ABI May-Jun 2023

INTERNATIONAL

MAY/JUNE 2023 | VOL.11 ISSUE No3 | www.AggBusiness.com

Driving quarrying efficiencies

INTERVIEW Letisha van den Berg: A new SA quarry operators’ champion p09

MARKET REPORT Korean aggregates challenges in sluggish construction market p13

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COMMENT

HEAD OFFICE EDITOR: Guy Woodford ASSISTANT EDITOR: Liam McLoughlin CONTRIBUTING EDITORS: Munesu Shoko, V.l. Srinivasan,

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EDITOR Fighting for a brighter industry future

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aving taken the reins as the new director of ASPASA (the Aggregate and Sand Producers Association of Southern Africa) in January this year, Letisha van den Berg has reiterated her commitment to giving a voice to small-scale miners. Driving the industry’s quest for zero harm, skills development and ensuring environmental compliance are some of her immediate key focus areas, she tells ABI correspondent Munesu Shoko in this issue’s big interview feature.

Reading through what is a must-read piece, I was struck by van den Berg’s view that environmental compliance will grow in importance to surpass industry safety objectives.

The new ASPASA director explains to Shoko why the issue of royalties will be a key issue for her and her management team. Over the years, payment of royalties has been a hotly contested issue among southern African quarry owners and operators regarding where the value of a mined product needs to be determined to calculate exact payments.

The industry’s dispute with the South African Revenue Services (SARS) exists over the first point of sale at which the value of royalties needs to be calculated. The ‘taxman’ argues that royalties should be calculated from the stockpile, while the industry insists it should be from the muckpile. It will be fascinating to see the new ASPASA leadership’s impact on this longstanding debate.

From southern Africa to southeast Asia.

Based on public declarations, it was great to hear that CEMEX Philippines recently achieved a new record CO2 emissions reduction in the cement industry, re-emphasising its Mexican parent group’s commitment to decarbonising its operations through its Future in Action programme.

CEMEX Philippines (CHP) achieved a 50% reduction in CO2 emissions generated by its two cement subsidiaries, Solid Cement Corporation and APO Cement Corporation, from 1990-2022.

From 2020 to 2022 alone, CHP reduced 18% of its net CO2 emissions, representing 36% of

the total CO2 reduction since 1990, demonstrating the company’s accelerated efforts to further reduce its cement operations emissions.

“This milestone CO2 reduction was possible because of our team’s high commitment to achieve net zero. We are on track to meet our ambition of less than 430kg of net CO2 per ton of cement by 2030 and deliver net-zero CO2 concrete by 2050,” remarked Luis Franco, CEMEX Philippines president and CEO. CHP’s vice president for operations, Santiago Ortiz, says the subsidiary has implemented various projects to help it reach its 2030 and 2050 targets.

He says the company is “challenged but confident” that it can reach an up to 67% reduction by 2030 as it continues to increase its use of alternative fuels and decarbonated raw materials while reducing its business’s clinker factor. Ortiz says CHP will focus more on using clean energy in its cement operations and pay more attention to water usage in cement production.

CHP has been making significant progress in reducing its carbon footprint with investments made in waste heat recovery facilities in Solid and APO cement plants. This has increased the use of clean energy in its operations.

Eco-minded CHP is also said to be leading the industry in the production of low-carbon cement products, such as APO and Rizal Portland and APO and Rizal High Strength.

These are categorised as as Vertua products with a CO2 footprint reduction of at least 25% for its Vertua Plus line and more than 40% for its Vertua Ultra category, making it the most sustainable cement in the Philippines.

CEMEX’s Future in Action programme recognises that the opportunity for reducing emissions is not limited to the production process but to the entire life cycle of its products and transforming the industry’s value chain. Future in Action focuses on achieving sustainable excellence through climate action, circularity, and natural resource management to become a net-zero CO2 company. GW © AGGREGATES BUSINESS INTERNATIONAL May/June 2023

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CONTENTS

QUARRY PROFILE

“Adopting new technologies is at the centre of improved product quality, increased productivity, reduced overheads and, more importantly, improved efficiencies” p47

INTERNATIONAL

MAY/JUNE 2023 | VOL.11 ISSUE No3 | www.AggBusiness.com

Vol.11 ISSUE No.3 May/June 2023

Regulars 03 COMMENT

29 HAULING Rigid haulers delivering fluid production gains

Fighting for a brighter industry future

32 ENGINES – 1 A revved-up engines & alternativepower sector

Driving quarrying efficiencies

All the key events in the quarrying & aggregates world

Features 23 CRUSHING & SCREENING The AI future of crushing & screening starts now

38 DUST SUPPRESSION

INTERVIEW Letisha van den Berg: A new SA quarry operators’ champion p09

A new era of dust-suppression innovation

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Southeast Asia’s first Volvo CE electric machines; Big start-up interest in GCCA net-zero concrete challenge; XCMG reports a strong export performance

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MARKET REPORT Korean aggregates challenges in sluggish construction market p13

COVER STORY: Danoher Group is championing technology-led operational efficiencies at its Bloemspruit Quarry

41 WEAR PARTS/SPARES Not all parts are created equal

43 PORTABLE POWER - 1 Portable-power sector power plays

27 LOADING Hydrogen-powered loading

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CONTENTS

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Specials 09 INTERVIEW ASPASA director Letisha van den Berg is a new voice for SA quarry operators

13 MARKET REPORT - 1 Aggregates demand remains strong in South Korea, driven mainly by new housing needs

16 LIUGONG LiuGong to continue along rapid global growth path

47 QUARRY PROFILE Danoher Group is championing operational efficiencies at its Bloemspruit Quarry

19 MARKET REPORT - 2 Despite numerous challenges within the French aggregates, quarrying and construction equipment markets, good sales opportunities remain

19 www.AggBusiness.com

© AGGREGATES BUSINESS INTERNATIONAL May/June 2023

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NEWS Pic: Volvo CE

Southeast Asia’s first Volvo CE electric machines arrive T he first fully electric construction machines from Volvo Construction Equipment (Volvo CE) for Southeast Asian customers have arrived in Singapore and were formally launched for the region’s market at a gala event on 7 June 2023 on the island of Sentosa. More than 100 guests gathered to celebrate the landmark moment and see the exciting new technology up close.

At the launch event were senior leaders from the country’s most important building and construction companies, Volvo CE dealers from Southeast Asia, and Volvo CE leadership from Asia.

Tomas Kuta, president of Volvo CE’s Asia region, kicked off the launch by sharing insight into the sustainability goals of Volvo CE. “Our company wants to reach net-zero emissions by 2040, and as part of that and our commitment to Science Based Targets, we want to reduce emissions from our product line by 30% by 2030, as well as reducing emissions from our operations by 50% in the same timeframe. For the Singapore construction equipment market – Change Starts Here. Singapore is a natural market for electric construction machines with a strong focus on sustainability,

efficiency, and safety in its construction industry. We are launching our first electric machines in Southeast Asia, and we believe it will act as a launchpad for further sales in Singapore and the wider regional market.”

Volvo CE aims to have 35% of the machines it sells powered by electromobility by 2030. It already has the widest range of electrically powered construction machinery available today. To begin in Singapore, the company has launched three models: the ECR25 Electric compact excavator, the L25 Electric compact wheeled loader, and the EC55 Electric excavator.

Jenny Egermark, chargé d’ affaires a.i., at The Embassy of Sweden in Singapore, was among the VIPs at the event and paid tribute to Volvo CE’s ongoing drive for change: “I am delighted to see Volvo’s innovative Swedish construction machines launching in Singapore. They are excellent additions to Singapore’s robust construction industry.

Both Sweden and Singapore have ambitious goals toward sustainability and reducing carbon emissions. The launch of Volvo’s first electric construction machines brings us one step closer to achieving these common goals.”

More than 70 start-ups worldwide have applied for a pioneering scheme to make low-carbon concrete. The Global Cement and Concrete Association (GCCA) says that its member companies are on a mission to fully decarbonise concrete, the world’s most used material after water. The Innovandi Open Challenge brings together start-ups and the industry’s leading manufacturers to work together on innovative ways to cut emissions and accelerate progress.

In April, applications were invited from start-ups interested in working with leading companies on new materials and ingredients for low-carbon concrete – a vital element in the

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GCCA’s Concrete Future 2050 Net Zero Roadmap. Applications were received from every region of the world.

A shortlist will now be drawn from applications by the GCCA and its member companies of the most promising and deployable technologies. Those ultimately accepted for this year’s Innovandi Open Challenge will gain unique access to industry plants, labs, key networks and the expertise and infrastructure of the GCCA’s 40 members worldwide. They will also receive guidance from the GCCA and its members to help them develop new technology and business strategies.

It is the second year the Innovandi Open Challenge has been running. The first

© AGGREGATES BUSINESS INTERNATIONAL May/June 2023

A ready-mix concrete plant programme, launched in 2021 and primarily focused on carbon capture and utilisation, has already seen two projects go to the pilot stage.

Claude Loréa, GCCA cement director and nnovation lead, expressed her delight at the number of applications: “To

© Maksim Safaniuk | Dreamstime.com

Big start-up interest in GCCA net-zero concrete challenge

receive more than 70 quality applications from start-ups for this year’s Innovandi Open Challenge is hugely encouraging and shows what level of interest and work is being done to help drive climate action, with applications received from every region of the world.”

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NEWS

XCMG reports a strong export performance C hinese construction machinery manufacturer XCMG reports healthy 2023 trading after a strong 2022 – including a vibrant export business. The firm had a total revenue of US$13.57bn last year and a net profit attributable to shareholders of $622.78mn.

In Q1 2023, XCMG posted revenue of $3.46bn and net profit attributable to shareholders of $216.9mn, with the company projecting growth.

“As a globally leading provider of construction machinery and sustainable development solutions, XCMG can consolidate its strategic advantages through the economic slowdown affecting the industry, prioritising technological innovation and internationalisation in its strategic roadmap to grow with resiliency,” said Yang Dongsheng, the company’s chairman.

In 2022, XCMG invested $831.45mn into R&D overall,

XCMG forecasts 19% revenue growth for 2023 as its export business continues to flourish.

Pic: XCMG a 6.13% increase year-on-year, and it accounted for 6.13% of the total revenue of the year, which was a significant increase compared to 4.64% in 2021.

XCMG had 5,767 R&D personnel as of the end of 2022, a 14.97% increase year-on-year, making up 21% of the total number of employees. Most of the new talent who joined XCMG in 2022 are experienced

researchers committed to tackling the most challenging bottlenecks. The firm benefited from sales development in overseas markets with significant export growth. It responded to a peak in China’s construction machinery industry during 2021, focusing on developing its exports instead.

In 2022, XCMG achieved US$4.03bn of international

revenue, a 50.5% growth yearon-year, and an export income of $3.13bn saw a 70.5% growth year-on-year. It also saw a higher gross profit margin in international markets of 22.33%, compared to 19.32% in the domestic market.

XCMG now exports to 191 countries and regions worldwide, and its export market share has increased by 2.42%.

XCMG’s international subsidiaries also showed strong performance in 2022. XCMG Brazil’s revenue grew by 86.35%, while XCMG Schwing grew by 30.33%. XCMG’s India company improved local production capacity in its first year of operation.

Strategic global R&D bases to support innovative technology development and international strategies have been established

by XCMG. The manufacturer is projecting a 10% revenue growth in 2023 based on industry, domestic, and international trends.

HD Hyundai Infracore targets MEA with DEVELON HD Hyundai Infracore is targeting the Middle East and Africa (MEA) market with its new brand, DEVELON, formerly Doosan Construction Equipment. The company recorded revenue of $330mn last year in the MEA region, a sharp increase of 116% compared to $150mn in 2020.

The number of machines sold has also exceeded 2400 units, marking a 60% increase in sales compared to 2020, mainly due to the company’s focus on securing large-scale customers with new advanced technology-equipped machine launches and customised services.

The construction equipment market volume in MEA increased from 16,720 units in 2020 to 32,786 units in 2022, which shows that the market is experiencing a steep growth with a 96% increase over the past three years.

According to a global market research agency, Research and Markets, the MEA construction equipment market is

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growing annually by 4% and is expected to grow to $6.4bn in 2028 from its current volume of $4.26bn.

HD Hyundai Infracore has been paying great attention to strengthening its presence in the Middle East through its office in Dubai and is contesting for first place in Saudi Arabia whilst pulling ahead of other global competitors after winning business on large-scale construction projects in UAE. This year, it aims to sell 1200 units in UAE, an increase from 1000 units sold last year.

With Saudi Arabia planning the world’s largest project, Neom City, which is expected to exceed $500 billion in volume, HD Hyundai Infracore anticipates that this will result in more constructionequipment demand shortly.

HD Hyundai Infracore has recently established a new African office in Accra, Ghana, to expand its network and secure more customers in Western and Central Africa, where the market is growing.

A Develon branded wheeled loader at work. Pic: Develon

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INTERVIEW

Letisha van den Berg, new director of ASPASA

New voice for SA quarry operators Having taken the reins as the new director of ASPASA in January this year, Letisha van den Berg has reiterated her commitment to giving a voice to small-scale miners. Driving the industry’s quest for zero harm, ensuring environmental compliance, and skills development are some of her immediate key focus areas. Munesu Shoko reports www.AggBusiness.com

© AGGREGATES BUSINESS INTERNATIONAL May/June 2023

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INTERVIEW

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uarries and small-scale mines play a crucial role in developing any economy.

As well as providing essential construction materials, these operations stimulate local communities through investment and providing jobs. Yet, in South Africa, they are currently faced with a number of challenges that threaten their existence. The lack of meaningful infrastructure investment in the past ten years has presented a major economic hurdle for the industry. In addition to tough economic challenges, small-scale miners have to grapple with their legislative obligations.

Compliance by its very nature costs money, and a lot of it, which is why van den Berg has set her sights on providing small-scale miners with cost-effective solutions to comply.

Her passion for the small-scale mining industry is not only rooted in her 25-year experience in the quarrying industry but also in the fact that she kick-started her decorated career at a small AfriSam (then Alpha Cement) aggregates and ready-mix concrete operation back in 1998.

“I started out as an admin clerk at an operation in KwaZulu-Natal. In this role, I was more of a ‘jack of all trades’, which exposed me to the various functions on-site, all the way from technical and plant maintenance

to cost management, and everything in between,” she says. “Managing costs for such a small operation was particularly critical, and we successfully found ways to comply within our limited means. That’s where my passion for small-scale miners stems from because I have first-hand experience of how things work in their world.”

However, from the onset, van den Berg had a great passion for health and safety.

In 2003, she moved to AfriSam’s Verulam Quarry, where she was granted her wish to focus on health and safety, and the rest is history. Two years later, she was appointed AfriSam’s regional safety practitioner for KwaZulu-Natal, before she assumed the role of group health and safety manager for the company’s Construction Materials Division in 2010.

After 17 years at AfriSam, she moved to Afrimat in 2017, where she was appointed group health and safety executive, a role she held until her recent appointment as the director of ASPASA in January this year.

Leveraging her wealth of health and safety management experience, van den Berg is determined to further accelerate the industry’s quest for zero harm. While ASPASA members have achieved a remarkable sevenyear fatality-free feat, she believes that a lot more can be done to eliminate accidents and injuries on sites.

“We cannot deny the fact that our industry works in a potentially dangerous environment. However, having been in the industry for so long, I understand the reasons behind some of the injuries we still record at our member operations. One of my immediate objectives is to find ways to curb these injuries, which is key to our quest to achieve zero harm,” she says.

On the health and safety front, van den Berg’s tenure at ASPASA coincides with the recent gazetting of the Collision Avoidance Systems (CAS) regulations by the Department of Mineral Resources and Energy (DMRE).

During the Zero Harm Forum of the Minerals Council South Africa (MINCOSA) in October 2022, the chief inspector of mines (CIOM) expressed his concerns about trackless mobile machinery (TMM)- related fatalities and the slow implementation of collision-avoidance systems. He consequently requested that the technology readiness date of December 2023 be brought forward to January 2023. At the Mine Health Safety Council summit last year, organised labour also advocated for early technology implementation.

In late 2022, MINCOSA met with the TMM technical team and offered reasons why this was not practical. However, the 17 TMM-related fatalities at both surface and underground operations did not help the industry’s case, says van den Berg. On December 6, 2022, the Minister of Mineral Resources and Energy subsequently signed an order for sub-regulations 8.10.1.2 (b) and 8.10.2.1 (b) in Chapter 8 of the Mine Health and Safety Act, 1996, to come into force.

However, advises van den Berg, operations can ask for exemption from all or part of the requirements of the Act. The Act gives provision that mines may request an exemption from the Minister. If satisfied that

Leveraging her wealth of health and safety management experience, van den Berg is determined to accelerate the industry’s quest for zero harm

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INTERVIEW

Under van den Berg’s leadership, ASPASA will further cast the spotlight on environmental compliance, which in her view will grow in importance to even surpass safety in the near future

the employer has consulted appropriately with the affected employees or their representatives, the Minister may exempt the employer from any or all of the provisions of the Act or from a notice or instruction under this Act. “If any mine owner decides to go the exemption route, firstly it is important to explain how they are going to manage the ‘significant risk’ on site – that is principal,” she says. “Then they also need to provide the basis or references upon which past and future CPS ecosystems are based on. These include traffic management processes, TMM fleet size, competencies of operators and an explanation of their environment (production throughput, blasting frequency, tonnes moved and employee complement).

“The motivation for exemption can also include issues such as skills shortage and the

prohibitive costs of installing CAS systems at small surface-mining operations. The motivation, however, should be based on how the operation is going to reduce significant risk, citing tasks that have been completed to date and those in the process of being implemented,” she adds.

Based on feedback from multiple industry stakeholders and those in the legal field, ASPASA has determined several options for its members. “Firstly, members can engage with the DMRE regarding the way forward in their respective regions. We have already spoken to the DMRE in various regions, and some have indicated that there is a threemonth window for implementation, as with any other code of practice that is gazetted,” she says. “Others have indicated that they are waiting for the head office to give guidance.

We are of the view that the department must

first determine how this legislation will be enforced,” she says.

Another option is to engage with OEMs on the technology, its availability and warranties. Mines can also apply for an exemption from the requirements of the Act. “Operations should use this time to reassess their risk-based approach and confirm that no CAS installation is required as reasonably practicable measures have been implemented and no significant risk to persons exists in terms of diesel/diesel collisions. It is also critical to keep documented proof of the process to present to the DMRE if required,” says van den Berg.

Under van den Berg’s leadership, ASPASA will further cast the spotlight on environmental compliance, which in her view will grow in importance to even surpass safety in the near future. “We cannot deny

#ReadyForBattle

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INTERVIEW

Owing to South Africa’s poor economic performance and a struggling construction industry, the quarrying sector has been under severe pressure during the past few years the growing focus on Environmental, Social and Governance (ESG) in the mining sector.

It is, however, still a concept that fits into the global environmental plan, but not everything has been legislated yet, but one can see that it’s coming,” she says.

The lack of environmental compliance, she says, can have dire consequences for operations. “Remember it is one of the key aspects that can lead to the revoking of a mining licence. In my view, it is as important as safety management, but not everybody understands that. To provide context, there are mining CEOs who are in jail and some who have paid up to R5-million fines related to the environment.”

One of van den Berg’s first initiatives in December 2022, well before she even officially started her tenure, was to run a survey to gauge ASPASA members’ sentiment on the growing importance of environmental compliance.

“They all rated their safety and environmental audits highly, but have also asked the association to close some compliance gaps. We will compile all the gaps and see how we can support our members,” she says.

Owing to South Africa’s poor economic performance and a struggling construction industry, the quarrying sector has been under severe pressure over the past few years. “We cannot downplay the economic situation and its impact on our members,” she says. “As an association, we have looked at various ways to help small surface mines to comply in a cost-effective manner.”

To help ease the burden of economic challenges, van den Berg has implemented a levy structure change, which at the time of writing, was awaiting approval by the association’s management committee (MANCOM).

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“As we continue to identify a few roofs that we can take off to unlock further cost benefits for our members, we believe this new levy structure will be a welcome relief for an industry that is reeling from the current economic burden,” she says.

Another key focus area for van den Berg and her team is the issue of royalties. Over the years, payment of royalties has been a hotly contested issue among quarry owners and operators as to where the value of a mined product needs to be determined in order to calculate exact payments.

The industry’s dispute with the South African Revenue Services (SARS) exists over

Letisha van den Berg has taken the reins as the new director of ASPASA

“We have hit the ground running, with a couple of initiatives already achieved since the start of the year.

We look forward to further providing immense value for our members”

the first point of sale at which the value of royalties needs to be calculated. The ‘taxman’ argues that royalties should be calculated from the stockpile, while the industry insists that it should be from the muckpile.

“We are busy exploring ways to join forces with other industry bodies on the royalties battle for small-scale miners. If successful, that will offer another economic benefit for members,” she adds.

Skills development is another area of critical importance for van den Berg. She acknowledges that the current skills shortage, exacerbated by the brain drain, is a major challenge, not only for the quarrying industry, but for the mining sector at large. This is particularly hostile to business growth.

To help the industry close the skills gap, ASPASA has taken a decision to work closely with the Institute of Quarrying Southern Africa (IQSA).

“One of the first decisions we made was to re-establish our collaboration with IQSA. We are handing over the whole training leg of our service wheel to IQSA. We are therefore looking for a young, dynamic professional to run the training department. We are also looking at starting a mentorship programme.

I believe we have some brilliant people within ASPASA who can drive this forward,” she says.

To further enable action on the ground, ASPASA is creating a new level within its setup. Traditionally, there has been the MANCOM and the director. “We are bringing in a new level called Steercom, which is basically a regional chairperson per region,” she says.

In addition, the association has reviewed its service wheel, based on the survey van den Berg conducted in December. This, she says, will help realign the association’s service offering with industry needs. AB

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MARKET REPORT

Aggregates challenges amid sluggish Korean construction sector Industry stakeholders say there are indications of gradual recovery in South Korea’s aggregates sector, with demand expected to increase this year for the first time since the pandemic. Liam McLoughlin reports construction activity in South Korea this year, though full-year growth will pick up to a marginal expansion of 0.8%.”

Cho Byoungyoung, head of marketing & retail support, KSS at Volvo Group Korea, says there are indications of gradual recovery in the country’s aggregates sector.

Last year the actual supply and demand for aggregates decreased by 4.8% compared to 2021, with a total of 232,190,000 m3 of aggregate supplied, according to data contained in the Ministry of Land, Infrastructure and Transport’s ‘Aggregate Supply and Demand Plan’.

However, Cho states: “Despite this decrease, the statistical data suggests that the South Korea quarrying and aggregates sector is on a path towards recovery, as aggregate demand in

2023 is expected to be 238,987,000 m3 based on the domestic construction investment forecast and the amount of aggregate input per billion won in construction investment.

“Although ongoing pandemic-related challenges may cause some fluctuations in production levels, the South Korean quarrying and aggregates sector is showing gradual signs of recovery. By observing this data, we can therefore conclude that the South Korean quarrying and aggregates sector appears to be on a path towards recovery, although there may still be some challenges and fluctuations in production levels due to ongoing pandemic-related obstacles.”

Market figures shared with Aggregates Business International by the World Cement Association show that cement production in South Korea rose slightly in 2022 to 46.8m tonnes from 46.7m tonnes in 2021, out of a total national capacity of 60.8m tonnes.

“The market situation is stable with only small changes in market share,” the WCA said in a statement.

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outh Korea’s aggregates sector is gradually recovering to pre-COVID levels of production, but ongoing challenges remain including a slowing domestic construction market and increasing materials prices.

Willis Rooney, economist at GlobalData, says the South Korean construction industry shows a continued weakness, with low external demand and a slowing of consumption growth likely to weigh on new investment in the short term. This directly impacts on demand for quarry and aggregates products in the country.

The construction industry in South Korea registered marginal growth of 0.2% in real terms in 2022, according to GlobalData research. This followed four successive years of decline.

“The industry’s growth was constrained by the impact of multi-year high rates of inflation, the aggressive unwinding of monetary support by the Bank of Korea and the slowing global economic growth on new construction demand,” says Rooney.

“These factors are expected to continue to weigh on the

“Statistical data suggests that the South Korea quarrying and aggregates sector is on a path towards recovery” Cho Byoungyoung, head of marketing & retail support, KSS at Volvo Group Korea

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The Global Aggregates Information Network (GAIN) says that aggregates demand in South Korea is driven mainly by new housing needs.

It adds that COVID restrictions have been lifted, and there is a determination in the administration of President Yoon Suk-yeol of the People Power Party that was elected in March 2022 to drive the economy forward.

“Access to aggregates resources is an ongoing challenge and marine aggregates are seen as a significant opportunity,” GAIN states.

In a report published in February this year by the Korean Society of Economic and Environmental Geology, authors Sei Sun Hong and Jin Young Lee wrote that, of the total aggregates produced in the country in 2021, 47 million m3 was sand and about 88 million m3 was accounted for by gravel.

The report states that the main sources of aggregates in the country have recently come from screening crushed aggregate and forest aggregate.

It estimates that of the 135 million m3 of aggregates produced in South Korea in 2020, about 49.6% came from screening crushed aggregate, 36.8% from forest aggregate, 2.6% from land aggregate, 6.8% from sea aggregate, 2.6% from washing, and 0.2% from river aggregate.

In 2021, aggregates were produced in 148 local government areas. The 10 leading producing local governments were, in descending order of volume, Hwaseong, Ongjin, Paju, Pocheon, Gwangju, Youngin, Cheongju, Gimhae, Anseong, and west EEZ. The combined production of the ten leading local governments accounted for 30% of the national total, and 47 local governments

produced more than 1 million m3 of aggregates.

In terms of quarrying equipment that is popular in the country Chris Sleight, managing director of Off-Highway Research says that there is strong demand for wheeled excavators in South Korea. He adds that they replace some of the demand which is more usually met by crawler excavators in many other countries.

Cho says that South Korean quarry operators are particularly interested in purchasing excavators and wheeled loaders that meet the requirements set out in ‘Article 19’ of the ‘Enforcement Decree of the Aggregate Extraction Act.’ “The trend seems to be moving towards the purchasing of larger equipment with higher performance capabilities to meet the goal of reducing labour costs that have risen significantly due to the COVID-19 pandemic and improving productivity,” he says.

In addition, quarry operators are looking to lower the number of worksite accidents by reducing the number of workers onsite by using larger and more robust equipment.

Cho says this is due to the introduction of the ‘52-hour workweek system’ across all workplaces in July 2021 and the ‘Severe Accident Punishment Act’ which took effect in 2022.

“By enlarging equipment, quarrying operators can reduce the number of workers required, which, in turn, can help reduce the likelihood of worksite accidents,” he says.

“These factors have shifted the specific type of quarrying equipment that South Korean quarry operators are interested in purchasing, particularly larger excavators and wheeled loaders with specifications that meet these legal requirements.”

The South Korean aggregates sector is being impacted by state policies on sustainability, and the government’s aim for a net-zero society. Environmental, social and governance (ESG) management is being highlighted to realise carbon neutrality, resulting in the need to minimise resource waste and promote resource circulation-type construction because, compared to other industries the construction industry has higher carbon emissions.

“This means it is now necessary to utilise recycled aggregates actively to improve and strengthen ESG management in the construction industry while changes in government policies are also required to secure sustainable aggregate resources,” says Cho. The South Korean construction industry declined by 0.5% in 2022, according to estimates by ResearchAndMarkets. This followed contractions of 2.6% in 2021 and 1.3% in 2020.

The research company said the industry's downturn in 2022 was primarily caused by a combination of rising construction costs, rising inflation, higher energy prices, and increased supply chain disruptions influenced by China's zero-COVID policy. According to the Korean Statistical Information System (KOSIS), the construction industry's value-add declined marginally by 0.2% in the first three-quarters of 2022, decreasing from KRW61.2 trillion (US$48.8bn) during January-September 2021 to KRW61 trillion (US$48.6bn) during JanuarySeptember 2022.

In addition, these disruptions had a significant impact on infrastructure and energy development projects, and consequently on aggregates and quarrying demand. The infrastructure construction sector contracted by 4.9% and the energy and utilities construction sector by 4.2%, respectively.

There is strong demand for wheeled excavators in South Korea

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Despite these persistent headwinds, ResearchAndMarkets says the construction industry is expected to record growth of 0.8% in 2023, aided by industrial project development.

In July 2022, the government committed to provide financial and regulatory support to pave the way for the semiconductor industry to invest KRW340 trillion (US$271.1bn) over the next five years.

The construction industry is expected to record an annual average growth of 4.1% between 2024 and 2026, supported by the development of transportation, energy, residential, and commercial projects. In 2021, the Korean government announced it plans to invest KRW114.7 trillion (US$91.4bn) in order to expand the railway network from its current 4,274km to 5,137km by 2030.

Furthermore, Hyundai Merchant Marine announced a five-year investment plan worth more than KRW15 trillion (US$12bn) in July 2022 to expand its South Korean logistical base.

In terms of the major current opportunities for quarrying-equipment providers in South Korea such as Volvo CE, Cho says the trend following the five-day work week and the Severe Accident Punishment Act has resulted in an increased preference for high-quality, large-sized equipment. He says this has been gradually increasing in the stone industry to reduce labour costs. “This presents an opportunity for Volvo CE to promote its large excavators and wheeled loaders, which are ideal for use in quarrying and mining operations,” he adds.

Cho says that articulated haulers are popular in quarrying and mining sites due to their excellent and reliable work performance, high productivity, low fuel efficiency, and strong durability. This creates an opportunity for Volvo CE to market its articulated haulers to complement its large excavators and wheeled loaders, potentially leading to increased sales in the South Korean market.

Over the next 18 months, Cho says the South Korean quarrying- and aggregatesequipment sectors are expected to experience major developments centred mainly around the need for equipment that prioritises productivity and safety. This is in response to the large demand for the aggregate supply required for the government-sponsored Social Overhead Capital (SOC) infrastructure construction projects from 2023.

“We predict that this is likely to result in accelerated equipment development and innovation in equipment design, technology and maintenance - presenting a potential shift towards equipment that is more sustainable and environmentally friendly,” says Cho. Also impacting the materials sector are the steps being taken by the South Korean government to address safety concerns in the construction industry by revising the Aggregate Collection Act’s Enforcement Decree in 2023. This is in response to an accident at a construction site in Gwangju

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Volvo CE says safety technology like its collision-mitigation system will become increasingly important in South Korea City. The revised decree aims to strengthen the quality-control standards for aggregates and prevent similar accidents from happening in the future.

Cho states that, while this may result in stricter quality-control standards, it may also potentially lead to a reduction in aggregates supply and demand which, in turn, may impact the demand for construction equipment.

“While this may impact the quarrying/ aggregates sector, the full extent of its impact remains to be seen and will depend on various factors including the specifics of the revised standards and how they are implemented and enforced,” he adds.

The South Korean Ministry of Land, Infrastructure and Transport is taking a number of measures to address the decreasing trend of natural aggregate sources and improve the promotion of recycling construction waste in the country. One of these is the passing of the Act on Promotion of Recycling of Construction Wastes (Act No. 17939), which was enforced on June 17, 2021.

In response to these efforts, Cho says the quarry industry is actively promoting the development of technologies to improve the quality of recycled aggregates.

“While the current usage rate stands at only 14.6% as of 2022, new technology that lowers the variability of recycled aggregate quality and meets the strengthened quality control standards is being developed rapidly,” he says.

“As a result, the usage rate of recycled aggregate is expected to accelerate at a rapid pace in the near future. We believe this is an important step towards sustainable development in the construction industry, and it will likely have a significant impact on the quarrying industry in South Korea.”

As part of its sustainability and electrification efforts in South Korea, Volvo CE has announced an investment into

battery-pack production at its excavator plant in Changwon.

With the SEK80m (US$7.8m) investment from Volvo Group, a new production facility and equipment will be built at the Changwon plant – which at around 1.1m m2, is the largest excavator production site in Volvo CE, producing around 55% of its total excavator volumes.

The new facility at the Changwon plant will produce a wide range of common electric-storage solutions (battery packs) for Volvo Group and become a core competence centre for electric excavators. This will enable Volvo Group to offer more sustainable solutions to its APAC markets in a more flexible, cost-effective and agile way and include supply chain, manufacturing and logistics.

Andy Knight, head of operations excavator and managing director of Volvo Group Korea, says: “As the largest plant in Volvo CE and the core site for excavator development and production, Changwon is at the forefront of our shift to a sustainable future.

“This investment is an important milestone in our electrification roadmap and supports our recent investments in production facilities for electric excavators.

Changwon is ideally located close to batterymodule supply partners and other key suppliers in South Korea to meet the needs of customers in the future. We are also home to a highly skilled and motivated workforce who are fully committed to meeting our future environmental targets.”

The new production facility will be built inside the current component workshop at Changwon – without disruption to the existing operation. Once complete, the facility will be approximately 2,500m2, including assembly and logistics areas. The building work will begin in April 2023, with batterypack production expected to commence in June 2024. AB © AGGREGATES BUSINESS INTERNATIONAL May/June 2023

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A LiuGong 950E excavator at work in a quarry. Pic: LiuGong

LiuGong to continue along rapid global growth path Chinese off-highway major LiuGong had a strong presence at CONEXPO-CON/AGG 2023, with trade media at the manufacturer's well-attended press conference hearing about a strong growth strategy reaping dividends in North America and beyond. Guy Woodford reports

Z

eng Guang'an, LiuGong chairman & CEO, and Andrew Ryan, president of LiuGong North America, were not short of things to highlight after welcoming those gathered for the LiuGong press conference at CONEXPO/ CON-AGG 2023 (14-18 March). But the pair need not have opened their mouths for their audience to realise there was much ground to cover. Anyone visiting LiuGong's Festival Grounds stand at the Las Vegas Convention Center will have seen the company's impressive 19-machine line-up, including eight new products and two new batteryelectric vehicles.

One of LiuGong's battery-electric vehicles, the mid-sized 856H-E MAX wheeled loader, was among the machine highlights. The 856H-E MAX can enhance job sites where traditional combustion engines aren't allowed or fixed-site operations where investments in charging infrastructure make sense.

The 856H-E MAX has already proven its reliability in the field, with more than 2,000 electric wheeled loaders operating in the world's toughest conditions as of October 2022, and exponential growth is expected.

LiuGong debuted two new quarrying application-suited, large-sized excavators at the exhibition. The 36-ton class 936F excavator is a step above medium-sized

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excavators, while the 95-ton class 995F excavator will become the largest in the LiuGong excavator portfolio.

LiuGong, whose North American subsidiary is headquartered in Katy, Texas, also featured its HV Series wheeled loaders at CONEXPO-CON/AGG 2023 (838HV, 856HV, 890HV). The HV Series of products have progressed to Stage V emissions standards and include updated transmission and hydraulic systems.

"While we have 19 pieces of LiuGong equipment on our stand, it is only a fraction of our global product line. We manufacture over 300 products and actively market about half that product line in Mexico and around 30% in the US and Canada. We expand that product line yearly as we invest more in research and development to update those products with emissions-compliant engines, enabling us to sell them into our [North America] markets," said Andrew Ryan during LiuGong North America's exhibition press conference.

The last two years for LiuGong have seen records in profit, revenue and growth. While other manufacturers scaled back production, LiuGong has increased its production and inventory, making it, the company claims, the world's largest single producer of wheeled loaders.

LiuGong ranks as the world's 15th-largest construction equipment manufacturer. In 2020, the Liuzhou-headquartered company achieved US$4.046bn in sales revenue, selling more than 75,589 units with 37.1% year-over-year growth.

Renowned globally for its wheeled loader design and production, since 1958 LiuGong has produced more than 420,000 of the machines. As well as wheeled loaders, Liugong manufactures excavators, forklifts, Dressta dozers, pipe layers, motor graders, rollers, pavers, cold planers, skid steer loaders, backhoe loaders, aerial working platforms, truck cranes, lorry-mounted cranes, off-highway trucks, rotary drilling rigs, hydraulic diaphragm wall grabs, hydraulic diaphragm wall drilling rigs, trench cutters and hydraulic cutting and mixing rigs.

"Regarding our forklift product business, it will represent nearly 50% of our US and Canada revenue in 2023," said Ryan. "That business has grown rapidly with the help of some very good dealer partners.

"The 856H-E MAX wheeled loader is the world's first commercially available, batteryelectric mid-sized wheeled loader. We've made the first sale of it in North America and will be handing over the keys [during the exhibition] to the Los Angeles County Sanitation Districts.

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LIUGONG

"These are readily available machines rather than science projects. We can have these machines on a customer site and operational within 90 days."

LiuGong employs approximately 10,000 people, with more than 1,000 engineers working in five world-class research and development facilities. In 2019, LiuGong invested more than $65mn into its R&D programme.

In the coming years, LiuGong expects to add to its current line-up of strategically placed regional offices in the United States, South Africa, Brazil, United Arab Emirates, India, the Netherlands, Poland, Singapore, Russia, China, Mexico, Indonesia and the UK. As well as its US parts distribution centre, LiuGong has overseas parts distribution centres in Mexico, Brazil, Indonesia, India, the Middle East, South Africa, Moscow and Chita in Russia, Singapore, Poland and the UK. A rapidly growing network of more than 300 dealers across six continents more than 100 countries supports LiuGong's global product lines.

Ryan said one of LiuGong North America's big CONEXPO-CON/AGG 2023 goals was to engage with its dealers and new dealer candidates. "We've significantly expanded our North American construction dealer network.

In the last 12 months, we've nearly doubled our footprint, securing some great partners in the US and Canada. I mentioned our great forklift business, and we've added 15 forklift dealers in the US, and another 15 are being appointed to fill out our distribution footprint.

"We want to continue to help our North American customers become acquainted with the LiuGong brand and its meaning. There

LiuGong's 856H-E MAX wheeled loader on show at CONEXPO/CON-AGG 2023 has long been an association with Chinese products being inexpensive. There might also be a perception of low quality. I am proud to say that we have very competitive prices and we have nothing to apologise for on quality.

LiuGong North America president Andrew Ryan (left) with LiuGong chairman & CEO Zeng Guang'an at LiuGong North America's CONEXPO/CON-AGG 2023 press conference

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These are top-notch, excellently engineered machines with world-class components that deliver great on-site performance.

"Our plans for North America are to continue to grow. In broad terms, our North American business grew by around 90% between 2020 and 2021 and by around 75% between 2021 and 2022. We also expect to grow by more than 50% this year."

As Ryan's press conference comments indicated, LiuGong places intense emphasis on quality, demonstrated by a commitment to Six Sigma methodology and compliance with ISO 9000 standards. As a result, after a rigorous review, LiuGong was awarded China's National Quality Award in 2008 and again in 2014.

Responding to a press conference question about LiuGong's partnerships with leading global machine telematics providers, Ryan said: "In the North American market, we have two different solutions on telematics: our homemade iLink for customers in Mexico and Central America offers all the basic telemetry functions like operating hours, fault codes, and monitoring fuel burn. In the US, we partner with Topcon.

We made a breakthrough with them in integrating all Cummins engine data into the Topcon database. This lets us share complete information about their machines with customers to help guide their fleet planning and maintenance."

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dozer productivity and durability with a customer-focused approach to design and manufacturing.

The company's global headquarters are based in Stalowa Wola, Poland, with seven global offices and parts distribution centres, a growing network of more than 70 dealers in 60 countries, and regional offices in the USA, Brazil, United Arab Emirates, South Africa, Russia and Singapore.

As one of only five dozer manufacturers in North America, Dressta places significant focus on this category of the heavyequipment space. Great emphasis is placed on maximising operator comfort, optimising owner costs and providing unrivalled technical support while reducing inspection time. Dressta offers crawler dozers that range from 190 to 575 horsepower (hp).

The company can configure its products to provide excellent performance in various applications.

In 2023, Dressta is launching two new crawler dozers to the North American market, the TD-15M and TD-25M. Built for mid-sized and heavy-sized classes, the duo offers operator-cab enhancements and a mix of versatility and power that follow Dressta's tried-and-true, rugged and reliable mantra.

Ryan commented on Dressta's telematics and machine control offer: "We will integrate Leica's machine control and guidance plate control technology into our Dressta products, ready for installation when they leave the factory. We are also brand agnostic on retrofitter aftermarket machine control solutions. We can work with Topcon, Leica, Trimble and others."

Guang'an highlighted the efficiency gains telematics solutions could deliver for the company's quarrying customers.

"We run these solutions in a quarry with a fleet of 30 to 35 machines. We connect all the machines, and the quarry's operating efficiency improves by 30% in the first year.

In the second year, it improves by 40%.

Just think how much this will reduce our quarry customers' operating costs. This new technology can also improve quarry site safety by identifying and acting on operators with bad habits."

Commenting on LiuGong's plans to develop its battery-electric product lines in North America and beyond, Ryan said: "We are proud to be out in front on this [with the 856H-E MAX], but we have a whole range of wheeled loaders that need to undergo electrification. Our view is that there will be more than one technology. We focus on battery electric if the available technology can power that equipment size. After that, we look at more hybrid solutions. Under the chairman's leadership, every LiuGong product line must create electrified options.

We have pilot lithium-ion battery skid steer loaders and a 20-ton lithium-ion battery excavator on test with a European customer.

We will be ready to scale up production on those machines before long. I expect any of our excavators from 1.8-20 tons to have an electric option in time."

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Guang'an added: "When you use a battery-electric machine, it is zero emission, and the noise level is 30% lower [than a diesel-hydraulic machine]. This bothers people in a city, for example, far less.

"Also, if the battery-electric machine works two or three shifts daily, you get a far bigger cost saving. In China, the average saving from these machines is 60 to 70% as electricity is very cheap. You don't have trouble with the engine and [don't] need so much weekly or monthly machine maintenance. You also get, on average, more than 10% more productivity."

Ryan said that LiuGong North America had not, unlike many original equipment manufacturers (OEMs), suffered from significant supply chain disruption in the

last couple of years. "We are joint venture partners with Cummins in China, and our very close relationship helps us supply customers. Similarly, we have a joint venture manufacturing arrangement with ZF on transmissions. We have partnered with them in research and development on axles and driveline components. Our ability to leverage our strategic partnerships and China-based supply chain throughout those [market] constraints put us in a good position to respond when dealers came calling in 2021 and 2022 and so far in 2023. The reality is that customers have good experiences with our products, and dealers are making good money selling them. We are seeing customers from 12-18 months ago returning for repeat purchases and buying in more quantity." AB

LiuGong’s 886H wheeled loader has proved a popular model with varied industry customers, including in construction and recycling. Pic: LiuGong

Dressta's TD25-M dozer is now available for North American customers pic: LiuGong-Dressta

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MARKET REPORT

Keeping a close eye on French building materials production. Pic: UNICEM

Growth potential despite many French market challenges There are numerous challenges to be faced within the French aggregates and quarrying and construction equipment markets, but good sales opportunities remain. Guy Woodford reports

T

he latest market overview from UNICEM, the trade association bringing together the French mineral-extraction industries and manufacturers of construction materials, highlights how the sluggishness in the French building-materials sector in 2023 follows on from a difficult trading landscape in 2021 and 2022. In just three years, the French building-materials sector, like many other sectors, has had to deal with great challenges linked to the COVID-19 pandemic and the Russia-Ukraine war. If the sector had shown itself to be resilient in its 2021 return to pre-COVID-19-crisis activity levels, 2022 saw it face the full aftermath of the pandemic, with high inflation and rising production costs linked to supply chain disruption affecting materials availability.

This contributed to aggregates and readymixed concrete (RMC) production falling 4% in 2022.

According to early 2023 production estimates, UNICEM says building-materials production is set to be down again in 2022.

Ready-mixed concrete production in March 2023 was down 8.2% compared to March 2022. Taking a 12-month rolling basis, the RMC trend was visible (-5.5% ) in March 2023.

On the aggregates side, activity again declined at the start of the year (-0.7%) between February 2023 and March 2023

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(CVS-CJO data). Production in the year to 31 March 2023 was down 11.8% compared to the previous corresponding period.

Part of this is down to a particularly good aggregates-production start to 2022.

During the first quarter of 2023, aggregatesproduction decreased (-3.5%) compared to the previous months. Moreover, it was down in the same period of 2022 (-11.8%). At the end of March 2023, rolling year-on-year aggregates production volume was down 7.5%.

After observing a decline of 3.6% on a year in the fourth quarter and 3.1% in 2022, the French building-materials indicator contracted 9.8% in Q1 2023 (CJO data). This includes the impact of reduced concreteproduct production in early 2023.

According to the monthly French construction industry survey conducted by INSEE, the deterioration of the business climate, which began in January 2023, continued throughout the first quarter and April. While its level is still well above its long-term average, many signals confirm that the high point has passed and that the erosion of industry confidence will continue.

While legacy orders are still keeping material-producerbusinesses fairly busy, sector entrepreneurs are fearful about the future health of the marketplace. Tensions are evident around declining new building-

material orders, while supply chain and staff recruitment difficulties remain.

Moreover, the latest indicators of the French new housing market testify to a decline in housing demand. New-home sales on a 12-month rolling basis were down 32.4% at the end of March 2023, according to Markemétron (at 88,300 units, the worst number in 15 years).

Among promoters, with barely more than 102,000 reservations for apartments and houses in 2022, the dropout reached -14.6% over the year, the trend worsening in the second semester. Social housing demand does not look better, with 15% fewer 2022 block sales (9,107 units). These trends correlate with a downturn in issued housing permits that started a few months ago. Permits issued increased by 3.2% year-on-year in 2022 (to reach the ‘comfortable’ level of 483,400 units) but plunged 25.4% year-on-year in Q4 2022 and 30.9% year-on-year in Q1 2023 (to 441,400 units).

As for housing starts, they show a decrease of 5.2% in 2022 (at 371,000 units), still visible in the first quarter of 2023 (12.8% over a year).

The non-residential segment is doing better with ‘authorised surfaces’, which, after an increase of +10.7% in 2022, remained positive Q1 2023 (+0.3% over one year). The economic climate to encourage new construction has taken a significant hit. The upgrading of the © AGGREGATES BUSINESS May/June 2023

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usury rate drives this. Meanwhile, the rate of French ‘loans to habitat’ (mortgages) continues to grow rapidly, reaching 3.15% on average in April, a multiplication of 2.4 in just over a year.

At the same time, real estate inflation in new construction continued (+2.8% in one year and + 15.6% since 2020 for a house) under the effect of rising material prices and the introduction of RE2020, which, according to the FFB Housing division, increased construction costs by an average of 7.4%.

With insolvency increasing, households face rapidly rising mortgage-refusal rates (+46.5% November 2022-January 2023 compared to the same months of the previous year).

Thanks to a new increase in activity in March 2023 compared to February 2022 (+1.5% in data CVS-CJO at constant prices), the volume of public works carried out rose compared to last year (+4.5%). However, over a rolling 12-month period, activity still showed a contraction of 5.1% as of 31 March 2023, according to the results of the investigation conducted by the FNTP (La Federation Nationale des Travaux Publics).

Orders did, however, experience a strong rebound at the start of the year (+22.4% in Q1 2023), but this is exclusively attributable to the contract award for the third line of the Toulouse metro and does not reflect wider, stronger investment by public and private players.

Bergerat Monnoyeur (BM) is Caterpillar’s France dealer. Farida Selmani, BM’s marketing manager, says that as the aggregates and quarry business is a demanding sector where efficiency and productivity can make the difference between profit and loss, the company offers French customers a wide range of Cat products and services to support their goals.

“With fleets usually working long hours, a strong fleet management and maintenance programme are key to remaining productive and maximising uptime. We see a significant take-up for Customer Value Agreements (CVA). Those include preventive maintenance, remote diagnostics and fleet connectivity with VisionLink, the web-based

A Cat 988H wheeled loader before (above) and after (below) a rebuild by Caterpillar’s France dealer Bergerat Monnoyeur

GLOBALDATA: FRENCH CONSTRUCTION TO REBOUND FROM 2024 GlobalData’s March 2023-published report, France Construction Market Size, Trend Analysis by Sector (Commercial, Industrial, Infrastructure, Energy and Utilities, Institutional and Residential) and Forecast, 2023-2027, states that following marginal growth in 2022, the French construction industry in France is expected to shrink by 0.6% in real terms this year, owing primarily to subdued investor and consumer confidence, high consumer and construction-cost inflation, rising interest rates and supply chain disruptions which are

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all expected to continue to weigh on the industry’s performance.

According to the National Institute of Statistics and Economic Studies (INSEE), the average construction-materials cost index registered a year-on-year (Y-o-Y) increase of 17.1% in the first nine months of 2022. A sharp decline in consumer confidence will also affect the industry’s output in 2023.

According to the INSEE, the average consumer-confidence index fell by 13.3% last year, following a growth of 3.5% in 2021.

The industry is, however,

expected to rebound at an average annual growth rate of 2.6% from 2024 to 2027, supported by investments in transport and renewable-energy infrastructure projects. The government aims to reduce greenhouse gas emissions by 35%, compared to 2015, by 2030. To support this target, it is focusing on increasing renewableenergy capacity across the country.

In November 2022, the French Senate approved new legislation which requires all car parks – with at least 80 spaces – to be covered by solar panels by 2028. Previously

in February 2022, the French state railway utility SNCF also announced a plan to install approximately 190,000m² of solar panels in 156 stations across the country by 2025 and 1.1 million m² of solar panels in railway station areas by 2030.

Moreover, in January 2023, the European Investment Bank (EIB) announced that it had provided €9.9bn in long-term financing to the private sector and regional authorities in France in 2022. Of the total, €5.9bn was allocated for renewable energy, green transport, and energy efficiency.

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MARKET REPORT

fleet management tool. CVAs allow customers to plan their future costs and limit uncertainty.”

Asked what type of quarrying equipment quarries in France are particularly looking for, Selmani says: “More than ever, quarry owners are looking for fuel-efficient equipment that delivers the lowest cost per tonne, as fuel costs remain a challenge. To reduce those costs and maximise efficiency, customers often opt for the Cat XE range, such as the 966 XE, 972 XE, 982 XE, 988K XE wheeled loaders and the D6 XE dozer as they provide increased fuel efficiency and premium performance.

“Large excavators and rigid trucks remain among the most popular equipment combinations to transport aggregates to stockpiles or distribution centres. The range of Cat next-gen quarry excavators is expanding with the introduction of the Cat next-gen 350 that joins the 374 and 395 models. The 350 consumes up to 13% less fuel than the Cat 349 and is equipped with technology features such as Assist that help increase efficiency and Payload on-board weighing, which gives real-time weight estimates to achieve precise load targets.”

Selmani notes that another solution for customers is rebuilding equipment that allows a machine to have a second or, sometimes, a third life. “Through Cat Certified Rebuild, we rebuild Cat equipment in our workshops and return machines, components and systems that have reached the end of their life to a like-new condition.

On average, we re-use 65% of the parts in a Certified Rebuild.”

Selmani also stresses that short- or longterm rentals through BM’s sister company,

BM Rent, allow customers to fill production gaps and expand their business without growing their balance sheet.

She says about large French construction projects influencing national aggregates and equipment demand: “Canal Seine Nord remains a huge opportunity over the next two years. Another large project is Tunnel Euralpin Lyon-Turin (TELT), creating the Tunnel de Base de Mont Cenis, which will run 57.5km from France to Italy. Early predictions call for the opening of many quarries to

“We believe that the building-materials market is continuing to grow in line with industry reports and forecasts” Trayan Dimitrov, general manager of Hitachi Construction Machinery (Europe) France

support the project, one is expected to be the largest in France, and extraction is estimated to last for the next ten years.”

Like Caterpillar, Hitachi Construction Machinery (Europe) does good business in the French quarrying and large construction equipment market. Trayan Dimitrov, general manager of Hitachi Construction Machinery (Europe) France, and Patrick Top, director of sales and marketing, Hitachi Construction Machinery (Europe), see good market opportunities.

“At Hitachi Construction Machinery (Europe) (HCME), we believe that the building-materials market is continuing to grow in line with industry reports and

forecasts. In addition, the demand for our core quarrying products – the large Zaxis-7 excavator range – remains strong due to their industry-leading reliability and durability, says Dimitrov. He continues: “The feedback from our customers is also positive, and we remain committed to serving their needs with our technical support, parts, fleet management systems and maintenance contracts. In addition, Hitachi Construction Machinery’s (HCM) Premium Used and Premium Rental products are gaining popularity in the French market.”

Dimitrov sees potential for HCME to further expand its quarrying sales and productsupport services in all regions of France, home to around 3,400 quarries. He sees further growth potential for HCME in other parts of the French construction industry.

“This is one of the reasons behind HCME’s recent decision to acquire its authorised dealer Cobemat (now rebranded as Hitachi Construction Machinery France – HCMF).

HCME’s ambition is to expand its sales and rental network in France, in line with its strategy to expand the value chain, and there will soon be a new dedicated HCM rental company established in the Île-de-France region,” Dimitrov explains.

Top says HCME’s “market-leading” 50-90 tonne excavators – the ZX490LCH-7, ZX530LCH-7, ZX690LCH-7 and ZX890LCH-7 – remain the number one choice among its French quarrying customers. “These customers have a wide range of options at their disposal. These include the availability of heavy-duty and bulk excavation arm and boom types and strengthened arms, booms and undercarriages for harsh conditions,” he notes.

Top adds: “In particular, the ZX490LCR-7, ZX690LCR-7 and ZX890LCR-7 models are reinforced to work in the harshest conditions.

And there is a wide range of high-quality attachments, such as buckets and breakers,

Hitachi Construction Machinery (Europe) continues to see strong quarry customer demand for its large Zaxis-7 excavator range, including the pictured ZX490LCH-7

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© AGGREGATES BUSINESS May/June 2023

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MARKET REPORT

and ground-engaging tools for HCM owners to choose from for their specific quarrying needs.”

Asked by Aggregates Business what role digitalisation, automation and machine telematics play in quarrying/buildingmaterials-processing-customers' application needs, Top responds: “The French market is one of the leading markets in this respect.

For example, the first HCME Customised Solutions Zaxis-7 excavator with factoryfitted Leica Geosystems 3D machine control solution was delivered to the French contractor, Kerleroux. This is one of the optional extras available directly from HCME’s Amsterdam factory, empowering our customers to work more independently, productively and precisely.

“Further signs of growth are seen in the digital side of the industry. HCME is not only a manufacturer of equipment and machines but also a solution provider. Digital solutions have cut through in almost all areas, both on- and off-site, from telematics and datapowered machines to remote and fleet management solutions.”

Regarding the importance of sustainability issues to HCME’s French quarrying/ building-materials-processing customers,

Top says: “As an indicator of the importance of sustainability within the industry itself, the annual UEPG [European Aggregates Association] sustainability awards receive an increasing number of entries every year.

Traditionally, quarrying may have been perceived as a polluting and noisy industry, but it is fighting against that view by playing a bigger role in local communities across Europe. An example of this can be found in France, where one site was used for theatrical productions when the quarry was not in use.

“Developments in technology are key to helping the aggregates sector to face the challenges of sustainability and lowering the cost per tonne. Equipment manufacturers are taking an innovative approach with electrification and alternative powertrains, but adopting such innovations will take time” Top notes that quarries find it difficult to go fully electric due to the infrastructure required. “There are more elements to be considered in a quarry than a mine, for example, and the associated costs. Quarrying is also a relatively conservative industry, and it is challenging to convert operators massively to a sustainable agenda.

“Nonetheless, they are interested in new

technology, particularly regarding potential fuel savings and reduced costs. While technology in mining is often considered too capital-intensive for quarrying, there is potential for both sectors to inspire each other, for example, concerning renewable energy and biodiversity.”

Dimitrov highlights major infrastructure projects using HCME machines: “The best example is the French government’s multibillion-euro investment between 2018 and 2037- the Grand Paris Express - the largest transport project in Europe and France’s biggest current infrastructure project.

“HCME’s acquisition of Cobemat and ongoing cooperation with its other dealers in France – will enable the company to take advantage of the new opportunities presented by key accounts. Existing customers will benefit from the availability of deals direct from the manufacturer and a nationwide service structure.

“Additionally, HCMF’s territory covers the Île de France province, the largest and most challenging region driven by OEMs. External trends influencing this acquisition include upcoming large projects, the high rentalpenetration ratio, and the needs of these key accounts.” AB

Heidelberg Materials’ Bussac-Forêt cement plant

HEIDELBERG MATERIALS’ FRANCE DECARBONISATION FOCUS Heidelberg Materials is investing €65mn to accelerate the decarbonisation of its Bussac-Forêt cement plant in western France.

The plant will be expanded to include a facility to produce calcined clay, which can replace parts of the CO₂-intensive clinker in the cement. This will allow the launch of a new range of lowcarbon calcined clay cements containing less clinker.

"Our most recent investment in innovative technologies in France demonstrates Heidelberg Materials' strong commitment to decarbonise our products.

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© AGGREGATES BUSINESS EUROPE May/June 2023

The launch of the transformative project in Bussac-Forêt will be supported by a favourable administrative and regulatory environment", said Dr Dominik von Achten, chairman of the managing board: "The project will reduce the site's CO₂ emissions by up to 20% and thus have a significant positive impact on Heidelberg Materials' carbon footprint in France."

Dr Nicola Kimm, chief sustainability officer and managing board member, added: "In Bussac-Forêt, we are investing in a technology with great potential. It will allow us to significantly expand the range

of low-carbon products. Using calcined clay as a clinker substitute is an important measure to reduce the carbon footprint of cement and concrete. In principle, a CO₂ reduction of up to 40% is possible when substituting cement clinker with calcined clay."

The company is currently piloting calcined clay technology in Ghana, where the world's largest flash calciner is being built with a capacity of more than 400,000 tonnes per year.

This latest investment is in addition to the €46mn already committed by Heidelberg

Materials to decarbonise the Bussac-Forêt cement plant by increasing the alternative-fuel rate from 30% to 80%. The Ecological Transition Agency financially supports the project as part of the France Recovery programme and benefits from support from the Nouvelle-Aquitaine region.

It is fully in line with Heidelberg Materials' climate strategy, which has set targets to reduce specific net-CO₂ emissions per tonne of cement by 47% by 2030 compared to 1990. The Group aims to achieve net-zero carbon emissions by 2050 at the latest.

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CRUSHING & SCREENING

SBM Mineral Processing’s new AI-featuring REMAX 600 impact crusher during its official launch in Ramsau,

The AI future of crushing & screening starts now The incorporation of technologies such as artificial intelligence can revolutionise the crushing & screening equipment sector. Liam McLoughlin reports

M

ore than 170 visitors to the Ramsau quarry in Lower Austria recently got an insight into the potential future of the crushing and screening equipment industry. The quarry operated by Hans Zöchling GmbH - was the venue for the official launch of SBM Mineral Processing’s revolutionary new REMAX 600 track-mounted impact crusher, which features AI capability.

The machine was a major attraction at the 2022 edition of bauma, and the Ramsau event featured performance demos in natural stone and typical recycling materials that demonstrated the all-round qualities of the new 600 t/h crusher.

SBM cooperation partners from the University of Leoben (Montanuniversität of Leoben) gave insights into the ongoing development work around AI-based "autonomous crushing", which should soon be possible with the REMAX 600 and other SBM plants.

Helmut Haider, SBM sales director processing, says that more than three years of intensive development work by SBM and external experts have gone into the new machine.

"We have once again delivered on time," says Haider in view of the closely timed model premieres in recent years, with which the processing specialist has expanded its range of track-mounted JAWMAX jaw crushers and REMAX impact crushers into a highly up-to-date, well-rounded portfolio with six models each ranging from 23 to

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160 tonnes transport weight. With the exception of the large jaw crusher JAWMAX 800, all models offer compact dimensions for economical one-piece transport, despite the diesel-electric hybrid drive with plug-in option and largely class-leading crushing and screening equipment.

SBM has been collaborating for several years with, among others, the Innovation Centre for Raw Materials (IZR) at the University of Leoben. The cooperation with the university has featured computeraided or experimental validation of new or further developed processing solutions and components from SBM’s own R&D department at its headquarters in Oberweis, Austria.

The aim is to develop "intelligent", selflearning mobile crushers that enable the decisive step from crushing, which is already largely monitored and optimised in terms of the interaction of all process steps, to autonomous, fully-automated production.

The first milestone and ideal technology carrier for further development is the now market-ready "conventional" REMAX 600 with its extensive technical equipment, the further optimised electric drive and the latest generation of the CRUSH CONTROL machinecontrol system, which already processes a large part of the machine data generated today.

The teams are currently working on the development of the advanced sensor technology that will enable the machine to automatically detect the type and composition of the feed material and the particle-size distribution of the end

products. Together with the load conditions of the crusher and conveyors, which are also determined in real time, the CRUSH CONTROL system transmits all the values determined in the field via a cloud solution to the SBM headquarters. A ‘digital twin’ created there compares the actual machine performance with thousands of stored reference data from 1:1 quality tests, laboratory tests and computer simulations (rock properties, grading curves, particle shapes, etc.). The resulting optimisation potential is fed back into the machine's control system and, thanks to innovative machine-technology solutions, enables all process stages, right down to the air classifier and magnetic discharge, to be adjusted immediately and continuously on-site without interrupting operation.

According to SBM, autonomous crushing is designed to provide significant support and relief for operators and operating personnel: for example, the system can be configured precisely to requirements on a data-based basis, even before a change of location or material, through the correct selection of screening media. An interactive menu-control system allows even inexperienced operators to set up production precisely, depending on whether maximum output, minimum fuel consumption (‘eco-mode’) or optimised production of certain valuable aggregates is required. A new type of integrated tool monitoring in the impact crusher also helps to reduce quality losses due to wear during production and provides important support for predictive maintenance.

With the newly-developed REMAX 600, © AGGREGATES BUSINESS May/June 2023

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CRUSHING & SCREENING

SBM Mineral Processing relied on the highly mobile plant concept, which offers natural stone producers and recycling companies alike the full flexibility and high productivity of a large impact crusher.

SBM says the REMAX 600 defines a completely new performance segment in mobile primary and secondary crushing with the 600tph of its further developed 1400 impact crusher 13/14/4 with an intake of 1,380mm x 1,000mm (W x H) for feed sizes up to 900mm. Up to five high-quality fractions can be produced in one pass, thanks to efficient pre-screening, triple air classifying and high-efficiency magnetic separation, as well as the optional single/dual/triple-deck secondary screen.

Depending on the equipment, the REMAX 600 only weighs between 60 and 80 tonnes on the low bed – even when fully equipped, the machine measures a slender 22.0m x 3.49m x 3.80m (LxWxH).

The REMAX 600 is designed to offer a complete package of standard and optional equipment that ensures high added value through a variety of high-quality end products. In addition to the standard pre-screening via a double-deck circular vibratory screen (W: 1,300mm x L: 2,400mm), these include in particular the three optional circular vibratory post-screening units (1, 2, 3 deck; W: 1,800mm x L: 5,500mm) – each with oversize return and high-projecting discharge conveyors for large product stockpiles.

According to SBM, a real innovation in this machine class is the highly efficient overbelt magnet with longitudinal discharge, which guarantees high purity of the end products, especially in recycling.

All equipment and the side walls of the 9m³ feed hopper can be hydraulically folded in and remain on the machine.

SBM says this means that, even in one-person operation, the column-free system can be set up quickly without the need for additional tools. The operator is supported by the start-up routines of the SBM CRUSH CONTROL system, with its central 25cm-display, multi-function radio remote -control and cloud-based remote access to all

Keestrack’s new B7H hydraulic jaw crusher

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© AGGREGATES BUSINESS May/June 2023

Quarry operator Hans Zöchling has been testing SBM’s new REMAX 600

operating states via smartphone or tablet.

As with all SBM mobile plants, the REMAX 600 features a fuel-efficient diesel-electric hybrid drive with optional mains operation: a compact unit consisting of a 15-litre Cummins turbo diesel (EU-V) and a 553kVa generator supplies all electric drives – from the 250kW electric motor of the crusher, to the complete conveying and screening technology, to the two electrically driven hydraulic units of the undercarriage and working hydraulics.

Thanks to this design, all plant functions remain available even in fully electric mains operation, which SBM says significantly reduces on-site emissions (exhaust gases, noise) compared to other hybrid concepts with short-term diesel intervention. The high-torque drive at permanently low speeds is also impressive in diesel-supported operation, which, in addition to the low

environmental impact, results above all in favourable fuel consumption, even when all the auxiliary units are working at high capacity.

According to SBM, the field tests , carried out since the beginning of this year by cooperation partner Hans Zöchling GmbH under construction-site conditions in the Ramsau quarry and adjacent recycling depots with several tens of thousands of tonnes of a wide variety of raw materials , have resulted in economic average values of 34–46 l/h diesel or an electricity consumption of 140–200kWh. "This SBM-typical consumption advantage was undoubtedly one of the reasons why the enthusiasm felt at the BAUMA trade fair very quickly turned into real interest and concrete orders long before the market launch," Haider says. "In addition to our own dealers, the first end customers have already signed up – we assume that we may significantly adjust our production plans for the REMAX 600 upwards next year."

Belgium-based Keestrack is launching a new B7H heavy-duty hydraulic jaw crusher, specially designed for the US market and the toughest of rock conditions in quarrying and mining applications.

The 70-tonne B7H hydraulic jaw crusher has a 30-tonne jaw and is adapted from Keestrack’s existing B7 electric jaw crusher which was launched in 2018.

It has a vibrating feeder with 2-step grizzly of 2,200mm x 1,080mm (LxW) and a bottom deck in wire mesh of 1,450mm x 870mm (LxW) to optimise crushing results and to reduce wear.

The feed size of the material is up to 700mm, the feed opening is 1,200mm x 830mm and the outlet adjustment CSS is min.-max. 75mm–250mm.

The jaw crusher is equipped with the patented NSS (non-stop system ) which protects the crusher from uncrushable feed and resets the CSS automatic during operations.

Keestrack sales director Frederik

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A WIRTGEN GROUP COMPANY

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THE MOBICAT MC 110 EVO2 AND MOBICONE MCO 90 EVO2

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TEAM PLAYERS THAT WORK TOGETHER INTELLIGENTLY AND STRENGTHEN EACH OTHER. In linked plant combinations, the MOBICAT MC 110 EVO2 jaw crusher and the MOBICONE MCO 90 EVO2 cone crusher really flex their muscles. SPECTIVE makes both plants easy and intuitive to operate. Also, an advanced drive concept ensures greater efficiency with lower consumption. Maximum throughput is achieved thanks to the material flow concept coordinated via line coupling across both crushing stages. Go for the perfect team!

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KLEEMANN GmbH · Manfred-Wörner-Str. 160 · D-73037 Göppingen · T: +49 71 61 / 206 0

CRUSHING & SCREENING

Hoogendoorn says the mobile crushing and screening equipment company is a pioneer in electric quarrying and mining machinery, having launched its first electric machine in 2006.

He adds that 90% of Keestrack machines are available in three versions: hydraulic, electric, and zero-emissions plug-in.

“A focus on sustainability is at the core of our company as this is the origin of our business,” Hoogendoorn said.

“Producing and recycling valuable raw materials is what mobile crushing and screening is all about, and our efforts are definitely having a positive impact on the ecological footprint.

“As these heavy-duty industries need very powerful drive systems, Keestrack kept on searching for alternative drive systems,” Hoogendoorn explains.

“From load-sensing hydraulics to e-drives to Zero drives, (Keestrack offers) equipment with no combustion engines on board but only electric motors. This request is also a pull from mostly the North European market.

This way we want to protect the planet and save money at the same time.”

He adds that 80% of US customers currently ask for hybrid machines and only 20% electric, but that this is changing with all-electric units becoming more common in the US market every year.

Astec unveiled its newest portable highfrequency screen plant at the ConExpo construction and quarrying equipment event in Las Vegas held on March 14-18.

The machine is equipped with 2.4m x 5.5m top deck and a 2.4m x 3.7m bottom deck, which the US-based manufacturer says makes it the widest high-frequency screen available.

The PTSC2818Vm features externallymounted vibrators at the ends of the tappets.

Astec says this unique design creates a higher G-force and reduces heat load from material to motors as compared to single, centremounted vibrators. It also allows for easier maintenance and adjustments. The screen is equipped with hydraulic operating angle adjustment, a fines collection hopper, top-

Astec unveiled its new portable high-frequency screen plant at ConExpo and bottom-deck discharge chutes and an aggregate spreader.

Similar to other PTSC plants, the 2818VM features a nominal 137.16cm x 1,158.2cm delivery conveyor with hydraulic drive and full-length skirtboards. The chassis is fitted with manually-operating support legs, outriggers for additional support and folding walkways along the screen.

The new portable plant is available with a variety of options, including: steel screen cloth, vinyl dust cover, hydraulic levelling jacks, immersion heaters for hydraulic reservoirs, and starters for three off-plant conveyors.

Northern Ireland-based compact mobile crushing, screening and stockpiling equipment maker Screencore is broadening its scope to produce a range of dual-power crushers and mobile pugmills.

Screencore is located in Coalisland, and although a relatively new entrant into the global crushing and screening market, it has a management team with over 100 years of experience in the industry. The company says this has enabled it to develop a range of mobile – and now stationary – crushing, screening, stockpiling and pugmill solutions in a relatively short period of time.

All members of the range have been designed for users who require a powerful and transportable unit without sacrificing productivity. “Our focus on quality and performance means that our customers can rely on our units getting the job done, no matter where they are located, and virtually

whatever the applications,” says company director Ciarán Ryan.

“While our product line has expanded to encompass the formidable 237 trommel and the 30-ton Trident 165 scalper, our fundamental concept remains consistent: simplicity of use."

Ryan says this simplicity is evident in features like hassle-free transport, swift set-up time, intuitive control systems, and distinctive design elements such as full-sized bottom decks on scalpers or augers within the trommel hoppers.

The Screencore range consists of a selection of tracked and highly mobile scalping screens, trommels and compact, yet productive jaw crushers.

Collen Bros (Quarries) Ltd, a family-owned and-operated civil engineering company located in County Armagh, Northern Ireland, recently took delivery of a Powerscreen Premiertrak 600E (PT600E) jaw crusher, which is the first of its kind to be delivered in the UK and Ireland.

The Premiertrak 600E jaw crusher is part of the growing Powerscreen Hybrid range. It has been designed for large-scale operators who require high production in recycling, quarrying, construction and demolition, and mining applications. With significant operational savings, reduced fuel consumption, and ultimately reduced CO2 emissions, this machine is a popular choice for customers who want to maximise efficiency and minimise their carbon footprint. AB

Screencore's product line now includes the 30-tonne Trident 165 scalper

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LOADING

Komatsu’s new concept medium-sized hydraulic excavator powered by a hydrogen fuel cell.

Pic: Komatsu

Hydrogen-powered loading An eye-catching alternative-fuel advance for quarrying-application-compatible excavators and how a leading global manufacturer’s wheeled loaders are a big fuel saver for a longstanding German building materials producer. Guy Woodford reports

K

omatsu has developed a new concept medium-sized hydraulic excavator powered by a hydrogen fuel cell.

The Japanese quarrying and construction manufacturer says that by advancing the PoC (Proof of Concept) tests it started in May 2023, it has accelerated its efforts to embark on the commercial production of medium-sized and large construction equipment powered by hydrogen fuel cells in the near future.

In its mid-term management plan, Komatsu committed to minimising environmental impact throughout its business, targeting a 50% reduction in CO2 emissions from using its products and production of its equipment by 2030 (compared to 2010 levels) and a challenging target of achieving carbon neutrality by 2050. Komatsu says it has been providing customers various products, services, and solutions that reduce environmental impact,

such as hybrid hydraulic excavators and electric mini excavators. The company adds that it is also engaged in research and development to provide products equipped with new power sources.

For the new concept machine, Komatsu adopted a hydrogen fuel cell system and hydrogen tank produced by Toyota Motor Corporation on Komatsu's medium-sized hydraulic excavator. In addition to Komatsu's control technology, the combination of Toyota’s hydrogen fuel cell system and Komatsu key components, Komatsu says it is working towards zero-exhaust emissions and a significant reduction in noise and vibration while delivering the same powerful digging performance and high operability as enginedriven excavators.

Medium-sized and large construction equipment require a power source with higher energy density than small construction equipment, leading to electrification with batteries. Because hydrogen has a higher

energy density and can be refuelled in a shorter time than is required for recharging batteries, Komatsu has been advancing its R&D efforts as a promising electrification choice for medium-sized and large models.

The global off-highway equipment giant adds that it will continue its efforts towards commercialising medium-sized and large construction machinery equipped with hydrogen fuel cells by conducting PoC tests of this new concept machine.

August Lücking (Lücking) is a 123-yearold building-materials producer in northwest Germany. About two years ago, the company purchased a DL420CVT-5 wheeled loader from DEVELON (formerly Doosan Construction Equipment) to feed materials for the brick-production process. The purchase decision was based on trials that showed enormous fuel savings of more than 9 l/h, confirmed when the new machine began operation. As a result, when the time came for a new wheeled loader to be bought, the

Volvo CE Connected Load Out improves jobsite efficiency Volvo Construction Equipment (Volvo CE) has launched a digital solution to simplify the load-out process - and help customers maximise their productivity.

Connected Load Out improves the efficiency and productivity of the load-out process by connecting the loader operator, site office and trucks. It is a digital solution for Volvo wheeled loaders with Load Assist and On-Board Weighing and Volvo excavators with Dig Assist On-Board Weighing.

It reduces administration and miscommunication by digitalising orders and load tickets, improves visibility and helps sites be more productive. A more efficient load-out process lowers fuel consumption, reducing costs and CO2 emissions. It is currently available on subscription in select markets in Europe and North America.

Cecilia Jonsson, product owner, Global Load Out Services at Volvo CE, says: “We continue to develop intelligent solutions that help our customers streamline operations and maximise efficiency.”

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© AGGREGATES BUSINESS May/June 2023

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LOADING

decision was made: the new machine should also be a DL420CVT, this time the nextgeneration DL420CVT-7 model.

When the purchase of the original wheeled loader was on the agenda about two years ago, a Doosan DL420CVT-5 was tested on-site in the company's brick factory. The requirements for the loading of clay for the bricks are particularly challenging. The clay has a high density and, therefore, a high weight. In addition, the material is extremely sticky and tough. A high degree of even force and heavy traction are required to penetrate the material with the shovel, especially on wet surfaces.

The tyres also play a major role here. Lücking

Develon DL420CVT-5 and DL420CVT-7 wheeled loaders are big fuel savers for German building materials company August Lücking. Pic: Develon

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© AGGREGATES BUSINESS May/June 2023

relies on special tyres whose profile is more like that of a tractor than a wheeled loader.

The grooves of the tread on 'standard tyres' clog up quickly due to the greasy consistency.

These difficult conditions also drive up fuel consumption.

The previous machine, a competitor's wheeled loader with a conventional converter transmission, required an average of around 23 l/h of fuel under these conditions. When the authorised signatory at Lücking, Richard Lemke, asked the wheeled loader sales manager at Develon, Marc Glesius, about the consumption to be expected under these conditions during the handover for the test operation, he cited 14 l/h, a value that Lemke found difficult to believe.

Lemke offered Glesius the following bet: "If the DL420 with the CVT transmission only consumes 14 l/h, i.e. around 10 litres less, I will buy it immediately." The rest is history.

The test consumption was the targeted 14 l/h, and the wheeled loader has been in service at the company for two years.

Lemke added: "In times of enormously high fuel and energy prices, 10 l/h naturally makes an enormous difference. In the last two years, the consumption of the DL420CVT-5 has levelled off at the 14 l/h already determined in the test operation. We also did not record any unscheduled machine failures during this period. Therefore, only a Develon wheeled loader with a CVT transmission was considered when purchasing a new vehicle. We are confident that the new wheel loader can confirm these positive experiences."

One of the main factors behind low fuel consumption is the variable transmission.

Glesius said: "This transmission combines the advantages of a mechanical and hydrostatic transmission and excludes the disadvantages of both systems. The variable transmission switches continuously from the hydrostatic drive to the mechanical drive as the speed increases and depending on the application-related requirements. This system's advantages include, in particular, the excellent traction that a hydrostatic transmission offers and driving over longer distances with direct mechanical transmission. It owes the fuel savings to the lower engine speed than conventional transmissions, which is necessary to achieve maximum speed and traction." AB

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HAULING

Volvo CE says its new R60 rigid hauler offers customers a higher payload and uptime. Pic: Volvo CE

Rigid haulers delivering fluid production gains Two major rigid haul truck launches offer much for quarrying customers looking for production gains from their hauling operations. Guy Woodford reports

V

olvo Construction Equipment (Volvo CE) says its new R60 rigid hauler offers customers a higher payload and uptime.

The new E-generation machine is suitable for heavyduty quarrying and mining.

Built for markets with Tier 2-compliant engines and based on the R100E model, the R60 has a higher payload than the D-generation model it replaces, along with a durable design and new comfort and safetyenhancing features – which Volvo CE says enables it to move more for less with every cycle.

Drew Watson, global product manager for the Volvo R60 at Volvo CE, says: “The Volvo R60 offers a 55-tonne payload and body volume of 36m³, enabled by a V-shaped body ensuring optimum load retention and minimal material carry-back.

“The rigid hauler is a perfect match for a 90-tonne excavator and meets the industry standard of 10/10/20 where it can take 10% overload for 10% of the time but should not exceed 20%. To help operators haul the optimum amount of material, an optional On-Board Weighing system provides realtime payload insight to the hauler operator via the on-board display and can predict the 10/10/20 payload.”

Contributing to speedy cycle times, the drivetrain combines high torque capability and high drive-axle multiplication to deliver the traction force needed to take on the steepest site gradients.

Volvo CE says the R60 is also fuel-

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efficient. Thanks to Volvo Dynamic Shift Control, gear selection automatically adapts to varying conditions, whilst ECO mode enables the hauler to default to the most efficient gear-shifting schedule. In addition, auto engine-idle shut-down eliminates unnecessary fuel consumption and engine wear.

The rigid hauler is available with the Volvo CareTrack telematics system to enable remote machine monitoring and help further boost efficiency. Moreover, customers can gain recommendations on the optimum fleet configuration and site set-up from their Volvo dealer with the support of Volvo Site Simulation.

Designed to deliver high uptime and low

operating costs, the R60 is built to last with a 60,000-hour life frame and a list of features that contribute to long-lasting performance and component life, including a low centre of gravity and balanced weight distribution to provide rock-solid stability and spread the impact of loads and stresses across the machine; a high-strength, flexible chassis and responsive MacPherson strut with lower wishbone connection to absorb shocks and vibrations and improve the operator ride; a V-shaped body, manufactured from highimpact and high abrasion-resistant steel, with a minimal number of panels and welds; and neutral coast inhibitor and engine-overspeed protection to further minimise wear.

Servicing of the R60 is required every 500

The R60 RDT is compatible with the Volvo CareTrack telematics system, enabling remote machine monitoring to help further boost efficiency. Pic: Volvo CE

© AGGREGATES BUSINESS May/June 2023

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hours and can be completed swiftly thanks to a straightforward machine design that includes grouped maintenance points located within easy reach either from the ground or the service platform, as well as commonsized bearings throughout.

On-board diagnostics provide insights into system pressures, temperatures, and fault reporting to facilitate and speed up troubleshooting.

Volvo CE says the R60 is built with operator comfort and safety top of mind.

Operators can enter the cab from both sides using anti-slip steps and walkways. The cab is now pressurised, roll/fall overprotective structure-certified (ROPS/FOPS) and features a left-positioned operator station to aid safe passing. Volvo Smart View is an option to improve further visibility with a 360° birdseye view of the work zone.

Ergonomically positioned displays, responsive fingertip controls and low-effort steering combine to make operation effortless. The adjustable air-suspended seat and a Bluetooth-enabled audio system add to operator comfort.

The Volvo R60 has two retardation systems to keep a steady speed and facilitate machine navigation when going downhill, reducing the need for operator input. When manually selected, the transmission retarder slows the drivetrain to limit wheel lock-up, which is particularly useful on steep declines or wet conditions. The modulating braking retarder can be automatically activated when the operator’s foot is off the accelerator to maintain a gear-selected constant engine speed. Moreover, fail-safe braking and secondary steering systems add to job site safety.

A Perlini DP265WD rigid hauler being showcased at SaMoTer 2023 in Verona, Italy

Italian rigid haul truck manufacturer Perlini says its new DP265WD machine combines the company’s decadeslong experience of mining haul truck manufacturing with the latest technologies, such as new control electronics, modern GPS monitoring and electronic weighing systems, to produce a versatile, economical and reliable machine.

The Gambellara, Vicenza provincebased manufacturer states: “With its small dimensions, the new Perlini DP265WD is the ideal vehicle for quarries and public

works; the width of under three metres also allows road transport without special transit permissions or escorts.”

The company adds that the DP265WD has the usual prized Perlini features, including a brake/retarder system with oil-bath brakes, oil-pneumatic suspension, and typical Perlini stability and operator cabin comfort. The new RDT also has a sustainability-minded Stage V Scania DC09 engine and an Allison 4430ORS transmission with updated electronics.

First presented at bauma 2022 in Munich, Germany (24-30 October), the DP265WD was

The Volvo R60 offers a 55-tonne payload and body volume of 36m³. Pic: Volvo CE

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HAULING

also showcased by Perlini at the 31st edition of SaMoTer (3-7 May 2023).

Speaking at the exhibition, Paola Pugliani, Perlini’s sales marketing executive, says: “This is our first completely digital machine; the start of a new era. It allows our technicians to remotely control the haul truck and do preventative maintenance remotely. We can check the machine’s operation parameters hour by hour, not just fuel consumption and productivity but also whether something is wrong and needs attention. This system makes for easy maintenance working together with our customers.”

Pugliani says the DP265WD’s under-threemetre width is in response to many smaller quarry operators in Europe and North Africa requesting that kind of RDT over the past decade. “It is a very flexible machine that can work in a quarry and other work sites.

We were recently contacted by an important customer in Ireland that was looking for a machine like ours. They have a narrow bridge to pass through in their quarry, and we are the only manufacturer currently offering an RDT of a suitable size.”

Perlini’s four-strong RDT range starts with the construction-and-quarrying-applicationsuited 26-tonne capacity DP265WD, followed by the also construction-and-quarryingapplication-suited 40-tonne DP405WD, the 65-tonne DP705WD, and the 100-tonne capacity DP905WD. “The last two models are aimed specifically at mining applications,” says Pugliani.

She adds: “Perlini is targeting many Central Asian countries full of iron and other material mines. Due to the war in Ukraine and sanctions against Russia, many BelAZ [Belarussian mining dump truck manufacturer] customers cannot get their trucks. So, they are now looking at other companies, like Perlini, to supply them with new machines.

“Many governments globally are also moving away from the gas and oil industry to the extraction of minerals in Central Asia and Africa. This means much finance is concentrated in this mining sector, which creates new opportunities for us. We are looking for good dealers in countries in these regions. They will need to do more than just selling trucks; they will need to offer customers quality after-service, including maintenance.”

At SaMoTer 2023, Perlini introduced its new Italian dealer, Rimini, Emilia-Romagnabased WR57. “The company is also a Hitachi Construction Machinery (Europe) dealer and provides our after-sales support, purchasing spare parts from us and selling them to Perlini customers. WR57 also offers Perlini dump trucks for rental. We are seeing more and more Italian customers wanting to rent our machines. Many of our customers see machine rental as the future. They are attracted by the ability to quickly change machines and always have the latest models, which is particularly important during busier periods.

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Aggregates Business editor Guy Woodford and Perlini’s Paola Pugliani at SaMoTer 2023 “During the exhibition, we were visited by an important Italian company that runs cement plants nationwide and stressed the importance of rental machines. They like to test a new machine through a rental before purchasing it.”

Pugliani says Perlini is pleased to see Giorgia Meloni’s new Italian government continuing the infrastructure spending of the previous administration, creating good domestic business opportunities for off-highway machine manufacturers. “The previous government greatly supported

manufacturers and equipment end users. We have a specific Industry 4.0 offer that helps sell machines. Many customers near our factory are working on big high-speed train works, and there are many infrastructure works in southern Italy.”

Perlini plans to treble its production capacity after a sustained period of investment. “By 2025, we will be able to produce up to 120 units annually, up from 40 units,” says Pugliani. “We are hiring many engineers and spending time training them. Our products are complex from an engineering perspective and very attractive.”

Turning to Perlini’s sustainability credentials, Pugliani says they are partly reflected in the company’s choice of engine supplier: “In 2019, we switched from another engine supplier to Scania, as the Scania engines complied with new EU Stage V emission standard, and also offer lower fuel consumption. We cooperate well with them, and now they supply engines for our Stage II emission market customers. Unfortunately, Scania doesn’t offer an engine with the horsepower required for our 100-tonne RDT, so we have a Fiat engine in that machine for Stage V and Stage II emission market customers.

“We also focus on lowering the noise that can be heard inside our truck cabins.

That’s important for our operators and the wider environment. Our customers are also interested in running hybrid diesel-electric versions of our trucks. It is a project we are working on, and I think we will be ready with our first hybrid-power models in a couple of years. The rigid hauler is in our DNA, and a sustainable product range is very important to us.” AB

With its small dimensions, Perlini says its new DP265WD rigid hauler is an ideal vehicle for quarries and public works. Pic: Perlini

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Cummins’ new fuel-agnostic 15-litre engine platform with hydrogen, biogas and advanced diesel engines

Revved up engines & alternative power sector A vibrancy in the global off-highway equipment engines and alternative power sector was evident at the recent CONEXPO-CON/AGG 2023 exhibition in Las Vegas, USA. Guy Woodford reports

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t CONEXPO-CON/AGG 2023 (14-18 March), Cummins reaffirmed its commitment to reach net-zero emissions from its products and business by 2050 in line with its Destination Zero strategy. The US off-highway-equipment engines giant says this will be achieved by advancing internal combustion engine technology while reducing carbon emissions without impacting operations, weight, or uptime.

Cummins says its net-zero goal will also be secured by building the broadest combination of zero-emissions technologies dedicated to the commercial vehicle industry, including battery-electric and fuel-cell electric powertrain solutions and electrolysers for green hydrogen production.

This complementary approach, says Cummins, lowers emissions today by matching technology readiness with infrastructure readiness to drive wide-scale adoption using the right technology at the right time.

Eric Neal, executive director of Cummins Off-Highway business, said: “We aim to support our customers on their path to zerocarbon emissions. This means meeting them wherever they are on their journey. We are leading the energy transition by providing our customers with the right technology and utilising our deep understanding of their needs and applications.”

Cummins emphasises that it has the

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Eric Neal, executive director of Cummins Off-Highway business, and Amy Davis, president of Accelera, at CONEXPO/CON-AGG 2023

knowledge, expertise, and scale across a range of solutions through growth and acquisitions to continue leading in the off-highway industry today and in the future.

“Cummins powers more types of machines and vehicles than anyone else. The breadth of our business across market segments and regions means we are the ideal partner to help our customers through this transition,” continued Neal.

Cummins showcased in Las Vegas its

new fuel-agnostic 15-litre engine platform with hydrogen, biogas and advanced diesel engines. It offers OEMs the opportunity to accelerate the decarbonisation of heavy-duty off-highway applications.

This new platform, designed for the next level of emissions, significantly increases power density with a more compact installation envelope, enabling OEMs to increase machine capability and productivity without impacting running costs.

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Volvo Penta’s D16 EU Stage V-EPA Tier 4 Final-compliant engine

Fredrik Högberg, president of Volvo Penta North America The fuel-agnostic architecture of the 15-litre next-generation engine utilises a common base engine with cylinder heads and fuel systems specifically tailored for hydrogen, natural gas, diesel and biofuels, including HVO. The 15-litre hydrogen engine will be available with ratings from 400-to-530hp and a peak torque of 2600Nm. For applications powered by renewable biogas, this engine will offer ratings from 400-to-510hp with a peak torque of 2500 Nm available. The advanced diesel version features a broad power range of 450-to-650HP, with an impressive 3200Nm peak torque.

Amy Davis, president of Accelera, the new brand for Cummins’ New Power business segment, said: “We understand that no single

John Deere’s crusher-suited JD9 engine

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solution or path to zero will work for all power needs, which is why we are developing the broadest combination of zero-emission technologies: fuel cells, battery systems and fuel-storage technologies.”

Cummins also highlighted at CONEXPO/ CON-AGG 2023 its next-generation fuel cell engine suiting heavy-duty off-highway applications' duty cycle, performance, and packaging requirements. Available in 150kW and 300kW fuel-cell engine configurations, it incorporates variable pressure technology, which provides improved power density, efficiency, and durability, all while delivering a lower total cost of ownership.

As a result of Cummins’ acquisition of Meritor last year, Accelera’s product portfolio was broadened to include complementary ePowertrain products and EV powertrain integration capabilities. As seen, the Electric Central Drive Unit (eCDU) is a remote-mount electric powertrain designed for space-limited off-highway applications. Its innovative architecture enables increased vehicle-design flexibility and the ability to be located as needed. It helps reduce investment in vehiclearchitecture changes such as hydraulic brakes and driveline parking brakes.

“Because of our global service, technical expertise, and ability to optimise the performance of applications, Accelera is in a unique position to help our end customers succeed during the energy transition.

Working together with customer partners, we are rapidly evolving our zero-emissions technology to meet the diverse needs of our customers and further our shared goals of lessening our impact on the planet,” concluded Davis.

Volvo Penta demonstrated its own road to net zero at CONEXPO-CON/AGG 2023. The company showcased its electric driveline alongside its current portfolio of ultra-efficient EU Stage V and EPA Tier 4 final combustion engines – the D5, D8, D13 and D16.

In addition to leveraging an array of proven technologies from across the Volvo Group, the innovative electric driveline solution would not have been possible without the firm foundation provided by Volvo Penta’s more mature

power solutions and the expertise of the company’s engineers. Volvo Penta also highlighted in Las Vegas how it’s delivering in its service offering, focusing on creating value with customers through connected solutions.

Fredrik Högberg, president of Volvo Penta North America, said: “To succeed on our transformation journey into new, sustainable technologies to meet the industry’s net-zero ambitions, as well as achieve the Science Based Targets initiative (SBTi) for net-zero value chain emissions by 2040, we believe that strong collaboration with customers and partners is crucial. We cannot deliver the changes that need to happen alone – that’s why we are working closely with our customers, supply chain partners, governments, societies and other stakeholders.”

A popular choice in a wide range of machinery from excavators and underground mining trucks to crushers and screeners, Volvo Penta’s industrial combustion engines have been proven and optimised to meet customer needs in terms of productivity, uptime and total cost of ownership (TCO).

Passive regeneration of the aftertreatment system eliminates unplanned stops during operation, while fuel consumption has been reduced by up to 5% over the previous models.

Since 2016, Volvo Penta’s industrial engines can run on renewable diesel (HVO), enabling a more sustainable choice. Further supporting customers looking to transition to low-carbon solutions is Volvo Penta’s dual-fuel hydrogen engine – an evolution of the company’s proven D8 model. The engine mainly uses hydrogen as a renewable fuel source, reducing CO2 emissions by a claimed up to 80% without impacting power or performance. Volvo Penta will continue to evolve its engine range to run on compatible alternative fuels, enabling the transition towards lower emissions in those markets © AGGREGATES BUSINESS May/June 2023

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Caterpillar’s C13D diesel engine on show at its launch event at Las Vegas Raiders football stadium

that cannot yet support fully electric solutions.

Another aspect of Volvo Penta’s transformation journey is its growing foothold in electromobility as a system supplier. Volvo Penta’s electric-power solutions are backed by connectivity to help customers actively monitor the health of their drivelines in a predictive way throughout their lifespan.

“No matter where customers are on their transformation journey, Volvo Penta can offer solutions to meet their machine, application and business needs,” concludes Högberg.

“We work closely with our customers and form long-term partnerships to create purpose-built power solutions based on their requirements. As part of the Volvo Group, we leverage proven technology, investments and competence from Volvo Trucks, Volvo Buses and Volvo Construction Equipment.

We combine this with our customer, market and application knowledge, allowing us to optimise designs and technology for specific machines and applications, considering the duty cycles, climate and environment in which they will operate.”

The JD9 is the newest addition to the robust John Deere off-highway engine line-up.

This powerful configuration is designed to deliver reliable power of up to 317kW while offering a lower complexity and installation cost. The JD9 is a new and improved iteration of the existing John Deere 9.0L engine and features Level 40 Engine Controls (ECU) and upgraded fuel economy.

The exceptional quality of the 9.0L has been improved by adding a low-pressure fuel system, which is common in 13.6L engines, and removing the venturi in the engine pipes. The crusher-suited JD9 also offers increased power with single and dual turbo configurations. Its simplified in-line aftertreatment solution contains a diesel particulate filter (DPF), diesel oxidation catalyst (DOC), and selective catalytic reduction (SCR) system, achieving Final Tier 4 and Stage V emission levels. (The current 9.0L in production will continue to be available.)

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Caterpillar claims that its new C13D diesel offers the highest power density for its class, replacing the previous C13B engine. Because of its high power output, the new C13D unit can replace the firm’s 15-litre engine and even the 18-litre diesel for some installations.

Development of the engine has utilised some of the latest digital technology, with the firm assessing assembly and servicing comprehensively to optimise these processes, even before the unit was in the metal.

Designed to meet future requirements, the engine can use HVO and is being tested on B100 biofuels. It also has the potential to be modified to run on propane or even hydrogen, with Caterpillar having benefitted from its long experience developing gas engines.

There are eight power ratings ranging from 340-515kW for the six-cylinder engine, which meets the current Tier 4 Final and Stage V emissions requirements. However, the unit has also been designed with the capacity to be able to meet the Tier 5 and Stage VI requirements if and when these are introduced.

The new engine platform is 10% more efficient and offers an increase in power of up to 20% and up to 25% more low-speed torque than the previous generation Cat engines in its class. It is designed to perform at altitudes of up to 3,700m, which is twice as high as legacy Cat engines, and in extremes of ambient temperatures as high as 60°C and as low as -40°C with aids. Engine oil and service schedules have been extended due to the engine’s high efficiency and clean running. Engine life is likely to be long, with key components able to be reworked for reuse.

A spokesperson for the firm commented, “We’ve intentionally designed the cylinder head for a second and even a third life.”

The high power density means that OEMs selecting the unit can install it more readily in their machines, while the engine can offer reliability even in more extreme applications.

So far, Caterpillar has carried out around 12,000 hours of engine testing, with the C13D now being used in the field to further prove the design. And Caterpillar is confident that the unit will meet customer demands when it is ready for market. Scheduled for production in 2026, the Cat C13D is targeted for a wide range of off-highway equipment, including rock crushers, screeners and grinders; trenchers; material-handling equipment; and large industrial pumps.

The new engine platform will be equipped with Cat Digital Services, an integrated suite of robust software and hardware solutions supplying the insight equipment owners need to make decisions on the fly, secure equipment health, and minimise downtime.

Hyundai Doosan Infracore (HDI) has announced its timetable to mass-produce hydrogen internal combustion engines (ICE). The new units will be installed on commercial vehicles such as trucks, large buses, and construction equipment for validation by 2024, and full-scale mass production is planned for 2025.

HDI's initial under-development hydrogen engine is an 11-litre-class engine that produces a power output of 300kW and a torque of 1700 Nm at 2000 RPM. It satisfies Tier 5 / Stage 5 / Euro 7 regulations which require the emission to be 90% reduced from the current level to meet Zero CO2 (below 1g/kwh) and Zero Impact Emission (Zero Emission in the EU). AB

Hyundai Doosan Infracore's initial under-development hydrogen engine is an 11-litre-class engine that produces a 300kW power output

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RECYCLING – 1 Wolfgang & Hans-Jürgen Büscher in front of the full electric plug-in R3e ZERO impact crusher Pic: Keestack- Büscher

Groundbreaking recycling Recycled construction materials played a key role in a claimed world-first build, while new and latest building materials processing machines are in demand for recycling applications Guy Woodford reports

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erman company Büscher has used Keestrack crushing and screening equipment to convert demolition waste into sustainable construction material to build what it claims is the world’s first complete house comprised of 75% recycled construction and demolition waste. The load-bearing and non-load-bearing interior wall elements are made of 100% recycled aggregates.

In June 2021, Büscher became the only company in Germany to receive general building approval (abZ) from the German Institute for Building Technology (DIBt) for load-bearing and non-load-bearing interior wall elements made of recycled concrete with a 100% natural stone substitute. In the prefabricated parts, the raw materials of

gravel and sand are completely replaced by mixed demolition material.

The company's choice to use Keestrack crushing and screening equipment is also driven by its commitment to sustainability.

Oppermann & Fuss, the Keestrack dealer in Germany, advised Büscher which ZERO equipment was the best fit for its applications and capacity at its recylcing site.

The Büscher site has solar panels that deliver up to 323kW/h of renewable electricity to power the concrete factory, the Keestrack R3e ZERO impact crusher, and the K4e ZERO screen. Both Keestrack machines are fully electric, powered by renewable energy, and do not have a combustion engine onboard.

As the electric motors drive most of the mobile crushing and screening equipment and power some necessary hydraulics

systems, both Keestrack machines run with ZERO CO2 emissions. Keestrack is known for being an innovator and early adopter of electric e-driven equipment, and most of the Keestrack product range is available in ZERO-drive.

When plugged into the grid, like at the Büscher recycling site, where they use renewable energy using photovoltaic solar panels, the R3 and K4 produce zerocarbon emissions. The energy cost will be approximately 152kWh. Operational and maintenance costs will decrease drastically as no engine is on board to maintain.

The innovative technology, its safety features and the design of the R3 impact crusher have won several European design prizes, one of them being the Red Dot award.

The very compact and easy-to-transport impact crusher is available in a diesel/

The Keestrack R3e ZERO impact crusher and the K4e ZERO screen are fully electric, and powered by renewable energy Pic: Keestack- Büscher

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Steve Harman (right), operations director at L&S Waste Management, and Jack Pilgrim, territory account manager for Finning UK & Ireland. Pic: L&S Waste Management-Finning UK& Ireland

hydraulic drive, electric plug-in drive (with onboard backup diesel gen-set) and ZERO drive: a fully electric plug-in without gen-set backup has a capacity of up to 250t/h.

The R3e ZERO is equipped with a vibrating feeder with a pre-screen of 1.200mm x 920mm to optimise crushing results and to minimise wear, an inlet opening of 770mm x 960mm (HxW) and a rotor diameter of 1.100mm and a rotor width of 920mm. The crusher equipped in a closed circuit with a recirculation conveyor and a precession screen of 3.100mm x 1.400mm produces a defined aggregate product size. The installed wind sifter eliminates contamination of plastics, wood or paper, and the overband magnet separates the metals. The R3e ZERO weighs 32t, and its plug-out of 125A powers the connected K4e ZERO of 28t.

The K4e ZERO has a high production capacity of up to 350t/h. The double-deck screen box of 4.200mm x 1.500mm, standard heavy-duty plate apron feeder and hydraulic adjustable screen angle gives it very good screening capabilities. The numerous options and screen decks make the K4 suitable for each job. At the recycling site of Büscher, they choose to have the fine and middle

fraction conveyor on the same side of the screen to improve the accessibility for the wheeled loader.

Both Keestrack machines at Büscher have remote controls to operate the crusher and screen from the excavator. They both have an integrated water spray system that can be used if the production is too dusty. Also, both are equipped with a Keestrack-er UMTS system. This telematics software system provides real-time data and analytics. The system enables you to check the location of the machines and if they are working correctly. All aspects of a machine can be checked, and remote updates to the software can be made if necessary. It is possible to run diagnostic tests for all components, including the feeder, screen, crusher and conveyors.

The Keestrack-er also functions well for maintenance planning by Oppermann & Fuss, helping to keep machines in optimum shape.

Company co-owner Wolfgang Büscher says that getting 100% prefab concrete certified was difficult and took the company eight years of research and development to gain approval. “Concrete specialists, laboratories and certification specialists were very doubtful this could be done. They all said it is impossible and not legal”, says Büscher.

Büscher asked researchers from laboratories and universities to scientifically prove what the material is capable of and what it’s not. They gave the parameters on what they wanted to achieve with the material and asked them to find out if it stood the test of time.

“By now, all scientific research has been done, and it shows exactly what is possible with 100% recycled prefab concrete and concrete elements. The new material functions perfectly, and the recipe has changed at Büscher,” says Hans-Jürgen Büscher, Wolfgang's brother and company co-owner.

Hampshire, southern England-based waste management and aggregates company L&S Waste Management has taken delivery of seven new Cat machines thanks to business expansion and fleet replacement, citing a “reliable plant with a great backup service” from Finning UK & Ireland, the world’s largest dealer of Cat machines and equipment.

With waste-treatment and recycling facilities in Portsmouth, Fareham and Southampton, the company processes 275,000 tonnes of construction and industrial waste each year and supplies ready-mixed concrete and aggregates from its facilities.

It has grown from 20 staff to 150 within the last 15 years. Having bought their first Cat machine 14 years ago, the relationship with Finning has gone from strength to strength as support from Finning’s expert team has minimised unplanned downtime.

The latest machines to join their fleet include five excavators and two wheeled loaders comprising two Cat 313s, two Cat 320s, a 325, and 962M and 938M wheeled loaders with additional fire suppression, guards, and belly plates due to the harsh environment they operate in. As all the machines come with a Finning premier warranty, each one is covered for all repairs

Kleemann’s new recycling-application-suited MOBISCREEN MSS 802(i) EVO will be showcased at steinexpo 2023. Pic: Kleemann

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RECYCLING – 1

for up to five years or 8,000 hours, giving complete peace of mind.

Steve Harman, operations director at L&S Waste Management, said: “We’ve been working alongside Finning for many years as we get great service backup from their team, and the Cat product is high-quality and reliable, which is key for us, as we have such high volumes of material going through our sites.

“They stand the test of time, and they hold a good residual value, and with the warranty package and guaranteed buyback from Finning, you know what your costs are going to be, and there are no hidden extras.”

Jack Pilgrim, territory account manager for Finning UK & Ireland, said the team supported L&S with asset management as their fleet is connected with Cat VisionLink, which provides data on fuel burn, machine health and idle times. Finning also proactively provides a monthly fleet benchmarking report sent to each site manager and senior staff.

He said: “Keeping their machines running is a top priority for L&S together with running their fleet efficiently, especially since the switch from red diesel last year, so our report for L&S breaks down their data to cover average run time (hrs) and idle time (%), the average fuel burn for their fleet, and the amount of operator-induced fault codes.

“We’re proud to support L&S as they continue to grow and expand their fleet, and our extended warranty package gives them complete peace of mind that if anything goes wrong with their Cat machine and it needs to come back into the workshop, there are no hidden fees, while our UK coverage means we can get an engineer on site fast.”

At steinexpo in Homberg/NiederOfleiden, Germany, from 23 to 26 August 2023, Kleemann will showcase a range of its sustainable, recycling-suited crushing and screening plants and the SPECTIVE operating concept from its comprehensive product portfolio.

With the MOBIREX MR 130(i) PRO impact crusher, Kleemann presents the latest member of the PRO line. The machine combines output, precision and sustainability as a primary and secondary crusher.

Thanks to its all-electric drive concept with the option of an external power supply and, therefore, operation with zero local emissions, the plant guarantees low energy consumption per tonne of final product. The optional large double-deck post-screening unit permits the production of two classified final grain sizes.

The MR 130(i) PRO covers a wide application range in natural stone and recycling. With its heavy rotor and powerful 250kW electric drive, the crushing unit guarantees a very high and stable throughput. The Continuous Feed System (CFS) guarantees a continuous crusher load.

Kleemann’s innovative digitalised operating concept SPECTIVE includes various components, such as an intuitive touch panel and different radio remote controls, that are ideally tuned to each other while accompanying the machine operator during

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their working day. All relevant process information and reporting are displayed on your smartphone without having to leave the feeding device. New to the SPECTIVE world is the ‘Smart Job Configurator’. The tool supports the operator in selecting the correct machine settings, facilitates day-to-day work and ensures even greater cost-effectiveness.

The new MOBISCREEN MSS 802(i) EVO has been designed as a powerful mobile scalper for evolving application challenges.

Its clever plant design and flexible conversion options guarantee an optimum material flow in natural stone and recycling applications.

Access to a large range of screen media and the simple setting of the screen parameters allow the MSS 802(i) EVO to adapt easily to new operating conditions. If a fine final product is to be screened from particularly coarse feed material, the machine can be quickly converted from three to two final grain sizes. Further advantages of the plant include its simple operability thanks to its intuitive control system, easy access to all relevant machine components and its drive concept with the option of an external power supply for operation with zero local emissions. AB

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DUST SUPPRESSION

A new era of dust-suppression innovation

DustCat5000's ability to operate in challenging environments and reduce water usage will, says EmiControls, be an industry game-changer.

Pic: Boreas/EmiControls

A leading Italian manufacturer has produced a new machine that it says will be a game-changer for quarrying and mining operators looking for a comprehensive dust-suppression solution. Guy Woodford reports

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miControls, a leading innovator in the field of dust abatement, offering tailor-made, watermist-based solutions for protection against dust, odour and fire, has recently launched a groundbreaking first all-electric dust-suppression vehicle, the DustCat5000.

Created in partnership with fellow Bolzano, northeast Italy-based companies E-Powertrac and Lanatec, the revolutionary machine is said by EmiControls to be designed to prevent and abate dust in difficult and inaccessible terrains, such as mines and quarries, minimising the impact of dust on the surrounding environment.

The idea was born at the request of one of Europe's largest mining and quarrying groups, which wanted to sustainably minimise one of its Swedish mine’s dust impact. In November 2022, the first vehicle was shipped and operated for test purposes.

The turbine-equipped vehicle is fully autonomous and flexible thanks to its six to eight hours of battery-powered operating time and a 5,000-litre water tank. Its crawler chassis allows it to navigate any ground condition and reach areas inaccessible by

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traditional vehicles.

The turbine is said by EmiControls to boast impressive operational capabilities, including the ability to function at temperatures as low as -25C, and a water-mist-throwing distance of up to 90 metres, allowing it to cover a large area while minimising water consumption and costs. This is said to make it an incredibly sustainable solution for dust abatement, something EmiControls has always been committed to.

EmiControls says it is excited to bring this cutting-edge technology to its industry markets and looks forward to helping businesses in the mining and quarrying sectors improve their environmental impact.

The DustCat5000’s ability to operate in challenging environments and reduce water usage will, says the company, be an industry game-changer.

Commenting on the prototype’s work at the Swedish customer’s mine, Alverman Soster, EmiControls Dust Division manager, says: “The mine extracts many different minerals. The problem is that an underground mine has this slag waste material generated by the extraction process. The mining group has to put that material somewhere, but it

is extremely fine and dry, so dust clouds can blow over many kilometres when the wind blows.

“The group had been looking for a solution for many years. They were using a helicopter to fly over the site and spray water – but you can imagine the cost of this approach. They were looking to buy rather than rent the helicopter, but then you also have the fuel cost, and a pilot is not a standard operator with a regular salary.

“I visited the Swedish mine in 2018, and we began thinking about a possible solution.

Another company within our group started looking for an electric-vehicle solution offering a low carbon footprint that could run everywhere on site. We then put our dust-abatement system with this vehicle. The mining group did not use the DustCat5000 much in January, February and up to the middle of March, as there was some snow around. But in the last five to six weeks, they have been using it more and more every day, as it is getting hot and dry. The DustCat5000 has already done more than 450 working hours.”

Soster says the same large mining and quarrying group is considering investing in

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another DustCat5000 machine to work at the same Swedish mine and further models to work at some of its other mine sites. “It is a very big group with other mines in Sweden, Norway and Finland,” he emphasises. “The group has one massive quarry in the north of Sweden and is looking at potentially investing in four DustCat5000s. The area they have to manage is like a huge lake.

“In the current test environment, dust can fly up to 30 kilometres! The main problem is the impact on neighbouring villages, which can occasionally be covered by white quarry dust. The slag in the fine dust contains metals, which creates a problem for agriculture, water ponds and local health. However, the DustCat5000 has been working well for the customer alongside our V22 Orca, which can also produce snow for dust abatement. Snow can be good for catching flying dust and is an effective alternative to spraying only water on a surface, especially in winter when water can easily turn to ice, creating another health and safety issue for site workers.”

Soster says he also has a copper mine in Poland whose operator is considering placing an order for four Dust Cat5000s.

“They have the same issue as the Swedish mining customer in needing an effective dust-suppression solution that can cover a big area.”

Soster says DustCat5000 operators at the Swedish customer’s mine site have praised the vehicle’s cabin. “They say it is huge, very comfortable and offers a really good view. They also like the vehicle’s heating system. In many other machines in colder weather, they have to work wearing heavy jackets, hats and gloves.

In the DustCat5000, they quickly remove

EmiControls innovative DustCat5000 dust-suppression solution Pic: Boreas/EmiControls

these items. The prototype also has a very good radio and music system that you can connect up to your smartphone.”

Commenting on the DustCat5000’s sixto eight-hour per electric-charge operating time, Soster says: “The operating time per charge depends on how much you drive the vehicle. The big advantage of its turbine is that you can park the machine in a certain position and leave it to do the [dust-suppression] job. Also, if you work in an area with wind, you greatly increase the spraying distance of the turbine. It can travel up to 150 metres. It takes a few hours to recharge the DustCat5000. Using our supercharger, you can reach 80% charge in a couple of hours.”

Soster says that EmiControls is creating more production capacity at its headquarters. Any customer placing an order for a DustCat5000 will have a lead time of around seven months. “We

eventually plan to offer the DustCat5000 as a fully remotely controllable autonomous vehicle, but at the moment, we are focused on taking it from being a prototype into full production.

“We see the DustCat5000 as initially being a vehicle for European customers.

We also have seen interest from markets like North America, South America and Australia. However, there are different regulations and potentially high maintenance and servicing costs in making the vehicle more widely available.

We will see how the product develops.

“We have a good partner in Australia, and business for all our solutions has grown there in the last year and a half.

From what I’ve read, the Australian government is pushing more and more mining companies to use good dustsuppression solutions to protect their employees. Many employees suffer from silica and other dust-related illnesses after 20 years of work.”

The DustCat5000 at work. Pic: Boreas/EmiControls

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The spacious and comfortable cabin of the DustCat5000. Pic: Boreas/EmiControls Soster says EmiControls is also growing its US business. “We have two partners, one in Salt Lake City, Utah, taking care of customers in Utah and nearby states. The other partner is in Albany, New York state. It’s a small but very active company we teamed up with a few months ago. Many New York state officials are going around construction and other industrial work sites measuring dust levels and asking for fees if deemed too high.

That is creating business opportunities for us.

We are also looking for another partnership in Texas, a rich state with many commercial opportunities.”

Commenting on EmiControls’ European market footprint, Soster adds: “Scandinavia is investing a lot of money in our market areas, especially Sweden and Finland. Germany and Italy are always big markets for us. We have opened a subsidiary, EmiControls Europe, in Frankfurt. We are also seeing business in Spain and Portugal.”

While set to benefit commercially from the world’s increasing focus on greater sustainability and environmental protection, including via dust suppression, Soster emphasises that EmiControls’ dustsuppression solutions always look to deliver optimal performance while limiting water use. “We need to spray water when it’s needed to spray water. You can do that with a high level of automation. An automated solution means that when you don’t have so many people on-site when working,

for instance, on weekends, the work still generates dust that needs to be suppressed.

“Our new software management system allows many EmiControls’ machines to be automated, managed and operated remotely.

We are working on it now and setting it up for remote use to control and monitor the system from anywhere in real time.”

Talking about the growth of EmiControls, Soster says: “I joined the company in 2015,

and there were just seven people, now there are 30 people. Our annual turnover in less than eight years has increased tenfold. We have invested a lot of money in development and research and are going forward. Of course, we are keen to sell the machines we manufacture, but we also want to sell more complete solutions. That means more aftermarket support on spare and replacement parts and product maintenance.” AB

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WEAR PARTS & SPARES

Metso says using an incorrect wear part that does not perform can be very costly

Not all parts are created equal The use of correct wear parts in applications such as crushing is vital, both in terms of plant efficiency and lifespan, and operator safety. Liam McLoughlin reports

W

hen crushers and screens are tirelessly working far from your home base, everything can be going smoothly – until it isn’t.

Applications can be demanding and when a component eventually fails, you need to be sure replacement parts perform as they should.

Maiju Niiranen, product manager, stationary equipment spares at Metso says that, although spare and wear parts may look the same from the outside, they may be very different in terms of quality and materials.

“The results of using an incorrect part that does not perform can be very costly – equipment can be damaged; the part’s lifetime may be considerably shortened, or the equipment could fail catastrophically putting the safety of workers at risk,” she adds.

Metso’s Nordberg C-series jaw crushers have been workhorses in quarries around the world for decades. When it comes to critical

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components for the crusher such as the pitman assemblies or frame parts, using components designed for the machine is an important step to caring for your producing equipment.

Niiranen says factors that affect the performance and reliability of components can be difficult to see, such as the raw materials used, the casting technology, pouring plan, the exact tolerances, and contactsurface quality. There are also hours and hours of engineering, quality assurances and testing methodologies that take place before the manufacturing process of the units and spare and wear parts even starts.

Maiju Niiranen of Metso

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“Fractions of a millimetre can make the difference between a correct and an incorrect fit, and between optimal machine performance and equipment failing”

She adds: “With Nordberg HP crushers, the case is similar. For instance, the thrustbearing design is very delicate and if not lapped correctly, may result in improper contact and having a different pressure profile than it was designed for.

“To the human eye, parts may look like the right fit but an important question to ask is whether it has been made to the right tolerances? Fractions of a millimetre can make the difference between a correct and an incorrect fit, and between optimal machine performance and equipment failing due to a wrongly-sized component. OEM parts are designed for fit and function and to bear the operating load at its design parameters, helping the crusher to avoid seizure or early failure.”

Unplanned issues can easily result in significant lost production and costly repairs so ensuring that replacement parts are made exactly to the specified dimensions, and fit, is a big part of maintaining the performance of your crushers and other machines.

Niiranen says that Metso premium spare parts are built to ensure crusher availability, uninterrupted work, and a long service life – in addition to safety and sustainability.

“An often-overlooked factor is an OEM’s ongoing R&D work that can take the engineering to the next level, bringing benefits to older Metso equipment,” she adds.

“Besides keeping it in original working order, premium spare parts can also enable a full upgrade – adding crusher availability and capabilities.” AB

CMS CEPCOR BUYS COLUMBIA STEEL CASTING ASSETS UK crushing parts manufacturer CMS Cepcor Group has reached an agreement with US-based Columbia Steel Casting to purchase key commercial and technical assets.

The agreement will see the CMS Cepcor Group incorporate a new company “Columbia Steel Cast Products LLC”, which will trade independently as “Columbia Steel” and retain the key engineering, sales, and commercial team of crusher wear parts provider Columbia.

CMS Cepcor says the move will expand its global footprint, as well as grow the respected reputation Columbia Steel has held in the aggregates and mining marketplace for decades.

A LONG WAY

TOGETHER

Mike Moehnke, Columbia sales and marketing director, commented: “Columbia Steel customers will be able to get the same parts in the same alloys they have come to depend upon, and moving forwards they will be able to do so at a more competitive price point. In addition, key individuals in engineering and sales will be coming on-board to provide a smooth customer-service transition.”

Chris Sydenham, the CEO of CMS Cepcor Groups US operations, said: “As a long-proven market leader in crusher liner optimiSation, with strong technical capabilities and genuine customer focus, Columbia Steel is well aligned with CMS Cepcor.”

WHEREVER YOU ARE, BKT IS WITH YOU No matter how challenging your needs, BKT is with you offering a wide range of OTR tyres specifically designed for the toughest operating conditions: from mining to construction sites.

Sturdy and resistant, reliable and safe, able to combine comfort and high performance.

BKT is with you, even when work gets tough.

For info: europe@bkt-tires.com

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PORTABLE POWER

Portable power plays The portable power sector has seen some significant developments including a major player changing its global branding and a new product launch. Liam McLoughlin reports

D

oosan Group-owned Doosan Bobcat has announced its global branding strategy which will see Doosan Portable Power (DPP) - a global manufacturer of air compressors, mobile generators and light towers rebranded under the Bobcat brand.

Doosan Industrial Vehicle (DIV), a supplier of quality material-handling equipment, including forklifts, will also be moved to the Bobcat brand.

“Bobcat is an iconic brand that changed the world with the invention of the compact equipment industry, and we are excited to unleash the brand in bold, new ways,” said Scott Park, Doosan Bobcat CEO & vice chairman. “Doosan Portable Power and Doosan Industrial Vehicle have long legacies of developing high-quality products. Bringing these strong Doosan brands into the Bobcat portfolio allows us to further expand these business lines, while also growing our overall Doosan Bobcat business and providing even more solutions to help our customers accomplish more.”

The rebranding of the portable power and industrial vehicle equipment lines — two key business areas for Bobcat — is intended

to further strengthen overall brand equity, market recognition and consumer recall of all product offerings. The transition will create a cohesive customer experience and grow the organisation’s footprint, thus making the brand accessible to more customers and in more places.

Bobcat has broadened its product portfolio significantly within the past five years, launching more machines during this period than previously in its entire history.

Doosan Bobcat says the Bobcat brand has successfully expanded its offerings with new technologies and innovations and expanded product lines, such as ground-maintenance equipment, which includes compact tractors, small articulated loaders, mowers and turf equipment.

“The Bobcat brand empowers ambitious and passionate groundbreakers to accomplish more," said Laura Ness Owens, Doosan Bobcat vice president of global brand. "Across the globe, big challenges get smaller because of our equipment; from breaking down walls to building up communities, we’re proud to provide people with what they need to be successful in their endeavours.

"By expanding the Bobcat brand to the portable power and industrial vehicle industries, Bobcat can help even more customers, in more ways than ever.”

With this refreshed identity, the DPP and DIV product lines will, respectively, undergo

design and aesthetic changes in alignment with current Bobcat branding.

The rebranded products were displayed at key global trade shows in March and April 2023: DPP displayed a portion of its product line-up rebranded in Bobcat trade livery at the CONEXPO 2023 fair in Las Vegas, 14-18 March. DIV also showcased rebranded Bobcat forklifts as part of the in-booth display at ProMat 2023 in Chicago, 20-23 March, as well as at LogiMAT in Germany, 25-27 April.

Bobcat-branded material-handling equipment and portable power products are expected to be available through Doosan Bobcat’s extensive, global dealer network at a later date. Bobcat and these rebranded product lines will proudly remain part of the broader Doosan Group portfolio.

Caterpillar has introduced the Cat XQ330 mobile diesel generator set, a new power solution for standby and prime power applications that meets U.S. EPA Tier 4 Final emission standards.

Powered by the efficient Cat C9.3B diesel engine, the XQ330 is rated for up to 288 kW in standby and 264 kW in prime operation at 60 Hz, and up to 341 kVA in standby and 310 kVA in prime power applications at 50 Hz. Engineered to operate at lower noise levels than competitive offerings, the XQ330 packages essential components in a weather-resistant enclosure that streamlines transport, deployment, and maintenance while offering exceptional sound attenuation.

It is also equipped with numerous rentalready features, including a block heater, battery charger, permanent magnet generator (PMG), switchable voltage outputs, and

Doosan Bobcat says bringing portable power into the Bobcat portfolio will enable further expansion in this business line

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PORTABLE POWER

Caterpillar’s new XQ330 mobile diesel generator set

optional mounting on a trailer.

The XQ330 is equipped with the EMCP 4.4 digital control panel, which provides all generator-set controls and system indicators in a single, easy-to-access interface, as well as a programmable logic controller (PLC) functionality that improves reliability and flexibility for accommodating changes in processes or application requirements.

Additionally, it includes fully featured power metering, protective relaying, engine, and generator parameter viewing.

It is equipped with Cat Connect technology to remotely track and manage the generator set and improve operational efficiency. The telematics send real-time information on fuel level, diesel exhaust fluid (DEF) level, battery voltage, and run status.

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

Cat diesel mobile generator sets meeting U.S. EPA Tier 4 Final standards can use up to 100% hydrotreated vegetable oil (HVO), a renewable diesel fuel meeting EN15940.

“Caterpillar has built a reputation for

offering customers mobile power solutions with exceptional versatility, and the Cat XQ330 is equipped with a wide range of easyto-operate features designed for numerous applications while meeting stringent emissions standards,” said Tom Caldwell, global general manager for electric-power rental solutions at Caterpillar.

Atlas Copco has unveiled its first battery-driven portable screw compressor.

The manufacturer says the B-Air 185-12 represents a major milestone in the company's roadmap towards a sustainable future.

“We are committed to accelerating the transition away from carbon-dependency and towards renewable energy sources,” explains Maarten Vermeiren, product marketing manager of sustainability and digitalisation at Atlas Copco's Portable Air Division. “By introducing the first battery portable screw compressor, we want to play our part in enabling a sustainable transformation and help build a better tomorrow – for society and the planet alike.”

The B-Air 185-12 features 5-12 bar of pressure, a stable flow rate of 5.4-3.7 m3/

The Atlas Copco B-Air 185-12 battery-driven portable screw compressor

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min and 55-kWh battery storage capacity. With power delivered from its onboard power pack, in operation a fully charged unit is independent of the need for fuel or a local power source to plug into, and has the capability to perform for up to a full typical work shift. In turn, it provides both portability and productivity for those working on sites where regular access to electricity is not practical.

Atlas Copco says that making the switch from an internal combustion engine (ICE) to electric motor brings with it a host of benefits, including less downtime and maintenance requirements. Due to having far fewer moving (and therefore wearing) parts compared to a diesel-powered unit, the electric B-Air 185-12 only needs to be serviced every 2,000 hours, as opposed to 500 hours for a typical ICE -powered unit. The machine’s state-of-the-art Variable Speed Drive (VSD) and permanent magnet motor drives down the total cost of ownership, automatically adjusting the motor speed to match air demand in real time and increasing energy efficiency by up to 70%.

Through Atlas Copco’s testing process, which includes rapid-ageing testing under harsh conditions and climatic-chamber testing, the B-Air 185-12 has been proven to perform optimally even in the most extreme of climatic conditions – ranging from +45°C (+113°F) to a glacial -25°C (-13°F); and 4,500 metres (14,764 ft) above sea level. The unit is also designed to excel in densely populated urban areas where emission and noise pollution are tightly restricted, thanks to it producing no local emissions and having low noise levels.

The quiet nature of the compressor enables operators to work without noise distraction, enhancing both productivity and safety.

The B-Air 185-12 was first unveiled at the recent Atlas Copco’s ‘Journey to a Sustainable Future’ event in Antwerp, Belgium. Here, the company gathered senior business leaders from across the industry to discuss how best to tackle the transformation to a climate-friendly, low-carbon future. The company says its new battery-powered unit marks a vital step in the electrification of its product offering, and is just one of many developments it currently has in store to deliver sustainable solutions to its customers. AB

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QUARRY PROFILE

The two-crusher-line work site in Sävsjö

FUTURE-PROOFING AGGREGATES PRODUCTION Metso is helping Swedish company Kross & Maskin i Kisa future-proof its successful aggregates business. Guy Woodford reports

K

ross & Maskin i Kisa is based in Smaland County in central Sweden. Established in 2008 by Mikael Pettersson and Mattias Pettersson, the company mainly uses Metso’s Lokotrack mobile crushers and screens. It also utilises the OEM (original equipment manufacturer) wear parts and services from Metso for its Lokotracks.

All its equipment is mobile, so it can move around to where the firm’s customers need materials for projects in central and southern Sweden.

Over the years, Kross & Maskin i Kisa has grown its reputation for producing high-quality aggregates and building good customer relationships. The company has varied customers for whom it produces housing, quarrying and construction aggregates. Its products, such as ballast and road base materials, vary from raw to finished aggregate.

The company has been busy crushing

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granite at two job sites. The newest of its two Lokotrack LT120 jaw crushers with Nordberg C120 crushers, delivered in 2022, has been crushing 0-150mm aggregate fraction in Vimmerby for road base.

The other job site, in Sävsjö, has been operating two crushing lines. The first line consisted of a Lokotrack LT120 jaw crusher, a Lokotrack LT330D cone crusher with the Nordberg GP series cone crusher, and a triple-deck dual-slope screen. The second line had a Lokotrack LT300HPB with Nordberg HP300 crusher and screen and a third-party screen.

The two crushing lines in Sävsjö produce five different fractions. “We use the LT120 and the LT330D to produce 16-90mm fraction suitable for road base,” explains Mattias Pettersson. “Then we use the LT300HPB to crush smaller fractions out of the 16-90 mm for asphalt production.” The smaller fractions are 0-4, 4-8, 8-11 and 11-16mm. In addition to the Lokotrack units at these two sites, Kross & Maskin I Kisa also operates a

Lokotrack ST4.8 mobile screen elsewhere.

The company uses Metso wear parts in its crushers. Both the company’s LT120 jaw crushers are equipped with MX jaw plates. “We have used the MX jaws in our jaw crushers for many years already,” says Mikael Pettersson. “The operation is more secure, we get better material quality, and there are less operation breaks as we don’t have to do maintenance on the machines the same way.”

Mattias adds: “I think that the MX jaws last about 2.5 times longer than traditional plates.” With the MX jaw plates, Kross & Maskin I Kisa has had fewer maintenance breaks and, therefore, more time for crushing. The MX wears are a patented solution by Metso, combining manganese and hard metallic wear-resistant inserts for abrasion resistance; the result is longer wear life in demanding applications.

The second- and third-stage crushers use Metso manganese wear parts: medium or fine cavity and XT720 alloy. The company © AGGREGATES BUSINESS May/June 2023

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QUARRY PROFILE

takes advantage of Metso’s Full Container Load (FCL) deliveries and orders wear parts for stock to have the worn parts on hand when needed.

“We selected Metso [Outotec] because we think that [their solutions] give us a good operating economy and more secure operations. Their machines are also safer to work with,” Mikael comments.

The additional Metso’s Equipment Protection Service (EPS) covers some machines. “The warranty for these machines has been really good,” says Mattias. “Help has been available when needed – even during evenings and weekends.”

One of the challenges in the business is finding employees with the right skill sets.

“Working in our line of business requires multiple skills – from maintenance to operating crushers, excavators and so on,” says Mikael. “We have solved the problem by training our employees ourselves.” Mikael and Mattias have a combined 30-plus years of experience in aggregate crushing.

A solid example of their skills is the LT300HP which is currently in the company’s workshop, having further work done on it. They built it by themselves from two different units. Now the crusher is getting an additional by-pass chute.

“I follow with excitement the future developments of the Metso crushers and the development of the whole industry,” says Mikael. “The future looks bright for our company. In the future, we hope to move more to electric machines eventually,” concludes Mattias. AB

Mattias Pettersson established Kross & Maskin i Kisa with his brother, Mikael, in 2008

“We hope to move more to electric machines eventually” Mattias Pettersson

Mikael Pettersson with MX jaw plates in Kroos & Maskin i Kisa’s workshop wearhouse in Kisa

Kross & Maskin I Kisa’s Lokotrack LT120s are equipped with MX jaw plates

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QUARRY PROFILE

To drive efficiencies, the company invested in a new, state-of-the-art static plant in 2017

DRIVING QUARRYING EFFICIENCIES With no massive infrastructure projects on the horizon, the South African construction sector has endured a protracted downturn in the past decade.

To run profitable operations in such a low-margin business environment, Danoher Group is championing operational efficiencies at its Bloemspruit Quarry. Adopting new technologies is at the centre of improved product quality, increased productivity, reduced overheads and, more importantly, improved efficiencies. Munesu Shoko reports

B

y their very nature, quarries produce high-volume, low-cost material. To run profitable operations, quarry owners must find ways to drive operational efficiencies. Based on that understanding, Danoher Group, southern Africa’s leading quarry operator and mining contractor, has heeded the call for innovation to drive productivity and improve efficiencies.

Situated on the outskirts of Bloemfontein, Bloemspruit Quarry is endowed with a highquality, sought-after dolorite rock. Acquired

by Danoher in January 2017, the operation produces all aggregate sizes, including crusher dust, washed super sand, 7mm, 10mm, 14mm and 20mm road and concrete stone, base and sub-base materials, as well as some specialised products.

During the initial days of Danoher’s ownership, the quarry operated mobile

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crushing and screening equipment. By November 2017, the company had invested in a new, state-of-the-art static plant. “From the onset, we understood that for us to run a profitable business, we needed to invest in a new, efficient and flexible 250 tonnes per hour (tph) plant, capable of reacting to fluctuating market demand and supporting bespoke customer requirements,” explains Johann van Niekerk, business manager, Bloemspruit Quarry.

Bearing in mind the constant pounding these machines take, it is good to see how these new crushers and screens, being subjected to a stringent maintenance programme, have proven to be reliable and less prone to breakdowns, thus bringing about maximum plant availability and productivity. In addition, the new equipment, such as the two Metso HP300 cone crushers, contains the most advanced safety features, thus reducing workplace injuries.

“The investment in a contemporary plant was essential for us to drive productivity, plant uptime, efficiency and ultimately run a profitable business,” says Van Niekerk. “We have seen high levels of efficiency, which makes us competitive in such a cut-throat market.”

To meet the high demand for washed sand and washed super sand (high-end fine sand) used as input material by concrete product manufacturers, Danoher invested in a leading-edge 80tph EvoWash 102 wet processing plant from CDE, becoming the first and only company in the Bloemfontein area to run this type of technology.

Before investing in the CDE plant in 2020, Danoher previously utilised a bucketwheel system. Traditionally, bucket-wheel technology was deemed the mainstay for sand production in South Africa. It was cheap to buy. However, a major downside was that a substantial proportion of valuable fine sand © AGGREGATES BUSINESS May/June 2023

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QUARRY PROFILE

The CDE plant produces two grades of sand, compared to just the one grade previously produced by the bucket-wheel system

For its yellow metal equipment, Danoher has always preferred Volvo Construction Equipment

An aerial view of the pit

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would be lost to waste dams.

In addition, high and variable moisture content and inaccurate material classification were some of the downsides of the bucket wheel that CDE’s cyclone technology has addressed. Unlike the bucket wheel, which relies on gravity as the means of separation, CDE’s cyclone technology uses centrifugal force to classify materials.

“We were aware of the quality variability and sand losses we incurred through the old-generation washing plant we had. We, therefore, had to seek ways to maximise our productivity and efficiency in difficult market conditions. With the investment in the CDE plant, we have seen massive benefits in terms of production, efficiency and reliable quality of the product,” says Van Niekerk.

The CDE cyclone technology has been an important technological advancement for the quarry. Firstly, Danoher is now producing two grades of sand – fine (0 - 1,5mm) and coarse (0 - 5mm) – compared to just the one grade of sand previously produced by the bucketwheel system.

More importantly, says Van Niekerk, production is up by 30%, while water usage has decreased by 15%. In addition, the quality of the product has improved significantly, thus setting Bloemspruit Quarry apart from competition.

“We have seen a high demand for our sand, particularly from brickmakers. They prefer it because of its high strength and quality. It is made from virgin blue rock, which is also good for the strength of the bricks,” he says.

Bloemspruit Quarry uses Loadrite beltscale technology from Loadtech Load Cells to further drive efficiencies. This has proved its worth in maximising equipment value by having it employed most efficiently.

The Loadrite belt scales give plant operators and the management team a range of powerful tools to measure the actual production from screens and crushers, analysing plant and machine downtime.

Besides these technologies, Van Niekerk and his team also pay special attention to their haul roads. Haul-road maintenance, he says, requires a dedicated focus and is addressed continually as part of the operational cycle since good roads improve production, extend tyre life and reduce overall operating costs.

“We haul around 500m one-way distances from the pit to the processing plant. To optimise our cycle times and trucks’ fuel efficiency and reduce tyre wear, we have tried to keep our haul roads as straight and free of inclines as possible,” he says.

Danoher has always preferred Volvo Construction Equipment for its load and haul equipment. Two Volvo A30 articulated dump trucks (ADTs) are deployed to haul material from the pit to the processing plant. These are loaded by a Volvo E480 excavator in the pit. Two Volvo wheeled loaders, L150 and L190 models, are deployed for stockpiling duties and loading customer trucks.

“As the Danoher Group, we have always

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QUARRY PROFILE

“We have seen a high demand for our sand, particularly from brickmakers. They prefer it because of its high strength and quality. It is made from virgin blue rock, which is also good for the strength of the bricks” Johann van Niekerk, business manager: Bloemspruit Quarry

standardised our yellow metal equipment with Volvo. We get a good life out of the machines, while they have, over the years, proven to be fuel-efficient. Fuel is one of the biggest cost drivers in a load and haul operation, and it is therefore important to pick the best equipment to reduce your fuel bill. After standardising our equipment, spare parts, repair procedures, equipment and repair training have become much less onerous,” says Van Niekerk. “We also get good service from the local dealer, Babcock, which is key to maximising our equipment uptime, productivity and efficiency.”

A strong focus on keeping every part of the business in-house, from drill and blast to load and haul, helps improve efficiencies and reduces the cost of the material for customers. Additionally, this also helps with quality control.

Despite the generally depressed market conditions in the South African construction industry, Danoher has grown the Bloemspruit Quarry’s market share, which has enjoyed a good market run in the past few months, buoyed by its wide client base and a few road projects in the area. The company’s existing customer base includes aggregates resellers, brickmakers, asphalt plants, readymix plants, and property developers.

“The three months between July and September 2022 were our best ever. We broke our production record three times in a row. We have been fortunate to have the capacity to ramp up and supply a few road projects in the area without letting our base volume customers down. We are supplying three projects on the N1 South, the R30 and a new project on the R48,” concludes Van Niekerk. AB

www.AggBusiness.com

Situated on the outskirts of Bloemfontein, Bloemspruit Quarry is endowed with a high-quality, sought-after dolorite rock. The operation produces all aggregate sizes, including crusher dust, washed super sand, 7mm, 10mm, 14mm and 20mm road and concrete stone

A strong focus on keeping every part of the business in-house, from drill and blast to load and haul, helps improve efficiencies and reduces the cost of the material for customers

© AGGREGATES BUSINESS May/June 2023

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

2023

2024

AUGUST

APRIL

3-4: 7th Future Heavy-Duty Powertrain Summit Shanghai, China 2023 Fiveo Events draymond@ma.fiveoit.com.cn Tel: +86 21 5650 0750

24-27 INTERMAT Paris 2024 Paris, France Organiser: Comexposium Email: laura.sanchez@ comexposium.com https://paris-en. intermatconstruction.com/

23-26: steinexpo 2023 Homberg/Nieder-Ofleiden, Germany Organiser: Geoplan GMBH Tel: +49 7229 606 30 Email: info@geoplangmbh.de https://www.steinexpo.eu/

JUNE 15-17: Hillhead 2024 Hillhead Quarry Buxton UK Organiser: QMJ Tel: +44 (0)115 945 4367 Email: hillhead@qmj.co.uk www.hillhead.com/

SEPTEMBER 20-23: BICES 2023 Beijing, China Organiser: AEM Tel: +86 (10) 67870972 Email: bob.ban@e-bices.org http://www.e-bices.org/engdefault. aspx

OCTOBER 04-06 SIM 2023 Bordeaux, France Organisers: Exosition SIM https://www.expositionsim.com/ en/index.htm

These dates were correct at the time of going to press, but please note that the COVID-19 pandemic means some events may be rescheduled with little advance notice

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INTERNATIONAL

MAY/JUNE 2023 | VOL.17 ISSUE NO3 | www.AggBusiness.com

Driving quarrying efficiencies

High-productivity hauling

INTERVIEW Dr Pascal Peduzzi outlines a roadmap to a sand tomorrow p11

MARKET REPORT French growth potential amid market challenges p19

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LIUGONG The rapid global growth journey continues p16

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Profitable quarrying in a low-margin market p47

Two major RDT launches promise big returns p29

QUARRY PROFILE Future-proofing a successful Swedish aggregates business p45

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MARKET REPORT Korean aggregates challenges in sluggish construction market p13

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