned to the supplier and ultimately sent to a tip. Given Goonvean Aggregates' commitment to sustainability, the company was looking for a solution to utilise all its material completely, eliminating the need to return any to the supplier or send any to tip.

To accomplish this goal, Goonvean Aggregates installed a McLanahan UltraWASH modular wash plant, UltraSAND plant and 10m EcoCycle high-rate thickener.

The feed material is introduced into the UltraWASH modular wash plant directly from the crushing process or through the feed hopper. The UltraWASH washes and sorts the material into three distinct aggregate sizes and a double-washed sand product.

Meanwhile, the UltraSAND plant processes the residual product, integrating it into one of the sand products.

The EcoCycle Thickener handles the waste streams from both the UltraWASH and UltraSAND plants. It concentrates the solids in

the slurry and allows Goonvean Aggregates to recover process water that can be reused in the washing process, enhancing the site's overall sustainability.

The McLanahan UltraWASH modular wash plant, UltraSAND plant and EcoCycle high-rate thickener are helping Goonvean Aggregates meet its sustainability goals.

“Our goals as a business are to be more sustainable in every facet of how we operate as a business,” Matthew Penny, general manager of Goonvean Aggregates, shared.

“It’s an ongoing process, and we’re looking to reduce our carbon footprint. With the McLanahan plant on site, that’s allowing us to do so.”

Processing waste through tailings management equipment can also increase sustainability while yielding clean, reusable water. This is another benefit of managing the waste stream effectively. Historically, quarries have not fully considered the advantages of recovering extra material and water from the waste stream. However, with increasing water scarcity and stricter regulations, many quarries now recognise the need to adopt mechanical methods for better water and tailings management.

Goonvean Aggregates chose a high-rate thickener to reclaim water. These thickeners

Goonvean Aggregates’ McLanahan UltraWASH modular wash plant.

Pic: McLanahan

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recover approximately 85% of water for reuse.

This efficient water recovery system ensures that water consumption remains sustainable and significantly reduces the volume of slurry sent to waste ponds.

The system is designed to recover immediately reusable process water, significantly reduce the demand for make-up water and help to maintain sustainable water consumption levels. It also leads to a drastic reduction in the slurry volume that must be sent to waste ponds. Thickeners can be supplied with flat-bottom, on-ground tanks or elevated tanks, which feature short suction lines that reduce the risk of plugging. The tanks can be supplied as welded-together or bolt-together units, with options for concrete or steel bottoms. A minimum-drag rake arm design reduces the torque needed to move the rakes through the settled solids while minimising disturbance to the already settled material. The system features a hydraulic drive to power the rakes and operate the rake lift, along with accurate rake torque monitoring. It allows the rakes to operate in both forward and reverse directions.

Using the McLanahan UltraWASH modular wash plant, UltraSAND plant, and EcoCycle high-rate thickener, Goonvean Aggregates has successfully met its sustainability goals.

The McLanahan equipment also allows the granite-based secondary aggregate supplier to utilise all its feed material and produce zero waste, eliminating the step of taking material to the tip.

“Since we’ve had the McLanahan plant on site, our productivity and efficiencies have increased. We’re able to provide additional products to the local and national market,” said Penny. “As part of this, it means as a company, we’re ‘zero to tip’. Every part of the product which comes into us, we’re able to process and resell as a finished product.”

Penny said that being “zero to tip” has huge environmental impacts for business.

Specifically, for Goonvean Aggregates, it means the company can process all its feed material to be more efficient and

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Looking towards the McLanahan UltraSAND plant. Pic: McLanahan more productive. It has allowed Goonvean Aggregates to reduce its carbon emissions as well as given the company an additional product offering, increasing profitability.

“It’s enhanced our product offering, our productivity, our efficiencies and our profitability,” Penny said about processing all the material with the McLanahan wash plants and thickener.

Overall, Penny is pleased with the McLanahan equipment and the support Goonvean Aggregates has received from McLanahan throughout the process.

“The support from McLanahan has been excellent and allowed us to proceed and to push on with our strategic goals as a business,” Penny said.

The first ProPress high-performance filter press commissioned by wet processing experts CDE has exceeded processing targets and significantly reduced reliance on costly settling ponds, says the owner of one of Scotland’s leading aggregate specialists.

The ProPress was developed to meet the evolving needs of the construction and demolition waste recycling, quarrying, and

mining sectors and integrates the latest technological advancements to deliver exceptional operational efficiency and maximum water recovery.

Collier Quarrying and Recycling is the first CDE customer to integrate the new ProPress into its wash plant setup. Commissioned in April this year at the company’s Goathill Quarry in Fife, its ProPress X4-200, the largest model in CDE’s new range of filter presses, benefits from 200 plates and can process 20m3 per mechanical cycle.

A longstanding customer, Collier Quarrying and Recycling operates two existing CDE wash plants.

“They’re very efficient, so when I found out CDE was designing its new filter press, I knew it wouldn’t let me down," said owner Duncan Collier. "We’re very familiar with the technology under the hood and fully trusted CDE to deliver – and they really have.”

By the end of the year, the ProPress will be found on eight plants across three regions, processing around 1000tph of material.

With the CDE ProPress, owners and operators can recycle up to 95% of process water for immediate reuse in their wash plant, eliminating the need for settling ponds, which typically require extensive maintenance, consume labour resources, and incur significant costs.

CDE business development manager Fergal Campbell said: “Settling ponds are known to be a source of considerable revenue losses. They occupy a very large site footprint, maintenance costs are high, and they adversely impact the production of saleable material due to the amount of management needed. With the CDE ProPress, we can

LEFT: Fergal Campbell, CDE business development manager. BELOW: Collier Quarrying and Recycling is the first CDE customer to integrate the new ProPress into its wash plant setup.

Pic's: CDE

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WATER RECYCLING, FILTRATION & MANAGEMENT

A Terex Washing Systems’ 165-plate filter press is part of a wash recycling solution for Albin Borer in Switzerland.

Pic: Terex Washing Systems

address many of these pain points with a single solution.”

When Collier Quarrying and Recycling acquired Goathill Quarry, it began recycling demolition waste into reusable aggregates and sub-base materials. This process requires significant water resources along with virgin material processing.

“We’ve been managing settling ponds for over a decade now. More and more, our business is focused on recycling demolition waste, and as that side of the business continues to grow, our water needs increase substantially,” said Collier.

“The time we spend creating and managing the ponds to ensure we have clean water readily available really impacts our productivity, so the integration of a new filter press to dispose of waste and contaminants while quickly returning clean water to our two wash plants has been a really positive development.”

Jordan McCooe, CDE programme manager in the UK & Ireland, said: “For Collier, the challenge with pond management was doubled because it required clean water to supply two active wash plants. Initially, it was thought that two filter presses would be needed, one for each plant. When we reviewed current and projected throughput, we found that a single, large filter press had the capacity to process materials from both plants.”

The CDE ProPress is available in eight different sizes to suit all markets and applications, ranging from the ProPress X1-60, which has 60 plates and can process 6m3 per mechanical cycle, to the ProPress X4-200, which has 200 plates and can process 20m3 per mechanical cycle.

A centrally located 600m3 buffer tank is receiving sludge from both wash plants simultaneously.

McCooe continued: “The ProPress features plates that are 25% larger. The combination of greater chamber volume, fewer plates overall, and the buffer tank means that just one ProPress unit had the capacity to receive and

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process sludge from both of Collier’s wash plants.”

Collier said it has allowed Collier Quarrying and Recycling to reduce its reliance on settling ponds.

He added: “This is hugely positive, not only from a production standpoint but also in terms of health and safety. There’s less maintenance involved, and open water areas have been scaled back greatly.”

With the CDE ProPress, safe and efficient maintenance is made possible by integrated plate-shaking technology, which addresses filter cake build-up within chambers to help reduce the need for manual intervention.

An access walkway provides clear and unobstructed means to carry out maintenance safely and efficiently, and flush-mounted drip trays reduce material entrapment and lock in place to provide a secure maintenance platform for operators.

Operational now for three months, the new ProPress is processing at a higher volume than anticipated,” Collier said.

“It’s capable of doing what CDE said it would do, and more besides. It’s absolutely first class and helping to really accelerate our return on investment.”

Commenting on the functionality of the CDE ProPress, Duncan Collier said it’s “very user-friendly.”

An innovative, multifunctional robot supports the smart design of the CDE ProPress. This robot serves as the main workhorse for the ProPress, controlling plate opening, plate shaking, cloth washing, plate winch, and the maintenance platform.

Once the ProPress is commissioned, every customer is also introduced to the CDE CustomCare team, which provides aftersales support to help customers achieve maximum performance from their equipment. On any given day, the UK and Ireland team has eight service vans and six pick-ups on the road, supporting customers in meeting their production targets.

The CDE ProPress’s range of sizes make is suitable for all markets and applications.

Available globally, it is also largely pre-assembled to minimise construction time on site and expedite commissioning, allowing operators to get up and running quickly to help achieve a fast return on investment.

Terex Washing Systems (TWS), a global leader with over 60 years of expertise in the design and manufacture of washing equipment, is proudly celebrating five years of manufacturing filter presses.

This milestone underscores the team’s commitment to environmental responsibility in quarry operations worldwide. TWS filter presses process around 100 million tonnes annually.

"Our journey in the design and development of our own filter presses began in 2019 and today, we stand as a global leader in delivering complete ‘Feeder to Filterpress’ solutions," says Mark Fisher, business line director of TWS. "The evolution of our filter press technology underscores our commitment to driving efficiency and sustainability in the quarrying industry."

One of the key advantages of the TWS filter presses is their efficiency in water recycling. They reclaim over 95% of the water used in the washing process, minimising water consumption and reducing the need for freshwater input. Filter presses also aid in waste reduction by producing a dry filter cake waste product.

This dry cake is easily transportable and can be reintegrated into the quarry or used for other applications. By maximising water recycling and minimising waste generation, these systems help quarry owners meet environmental regulations and demonstrate a strong commitment to responsible quarrying practices. Another benefit of filter presses is improved overall efficiency of the wash plant by streamlining the water treatment process.

By effectively separating solids from liquids, they produce cleaner water for reuse and optimise the performance of downstream equipment. Quality assurance is another significant advantage as filter presses provide clean, recycled water to re-enter the washing process, improving the quality of washed sand and aggregates.

Since the inception of in-house filter press manufacturing in 2019 at TWS headquarters in Dungannon, Northern Ireland, the team has refined its filter press technology and integrated it into their comprehensive ‘Feeder to Filterpress’ washing solutions. These systems divert waste from landfills while recycling the water used during the process, significantly reducing environmental impact and improving aggregate production for quarry customers.

Beyond innovation, TWS offers comprehensive global support and service.

With 40 distributors worldwide and regional offices in the US, Europe, Asia-Pacific, and Australia, Terex Washing Systems provides localised expertise and service. Supported by a dedicated technical team and advanced laboratory facilities, TWS ensures optimal equipment performance and sustainability throughout its customers' operations. AB © AGGREGATES BUSINESS September/October 2024

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DRILL RIGS, HAMMERS & BREAKERS

Lekatech’s electric hammering technologies are used in mining, quarrying and construction

Electrifying the hammers and breakers sector Two Finnish companies have combined to provide a major new force in the hammers and breakers market, while an advanced surface automation solutions business has rebranded in the US. Liam McLoughlin reports

I

n a major move in the hammers and breakers sector Normet has taken full ownership of fellow Finnish company Lekatech, a start-up founded in 2018 with the ambition to revolutionise hammering technologies by introducing linear electric technology for hammering applications.

Prior to the full takeover announced in August 2024, Normet had initially made a minority investment in 2023 in Lekatech, whose electric hammering technologies are used in the mining, quarrying and construction industries. Lekatech has its premises in Iitti, Finland.

Founded in 1962, Normet’s main products are solutions for charging and blasting, drilling processes, and ground support in tunnel construction and underground mining.

It employs over 1,800 dedicated professionals in more than 50 locations in 30 countries around the world Normet says the ownership aligns with its overall strategy for expanding its electric offering portfolio and demonstrates its search for related, mutually beneficial technologies.

It adds that Lekatech’s fully-electric hammer combined with Normet SmartDrive batteryelectric architecture and Normet XRock boom and breaker systems will define the future of underground scaling and breaking.

“Lekatech’s revolutionary linear electric

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hammering technology further strengthens our resolve to lead the electric transformation in the industry. We are proud of what has been achieved at Lekatech and we now look forward to the next steps in the joint journey.

We are excited to welcome Lekatech’s experts to Normet,” comments Kari Hämäläinen, executive vice president, Strategic business development at Normet.

Lekatech CEO Antti Anttila adds: “Normet enables us to expand and speed up the adoption of the electric hammering technology across industries on a global scale. Having collaborated with Normet for several years we have realised that there is a strong cultural fit and that we share the same values.”

Following the transaction Lekatech will continue to operate as an independent company as part of the Normet Group.

Lekatech unveiled its latest development at Hillhead 2024, the new Electric Hammer LEKA Toras 35.

The patented Lekatech linear electric motor technology is the result of many years of dedicated research and innovation. Its development is now disrupting the traditional hydraulic impact hammer market as its electric technology produces high levels of performance, delivering huge benefits on urban construction projects and in quarry or mine environments, above or below ground.

Lekatech says its electric hammer

technology is a major advance in hammer design and construction. Of light weight and high power, but producing low vibrations, Lekatech hammers are built for operator comfort, economic use and high productivity.

Electrically powered, Lekatech’s linear electric motor produces low emissions and operating costs, and as such, is transforming breaking globally.

Designed to seamlessly integrate with electric carrier machines, Lekatech electric hammers have been designed to be the perfect match for electrically powered machinery. The original Lekatech Electric Hammer delivers up to 70% energy savings when factoring in overall energy consumption of the equipment.

In addition to energy efficiency, the Lekatech Electric Hammer has been able to significantly outperform comparable traditional technology, providing twice the blow impact energy of a hydraulic hammer of the same size.

Lekatech CEO Anttila commented on the newly-launched LEKA Toras 35: “The Lekatech Electric Hammer is highly efficient and has a power-to-weight ratio superior to similar traditionally powered hammers.

Furthermore, it was introduced to the market at the same time as electric excavators and is thus a natural partner for electric-powered equipment and the ideal choice when working in zero or low-emission areas. Through listening to our customers and distributors,

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DRILL RIGS, HAMMERS & BREAKERS

we have now improved the Lekatech Electric Hammer.

As with its existing electric hammers, the LEKA Toras 35 has been developed using the latest technology in conjunction and working with breaking experts in the field. The LEKA Toras 35 is based on tubular linear (permanent magnet) electric motor technology which is designed to withstand the harsh conditions of breaker hammer use.

Despite weighing only 540kg, the structure is robustly constructed with a minimum number of wear parts.

“For an operator, the effectiveness of the hammer is often the most important feature of a working machine. With LEKA Toras 35, significantly higher performance values are reached than with conventional technologies.

It is also highly flexible, with adjustability being integral to its development. Every blow and every gap between the blows can be adjusted individually and dynamically, enabling unprecedented possibilities for hammering applications,” explains Anttila.

“In designing the LEKA Toras 35, we built on the success of our original Lekatech Electric Hammer. This was developed so that users could benefit from using a breaker where each hit of the hammer is optimised with the machine adapting to changing conditions. In effect, using a high precision force that learns. Lekatech technology is an embodiment of digitalisation in hammering and is a catalyst for the electric transformation in the ecosystem.

“Through the latest development, the LEKA Toras 35, we have developed an electric hammer which further revolutionises the breaking and hammering industry. It has been tried and tested in demolition, hard rock quarrying and many other applications, and we are now proud to introduce it to professionals and companies who will truly benefit from its unique and marketchanging features. We feel that given the historical importance of Hillhead to the global hammering and breaking industry, that the show will be the perfect environment to introduce our latest development to the world.”

As with the original Lekatech Electric Hammer, the LEKA Toras 35 is based on Lekatech’s patented linear electric motor technology and uses electric impact hammer technology. This technological breakthrough not only enables more energy-efficient earthmoving, quarrying and mining operations but also strengthens the realisation of a green transition in these fields.

“Environmental friendliness and performance go hand in hand with the LEKA Toras 35, with its programmable features providing flexibility that enables continuous digital development. Furthermore, the innovative hammer eliminates the need for oil and the oil-associated environmental impact of hammering, with oil consumption being reduced by 98% when compared to hydraulic hammers,” concludes Anttila.

The LEKA Toras 35 is now available in a limited number of European countries and its strategically located partners worldwide.

Epiroc, the Swedenheadquartered, global market manufacturer of drill rigs and hydraulic breakers for the quarrying, mining, and construction industries, has unveiled its new generation PowerROC T35 surface drill

Lekatech's new LEKA Toras 35 Electric Hammer

rig, offering increased fuel efficiency and faster operations. This updated edition to the well-known and trusted PowerROC family of surface drill rigs is good news for quarries and construction companies worldwide.

“We are very excited to launch an updated version of this highly regarded surface drill rig. This new generation PowerROC T35 is our most fuel-efficient PowerROC rig ever, says Masanori Kogushi, senior product manager, Epiroc Surface division.

The new generation PowerROC T35 is loaded with benefits that will add value and bring efficiency to quarry and construction operations around the globe.

Fuel consumption is up to 40% lower than the previous PowerROC T35 rig. This is due to the Auto engine speed control, which optimises automatic engine speed for all operations.

The PowerROC T35 will also boost production. It is 45% faster at changing rods than the previous version, which decreases the total time to finish the hole. The updated PoweROC T35 data is presented to the operator via a 12-inch touch screen. The intuitive display makes the rig easier to run and will speed up the training of new operators. Operators can drill only with a few actions, reducing the lever operations required by the operator to approximately 80 % compared to the current version.

“The assisted control will certainly

Epiroc’s next-generation PowerROC T35 surface drill rig

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DRILL RIGS, HAMMERS & BREAKERS

improve operability”, says Kogushi.

A troubleshooting function is also built into the touch-screen display. A new hydraulic return filter has been included with the compact design, which reduces the amount of hydraulic oil required by 50%. Service points are also easily accessible, which makes maintenance easier. In addition, the longer service intervals will help to lower the Total Cost of Ownership (TCO) The operator will also be happy to discover several improvements in the cabin. The cabin is now equipped with updated ergonomic joysticks, which make operation more comfortable. The upgraded air conditioner, with higher cooling performance, will also positively affect the cabin environment.

The new PowerROC T35 is equipped with a COPSC19 rock drill. The drill features a frequency of 50 Hz, which gives it higher performance in hard rock conditions. The SC19 rock drill is also fitted with a dual damper, which helps to improve energy efficiency during drilling.

The new generation PowerROC T35 offers two engine alternatives: a Tier 4 Final/Stage V or Tier 3 engine.

Italian attachments specialist Indeco, whose products include hydraulic hammers, has announced the opening of a new branch in Canada, which it says marks an important step in the process of strengthening its foothold and impact in the North American market.

Indeco has opened a new subsidiary in Canada

Indeco comments: “This important new development demonstrates our commitment to offering superior-quality products and services, maintaining a high standard of excellence and providing top-tier customer support.”

The new subsidiary will be headed up by a team of highly qualified professionals with in-depth knowledge of the industry and consolidated expertise: Mike Pietroniro, a heavy equipment industry veteran with 40 years of experience, in the role of chairman and general manager; Pierre Cloutier, with over 25 years of experience in the heavy

equipment industry, will lead the Canadian sales team; Denis Forget, who has been at Indeco North America for three years and Jason Pietroniro, with 20 years of experience in the sales and manufacture of boom systems, will be the sales managers; Andrew Caruana will be in charge of parts and services.

Indeco adds: “This new chapter not only strengthens our global network, it also represents a unique opportunity to consolidate the direct collaboration with our clients, listening to their needs and responding with targeted solutions.” AB

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© AGGREGATES BUSINESS September/October 2024

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TYRES – 2

Big acquisition amid strong tyre sustainability focus A major sector acquisition has further enlivened an off-highway equipment tyre market focused on sustainability. Guy Woodford reports

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he Goodyear Tire & Rubber Company (Goodyear) has signed a definitive agreement to sell its off-the-road (OTR) tyre business, which provides tyres for applications including quarrying and construction, to The Yokohama Rubber Company for US$905 million.

The cash transaction follows a previously announced strategic review of the OTR tyre business, part of the Goodyear Forward transformation plan.

The Goodyear OTR tyre business provides OTR tyres worldwide for surface and underground mining, construction and quarry, and port and industrial end markets.

Goodyear OTR offers a suite of products, services, and tyre management solutions to help customers optimise their operations and improve productivity and efficiency.

"The sale of the OTR business marks an important milestone as we continue to execute against our Goodyear Forward transformation plan," said Mark Stewart, Goodyear CEO and president. "We are grateful to our OTR colleagues who have driven the success of the business and are committed to working closely with Yokohama to ensure a smooth transition for customers and associates."

Goodyear will retain its business supplying OTR tyres for US military and defence applications. Adhering to a product supply agreement to be entered into with Yokohama

in connection with the closing of the transaction, Goodyear will also manufacture certain OTR tyres for Yokohama at some of its manufacturing locations for an initial period of up to five years after the closing of the transaction.

The deal is subject to regulatory approvals, other customary closing conditions and consultations. It is expected to close by early 2025. Goodyear says it intends to use transaction proceeds to reduce leverage and fund initiatives related to the Goodyear Forward transformation plan.

Evercore is Goodyear's exclusive financial advisor, and Sullivan & Cromwell is its legal advisor.

Off-highway tyre manufacturer BKT is making a major move towards greater sustainability by adopting greener principles.

The firm has joined the Global Platform for Sustainable Natural Rubber (GPSNR).

According to BKT, this will help promote longterm sustainable practices, culminating in environmentally conscious production in line with the principles defined by GPSNR. Natural rubber production offers environmental and social opportunities for improvement. Expanding rubber plantations will likely influence tropical forests, but sustainable practices can help protect biodiversity and reduce greenhouse gas emissions. Similarly, ensuring dignified working conditions and respecting workers' rights on rubber plantations can help promote

an ethical and sustainable industry.

To address these challenges and promote sustainable solutions, the GPSNR unites natural rubber producers, traders, tyre manufacturers, non-governmental organisations, academic institutions and other industry partners.

Through its membership of GPSNR, BKT is strengthening its commitment to aligning the natural rubber supply chain with the organisation's guidelines. As a member of GPSNR, the company has access to a platform that aims to standardise manufacturers’ sustainability reporting and digital platforms for compliance with the European Deforestation Regulation (EUDR) requirements, which will come into effect in December 2024.

"The principles on which GPSNR bases its roots align with our ESG policy. This path will allow us to develop and align our digital tracking initiative for the sustainable sourcing of natural rubber under internationally accepted principles. At the same time, the GPSNR membership allows us to sustain and expand our sustainability initiatives to accelerate structural and quality changes in our natural rubber supply chain over the next five years," said Rajiv Poddar, joint managing director of BKT. To support its mission, BKT is cooperating closely with several Indian government agencies, including the Rubber Board and Automotive Tyre Manufacturers Association of India, as well as some of the world's leading players in the natural rubber industry.

"Being a member of GPSNR also means that we have direct contact with suppliers of premium natural rubber across the world, which is crucial for a company like ours that has always focused on high-quality standards," said Poddar. "This is a strategic and conscious choice that supports our growth ambitions and allows us to pursue ever higher levels in sustainable production."

By joining GPSNR, BKT further confirms its compliance with core principles in sustainable forestry, water resource management, protection of rights and territories, human and labour rights, equality, traceability, transparency and anti-corruption, and training and education.

Goodyear has signed a definitive agreement to sell its OTR tyre business to The Yokohama Rubber Company for US$905mn. Pic: Goodyear

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A LONG WAY

TOGETHER

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TYRES – 2

Anteneh Gebremeskel, GPE Product Manager at Volvo Construction Equipment (Volvo CE), has explained the importance of proper tyre management and how the OEM’s Tyre Pressure Monitoring System makes it easier and more convenient to keep tyres in optimum condition.

As construction companies and quarry operators strive for better efficiency, costeffectiveness, and safety in their operations, one crucial factor that could be overlooked is the tyre pressure on their articulated haulers and wheeled loaders. When these machines move, their tyres encounter rolling resistance, a force that opposes their movement, and the right tyre pressure plays a vital role in how well they perform on the job.

If tyres are underinflated, they have a larger contact area with the road, generating more friction and increasing the rolling resistance. This means the engine needs to work harder to overcome the resistance and consumes more fuel. In addition, the tyre carcass will be exposed to unnecessary loads, which causes premature failure. On the other hand, overinflated tyres wear prematurely in the centre of the tread pattern, leading to decreased tyre service life, operator comfort, and increased fuel consumption.

Furthermore, incorrect tyre pressure can pose a serious safety risk as underinflated, or overinflated tyres make it more difficult to handle an articulated haulier or wheeled loader. Traction and stability decrease, braking distances are longer, and blowouts are more likely. This is when a tyre rapidly deflates during operation and can lead to a sudden loss of control.

Regular tyre pressure checks and maintenance following the operator's manual are essential to maximise fuel efficiency and safety. This straightforward step can save money on fuel costs and reduce the risk of accidents for everyone on site.

To make it easier and more convenient for operators to maintain optimum tyre

A BKT EARTHMAX SR 468 tyre for rigid haulers Pic: BKT

BKT joint MD Rajiv Poddar has welcomed the company joining the Global Platform for Sustainable Natural Rubber (GPSNR). Pic: BKT

pressure, Volvo CE has included a Tyre Pressure Monitoring System as an app on Volvo Co-Pilot with Haul Assist for articulated haulers and Load Assist for wheeled loaders.

The system, consisting of a transceiver and six tyre valve sensors, can also be fitted retroactively.

Tyre pressure and temperature are displayed in real time on the cab screen. Each tyre is monitored independently, and pressure limits are set per axle. If any tyre deviates from the set parameters, the operator is alerted—alarm limits are displayed as nominal values and percentages.

Correct tyre pressure significantly impacts machine performance and site safety. Pic: Volvo CE

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A blue message lets the operator know there are inconsistencies in pressure or temperature and that the situation should be monitored. In contrast, an amber message indicates that these inconsistencies have worsened, and the operator must take action.

All Tyre Pressure Monitoring System data is fed to the cloud and displayed in real time.

Deviations in pressure or temperature are displayed as error codes in the CareTrack telematics portal. Users can make informed decisions on tyre parameters based on similar site conditions by reviewing and analysing trends.

Tyre pressure management is not just a maintenance chore; it's an essential aspect of construction equipment management that directly impacts operations. With the cuttingedge Tyre Pressure Monitoring System, customers can conveniently benefit from increased safety, lower fuel consumption and emissions, enhanced operator comfort, greater uptime, and lower maintenance costs.

Triangle Tyre has always been committed to the ongoing development of its earthmover tyre range with continuous product testing and go-to-market of new products for quarries, underground and surface mining, construction and port-industrial applications.

The range includes radial tyres up to a 63-inch rim, the largest size currently existing in the world in this segment: it is fitted in mines on rigid dump trucks with a load capacity of up to 300 tons and confirms

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TYRES – 2

Triangle as one of the world's leading manufacturers in the Earthmoving tyre sector.

Triangle’s road ahead has marked an important step during the current year, thanks to the introduction of new patterns using cutting-edge technology.

The TL578S E4/L4 tyre in size 35/65R33 has been the perfect example of a new product introduction: a dual-marking tyre for wheeled loaders, characterised by maximum load capacity for use on Block Handler loaders, suitable for handling extremely heavy loads on abrasive and aggressive surfaces and in underground transport.

The TL578 range has been extended by introducing new sizes, such as 29.5R25 and 29.5R29, to make the product compatible with wheeled loaders and underground mine operators seeking higher speed capabilities.

The year 2024 also saw the launch of the new TB577A SUPER in size 24.00R35 for the rigid dump truck segment: the tyre is available in 5 different compounds aimed at improving performance and preventing overheating during long hauls, with customised performance able to meet customer needs.

Triangle has further reinforced its leadership in this segment by enlarging its existing TB526S E4 range with the introduction of the new “3 stars” sizes 18.00R33, 21.00R33, and 24.00R35, which offer increased load capacity and productivity.

All products with alternative tread compounds are available to meet all end users' demands regarding tons per kilometre per hour productivity.

The Forklift and Reach Stakers segment commonly used in materials handling operations has also been involved in the

LEFT: Anteneh Gebremeskel, GPE product manager, Volvo Construction Equipment. BELOW: The pressure and temperature of each tyre are shown on a screen in the cab. Pic's: Volvo CE

process of new product introduction with the launch of TL 619 IND-4, a new line currently available in sizes 14.00-24.

The TL619 IND-4 is ideal for meeting customer needs in Port-Industrial applications, thanks to the reinforced casing, which assures higher load capacity with a reinforced bead area and cut and chip resistance.

LEFT: A front-on view of Triangle’s TL578S tyre. The tyre suits wheeled loaders and underground mine operators seeking higher speed capabilities. RIGHT: Triangle’s new TB577A SUPER tyre in size 24.00R35 for rigid dump trucks. Pic's: Triangle Tyre

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Alongside all these new additions to the Triangle OTR portfolio, the Chinese tyre manufacturer range for wheeled loaders and articulated dump trucks will be completed by the end of the year with the introduction of the TSMS PRO L5S pattern in sizes 20.5R25, 23.5R25, 29.5R29, and 35/65R33 for loaders operating in glass and waste recycling work and underground mining. The new reinforced 3-star casing design and a new tread compound will be used.

Another launch by the end of 2024 will be the new dual-marked TL538 PRO E4/L4 for articulated dump trucks and loaders, initially available in 26.5R25 and 29.5R25 sizes.

Introducing new 3- and 4-star-rated patterns confirms Triangle’s pursuit of meeting the highest load-carrying capacity requirements, providing the end users with the best cost per hour, and representing the number one alternative to premium brands.

These developments were presented at prominent industry exhibitions in 2024, such as Intermat in Paris and Hillhead in the UK. In April 2025, Triangle will attend bauma in Munich, Germany, displaying its TPMS system and sharing best practices and knowledge with professional operators.

Triangle maintains a close relationship with the market and end users thanks to its solid collaboration network with leading specialist dealers in the OTR sector. This allows the company to fully understand customers' needs and develop a product range to meet their requirements, including the highest safety standards.

Triangle provides tyres and services for many of the world's top machinery manufacturers, including Caterpillar to Sany, Hyundai, Komatsu, Liebherr, Hitachi, Zoomlion, Terex, Develon, and CNH. Caterpillar, the world's biggest manufacturer of off-highway equipment, has awarded Triangle with the ‘Supplier Excellence Recognition’ for nine consecutive years. AB © AGGREGATES BUSINESS September/October 2024

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BLASTING & ALTERNATIVES

Increasingly sophisticated blasting analysis A vibrant blasting technology sector offers cutting-edge productivity and efficiency gains to the global aggregates industry. Guy Woodford reports

D

rilling and blasting specialists EPC-UK and EPC Metrics have released their ‘next generation’ drilling and blasting service, ROG+ (Rock on Ground Plus), to customers. This development streamlines operations from a cost management perspective and enables greener credentials through more optimised processes.

Sister companies EPC-UK and EPC Metrics have delivered proven results using ROG tools for many years. However, the recent groundbreaking development of ROG+ coherently brings together the concepts and technologies to create bespoke packages for customers.

ROG+ is a highly sophisticated and accurate blasting service. It involves EPC-UK customers choosing only the specific drill and blast elements needed to support equipment and tools already on site or adding new telematic measurements. This enables entire value chains to be improved, from faceto-gate or mine-to-mill. It also streamlines operations from a cost management perspective and supports greener credentials.

ROG+ involves measuring blast impact through many advanced tools on a continual

feedback loop basis, using a combination of accessible site data and engineer expertise.

“By creating a ‘continuous feedback loop’, we’re able to see how our blasting activities are impacting the overall downstream of a customer’s quarrying operation,” EPC-UK and EPC Metrics’ commercial manager Ryan Ward explains. “As well as the performance and value gained from the materials that are being extracted. We feed that information into the next blast decision-making process and, by making slight adjustments each time, can progressively enable customers’ blasts and operations to become even more optimised.

“Using ROG+’s data suite and our engineering team’s expert knowledge, we’re making better, tailored decisions about how customers blast in the ‘ever-changing’ quarrying environment,” he continues.

“The advantage of choosing only the tech elements from the service offers that apply to each site means customers can significantly improve activity and expenditure within their quarry—whether linked to loading, hauling, fuel usage or crushing to get all the value possible. Equally, it’s helping us to improve choices regarding emulsion types and blends, detonators, timings, top and bottom priming

and blasting parameters. Furthermore, by putting holes in the ground as accurately as possible, the maximum performance is realised from the explosive products used.”

EPC-UK’s general manager, Blasting and Explosives, Ben Coppock, adds: “As the need to operate more sustainably becomes increasingly important, customers can rely on the ROG+ service to optimise their blast performance to improve carbon reductions.

This is because more optimised fragmentation requires less fuel for loading and hauling, and the power consumption for crusher systems is reduced. In addition, the ROG+ service works alongside customers who are introducing a ‘green multi blend’ into their operations to improve environmental performance through sustainable products and blasting efficiency.

“Furthermore, as we use technology to assess performance, measure optimisation and digitally report data from the entire value chain through advanced, real-time KPI dashboard visuals, efficiencies made aren’t just environmental, but also financial.”

EPC-UK and EPC Metrics’ ROG+ service is integrated with EPC-UK’s state-of-the-art software solution, VERTEX. Vertex combines the highly advanced platforms of EXPERTIR, EXPERTAB, and EXPLORE to upload, analyse, and store information used to optimise relevant blast performance. By centrally storing current and historical information and making it easy to access and straightforward to understand, engineers and operators can review past blast performance more effectively and improve future blast designs.

EXPERTIR is a blast design software programme that uses site-collected data to produce the best blasting specifications and outcomes for each blast. It incorporates data from drone surveys, GPS, and hole probes to facilitate design from initial drilling to initiation.

ROG+ involves measuring blast impact through many advanced tools on a continual feedback loop basis. Pic: EPC-UK

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EXPERTAB is a notebook version of the EXPERTIR software designed to support MEMU truck and drill rig operators in the field. Using EXPERTAB, operators can capture digital drilling information while on-site and transfer it back to the drill and blast engineers. The data enables the required blast to be designed and sent to the MEMU for hole loading. All the results are recorded, and information and relevant data are stored and then sent back into EXPERTIR. EXPLORE allows all drill and blast KPI data to be submitted, stored, and analysed together within an online cloud-based database. The digital solution enables engineers to make effective decisions regarding future blast designs and blast parameter changes to improve fragmentation and efficiencies and deliver a true ‘mine-to-mill’ understanding.

Coppock adds: “Our tailored ROG+ service is just one element within a suite of capabilities that EPC-UK will use to shape the future of the drilling and blasting industry for the better. Using knowledge and expertise, we’re succeeding in improving customer efficiencies across the sector with passion and purpose.”

Maptek will soon release BlastMCF, targeting automated blast design. This move will lighten the engineering load while allowing drill and blast engineers to control parameters and outcomes.

Fixed factors like geology, bench height, drill setup, and variable inputs like geometry, explosives, and timing all influence blast outcomes. Balancing these interrelated factors can be time-consuming. Maptek BlastMCF revolutionises blast design for surface operations, quickly generating scenarios that consider competing objectives.

The Maptek Compute Framework (MCF) leverages cloud computational power for rapid results.

BlastMCF automates optimised and detailed blast designs encompassing drill patterns, per-hole charging, and timing, reserving more time for engineers to concentrate on scenario analysis and fine adjustment before exporting to downstream applications.

A large iron ore mine tried a pre-release of

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LEFT: EXPLORE allows all drill and blast KPI data to be submitted, stored, and analysed together within an online cloud-based database RIGHT: The EPC-UK ROG+ Blast Dashboard. Pic: EPC-UK BlastMCF for ease of use, speed to generate scenarios, and value of results, assessing it against day-to-day design and mediumterm planning horizons. BlastMCF was significantly more intuitive and easier to use than traditional CAD-based drill pattern tools. Optimal designs were achieved with fine-tuning to remove, add, or move holes in post-processing.

According to Mark Roberts, Maptek's global strategy manager, BlastMCF is the first important step in orchestrating and automating blast design routines incorporating measured outcomes like vibration, dig rates, and crusher throughput.

Mines can optimise designs to achieve their desired outcomes based on what happens in production. Production and blast performance data will become inputs to continually refine designs, aiming to achieve low fly rock, good dig rates, low vibration, and good crusher throughput.

Five design objective calculators—cost, fly rock, powder factor, fragmentation, and

vibration—are integrated with BlastMCF to measure the quality or fitness of each design generated. Competing objectives are optimised only after honouring the constraints. Where constraint thresholds are very tight, the design with the least violation is returned for review and parameter adjustment.

BlastMCF requires only a polygon, surfaces, and user-defined design bounds like min/max spacing. Hundreds to thousands of possible designs are generated to target good fragmentation and low-vibration objectives before converging on the most optimal.

Engineers are presented with an array of 15 results for evaluation. Graphical and 3D view displays allow them to easily understand the trade-off in design parameters for every blast as they choose the optimum.

Blast designs are readily applied downstream through native integration with Maptek BlastLogic; charge plans and timing designs can be refined before accurate execution on-bench or export to third-party systems.

The Maptek cloud ecosystem will provide the platform for automation and orchestration, centrally connecting up-to-date data formats and sources using Open API.

A Maptek BlastMCF 3D window pattern.

Pic: Maptek

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material. Before Orica’s FRAGTrack was This would be the ideal location to monitor ‘Mines are investing heavily to measure deployed, the New Windsor site team had to the resulting crushed sizes produced by the key outputs across the mining value chain. stop the belt and take a belt cut to sample the primary crusher and help improve quality Automating scripts and workflows to handle belt contents and monitor the particle size control over the first processing stage. repetitive tasks and integrating these with distribution using traditional manual sieving As part of the FRAGTrack deployment, processes and cloud computing allows them techniques. This was performed as often as Orica’s regional technical services team to orchestrate blast design routines that once a week all year round. would assist the quarry operators in targeting optimise based on measured performance,' Over-crushing could also occur due to the an ideal powder factor using the measured Roberts said. lack of real-time monitoring, which increases results from FRAGTrack. Automated reporting This approach is crucial for managing costs associated with crusher power draw dashboards were created using Microsoft complex orebody knowledge or mine and equipment wear. FRAGTrack technology PowerBI and the FRAGTrack external API planning processes and will deliver valuable was shared with Heidelberg Materials as as part of FRAGTrack’s data services in insights that enable miners to make better a potential solution to these operational collaboration with New Windsor. This work decisions. constraints. ensures that important metrics are quickly The Maptek BlastMCF web-based solution Kwaku Boakye, regional mining manager viewable and summarised in an automated will be available soon. It will be natively at Heidelberg Materials North America, says: daily email without additional work. This integrated with BlastLogic Enterprise System “Since installation at New Windsor quarry, custom dashboard is used to quickly review (on-premise) and BlastLogic Single Site Cloud I've had a great experience with FRAGTrack, the fragmentation performance of the past Access. with several operational impacts. day.

In Mongolia, drill and blast specialists “FRAGTrack eliminates crusher standby Due to the improved data visibility from Blast LLC employ Maptek Vulcan and time for a belt cut needed for the lab's PSD FRAGTrack, several key changes were BlastLogic to optimise resources and implemented in the quarry operation. The improve customer productivity. Applying fast data collection and presentation of Maptek decision-support systems is helping the FRAGTrack results allowed a quicker them achieve a data-driven approach that response to size control, helping to better incorporates production metrics, vibration 3D Planning target needed product sizes. Results only modelling, and fly rock data.

Pre-drill updated once a month before, are now Vulcan is used for the precise Post blast profiling available within minutes without design and execution of drill and measurement operational downtime. blast plans, where customisation With the introduction of aligned with geological conditions automated fragmentation improves fragmentation and measurement, New Windsor was overall efficiency. Advanced able to end the need to perform data management and realDigitalised the belt cuts required to sample time analytics in BlastLogic drilling Environmental the size distribution. In addition support better decision-making monitoring A VERTEX surface mining infographic to the safety benefits of avoiding and enhanced safety protocols. working around the belt, this Together, these technologies led to an estimated savings of streamline processes, establishing US$10,000 per monthly stoppage. cost-effective pathways and highEnding the sampling of belt quality outcomes for every project.

Post-drill Controlled stoppages avoids restart costs and According to Blast LLC, one profiling hole loading added strain on equipment, which of the standout benefits of working can cost $8,000 per event. On an with Maptek was the significant annualised basis, this would contribute improvement in drill and blast accuracy over $216,000 in operation efficiencies and efficiency. This is particularly important Optimised Hole gained through added production, reduced for complying with new regulatory standards. design surveying power charges, and reduced equipment wear.

Boosting data analytics around performance New Windsor utilises the FRAGTrack metrics, vibration, and fly rock data will [particle-size distribution] analysis. "This system in day-to-day operations, which deliver further value to local clients in was required as part of our BPM [business allows for a quick check that crushed rock managing resources. process management] once a month. It also is in the expected size range of 4.5-5 inches In other Maptek drill and blast eliminates labour to perform belt cuts for PSD (P80). This allows for rapid response and developments, a new BlastLogic API will lab analysis, saving on tangible and intangible adjustment if the rock exceeds the expected integrate third-party systems, custom costs and possible injuries. It also gives product size. Using the automated dashboard, software, scripts, and tools with the real-time analysis of PSD data, so an impact the quarry can now reset the closed-side BlastLogic ecosystem. The primary focus is to crusher spacing adjustment can be made to setting on the crusher to help meet the make adding new data easier. reduce over-crushing," said Kwaku Boakye, PSD target for the raw mill. Helping avoid BlastMCF and the BlastLogic API are regional mining manager at Heidelberg over-crushing (creation of fines) minimises earmarked for release before the end of 2024.

Materials North America. undesirable byproducts and reduces power Heidelberg Materials North America’s New Boakye says FRAGTrack allows producers use. The formerly used belt-cut method did Windsor (New Windsor) quarry is located to reduce crusher power usage and wear rate not allow for this fast adjustment. near Frederick, Maryland, USA. The quarry while adjusting drilling and blasting designs Collaborating with Orica technical processes approximately 3.4 million tons of to reduce fines and improve fragmentation. services, a typical blast pattern size was material annually and supplies limestone to “This helps the overall optimisation of the increased from 15x15 to 16x16 ft, reducing the Baltimore and Washington, D.C. region. operation,” he concluded. blasting costs. Using the measurements from New Windsor is a large operation with Orica’s FRAGTrack conveyor solution the FRAGTrack system, blasting performance multiple beltlines, and its management was launched in November 2022 as a and effects on the processing circuit were must carefully consider any downtime and complete solution for automated capture and closely monitored for optimum throughput. the operational effects that will have on its aggregation of particle size for the conveyor Data from FRAGTrack helped achieve a production. system at New Windsor. A post-primary target powder factor of 0.6 lbs per ton, which Control of product sizing is important location was decided upon for the installation. improved floor control. AB to maximise returns and minimise waste

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FOR A FULL LIST OF EVENTS VISIT WWW.AGGBUSINESS.COM/DIARY | EVENTS

2024

ADVERTISERS INDEX

NOVEMBER

MARCH

26-29: bauma China 2024 Shanghai, China Organiser: Messe Munchen +86 21 2020 5500 baumachina@mm-sh.com https://bauma-china.com/en/

12-13: SaMoTer Paving Show & Congress 2025 Verona, Italy Organiser: Veronafiere +39 045 8298 133 exhibitors@samoter.com https://www.samoter.it/en/pavingshow-and-congress-2025

DECEMBER 11-14: bauma CONEXPO INDIA 2024 New Delhi, India Organiser: Messe München +49 89 949 20255 franziska.dorfmueller@messemuenchen.de https://bauma.de/en/india/

2025 JANUARY 21-23: World of Concrete 2025 Las Vegas, NV Organiser: Informa +1 212 951 3525 registration@worldofconcrete.com https://www.worldofconcrete.com/

25-27: World of Asphalt 2025 St. Louis, MO Organisers: NAPA, AEM & NSSGA +1 (864) 208 3372 exhibitors@aem.org https://www.worldofasphalt.com/ 25-27: Agg1 2025 St. Louis, MO Organiser: NSSGA Tel: +1 (800) 867 6060 exhibitors@aem.org https://www.agg1.org/

APRIL 07-13: bauma 2025 Munich, Germany Organiser: Messe München +49 89 949 11348 info@bauma.de https://bauma.de/en/trade-fair/

COMPANY

PAGE NO

WEBSITE

Ammann

p4

www.ammann.com

BKT

p45

www.bkt-tires.com

CAT

IFC

www.cat.com

CDE

p43

www.cdegroup.com

Epiroc

p7

www.epiroc.com

Hitachi

p23

www.hitachicm.com

Indeco

p41

www.indeco.it

Komatsu

p19

www.komatsu.eu

McLanahan

p31

www.mclanahan.com

ROKBAK

p18

www.rokbak.com

Volvo

OBC

www.volvoce.com

Wirtgen

p27

www.wirtgen-group.com

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Instagram @aggbusiness_magazine

AGGREGATES BUSINESS EUROPE September/October 2024

51

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