ABE Mar/Apr 2025

MARCH/APRIL 2025 | Vol.19 ISSUE No.2 | www.AggBusiness.com

Monetising construction waste Kleemann plants deliver for the Spanish capital p24

INTERVIEW Sami Takluoma: Metso’s new president and CEO p20

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QUARRY PROFILE A CheckProof masterclass at HMUK Whatley p12

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CONTENTS

QUARRY PROFILE

“A key benefit of CheckProof is that any deviation in production generates an alert that goes straight to the maintenance team’s phones so that they can react immediately.” p12

MARCH/APRIL 2025 | Vol.19 ISSUE No.2 | www.AggBusiness.com

Vol.19 ISSUE No.2 March/April 2025

Regulars

Features

05 COMMENT

06 ASSOCIATION NEWS

Can Europe write its own critical minerals success story?

The latest association news from Aggregates Europe – UEPG.

50 EVENTS

20 INTERVIEW

All the key events in the quarrying and aggregates world.

Metso CEO Sami Takaluoma on his vision for the company’s future as he takes on the top job.

Specials A wrap-up of the key announcements and insights in the German aggregates sector.

Kleemann has given its support to one of Spain’s largest processors of construction waste.

INTERVIEW Sami Takluoma: Metso’s new president and CEO p20

WASHING – 1 Big final product quality and sustainability gains p40

QUARRY PROFILE A CheckProof masterclass at HMUK Whatley p12

28 LOADING

12 QUARRY PROFILE CheckProof is integral to daily operations at Heidelberg Materials UK’s Whatley Quarry.

Hitatchi’s wheeled loader has lifted efficiency for an Italian construction firm.

30 HAULING

18 QUARRY BUSINESS Cemex has continued to strengthen its position in the UK market.

Rokbak’s latest hauler has made an impression in Northern Ireland.

32 DRILL RIGS, HAMMERS AND BREAKERS Epiroc’s new DTH 5 hammers are becoming a sought-after option for their versatility.

34 DUST SUPPRESSION Why dust suppression is becoming increasingly important in the quarrying sector.

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Kleemann plants deliver for the Spanish capital p24

24 CRUSHING AND SCREENING

08 MARKET REPORT

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Monetising construction waste

36 SCREENING MEDIA Acquisitions and several product introductions have created a lively global screening media market.

COVER STORY: Kleemann is supporting one of Spain’s largest construction waste processors.

Image: Kleemann

40 WASHING – 1 Premium aggregate and recycling wash plant solutions are providing significant gains for customers.

44 SCALES AND WEIGHING Weighing tools continue to improve amid the industry’s continuing embrace of digitalised solutions.

46 SUSTAINABLE POWER CHALLENGE Power expert Steve Nendick examines how fleet managers can be empowered to be their best for the business. © AGGREGATES BUSINESS EUROPE March/April 2025

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“It’s been a real game-changer for us.

We’re now producing aggregates and sands that are 10% derived from recycled concrete from demolition waste.”

TRANSFORMING WASTE Complete Solutions For Constructing A Sustainable Future

WASHING // SCREENING // SCRUBBING // CLASSIFYING // CRUSHING // FEEDING // TAILINGS & WATER MANAGEMENT mclanahan.com

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COMMENT

HEAD OFFICE Prime Global Publishing Capitol Square 4–6 Church Street Epsom, KT 17 4NR EDITOR

Guy Woodford +44 (0) 7879 408 069 guy.woodford@primeglobalpublishing.com ASSISTANT EDITOR

Adam Daunt adam.daunt@primeglobalpublishing.com BUSINESS DEVELOPMENT MANAGER

Les Ilyefalvy +61 423 177 966 les.ilyefalvy@primeglobalpublishing.com CHIEF EXECUTIVE OFFICER

John Murphy CHIEF OPERATING OFFICER

Christine Clancy GROUP MANAGING EDITOR

Paul Hayes CLIENT SUCCESS MANAGER

Janine Clements +61 432 574 669 janine.clements@primeglobalpublishing.com ART DIRECTOR

Michelle Weston COVER IMAGE CREDITS

Kleemann Metso Terex Washing Systems Heidelberg Materials UK SUBSCRIPTIONS subscriptions@primeglobalpublishing.com No part of this publication may be reproduced in any form whatsoever without the express written permission of the publisher. Contributors are encouraged to express their personal and professional opinions in this publication, and accordingly views expressed herein are not necessarily the views of Prime Global Publishing. From time to time statements and claims are made by the manufacturers and their representatives in respect of their products and services. Whilst reasonable steps are taken to check their accuracy at the time of going to press, the publisher cannot be held liable for their validity and accuracy.

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GUY WOODFORD

EDITOR

Can Europe write its own critical minerals success story?

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fficial recognition of ‘aggregate and sand’ as critical mineral resources could have far-reaching impacts on the European quarrying sector.

Regular readers would have noted with great interest the call from Aggregates Europe – UEPG president Antonis Latouros in the November–December 2024 issue for an amendment to the Critical Raw Materials Act or a new Essential Raw Materials Act that prioritises approving new quarry licences and extending existing licences to enable European quarrying firms to access more of their mineral reserves.

Latouros believes the widespread adoption of a ‘one-stop shop’ for licensing (permitting) could significantly reduce the time and complexity of securing approvals, avoiding a scenario where the aggregates supply cannot keep pace with demand, leading to potential shortages and increased prices.

Securing national government and, ideally, EU regional government recognition of aggregate and sand as critical minerals would likely go a long way to relieving the hurdles European quarry operators face in trying to meet mineral product demand.

Europe can look to the Southern Hemisphere for inspiration. The New Zealand Government recently included aggregate and sand on its first-ever critical minerals list, identifying 37 minerals essential to the country’s economy and technological needs, including clean energy and international trade.

Wayne Scott, CEO of the Aggregate and Quarry Association (AQA) and MinEx (the health and safety organisation for New Zealand’s mining and extractive industries), welcomed the inclusion.

“It is important that aggregate and sand are on the critical minerals list, as this will influence strategy and policy decisions by central and local government,” he told Aggregates Business.

“New Zealand cannot import aggregates at scale due to limited port infrastructure and long cartage distances to many markets. Therefore, local aggregate resources throughout the country must be identified, protected and effectively managed to build resilient new infrastructure and homes.

“As an example of government policy driven by the critical minerals list, the recently passed Fast Track Approvals Act is important, as it is a ‘one-stop-shop’ for applications requiring multiple consents from different government departments.

This Bill will be more enabling so that resource consents are quicker to obtain and are less costly.

Where appropriate planning zones and controls exist, the time and cost of obtaining consent for a quarry can be extremely long. Even a favourable decision can take three to five years before a quarry produces its first tonne of aggregate.”

The New Zealand Government called minerals “essential to modern economies”.

“Their use in key industries and products supports economic growth and stability, national security and technological advancement,” the Government said. “In New Zealand, we produce many of the minerals we need, such as aggregate for roading and construction. We also import minerals as raw materials or within products, such as those used for clean technology, electronics, aviation and medical equipment.

“Developing a list of critical minerals is an important first step to ensuring a secure supply of the minerals we need for economic growth and resilience. The list identifies the economically important minerals vulnerable to supply risk or essential to unlocking other critical minerals.”

Aggregates Business stories on the subject met a positive reaction. Mark Russell, Mineral Products Association executive director of planning, mineral resources, and British Marine Aggregate Producers Association director of marine aggregates, called it “a really interesting development”.

“In a sense, it doesn’t really matter whether you consider domestic mineral needs essential or critical. The important thing is that their availability and supply must not be assumed,” Russell wrote.

“It needs to be planned and managed, supported by policy frameworks that recognise the sector is responsible for delivering long-term needs that underpin society and the economy as a whole.

Other national governments take note.” GW

guy.woodford@primeglobalpublishing.com

© AGGREGATES BUSINESS EUROPE March/April 2025

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NEWS

Nature Restoration Regulation What is the role of the raw materials industry?

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industry, offering a space to reflect on strategic policy developments, exchange good practices, and position the industry as a solution-provider in the transition towards sustainability. This year’s edition will focus specifically on the implementation of the EU Nature Restoration Regulation, highlighting the sector’s unique contribution in site restoration, enhancing biodiversity, and supporting local communities, as well as other provisions of services.

A central element of the programme will be a high-level panel discussion, featuring representatives from the aggregates and extractive industry, EU and Polish policymakers, and representatives from academia and non-government organisations. The panel will explore how different actors can collaborate to ensure the

regulation delivers tangible results on the ground, and how restoration objectives can be integrated into the European aggregates industry without compromising competitiveness.

The Entrepreneurs’ Forum is open to business leaders, policymakers, researchers and stakeholders who are interested in the intersection of industry and sustainability. Attendees will better understand how the new regulatory landscape affects their sector, while also contributing to shaping a shared vision for nature restoration in Europe.

As part of our close cooperation with Eurogypsum, the European association of gypsum producers, this edition of the Forum will also serve as the occasion to sign a common letter of intent with the World Conservation Union (IUCN).

This continues a longstanding cooperation that started in 2007, committing to the industry’s contribution in halting biodiversity loss by 2010 (Countdown 2010 project of IUCN).

Aggregates Europe – UEPG signed the first letter of intent with IUCN in 2012 and was invited to the IUCN World Congress in Marseille in 2021 to present its achievements in sustainability. The 2025 letter of intent envisages progress in quarry and nature restoration and developing biodiversity indicators applicable to the many small and medium enterprises in the industry.

The 2025 Entrepreneurs’ Forum will underscore a powerful message: that nature restoration is not only an environmental obligation but also a strategic opportunity for responsible industries to lead by example. AB

Image: Aggregates Europe – UEPG

oining Aggregates Europe – UEPG as a full member when Poland took over the EU council presidency on January 1 2025, the Polish Aggregates Producers’ Association (PZPK) will host the 2025 edition of the Entrepreneurs’ Forum under the timely theme, “Nature Restoration Regulation: What role for the raw materials industry?”

The Forum has been recognised as an official event under the Polish EU council presidency. It will bring together leaders from the extractive industry, European and national policymakers, scientific institutions, and environmental organisations to discuss how the private sector can lead in implementing the EU nature restoration regulation.

The Entrepreneurs’ Forum has become a landmark event for the European aggregates

The Polish Aggregates Producers’ Association will host the Entrepreneurs' Forum in 2025.

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MARKET REPORT

J. Obermeier engaged CDE to a new wash plant.

Images: CDE Group

Securing a sustainable future

As a key market for European and global aggregates, Germany is increasingly shaped by growing demand for recycled materials and sustainable solutions.

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rom its headquarters in Abersberg, J. Obermeier operates in earthworks, demolition, civil engineering and haulage, with a long list of clients throughout Germany’s greater Freising and Munich areas.

Just a few years after it was established in the late 1970s, J. Obermeier invested in a five-hectare gravel pit that supported major projects such as the Munich Airport, as well as construction in the surrounding region.

“In simple terms, across all the different divisions of our business, we dig, haul and process materials that are critical to the construction industry,” J. Obermeier owner Josef Obermeier said. “However, conserving natural resources is at the forefront of everything we do.”

As the industry’s expectations have changed in line with environmental considerations, the family-run business has adapted its operations to match. J. Obermeier has taken to dry recycling construction and demolition (C&D) waste.

“We continue to run natural sand and gravel operations because of industry demand, but we are actively investing in

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our recycling capabilities, now and into the future, to offset the impact of this work and to eventually transition to a business where the majority of what we produce is recycled material,” Obermeier said.

This desire to focus on conserving natural resources and minimising its environmental impact was front and centre when J. Obermeier engaged CDE Group, whose specialists devised a wet processing solution that would enhance operations and bring them into the 21st century.

The solution needed to ensure sand and aggregates production remained efficient and unimpeded. J. Obermeier needed to meet its current requirements and futureproof operations as the German market increasingly sought recycled materials.

“We wanted to make the best use of our existing natural resources to expand and improve our product range, while retaining the option of converting the plant to a recycling operation once the permits were in place,” Obermeier said. “That’s where CDE came in.

“I heard about CDE through a recommendation and ended up visiting

several sites where their equipment was in operation. I was impressed by what I saw, and I left convinced that we had found a partner aligned with our values.”

CDE devised and commissioned a highcapacity plant with recycling capabilities and a capacity of 150 tonnes per hour for primary sand and gravel. The plant featured CDE’s M2500 modular sand washing plant, the AggMax scrubbing and classification system, and the AquaCycle thickener, which is designed for primary stage water management.

The M2500 allows for feeding, screening, washing and stockpiling on a single chassis, while the AggMax integrates pre-screening, scrubbing, organics removal, sizing, stockpiling, fines recovery, and organics removal into a compact chassis.

According to CDE, the AquaCycle allows up to 90 per cent of process water to be recycled and recirculated for re-use within the system and reduces operating costs.

“This solution has been carefully designed to serve two purposes: to integrate seamlessly with the company’s existing primary sand and aggregates process, while benefiting from our modular approach so that it can be easily adapted to process highly variable feed materials, including C&D waste,” CDE business development manager for DACH region Andrew Wilson said.

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MARKET REPORT

“It has been commissioned and is currently supporting Obermeier to process its natural resources with greater efficiency.

The plant in operation today will facilitate an easy transition to waste recycling for the business tomorrow and provide it with great recycling capabilities and a recovery rate of 60 to 80 per cent.

The CDE plant has been operational for close to a year. During that time, J. Obermeier has expanded its product range to include fine sand, 0/4mm concrete sand, 4/8mm and 8/16mm washed aggregate, 16/32mm aggregate and +32mm oversized.

“Our partnership with CDE will really help to ease pressure on these finite resources so that we can better meet the demands of the market today in the most sustainable way possible while also building a facility that can pave the way for a circular economy into the future,” Obermeier said.

Sustainable succession Sustainability is an increasingly used word across the global aggregates industry, and its importance is shaping construction material producers and original equipment manufacturers (OEMs). As businesses on both sides of the equation try to manage the push towards decarbonisation, modern equipment is pivoting in key European markets, including Germany.

“Sustainability plays an increasingly significant role in the German aggregates

industry. Volvo CE supports its customers in this area by offering compatibility with hydrotreated vegetable oil [HVO] for its machines, providing a cleaner fuel alternative,” Volvo Construction Equipment commercial manager Frank Schmitt said.

“Additionally, Volvo CE implements a CO2 reduction program to help

The wash plant is capable of processing up to 150tph of primary sand and gravel. customers achieve their sustainability goals.

Our CO2 reduction program is a key focus for us in this area, and the advantage is that every save we make is also a save for the customer.

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© AGGREGATES BUSINESS EUROPE March/April 2025

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Image: CDE Group

MARKET REPORT

CDE’s system features an AggMax scrubbing and classification system.

Supply certainty In the backdrop of the local aggregates markets is the German Mineral Resources Association’s (MIRO) push to secure government support to secure the domestic aggregates supply.

Germany has a strong supply of aggregates, including sand, gravel, quartz sand and natural stone, which, according to the MIRO, are extracted in 2700 locations nationwide.

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But the MIRO has said such operations are declining because the necessary extension permits are not being approved. This has the potential to strain domestic and place pressure on infrastructure projects.

“Mineral raw materials are at the heart of many value chains. Without them, construction and infrastructure projects cannot be implemented – especially now, when roads and bridges also need to be made fit for military transport,” MIRO management team member Susanne Funk said.

The MIRO has begun seeking support from the German Government so construction material producers can be certain of their future.

The organisation’s wishlist includes simplifying the current approval procedures. In addition, it wants to see uniform technical standards, automatic approvals in the event all legal requirements are met, and consistent adoption of these changes across all construction materials industries.

“Mineral raw materials are the foundation of construction and industrial production in Germany,” Funk said.

“Without a reliable supply of domestic resources, key infrastructure and climate protection projects are at risk.” AB

Volvo CE Co-Pilot Assist System for wheeled loaders.

Image:Volvo CE

“There is growing demand for CO2 reduction, and Volvo CE provides targeted solutions in this area.”

Volvo CE has significantly invested in technologies linked to its sustainability goals, including electric-drive machines, equipment, and digitalisation and automation tools.

Schmitt told Aggregates Business that these areas represent growth opportunities for customers and manufacturers.

“Digitalisation in German loader and hauler production holds significant potential and is only now beginning to gain traction,” he said. “Customers are starting to recognise the benefits and are becoming more open to solutions such as site optimisation, data collection, and analysis of machine data through tools like CareTrack.

“A surge in investment in machinery occurred during the previous peak, but now the market has stabilised to a normal level, reducing pressure. The current fleet of machines is relatively young and operating at typical levels, leading to a delay in new investments.

“Utilisation rates are expected to decline, with fewer operational hours per year.

However, the industrial sector is expected to maintain a steady level of activity.

To address these challenges, Volvo CE offers solutions to increase efficiency and actively helps customers by presenting and implementing these solutions.”

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QUARRY PROFILE

CHECKPROOF IS THE BUSINESS FOR HMUK WHATLEY

Image: Heidelberg Materials UK

CheckProof has become integral to daily operations at Heidelberg Materials UK’s Whatley Quarry. See how the Software as a Service solution is used and learn about the site’s rail aggregates freight operation and development plans.

An aerial view over Whatley Quarry.

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QUARRY PROFILE

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Image: Prime Global Publishing

H

eidelberg Materials UK’s (HMUK) Whatley Quarry (Whatley) planning maintenance engineer Dave Short recounted how CheckProof's early flagging of a production issue one day last year potentially saved HMUK tens of thousands of pounds in repairs.

“CheckProof identified a shock to a driveend bearing on our X1 primary crusher’s 1200kW motor – an extremely valuable asset worth up to £200,000. If there had been a delay in flagging it, the fault could have led to serious damage and production could have been down for a long time,” he told Aggregates Business. “I was able to do an independent vibration analysis that alerted us to do something about the problem in a controlled way. We then constantly monitored the primary crusher until our Christmas shutdown, and then we had the crusher removed, and new drive-end bearings were resealed and realigned.”

Short said a third party ran Whatley’s previous maintenance planning and checks system.

“We had no access to it,” he said. “But with CheckProof, after trialling it with some of my maintenance inspections, we built our version of the system how we wanted it to be. We have modified it several times, including on our conveyors, reducing the number of necessary checkpoints. We have set tasks, oil and lubrication checks, non-running checks, and a maintenance diary on the system.

“If I nominate a team member to do something, they will get a CheckProof alert on their mobile saying this check is due. I have a diary with my team where I can set tasks for our daily full plant checks. I can also create a deviation for additional checks, such as those relating to something supplied by a third party.

“When a maintenance team member arrives on site that morning, they will know, for example, that they have to do an oil check on asset S20 or a 40-hour oil drop on a new gearbox. We now have 17 mobile plant areas whose maintenance needs we have incorporated into CheckProof.”

HMUK Whatley engineering manager Shaun Eaton said CheckProof suited the nature of the limestone aggregate quarry in Somerset, southwest England.

“We are a very dynamic site. A key benefit of CheckProof is that any deviation in production generates an alert that goes straight to the maintenance team’s phones so that they can react immediately,” he said.

“We have a 24-hour [weekday] operation.

Production can deteriorate extremely quickly if things go wrong. CheckProof is easy to use, and the company has assigned us a dedicated manager who we speak to regularly. We initially had an issue with a lack of site Wi-Fi coverage affecting our CheckProof use for maintenance work, but now we have installed a booster, and there is Wi-Fi coverage for the whole mobile plant area.”

Safety solution CheckProof is a mobile-first platform simplifying maintenance management and health, safety, environment and quality (HSEQ) processes.

Combining intuitive technology with actionable insights helps companies in the construction materials sector and heavy industries follow routines, mitigate risks, minimise costs, and enhance safety procedures.

The platform connects to telematics systems across various machines and vehicles, regardless of brand. This integration enables seamless access to vital data such as fuel consumption, geographic location, idle time, error codes, and CO2 emissions.

CheckProof merges this machine data with frontline employee reports. This holistic approach allows businesses to proactively address deviations, monitor performance trends, and ensure compliance with maintenance routines, all from one platform.

In addition, CheckProof offers integrations with original equipment manufacturers (OEMs) and third-party providers offering vibration and temperature sensors and belt-weigher software. Users can harness real-time insights and automate maintenance workflows, bringing the idea of a connected plant to life.

This approach transforms raw telematics data into actionable insights, driving operational improvements and creating smarter, more connected plants and sites.

Kyle Smith (left) and HMUK Whatley recycling manager Daniel Billing inspect stockpiled material.

HMUK WHATLEY FLEET LIST Crushing plant 3 x Hazemag impact crushers 1 x Sandvik cone crusher 1 x Metso Nordberg cone crusher 1 x QMS B3 cone crusher Mobile plant (Heidelberg Materials UK) 4 x CAT 988 wheeled loaders 4 x Komatsu 605 RDTs (63t) Mobile plant (Walters) 6 x CAT 777 RDTs (100t) 2 x CAT 992 wheeled loaders 1 x Hitachi 1200 excavator 1 x CAT grader 1 x CAT D8 dozer 2x Volvo A25 water and fuel bowser 1 x CAT 966 wheeled loader 1 x CAT 980 wheeled loader 1 x CAT 336 excavator 2 x Hitachi 490 excavator 1 x CAT 374 excavator 1 x CAT D6 dozer 12 x Volvo/CAT ADTs (40t)

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Image: CheckProof

QUARRY PROFILE

CheckProof suited the dynamic nature of Whatley.

CheckProof has been fully used at Whatley since September 2022, with planning for its full introduction starting in 2020 as part of HMUK’s rollout of the Software as a Service (SaaS) platform across its site network.

“Tom O’Boyle, our former maintenance planning manager, was quick to tell us about CheckProof when it was first introduced to help with plant maintenance inspections and planning,” HMUK area general manager for Mendips and Masters Vincent Pitt said.

“He, Dave Short and James Veakins worked to get it up and running at Whatley.

He’s now the lead project manager for a new rail aggregate installation at HMUK Horton Quarry in Ribblesdale, Lancashire.”

“The system we used before CheckProof was largely Microsoft Excel spreadsheetbased. It required a lot of manual input before it generated a work order. It did not reduce workflows.”

HMUK Whatley rail logistics manager Daniel Welch was equally effusive in evaluating CheckProof.

“There is so much we can do with this system. The potential is huge,” he said. “Each business area at Whatley that uses it has tailored it to their needs, and the collective way we use it is for inspections.”

Rail shunting, like that done at Whatley, is an essential process that keeps railway networks running efficiently. The shunting process allows individual railcars to be strategically sorted and reassembled into new trains with different cargo and destinations.

This manoeuvring of rolling stock is critical for consolidating freight shipments, distributing rail traffic, and enabling flexibility in railway operations.

“From a rail aggregates perspective, a shunter must make sure the rail wagons are safe for loading,” Welch said.

“There is a visual inspection which takes in, for example, whether any wagon doors are open or if a wagon has any holes. This information was not being captured. ”But with CheckProof, we compiled a checklist showing compliance, including taking and storing time and date-stamped pictures. It means that when a maintenance deviation task is set, it can go to the right people to handle it. We do locomotive pre-start checks in the same way.

“Checks done through CheckProof remove what can be a tick-box exercise, create accountability, and give us much more detail. A picture of a bad area speaks a thousand words.

“We also developed in CheckProof a ‘presenting a train’ pre-trip checklist for our shunting team. Freightliner, our rail and freight logistics company, deliver rail aggregate wagons to us. We do the required shunting, take the wagons into the quarry, load them, and then hand them back to Freightliner in a fit and safe manner. The checklist will ask, for example, if the [locomotive] brake pipes have been coupled up. What time was the shunter presented? Are all the wagons in a tidy and safe state?

“All this is ticked off, and the final check sheet comes through digitally, is stamped, and stored in CheckProof.

Image: Prime Global Publishing

Around two-thirds of Whatley’s annual production is transported by rail to 20 depots.

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QUARRY PROFILE

“We also do our rail track inspections to ensure it is in a usable and safe state.

Once a week, a team walks our entire rail track length, highlighting any defects in CheckProof. This information, including images of defects, goes instantly via email to our track maintenance partners, Mendip Rail, a joint venture with Aggregate Industries [and its Torr Quarry].”

Close collaboration Whatley is talking to CheckProof and its contractors about how its system can communicate with all contractor work systems to enable more efficient collaboration and operational accountability.

In addition to having all maintenance data integrated into CheckProof, the Whatley management team is keen to integrate its Hayley Dexis-managed stockpile management data into its set-up. This will allow quicker and easier access to live stockpile inventory, saving valuable time in fulfilling customer product orders.

Heidelberg Materials’ third biggest quarry globally and the UK’s biggest limestone quarry, covering 120 hectares and equivalent to 168 football pitches, Whatley produces Mendips’ limestone aggregate, with two-thirds of its Type 1 and -100mm range used by different areas of HMUK’s business.

Around two-thirds of Whatley’s annual production is transported by rail to 20 depots via its close working partnership with Network

Rail, Mendip Rail and Freightliner, with the remainder delivered by lorry.

The quarry supplies materials to major projects, including Hinkley Point C nuclear power station, Thames Tideway, and HS2.

Regional projects include Frome Medical Centre, Royal United Hospital (RUH) Bath, new housing in Warminster and Frome, A303 improvements, Sainsbury’s Bath, and Selwood School. Other customers include local county and borough councils and highway infrastructure contractors.

Whatley features 97 HMUK and 38 contractor employees. There are four aggregate processing stages, with Walters contracted to do the site’s primary loading and hauling work.

The primary crusher can produce up to 2200 tonnes per hour. Whatley averages 60–65 train deliveries a week, and each train delivers 1400–2300 tonnes to the southeast England market. Whatley also pumps up to 35 million litres of water daily into two local brooks. The quarry excavates at 9.3m above sea level, with permission to excavate to level 11.

HMUK quarry manager Kyle Smith spoke to Aggregates Business about each step of production at Whatley.

“We are blasting around three times a week, averaging around 50,000 tonnes of stone per blast. We contract this process to EPC-UK,” he said. “We use two to three Epiroc drill rigs, depending on how busy we are.

OPEN DAY

J. OBERMEIER

SCALING SMARTER MAINTENANCE WITH CHECKPROOF “Heidelberg Materials UK’s Whatley Quarry, one of the largest aggregates sites in the country, required a smart approach to digitalising its maintenance operations,” CheckProof head of customer success Joe Cage said.

“Given its vast scale, traditional unit-based tracking wasn’t practical. Instead, Whatley’s team, led by Tom O’Boyle, implemented an innovative route-based system within CheckProof. Maintenance and issue reporting was structured along predefined routes rather than individual units. This ensured issues were precisely tracked within specific routes and eliminated unnecessary back-and-forth across the expansive site.

“This restructuring improved user experience and optimised back-office data management, making cost centre tracking more efficient. CheckProof’s flexibility was key to this success — adapting to Whatley’s needs rather than forcing a rigid system. Combined with CheckProof’s offline mode, the platform became indispensable in quarry areas that sometimes had network issues, ensuring no data was lost.

“Whatley Quarry’s openness to innovation extended beyond workflows. They actively embraced new technology, trialling RFID tags and telematics integrations, helping push the boundaries of digital efficiency in the aggregates sector.

“By thinking differently and working smarter, Whatley transformed its maintenance processes, demonstrating both the ingenuity of its team and the adaptability of CheckProof’s platform. Whether for small operations or massive industrial sites, CheckProof can scale and optimise workflows for any environment.”

CDE is pleased to be organising, in collaboration with J. Obermeier e.K., an open day in May to showcase this 150tph sand and gravel wash plant located near Munich.

150TPH WASH PLANT GERMANY ZOLLING

22

22 MAY

08.00-16.00

Registration required at cdegroup.com/obermeier-open-day

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“We have mine plans that we work to, and Walters is contracted to do our primary load and haul. They run three teams working between them 24 hours a day, seven days a week.

“We are crushing five days a week from 6.00am to 11.00pm, and then from 11.00pm to 5.00am we are secondary crushing. We do plant and fleet maintenance work at weekends. We also constantly pump water into the two lagoons on-site.”

Whatley’s large capital expenditures in recent years have included £4.6 million on a new mobile plant fleet, £2.2 million on new dewatering pumps, £1.5 million on wash plant modifications, £1.4 million on a new electric-powered switcher locomotive for its aggregate rail operation, and £600,000 on rail track replacement.

Whatley has new and long-established equipment supply partnerships with OEMs, including McLanahan, Metso, Sandvik, Hazemag, Diefenbach, Atlantic Pumps, and Pioneer Pumps.

“We’d love all our rail aggregate operations and mobile plants to be electric at some stage. Our issue is getting enough power to the quarry,” Pitt said.

“We want to increase our potential electric usage. It does offer a big saving on fuel [cost], but there are challenges with securing increased power supply as the local electric authority says they can’t add to our power supply for at least two years.

“Anything bigger than that and new connections, like at nearby Westdown Quarry, which will reopen soon, will have to run off power generators, as new connections could take longer.

“If we want to run any electric dumpers and loading shovels in the future, we need to apply to the local electric authority now.”

In operation since 1937, Whatley has 75 million tonnes of mineral reserves.

Meanwhile, HMUK is reopening Westdown Quarry, around a mile from Whatley after successfully applying to Somerset Council to update existing planning conditions.

Production is expected to begin in 2026, with the site earmarked to produce around two million tonnes of limestone aggregate a year.

Another eye-catching project is the planned introduction of six autonomous Cat 777 rigid haulers at Whatley from 2027. A similar 100-tonne autonomous RDT pilot project will run at Ketton, another HMUK limestone quarry in Rutland.

Whatley is keen to be a good neighbour and maintain strong relationships with its local community. The quarry supports local

Image: Prime Global Publishing

Blasting at Whatley occurs around three times a week, averaging around 50,000 tonnes of stone per blast.

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Image: Prime Global Publishing

QUARRY PROFILE

Rigid dump trucks transporting aggregate at Whatley Quarry. initiatives through financial donations, material supplies and voluntary labour.

Projects have included part funding the Whatley field play and picnic area redevelopment, and supporting local charity Mates in Mind, Santa’s Grotto in Frome, Westfield Football Club, and Community Fridge Frome’s voluntary food collections.

Whatley volunteers also repaired and painted fences at Mells Primary School.

HMUK is committed to having a minimum of five per cent of its UK workforce enrolled in formalised apprenticeship, sponsored student, and/or graduate development schemes. It offers opportunities for craft apprentices, higher apprentices (LEAF), and graduate programmes.

The quarry works closely with the Environment Agency and the National Trout Association, while collaborating with Frome Angling Club in annual river clean-ups. It participates in Vallis Vale ash dieback felling, performs geological feature maintenance, assists with Railford footpath repairs and Asham Wood deer management, and has installed a public footpath around the quarry.

“Each of our final benches is seeded, and we resoil parts of the site that have started to see vegetation grow,” Pitt said. “We have had a couple of local water authorities approach us about purchasing finished quarry areas to create a reservoir. All the quarries around here will have had similar approaches about their timescale for finishing production.”

Finishing production is not on the agenda at Whatley, a ‘super quarry’ with an ambitious and exciting technology and sustainability-minded future. AB

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QUARRY BUSINESS

English investment Cemex has continued strengthening in key aggregates markets following recent investments in the UK.

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emex’s latest investment includes a new lower carbon mortar plant near London, which is expected to be operational in the second half of 2025. The UK announcement follows Cemex chief executive officer Fernando A. González’s discussion of the company’s strategy earlier this year.

“As part of our growth strategy, we are pursuing targeted acquisitions and greenfield projects in developed markets,” he said.

“This strategically located plant will enhance our production capacity in the country, advance our decarbonisation goals and allow us to provide an even better experience to our customers in the region.”

The new facility, located in Swindon, Wiltshire, will specialise in lower carbon dry mortar and sprayed concrete production, further expanding Cemex’s role as a producer. The company expects the new facility to position it as a national supplier of both products.

The new plant will feature an innovative drying process that reduces heat and leads to fuel savings. It will also have an undercover storage area that will protect the material supply from adverse conditions.

“We have seen our mortars business grow from strength to strength in recent years, with demand reaching capacity for dry mortar and sprayed concrete

at Dove Holes in Derbyshire and at our dry mortar plant in Braintree, Essex,” Cemex European sales manager of dry and special mortar Mike May said.

“It is a nice problem for us to have and Swindon offers us the solution.

“The new Wiltshire plant is strategically located and will enable us to increase capacity and penetrate new regional markets while expanding existing markets.

Additionally, it provides a surety of cement supply plus good aggregate reserves from the local area.

“The UK team is looking forward to an exciting 2025 serving our existing customer base and welcoming more to Wiltshire.”

The Swindon investment follows Cemex UK’s unveiling of a new sand and gravel quarry in Surrey at the start of the year. The site, located in Shepperton, North Surrey, will produce construction materials for infrastructure projects and ready-mix plants in the West London area.

Cemex expects 1.2 million tonnes to be extracted from the site over five years before it is restored to agricultural use once the reserve is exhausted.

“The opening of this new quarry is crucial to ensure we can continue to supply the important London market,” Cemex UK aggregates operations manager Wayne Stevens said.

“Sand and gravel reserves in this area are becoming harder and harder to secure.

For this reason, we are extremely excited to open our new Shepperton quarry following a significant investment into a new on-site processing plant.

“Shepperton will play a vital role in the future of our capital’s infrastructure development, ensuring that we can meet the city’s growing demands with a reliable supply of high-quality aggregates.”

The UK arm of Cemex recently welcomed North Warwickshire and Bedworth MP Rachel Taylor to the company’s Coventry ready-mix plant, where she praised its contribution to local building and construction sectors.

The Midlands region is key to Cemex UK’s operations. Its head office is based in Coventry, and one of its largest UK cement plants is located in Rugby, Warwickshire.

“Visiting Cemex’s Coventry ready-mix plant in Exhall gave me the opportunity to see how Cemex are supporting local economic growth in the region through the role they play across the building and construction supply chain,” Taylor said.

“Foundation industries such as the mineral products sector are essential to support the UK’s wider growth ambitions through the provision of vital construction materials that support house-building, infrastructure and help to maintain our roads and highways.” AB

Image: P.Cartwright/shutterstock.com

Cemex has invested significantly in its UK operations.

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Welcome to your one-stop aggregates business world.

Aggregates Business is a go-to source for up-to-date news and views on the European, Asian, African and Middle Eastern aggregates and building materials sectors. Our wide-ranging features line-up includes in-depth articles on the latest crushing and screening, loading and hauling machines.

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Going with the CFlo

ves CFlo Restructure lea success p40 poised for MEA

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MARKET REPORT East Building in Middlep8 and North Africa

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INTERVIEW

Sami Takaluoma became Metso's president and CEO on November 1 2024 after leading the company’s services business area since 2021.

SAMI TAKALUOMA Pursuing a new era of Metso success New Metso chief executive officer Sami Takaluoma shares his plans to build on the company’s market position and sustainability goals while continuing a culture of innovation.

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INTERVIEW

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any have spoken of how the first 100 days in office can define a government.

After taking up the leadership role of president and chief executive officer (CEO) of Metso, Sami Takaluoma was keen to show that the sentiment was just as valid in the world of aggregates and mining products and services.

“We all knew that Pekka [Vauramo] was finishing at the end of 2024, and I wanted people to focus on their work and get energised about the future. With that in mind, I established our new leadership team on my second day as president and CEO,” Takaluoma told Aggregates Business.

“I also spent a lot of time in November and December [2024] with our investor community so they could meet me and understand that the company would be in good hands. After the Christmas break, we started a strategic review of our aggregates and minerals [mining] business segments and laid out what the next three to five years for Metso will look like.

“That work will continue until the summer, and then there will be a capital market day in early October where we will explain the full strategy. As I come from inside the company, I know where to look and what questions to ask to gain some improvements.”

Takaluoma said Metso is focused on the current global demand its products and services in several key markets. “[The year] 2024 was a low capital investment year in the global aggregates and minerals industries,” he said. “We know that the aggregates market is cyclical and is driven by site operators’ trust that there will be demand in the future. The drivers in this market are also more regional. Europe has its [growth] drivers, as does the US, China, South America and Africa.

“Whatever macro-level indicators you look at, there is still a need to do a great deal worldwide on infrastructure, like building and maintaining roads.

“I think construction will come back.

There are still a lot of developing countries that need aggregates to realise their growth ambitions.

“There are many roadwork project opportunities, and I want to ensure we are fully equipped to go after them. I am looking at how processes flow when we are serving customers. For instance, are we getting all the benefits from our acquired data to best support them?”

Having been a member of Metso’s leadership team since 2017, Takaluoma became president and CEO after leading the company’s services business area from 2021 until his appointment to the top job.

Under his leadership, the services business grew and added significant value, partly through Metso’s July 2020 merger with Outotec, a Finnish-headquartered global provider of process technologies and services for the world’s metals and mining, industrial water treatment, and chemical industries.

After nearly three years of trading as Metso Outotec, Metso Corporation (Metso) was born in May 2023, reflecting the successful integration of Metso and Outotec into a single company.

Metso is a global business staffed by more than 17,000 employees from over 100 nationalities. Aggregates-related business accounts for 25 per cent of its annual revenues, with mining-related trading accounting for 75 per cent. Combined (aggregates and mining) equipment and solutions sales represented 42 per cent of total sales, with 58 per cent being (aggregates and mining) services sales.

In 2024, Metso achieved total business sales valued at €4.9 billion, including €1.3 billion Metso Plus sales. The latter sustainability-focused sales included, among others, optimised spare and wear parts for more efficient processes, repairs and upgrades extending the lifetime of customer assets for reduced waste, Metso Truck Body units for offering more payload and less fuel burn per hauled tonne, and energy-efficient modular in-pit crush and conveying.

Geographically, 24 per cent of Metso’s sales (mining and aggregates segment) were in Asia Pacific, 22 per cent were in North and Central America, 21 per cent were in South America, 18 per cent were in Europe, and 15 per cent were in Africa, the Middle East and India.

“Metso benefits from being a truly global business – as two slowing market regions are balanced by two or three others seeing far stronger demand for aggregates and minerals products and services,” Takaluoma said.

Metso’s new president and CEO said the ‘green’ evolution of the Chinese quarrying industry has created attractive new business opportunities in the world’s biggest aggregates market.

Fuelled by the Chinese Government’s focus on carbon reduction and key industries’ sustainability, China’s extraction sites are down from 56,000 a decade ago to around 13,000. While this has seen production drop from nearly 20 billion tonnes in 2020 to around 16.8 billion last year, a sizeable number of the remaining extraction sites – dubbed ‘super quarries’ – produce around 100 million tonnes of aggregates annually.

“The super quarries in China want the best production plants and technologies.

Some of these producers hadn’t been in quarrying before. They have said they need the best equipment to produce the best final aggregate products,” Takaluoma said.

Images: Metso

Metso NW Rapid plants at a Veidekke quarry in Norway.

Metso’s significant global services expertise includes 3700 field service professionals and technical support experts.

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INTERVIEW

“When working your site 24–7, 365 days a year, having the best and most reliable plants and machines makes sense.

“They also appreciate our comprehensive after-market services and solutions offered through Metso Life Cycle Services. Some Chinese quarries can lack some of the technical competencies required to get the best out of their operations, and we can help supply that.

“We have benefited from the super quarries being, in effect, ‘mini mines’. We could take the service support we offer to our mining customers and offer something similar to our aggregates customers.

“We have also invested in our service workshops and spare parts warehousing in China, and recently we announced an agreement to acquire the screening solutions business and operations of Selm (Beijing) Technology Company.

It is renowned for its heavy-duty industrial screens and will further enhance our offering to Chinese mining and aggregates customers.

“China will be a very important market for us in the future.”

Metso’s comprehensive global services expertise includes 3700 field service professionals and technical support experts, 140 service locations and repair centres, three performance centres, six own foundries and selected partner foundries, seven rubber and poly-met part factories, and five aggregates equipment factories for the Metso brand and five for other brands.

Metso has invested big numbers regarding its innovation and research and development (R&D) capacity.

The company invested €103 million in R&D in 2024, has 40 locations around the world with R&D, testing or laboratory capabilities, and has secured 7900 patents.

Furthermore, 24 Metso Plus-inclusive products were launched last year (now totalling over 100).

Metso Plus helps customers cut their CO2 emissions and achieve their other sustainability priorities, such as water and energy efficiencies, by operating Metso’s

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Metso Plus-inclusive products. In addition to direct emissions reductions, Metso Plus products can decrease the carbon emitted in manufacturing and delivering products and offer the potential for recycling materials.

Metso has invested significantly in its aggregates segment offer in recent years by acquiring McCloskey International, McCloskey Environmental, MWS Equipment, Lippmann, Jonsson, Tesab Engineering, Screen Machine Industries, Diamond Z, SR Heavy, and Tedd Engineering.

“These brands are performing well within the Metso family, and each has a business development plan,” Takaluoma said.

“We are not the kind of company that acquires another company and says, ‘Right, over to you to get on with it’,.”

A consistent annual global aggregates demand of around 45 billion tonnes creates many commercial opportunities for Metso and its aggregates segment brands.

“The election of Donald Trump as US president will likely see the return of investments in federal and state infrastructure. This means that 2025 should be a year of growth for us in America,” Takaluoma said.

“I would love to say the same about Europe; much of it depends on the situation in Ukraine.

“If a firm enough resolution and peace are achieved, it would lead to renewed infrastructure investment across Europe, with aggregate producers feeling confident about investing in new plants and services.”

South America is another big business portfolio growth region for Metso.

“It’s a hot spot for greenfield mining development, and there’s a lot of infrastructure work needed to build roads and rail links for these mines – which creates great need for aggregates,” Takaluoma said.

“Like in China, we have developed our services network and improved our wear

Metso’s Life Cycle Services packages are becoming increasingly sought after.

parts distribution capabilities to meet growing customer needs.”

In addition to being a big hit among Chinese super quarry operators, Metso’s Life Cycle Services (LCS) packages are becoming increasingly sought after in other big regional aggregates and mining markets.

In 2024, Metso secured over 100 new LCS contracts with global and regional mining companies, large quarries and aggregate contractors.

LCS encompass Metso’s after-market portfolio, from spares and wears to advanced maintenance, remote monitoring, and other expert services. The company assists customers in enhancing safety and environmental standards, boosting reliability and production for greater resource efficiency, and optimising the overall cost of ownership.

Takaluoma said that Metso’s aggregates business segment customers now account for around a third of the over 550 active Metso LCS contracts.

“Through Metso LCS, we are increasing equipment lifetime by taking good care of it,” he said.

“It is good for sustainability, as the customer does not need to replace their equipment earlier than before, and it is good economically, as the customer gets more productivity and efficiency from wellmaintained equipment.

“We are an [aggregates crushing and screening plant] market leader – in our plants, our wear parts and the services and support we offer our customers. Our Metso Plus offering supports this, helping customers get extraction permits through dust and noise suppression and lower emissions. Our new Lokotrack EC diesel-electric [plant] range is an example of this kind of equipment and wider operating solution.”

Future ambitions The first two products of Metso’s new Lokotrack EC Series crushers and screens were launched in the spring of 2024.

The Lokotrack LT400J is a 68-tonne mobile jaw crusher designed for the primary crushing of hard rock and recycled aggregates. The Lokotrack LT350C is a 50-tonne mobile cone crusher for secondary and tertiary crushing.

The LT350C features the new Nordberg HP350e cone crusher for high-capacity production, while the LT400J counts on the proven Nordberg C120 jaw crusher. Both units can be seamlessly combined with the Lokotrack mobile screens to produce highquality aggregates.

The Lokotrack EC range has been developed using new modular architecture, which reduces the number of components and provides scalable solutions that can be adapted for different applications and capacities. The full range will be introduced to the market over the next few years.

“There is great demand for the first Lokotrack EC Series crushers. Our factories have a good amount of them in

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INTERVIEW

production,” Takaluoma said. “The feedback has been really good.

“These plants are hitting the sweet spot in helping our quarry operator customers secure their environmental permits.

In 2025, Metso is celebrating the 40th anniversary of its Lokotrack mobile crushers at various industry exhibitions and company events worldwide. At April’s bauma 2025 in Munich, one of the world’s biggest quarrying, mining, construction and recycling machinery exhibitions, Metso showcased its Nordberg HP450e cone crusher, designed to improve performance and efficiency in tough environments. Another successful product is the HRC8 crusher, which transforms quarry waste streams into valuable, sellable materials such as manufactured sand.

“The HP450e is perfect for European aggregates processing customers, especially when fines are re-crushed with the HRC8.

Both are great innovations by Metso, and you can see the energy efficiency and productivity gains they offer,” Takaluoma said.

Before bauma 2025, Metso displayed its Nordberg HP600e cone crusher and promoted two larger plants from the same series, the HP800e and HP900e, at the AGG-1 exhibition in St Louis, Missouri, in March.

“The Nordberg HP cone crushers are the crushers for the US market. The ‘e’ models ensure less downtime and servicing requirements while offering the best cone crusher productivity worldwide,” Takaluoma said.

“I believe strongly that all the HPe crushers will be a success in America. They are great for large quarries and meet a need for mobile crushers. Our excellent distributor partners in the US are part of why we are strong there. It is a very important market for Metso.”

Takaluoma sees the development of Metso’s screening plant and screening media offering as just as important as the company’s crusher plant and linked technology advances.

“I think we had a scattered screening plant portfolio in the past. Now we have a very clear screening plant offer for mining and aggregates customers. That side of our business is in very good shape,” Takaluoma said. “We offer polyurethane and wire mesh screening media depending on the customer's application. We will continuously

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A Metso Lokotrack ST4.10 high-capacity mobile aggregates screen at work. develop our screening offer regarding what we are doing and potentially through further mergers and acquisitions like the recent one we announced in China.”

Takaluoma said Metso has seen a notable increase in its crusher remanufacturing and upgrade retrofitting business.

“Around four years ago, we started considering extending our offer in this area,”he said. “We’ve always offered a repair service, but then we did some R&D and engineering work to see how that might work. There is definitely a market for extending the life of each piece of equipment.

“An upgrade retrofit can reduce crusher energy usage or increase production capacity.

It’s great news for the customer at a fraction of the cost of purchasing a new crusher.

“An upgrade can also include installing enhanced digital services, ensuring more production optimisation. With our digital services, our experts can offer better advice and support when we can remotely see what is happening with a customer’s production.

The remanufacturing or upgrade retrofitting option best suits longtime quarry operators running fixed sites. It also fits well with our Metso Plus philosophy.”

Metso is investing €150 million in a modern technology centre in Tampere, Finland. The company will gradually move its operations in Hatanpää, Tampere, to a new Lokomotion technology centre built in Tampere’s Lahdesjärvi district.

In the future, Metso will design, test and manufacture technologies, equipment and components for the production of aggregates and sand at the new Lahdesjärvi facility.

Acquired by Metso in 2021, the Lokomotion Technology Centre site covers 23 hectares. It will host over 900 Metso employees. The initial total building area of the centre is about 66,000m², the first phase of which will be about 34,000m².

Construction began in July 2024 and will include assembly and testing facilities for manufacturing mobile crushers and storage facilities for components and materials used in aggregate equipment.

Investment in 2024 is estimated at around €30 million. Production of the Lokotrack track-mounted crushing plants is scheduled to start in Lahdesjärvi during the third quarter of 2027.

According to Metso, the crusher factory, research centre, maintenance workshop and office facilities will move from Hatanpää to Lahdesjärvi later. The new technology centre is expected to be fully completed by the mid-2030s.

“R&D is at the core of Metso. We significantly invest in it, and we will continue to do so in my time, perhaps investing even more,” Takaluoma said.

“We want state-of-the-art facilities for our R&D teams. We must keep innovating and bringing new technologies to the market to improve our industries. This will lead to more and more energy-efficient production and less waste.”

Takaluoma said Metso is particularly interested in producing new premium crushing and screening plants that can recycle concrete and building debris into new, sellable aggregate products.

“This area of our business led to the acquisition of Diamond Z, a US company specialising in equipment that crushes debris from natural disasters, like hurricanes, and turns it into reusable building products.

Sustainability is not just a buzzword,” he said.

“We need to recycle more, and what better way to do that than to recycle a widely used material like concrete?”

Takaluoma said that a crucial aim of his new leadership role is to simplify life for his leadership team as it navigates Metso’s next chapter.

“There was not a need for a full transformation of the company. We will accelerate certain things and identify areas where we can do even better,” he said.

“The foundation is very strong. My leadership style is about removing obstacles from my executive team’s way. I want to see just how good a business can be. I like a very open team discussion that leads to the execution of our goals.” AB © AGGREGATES BUSINESS March/April 2025

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CRUSHING AND SCREENING

Kleemann crushing plants are used by Spanish producer Recicam.

The Madrid marvel Kleemann has given its support to one of Spain’s largest processors of construction waste.

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to get hold of spare parts and, in production, the costs per tonne are unbeatable.

“The plants are intuitive to operate, welldesigned and very robust – key factors when you consider that we process thousands of tonnes of material here every day.”

Depending on Recicam’s requirements, the Kleemann plants can be deployed in different combinations to suit their needs.

Recicam combines the MOBIREX MR 130i PRO impact crusher with the MOBISCREEN MSS 802i EVO coarse material screen for processing contaminated demolition material.

The screen can handle 260 tonnes per hour, with one-third directed to the crusher and the remainder used for drainage construction.

For large feed material, Recicam can pair the MOBICAT MC 120i PRO jaw crusher with the MOBIREX MR 130i PRO impact crusher.

This combination is utilised to produce final

Image: Kleeman

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ecicam has earned its reputation as one of Spain’s largest recyclers of construction waste over many years.

The family business, located in central Spain, has a daily throughput rate of 4000 tonnes of material and, for its core business, relies on Kleemann plants for its crushing and screening requirements.

“Our collaboration with Kleemann came about through a customer and friend who was working with a Kleemann MOBICAT MC 110 EVO2 at the time,” Recicam managing director Juan Manuel Camacho said.

“We took a look at the plant, and it was an excellent match for our application.”

Recicam’s initial investment in Kleemann saw it purchase two used plants. The recycler was impressed by their performance and product quality, and its employees shared positive feedback on the machine’s handling and design.

Recicam’s management experienced Kleemann’s equipment again at bauma 2022 and decided to invest in the latest Kleemann equipment at the time. Soon after, a MOBICAT MC 120i PRO jaw crusher, a MOBISCREEN MSS 802i EVO coarse material screening plant, and a MOBIREX MR 130i PRO impact crusher were headed to Madrid.

Overall, Recicam has eight Kleemann plants within its machine fleet and is supported, like all Spanish Wirtgen Group customers, by Spanish dealer EMSA Maquinaria y Proyectos S.L. “Of course, the machines are powerful and efficient. But what really convinced us was the overall package,” Camacho said. “We feel very well looked after locally, it’s easy for us

grain sizes of 0–20mm and 20–40mm while maintaining a high load as part of Recicam’s daily production of 4000 tonnes.

“These two effortlessly handle materials in sizes of up to 1200mm and deliver an end product of excellent quality. And all that with an impressive output of up to 250 tonnes per hour,” Camacho said.

The Kleemann plants have a range of features, such as magnetic separators and wind sifters, to help remove ferrous foreign materials and light materials like wood and plastic from the final product. These features help to provide Recicam with greater confidence in product quality.

“The quality of our end product is decisive because, as a supplier of recycled material, we are always in competition with natural stone suppliers,” Camacho said. “Consistent cubicity and purity of the material are our hallmarks.”

“The quality of our end product is decisive because, as a supplier of recycled material, we are always in competition with natural stone suppliers.

Consistent cubicity and purity of the material are our hallmarks.”

Juan Manuel Camacho

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Image: Kleeman

Image: Metso

CRUSHING AND SCREENING

All of Kleemann’s crushing plant is equipped with its SPECTIVE CONNECT platform, which enables operators and managers to see key machine data in real-time. Camacho said these features have helped operators easily operate the Kleemann crushing plants.

“Previously, we had to keep going back to the plant to read information. Now we get all the data directly on the display, no matter where we are on the site – production capacity, consumption, everything,” he said.

“This makes a huge difference. We can respond immediately when we notice that something needs to be optimised. This saves a lot of legwork, and is more efficient and much safer.”

The Lokotrack mobile crushers debuted in 1985, and over 11,000 units and more than 300 diesel-electric units have been sold around the world in that time.

When it was known as Lokomo, Metso developed the Loktrack prototype in collaboration with its customer Telamurska, which specialised in crushing contracting.

The goal was to create a mobile, trackmounted crusher that would eliminate the need to transport rock to quarries and the finished product back to job sites.

The prototype was enthusiastically received in the aggregates industry, and by 1987 Metso was serially producing Lokotrack crushers.

According to Metso, Lokotrack crushers can be found on every continent on Earth – even Antarctica.

The current Lokotrack range features a portfolio of 23 machines, each with 50 configuration options. Metso launched the Lokotrack EC range last year for businesses looking for low-carbon production options.

ABOVE: Metso is celebrating 40 years of Lokotrack crushers.

BELOW: The Lokotrack crusher was launched in 1985.

“We are excited to make the 40th anniversary of the iconic Lokotrack line a key highlight at all our events and trade shows throughout 2025, celebrating this milestone with our customers, partners, and industry peers,” Metso track solutions vice president Jarmo Vuorenpää said.

“The latest Lokotrack units feature a new diesel-electric power line, enhanced design and lighting, and improvements for easier, safer use and maintenance. Equipped with cutting-edge crushing technology and digital tools, the EC range ensures high-quality products on time and at the right price.”

Optimised for industry Superior Industries has launched its new learning platform to support construction aggregate producers. The OptimizeU initiative is a flexible, on-demand learning

Image: Metso

Metso’s mega milestone Metso has celebrated the 40th anniversary since its Lokotrack mobile crushers were introduced to the global aggregate crushing industry.

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Image: Finlay

CRUSHING AND SCREENING

Finlay has introduced the C-1550+ tracked cone crusher. program for operators who want to study real-world challenges and how they can achieve high production rates.

OptimizeU features crushing, screening, washing and conveying courses to improve technical skills, expand product knowledge and develop best practices. Current courses include Cyclone Fundamentals and Understanding Gradations.

Options are available for beginners through to advanced workers, who can learn everything from troubleshooting to understanding applications without the need to travel or rely on classroom-based training.

The current catalogue has 60 training programs, while Superior Industries plans to expand the platform by 50 sessions a year.

“OptimizeU was created to meet the needs of today’s aggregate producers,” Superior

Powered up in India Powerscreen has added two new distributors to its global dealer network.

Time Equipment has signed on to be Powerscreen’s new dealer in north India and cover the Delhi NCR, Uttar Pradesh, Uttarakhand, Haryana, Punjab, Himachal Pradesh, Jammu and Kashmir territories.

Time Equipment will facilitate Powerscreen machine sales and stock genuine spare parts for customers in these territories.

Druk Trading Equipment has been added to Powerscreen’s network as Bhutan's dealer.

The agreement furthers Druk Trading’s

Image: Powerscreen

Powerscreen added Time Equipment and Druk Trading Equipment to its dealer network.

Industries training coordinator Kristen Randall said.

“We understand the value of flexible learning in an industry where time and resources are precious, and our goal is to equip producers with the tools they need to succeed at any experience level.”

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portfolio of heavy equipment, which has continued to grow since it was established in 2006. Druk Trading Equipment will offer Powerscreen’s mobile crushing and screening solutions in Bhutan.

“We are delighted to strengthen our Powerscreen coverage in south Asia with the additions of Time Equipment and Druk Trading Equipment, respectively,” Powerscreen sales director Indra Gokhale said. “Both companies have a shared philosophy of providing exceptional customer support, and we look forward to many shared successes.”

Finlay’s finest Finlay has launched its C-1550+ tracked cone crusher for customers looking for high-capacity crushing in the aggregates industries.

The new model takes over from its predecessor, the C-1550, and features the Terex 1300X cone crusher at its core.

According to Finlay, this crusher can achieve 15 per cent increase in tonnage and production compared to the C-1550.

“At Finlay, we are committed to delivering innovative solutions that drive productivity and profitability,” Finlay business line director Matt Dickson said.

The C-1550+ is lighter for transportability with a hydraulically folding hopper, which adds to its versatility for owners, operators and contractors. It has a full hydraulic closedside setting (CSS) adjustment with electronic monitoring for precise operator control.

The large hopper/feeder has an automatic reset hydraulic tramp relief system that protects the chamber and minimises downtime if uncrushable material enters the chamber. This system helps to minimise downtime by automatically removing contaminants via the purge chute.

“The C-1550+ combines increased production capacity with features that enable our customers to achieve more with less, all while ensuring safer, more streamlined operations,” Dickson said. AB

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LOADING

CarBa srl purchased a second ZW250-7 wheeled loader.

Image: Hitachi

Loaded in Europe Wheeled loaders are at the heart of many operations because they maintain productivity and efficiency. The latest updates from manufacturers are prioritising these key factors.

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itachi’s wheeled loader solutions are used all around the world, including in Italy, where a construction company has utilised one of these machines to boost its production capabilities.

Italian company CarBa srl has taken on a second Hitachi ZW250-7 wheeled loader at its facility in Soncino. The ZW250-7 was delivered at the end of 2024 by Hitachi authorised dealer SCAI, as CarBa srl looked for a machine to help its concrete and asphalt production.

CarBa has long specialised in roadworks, adding asphalt production to its operations in 2024 to complement its concrete and steel production. This expansion in operations facilitated the need for another wheeled loader as the company, led by chief executive officer Mauro Carminati, wanted to optimise its supply chain.

CarBa already operated one ZW250-7 wheeled loader, and positive operator feedback led to the purchase of a second model from SCAI. “This machine will remain exclusively at the Soncino site, managing aggregates for our batching and asphalt plants,” Carminati said.

“It’s a vital all-rounder that allows us to keep operations running smoothly and efficiently.”

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CarBa operators were impressed by machine’s user-friendly design, including its multifunction joystick and all-round visibility from the cabin. The ZW250-7 wheeled loader features the Aerial Angle camera system, which provides a 270° bird’s eye view and rear obstacle-detection system.

“With two plants now in operation, internal traffic has increased,” Carminati said. “The obstacle-detection system was a necessary addition to enhance site safety.”

CarBa opted for additional enhancements to its second Hitachi ZW250-7 wheeled loader.

The newer model has a larger 3.60m³ bucket and an integrated payload weighing system to provide precise load measurements.

“We knew exactly what we were getting with this machine,” Carminati said.

“The ZW250-7 has already proven its reliability, and these new features make it an even more valuable asset for our operations.”

The next generation When Caterpillar unveiled the Cat 395 front shovel (FS) large excavator as part of its bauma 2025 showcase, it marked the company’s first new front shovel configuration in more than a decade.

While it is expected to be officially launched to the market later this year,

attendees of bauma 2025 in Munich had the opportunity see the new machine up close.

The Cat 395 FS is designed for quarrying and mining operators, delivering better fuel economy and low maintenance costs than previous models.

The new excavator is equipped with a reinforced, extra-durable undercarriage, additional cylinder guards, and long-life fuel and hydraulic oil filters. The cabin is designed with the operator in mind and features include an ergonomic seat, touchscreen display, climate control, noise insulation, and vibration reduction.

“The 395 FS has an official target launch of October 2025, but there’s no better place than bauma to showcase the pre-production model and have potential customers ‘see it in the metal’,” Caterpillar product and sales consultant Vincent Migeotte said. “We’re excited to have the 395 FS join the large excavator line-up.

“At the top of the design wish list for the 395 FS were three primary objectives: robust digging and breakout force, lightning-quick loading cycles, and rigorous bucket full.

“Customers repeatedly told us that they need a machine that not only offers peak performance but can operate consistently at those peak levels.

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LOADING

The WA700-8 was featured in a live demonstration at bauma 2025. product support and fleet operations Matt Gavin said.

“Our partnership with Volvo is invaluable.

They resonate with our core values and prioritise what truly matters to us, demonstrating their commitment to creating an exceptional customer experience.”

Ready to work Komatsu Europe has debuted the new WA700-8 wheeled loader after more than a “decade of development”.

Komatsu showcased the WA700-8 in a live demonstration at bauma 2025.

The engineers at Komatsu Europe have revamped the WA700-8 based on customer feedback, emphasising safety and operator wellbeing as essential considerations during the purchasing process.

A new safety package comes as standard in the WA700-8, including emergency push buttons, certified anchorage and tie-down points, and battery, starte, and hydraulic lockouts. A new advanced joystick steering system and electronic pilot control levers are designed to make it easier for the operator.

“I'm very excited to introduce our WA700-8 in Europe, which offers a perfect match with our 60-tonne rigid dump truck,” Komatsu Europe deputy general manager of product marketing Jo Monsieur said. “Without any doubt, it will excite any operator with its performance, large cabin and wealth of safety features.

“After more than a decade of development, this reinvented giant is now fully ready to claim its place in quarries across Europe and beyond.”. AB

Komatsu Europe has debuted the WA700-8.

Image: Komatsu

Expanding in North America Volvo Construction Equipment (Volvo CE) has announced a multi-year agreement with Herc Rentals, expanding its presence in North America.

The new agreement will see several hundred Volvo EC37 compact excavators added to the rental company’s fleet across North America and be made available to customers in the region. The first phase of Herc Rentals’ order was completed earlier this year, and more models are expected to be delivered to branches in the US and Canada throughout 2025.

“This is the culmination of a cooperative effort to build a machine spec that renters will appreciate, and we’re excited for Herc Rentals customers to have such great access to the EC37,” Volvo CE head of national rental accounts Kent Somerville said.

“The three-to four-tonne range makes up more than a quarter of the compact excavator market in North America. It’s a competitive market, but the versatility and comfort of the EC37 definitely make it stand out.”

Volvo CE sought feedback on the EC37 excavator from Herc Rentals technicians, salespeople, and other staff at the Herc Rentals ProExpo in early 2024. This input directly influenced the final version of the model, including updates that made it easier to change attachments, a larger cabin with enhanced ergonomic features, and factoryinstalled telematics.

According to Volvo CE’s data, the EC37 excavator provides 10 percent better fuel efficiency compared to earlier Volvo models.

“Collaborating with Volvo on the EC37 allowed us to incorporate essential features that significantly impact our customers’ success,” Herc Rentals vice president for

Image: Komatsu

“That’s borne out in the 395 FS, with a maximum ground level digging force up to truck height, matched by a powerful breakout force at the bucket cutting edge that promises superior material penetration and optimal bucket fill factors.”

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HAULING

Hauling to the top Rokbak’s global customer base has been impressed by the manufacturer’s articulated haulers, which are delivering results from Scotland to Spain.

“We proposed the RA30 to Loughran Rock for the truck’s agility, dependability, independent suspension for operator comfort, and the ability to carry lighter products efficiently,” Sleator Plant general manager Aaron McCaul said.

“We thought the RA30 was the perfect choice for Loughran Rock’s needs, offering reliability, durability and the backing of our responsive aftersales support.”

The RA30 articulated hauler has a 28-tonne maximum payload and a 17.5m3 heaped capacity. Its double wishbone design allows for fully independent suspension and wheel movement.

The RA20 was tailored to Loughran Rock’s requirements with body side extensions to enhance its load capacity. Loughran uses the RA30 to transport stone, sand and rock fill from the quarry to the main crusher and to fill up lorries and block machines.

The Rokbak RA30 has drawn praise from Loughran Rock’s operators, who believe it is suited to the Northern Ireland quarry.

“Visibility is important on any site, especially a big quarry such as this,” Loughran Rock operator Cathal Devlin said.

“The rear vision camera and monitor and heated mirrors makes my life a whole lot easier when I’m reversing into tight spots. When you’re driving around quarries,

Sleator Plant general manager Aaron McCaul.

Image: Rokbak

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cottish engineering has become a driving force at Loughran Rock’s quarry in Northern Ireland.

The family-owned Loughran Rock Industries runs its quarrying and aggregates business in County Armagh.

The operation, supported by Sleator Plant, recently received a Motherwell-manufactured Rokbak RA30 articulated dump truck (ADT).

“We’ve not only reinforced our quarry operations with the addition of the Rokbak truck, but we believe we’ve also strengthened our position as a trusted supplier in the region,” Loughran Rock quarry manager Colin Loughran said.

Loughran Rock relies on robust equipment to support its operations, which have thrived since 1985. Its concrete production and stone supply facilitate significant infrastructure projects.

The Rokbak RA30 articulated hauler has been operational in Cláidigh Bheag, about an hour south-west of Belfast.

Loughran Rock produces 450,000–500,000 tonnes of aggregate each year, supplying it to local contractors, housing developments and farmers. Such a high level of production requires durable equipment, and that is why Loughran approached Sealtor Plant, the authorised dealer of Rokbak trucks in Northern Ireland.

you need comfort – I’ve been operating for three years now with trucks of all sizes, and the Rokbak truck is definitely the comfiest machine I’ve driven to date.

“I’ve also been impressed by its fuel efficiency. With our previous truck, we had to fill it up approximately every two days. With the Rokbak, it’s now every three to four.”

Loughran Rock has been supported by Sleator Plant’s engineering team and local presence in Northern Ireland since it took delivery of the RA30. Sleator Plant has been

Image: Rokbak

Loughran Rock has added a Rokbak RA30 articulated dump truck.

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Image: Volvo CE

HAULING

able to help the construction materials producer with maintenance support and spare parts on its newest articulated hauler.

“The RA30 has been nothing but reliable, with minimal maintenance requirements and prompt support from Sleator Plant when needed,” Loughran said.

“It’s well made and it’s a good, sturdy machine. In the future, I would not hesitate to use Rokbak again.”

A cleaner future Volvo Construction Equipment (Volvo CE) will implement low-carbon emission steel into all of its serially produced haulers manufactured in Braås, Sweden.

The announcement builds on Volvo CE’s previous showcase of a concept hauler, which was built using fossil-free steel in 2021 in partnership with Swedish steel manufacturer SSAB. Volvo CE delivered a construction machine made from fossil-free steel to a customer for operational use in 2022.

“We are proud to lead the way in the industry and move forward towards minimising our climate footprint across the entire lifecycle of our products,” Volvo CE head of lifecycle assessment program Rickard Alm said.

“While emissions from product use represent the vast majority of carbon output in our industry, it is important to also act to cut emissions in the production phase, including materials like steel, in close collaboration with our global supply partners.”

Volvo CE has committed to using low-carbon emission steel.

“As a company leading the way in transforming our sector, we strongly believe in fostering strategic collaborations across industries. This partnership will accelerate the adoption of cutting-edge solutions across our sites and regions, leveraging synergies on a global scale.”

The announcement builds on the previous collaboration between Heidelberg Materials and Pronto, which saw a pilot project in Bridgeport, Texas. The successful pilot program at Heidelberg Materials’ quarry was subsequently deployed on a fleet of mixed original equipment manufacturer haul trucks.

The global agreement will roll out the Pronto system to more than a dozen North America, Europe, and Asia Pacific sites.

“By teaming up with Pronto, we will deploy a scalable solution to our fleet of haul trucks that will contribute significantly towards our production efficiency, safety and sustainability efforts while also addressing the challenge of recruiting skilled operatives,”

Heidelberg Materials chief technical officer Axel Conrads said.

Expansion in Germany Develon Germany has unveiled its new headquarters in Mannheim Friedrichsfeld, Germany, as it looks to expand its presence.

A brand of HD Hyundai Infracore, Develon has set a goal of growing its market presence in the German, Swiss, and Austrian regions (GSA) following the opening of its headquarters. The company has also confirmed it is looking into expanding its rental services for those within the GSA dealership network.

The new German headquarters features 10,650m2 of usable space and houses sales, service, rental and spare parts alongside a training centre, training workshop and test area.

“The new headquarters of Develon Germany is a clear commitment to Germany as a location,” Develon said. AB

Heidelberg Materials and Pronto have signed a new agreement.

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Image: Pronto

Heidelberg Materials turns to the future Heidelberg Materials has provided a glimpse into the future of its operations after signing an agreement with US-based autonomous technology provider Pronto.

The agreement will see Pronto’s Autonomous Haulage System (AHS) deployed on more than 100 trucks in Heidelberg Materials’ fleet worldwide. Pronto’s system is designed to be retrofitted onto an existing fleet and leverages advanced sensors, cameras and artificial intelligence (AI) to autonomously operate haul trucks.

“Meeting industry challenges with technological innovation has always been a central part of our target to create a more productive and sustainable future,” Heidelberg Materials managing board chairman Dr Dominik von Achten said. © AGGREGATES BUSINESS March/April 2025

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DRILL RIGS, HAMMERS AND BREAKERS

Be even better drilled with Epiroc

The cut-open casing of a DTH 5 hammer.

Epiroc’s new DTH 5 hammers are designed to deliver in the face of all drilling requirements.

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piroc, a global market manufacturer of drill rigs and hydraulic breakers for the mining, quarrying and construction industries, has launched its DTH 5 (down-the-hole) hammers.

The Swedish manufacturer describes this as a revolutionary new range designed to maximise efficiency, boost profitability, and redefine versatility in drilling operations.

The Epiroc DTH 5 hammers are said to deliver an exceptional rate of penetration (ROP) and longer service life, setting a new standard for performance and cost-effectiveness.

Designed to excel in all drilling assignments, Epiroc said these hammers are the perfect choice for companies looking to expand their capabilities, take on new lucrative projects, and increase their competitiveness.

Among the key benefits is versatility, making them ideal for high- and low-impact energy scenarios.

Epiroc stressed that its DTH 5 hammers tackle any rock formation and feature many configurations in a single system. The new range is said to offer superior performance, boosting productivity with fewer interruptions and quicker task changes.

There is also an eco-friendly impact, as with the DTH 5 hammers’ reduced manufacturing and transportation needs contribute to lower CO2 emissions and customer sustainability goals.

“We’ve combined the best of our hardstriking QL and robust COP

Gold hammers to create a product that not only performs but transforms operations,” Epiroc Rock Drilling Tools global product manager DTH Delaney Erickson said.

“The Epiroc DTH 5 hammers truly pack a serious punch, offering our customers the tools they need to take their businesses to the next level.”

Epiroc said the DTH 5 hammers allow operators to drill more metres per shift, rebuild hammers up to three times with its exclusive E-Kits, and enjoy a lower total cost of ownership (TCO). They can fit all leading brands of compressors and rigs, representing an ideal opportunity for growth and cost savings.

From rig to bit, the Epiroc DTH 5 hammers are designed to optimise every part of your operation, delivering maximum efficiency, profitability and reliability. AB

Images: Epiroc

Epiroc’s DTH 5 hammers deliver an exceptional penetration rate and longer service life.

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THE NEXT GENERATION OF MINING ASIA-PACIFIC’S INTERNATIONAL MINING EXHIBITION 23-25 SEPTEMBER 2025 Adelaide Showground, South Australia

Register to attend AIMEX’s inaugural event in South Australia 32-33 Drill Rigs, hammers & breakers.indd 33

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DUST SUPPRESSION

Dust busting in quarries and mines Dust suppression is vital to maintaining site workers’ health and wellbeing, and meeting increasingly tight environmental licensing conditions.

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elping prevent haul road overwatering and underwatering, the new Cat 789D autonomous water truck (AWT) enhances productivity by enabling mine operations to digitally track water consumption and reduce waste.

Fully integrating into a site’s Cat Command autonomous haulage fleet to control haul road dust, the market’s first commercially available AWT is built on the field-proven 789D mining truck chassis and integrates the truck, tank and Cat water delivery system (WDS), connected with Cat MineStar technology.

Featuring Command for hauling, the new 789D AWT offers the same potential for greater utilisation than staffed equipment.

The fully autonomous truck reduces shift changes, meal breaks and other operational delays to help improve efficiency. Complying with watering plans, the truck seamlessly interacts with other autonomous equipment and integrates with customer processes and systems managed by MineStar.

The 789D is the largest Cat water truck product offering, accommodating up to 165,000L, depending on tank configuration.

The AWT senses when the water tank is running low and can be programmed to integrate with the refill station to fully automate the process. The auto-shutoff feature prevents tank overfilling.

Image: Caterpillar

The flat, controlled spray pattern of the Cat 789D delivers optimal litres-per-square-metre.

“To meet customer requirements for dust control, Caterpillar implemented a MineStarintegrated watering model based on many years of site watering studies and Cat WDS performance data,” Caterpillar, general manager and vice president, technology and global sales support Corey Wurtzbacher said.

“This model allows the truck to monitor traffic, weather and road conditions, prioritise what areas need to be watered, when the areas need to be watered, and how many passes it should take to apply the correct amount of water saturation for the given conditions.

“The integration of Caterpillar’s many years of autonomous truck operations and water delivery development have been combined to make a high-performing autonomous watering solution.”

When Caterpillar set out to develop an autonomous water truck, integration with Cat MineStar Command for hauling and the Cat WDS was key to the integration process.

The team began building communication between the truck’s on-board systems and the office control console to work with the Cat WDS interface.

To ensure seamless operation and proper communication between the WDS and MineStar, a compatibility check has been implemented in Cat WDS to confirm all truck control systems were running compatible software and reporting any on-board failures to the MineStar system for appropriate corrective action. Fully integrated into the truck’s design, the exclusive Cat WDS varies

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waterflow based on speed and automatically determines the correct amount of water needed to control dust. Knowing where, when and how much water to dispense, the 789D AWT helps customers conserve water, a scarce resource at many quarrying and mine locations.

When truck speed drops below the minimum watering speed setting, which determined by site operations, the system halts water delivery to help prevent overwatering, poor traction and damage to haul road intersections and other stopping areas. When the minimum watering speed setting is exceeded, the system begins depositing the specified amount of water commanded by MineStar.

Cat WDS actively monitors the water level and automatically turns off watering once the tank is empty. To reduce potential damage, the system has multiple safeguards to prevent the pump from running dry, which helps prolong water pump life and extends service intervals.

The automated system’s flat, controlled spray pattern delivers optimal litres-persquare-metre (gallons-per-square-foot) coverage across the haul road. Larger, heavier droplets designed to reach the ground help reduce spray loss to wind and evaporation.

Reducing health hazards associated with airborne particles, automated water delivery supports the reduction of dust that limits operator visibility for staffed equipment to enhance overall site safety. Remote tankfill control, complete with auto shut-off to prevent overfilling, eliminates the need for a worker to be involved in refilling, reducing the potential of slips and falls.

Mines can quickly switch the flexible 789D AWT from autonomous to staffed mode for tasks like front water cannon operation.

The cannon can distribute up to 2839L/min (759gal/min) and has a spray distance of 60m (200 ft). Even with the staffed operation, auto mode water delivery automates the process to leverage variable water flow and automatically determine the correct amount of water needed to control dust.

Cat Water Solutions integrates the 789D truck chassis with the proven Cat WDS and innovative MineStar technology.

In the event a site is not yet ready for a fully autonomous water truck, MineStar has cloud-based solutions that will work in the interim and allow customers to utilise, track and measure the productivity of the 789D before it is put into autonomous operation.

Basic and premium packages are available.

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The basic package allows sites to track their asset and see when, where and how it is performing in terms of location of truck, water level, fuel level, watering mode, truck speed, truck refills, water dispersed, and truck utilisation per shift.

Premium will allow sites to track how their water trucks are tending to the site’s watering needs: • Watering heat map to show the age of water currently put down by all trucks in a shift • Watering heat map by truck to show where each truck watered and what mode was used • Utilisation of fill spots by each truck • Replay of truck watering activity for up to eight previous weeks of data, depending on how many assets are tracked • Suggested area to water based on age of water and traffic utilisation When the site is ready for full autonomous mode, the water truck can be integrated into the MineStar ecosystem to work alongside the rest of the mining fleet.

The Cat dealer and parts network fully support this integrated autonomous water solution. Covered by a Caterpillar factorystandard warranty, the 789D AWT is eligible for Cat equipment protection plans) and customer value agreements. Retrofit kits are also available for existing Cat 789D truck platforms in the field.

A holistic approach RST Solutions is an Australian business that operates around the world. It has three decades of experience developing tailored solutions for various fine particle challenges across numerous industries, processes and material types.

The company notes that sediment control in quarry and mining operations is a critical challenge, particularly in regions that experience high levels of rainfall.

Uncontrolled sediment runoff can lead to significant long-term dust challenges, as well as initial operational inefficiencies, increased costs, and environmental compliance issues.

A holistic approach to sediment management is needed to prevent fine particulate movement from all open ground areas, reducing the need for costly remediation efforts.

Sediment build-up at quarry and mine sites typically results in several issues: • Sediment runoff from open ground areas – fine particles erode from all open surfaces, including benches, stockpiles, waste dumps, roads and exposed working areas, contributing to significant sediment loads • Roads as major sediment pathways – roads are a major source of sediment generation and act as large drains, channeling turbid water across the site and accelerating sediment transport • Pit floor sediment build-up – fines washed down from open ground areas accumulate at the pit floor, forming material that is too thick to pump and too sloppy to excavate and haul www.AggBusiness.com

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Image: RST Solutions

DUST SUPPRESSION

•

Dust emissions – once dried, these fines become a major source of airborne dust, posing environmental and health risks • Drainage issues – channels and drains act as pathways for sediment transport, contributing to further sedimentation problems downstream Treatment with flocculant-based dust suppressants prevents fine particles from becoming airborne dust when dry and from washing out as sediment when wet.

A three-tiered approach tailored to treat the key areas of a quarry or mine site is recommended to obtain a long-term solution while achieving immediate results.

These three high-trafficked areas need to be treated simultaneously.

Open ground areas Flocculant-based sediment binders/crusting agents can be sprayed on open ground areas – including faces, benches, stockpiles and waste dumps – to prevent fine particulate movement.

Strategic drainage design to effectively direct water flow is achieved through excavation of controlled drainage channels.

Flocculant blocks placed within these drains settle sediment in runoff water before it reaches sediment ponds or other water collection points.

Roads (major sediment pathways and drains) The type of treatment can vary depending on application methods. It is highly recommended to implement two or more approaches for enhanced sediment control: • Liquid additives compatible with dosing/ injection pumps for automated application • Water cart application (or additional protection, a wider spray pattern to cover spoon drains along roadsides is recommended) • Flocculant blocks placed in spoon drains to capture additional sediment levels along road drainage pathways • Effervescent powder in a dissolvable bag is an easy and cost-effective alternative treatment for up to 20,000L of water per bag, simplifying application without bulk liquid storage or pumps Channels and drains A simple method of strategically placing flocculant blocks in secondary channels and drains to further reduce sediment loading

A liquid treatment being applied at an Australian coal mine. in water before it reaches sediment ponds or final discharge points.

Despite best efforts, some sediment will inevitably reach collection dams. To meet approved discharge levels, a range of liquid flocculants and coagulants are used to clarify water by rapidly dropping turbidity and separating fines.

When sediment fines aggregate in a wet form after treatment, they become larger, more stable particles that are easier to control rather than stay as fine particles that turn into dust when dry and silt and sediment when wet.

Using a flocculant treatment reduces future dust emissions by binding fines together more effectively. This results in enhanced material stability and a reduction in the likelihood of recurring sediment issues. It also improves overall site management, streamlines operations, and reduces ongoing maintenance costs.

RST Solutions takes a comprehensive approach to fine particle management, designing cutting-edge solutions that can be applied using standard mining equipment.

Strategies are designed to integrate advanced technologies and systems to address challenges across the entire supply chain, from quarry and mining operations to material transportation.

Innovative approaches designed by fine particle specialists such as RST Solutions treat the causes, not just the problem. Dust control, soil stabilisation and erosion control all come into play when designing a solution, with regular site visits an integral part of their service. This enables the team to customise solutions to a site’s specific attributes – topography, earthworks, materials and weather conditions – and think outside the box to deliver solutions for unique problems.

A holistic approach to sediment control addresses many aspects of fine particle management. It helps to prevent problems in other areas of an operation by stopping fines from moving, stabilising roads, clarifying runoff, and ensuring long-term dust control.

Implementing this multi-tiered strategy can help operations achieve significant cost savings, improve environmental compliance, and streamline sediment management processes. AB © AGGREGATES BUSINESS March/April 2025

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SCREENING MEDIA

RFID tags eliminate guesswork by providing digital access to specifications.

Screening media matters A big acquisition by a major quarrying name and several product introductions have created a lively global screening media market.

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“This move will enable us to provide comprehensive screening solutions in China, where Metso has a strong customer base and service capability in the mining and aggregates industries.”

The acquisition is subject to conditions precedent and is expected to close during the second quarter of 2025. The parties have agreed not to disclose the transaction value, which has no material impact on Metso’s financials.

Selm is a Chinese manufacturer of mining and aggregate screens and technologies,

Image: Metso

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etso, the Finnish quarrying and mining equipment market giant, is expanding its screening solutions in China. The initial investment includes an agreement to acquire Selm (Beijing) Technology Co, a privately owned company’s screening business, operations and key assets.

By combining the new offering with its own expertise in screening equipment, media, repairs and services, Metso can strengthen its services to better support mining and aggregate customers in China.

“The acquisition is a significant step in advancing our screening regional strategy of being closer to our customers, fostering a market-focused approach. We are excited to enhance our role in China as a leading provider of screening solutions for large projects like super quarries,” Metso vice president of screening Jouni Mähönen said.

“We warmly welcome new colleagues to contribute to our growth targets and improved customer service.”

Xiaofeng Liang, Metso president of the Great China market area, is happy to be acquiring a company with “products and services well recognised by customers in the mining and aggregates industries”.

“The acquisition will further enrich Metso’s product portfolio and strengthen our competitiveness and market position,” he said.

including micro-sizing screening solutions. The company has around 180 employees and operates in Shenyang, northeast China.

“We have been developing our screening business over the past years, building expertise and a strong reputation among customers,” Selm founder Huifeng Tang said.

“Moving forward, the screen offering will benefit customers as part of Metso, and our employees will get a valued new employer.”

Metso’s screening solutions for aggregates and mining customers include banana screens, horizontal screens, inclined screens, mobile screens, portable screens, ultrafine screens, screening media, and capital screen-related parts, repairs and services.

Metso vice president of screening Jouni Mähönen during a recent visit to the company’s facility in Alwar, India.

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Simplified screening MAJOR vice president of global sales and marketing Ian Edwards explained how radiofrequency identification (RFID) technology is simplifying screening.

“Each aggregate and mining application is unique, meaning that screen media must be sized specifically to fit the quarry or mine’s needs,” he said.

“Traditionally, inventory management and ordering new screen media processes have been time-consuming and prone to sizing errors. To address these challenges, some manufacturers are integrating RFID technology, specifically near field communication [NFC], to streamline these procedures.

“These electronic tags are inserted into the polyurethane strips or frames for easy access. The tag can be scanned and read through an RFID reader or an app, which transmits data, including the inventory number for the screen media, the sizing of the wire, wire openings, and more.”

Edwards outlined the key benefits of RFID technology.

Convenience for inventory management Many RFID inventory management systems require a specialised RFID reader. Operations should look for a manufacturer that includes an integrated RFID reader tool into its company app, allowing operators to use only their smartphones. This simplifies tracking inventory in a single, easy-to-use platform.

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If Wi-Fi is unavailable, NFC technology can store data offline and sync it once a connection is restored.

Some manufacturers also include inventory management alongside the RFID reader in their app. Features often include additional options like product ordering and the ability to calculate screening efficiency and open area.

Orders are recorded electronically, ensuring easy access to order histories and reducing the risk of misplacing essential information.

Sizing accuracy Previously, operators manually measured each screen media panel with a measuring tape to determine the size of new panels to order or to ensure the correct panel was being placed.

In this situation, even the slightest error meant ordering or installing the wrong size screen media. Not only does this result in the screen media not fitting the screen box, it can also mean the final product doesn’t fit specification, leading to lost profit over time.

RFID technology reads the specifications of the screen media through the tag, which means operators can be sure they’re putting in the proper screen media before start-up.

The RFID reader also makes it easier to switch out screen panels with different open areas by recording the size of the screen media. If a screen media panel needs to be replaced, operators can use the reader to

Image: MAJOR

Image: MAJOR

RFID technology reads specifications through the tag, so operators can be sure they’re putting in the proper screen media before start-up.

quickly pull up the specs of the screen media and the wire.

Simplified reordering While traditional screen media specifications – including part numbers, sizing specs and inventory data – are printed on the side of the panels, these markings can wear off over time. RFID tags eliminate guesswork by providing digital access to these specs, ensuring operators always have the necessary information on their devices. In addition, this technology allows for custom notes and details tailored to each operation’s specific requirements.

Edwards notes that RFID technology makes inventory management simpler and more precise, regardless of the material being screened. He advises looking for a manufacturer who embraces this technology and provides easy-to-use, intuitive, app-centred warehouse management options.

Top-tier solutions After a rigorous three-year testing period, FLS used Electra Mining 2024 to officially launch its NexGen polyurethane, a heavy-duty and hard-wearing screen panel for large particle applications. Combining the physical properties of rubber and polyurethane elastomers, NexGen offers excellent wear resistance in © AGGREGATES BUSINESS March/April 2025

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The FLS NexGen polyurethane screen panel is a robust and durable solution that blends the strength of rubber with the flexibility of elastomers.

Images: FLS

The NexGen panels being poured at the FLS facility.

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highly abrasive applications such as early-stage screens and trommels.

As part of its dedication to providing top-tier screening media solutions tailored to meet the demands of commodity areas, FLS has brought its NexGen polyurethane screen media panel to market. Designed to offer long wear life, the NexGen polyurethane panel is ideally suited for early-stage screens and trommels where high abrasion is the order of the day.

“Due to its extremely durable properties, it lasts longer than rubber or standard polyurethane in high-impact applications. In some instances, it has been proven to offer double the screen panel wear life of rubber in these high-abrasion environments,” FLS service line manager Chris Currie said.

One of the major benefits of long wear life is the reduction of costs. Frequent replacement of screen panels increases maintenance and operating costs while lowering equipment productivity. Regular replacement also means maintenance personnel have to spend a considerable amount of time on the screen changing panels, increasing the safety risk in the process.

“With increased wear life also comes a significant reduction in waste, not just in the material itself but also in the supply chain,” Currie said. “Less frequent panel changes mean that there is less energy used, less transport required and less stock needed, which in turn is a huge sustainability tick for our customers.”

According to Currie, screening efficiency is a very big factor in profitable operations with

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Informed decisions The right screen media can unlock a new level of efficiency within an aggregate processing plant.

FLS service line manager Chris Currie.

Image: FLS

screen panels, which is why FLS maintains a minimum 95 per cent screening efficiency target in all of its designs.

The premium material used in the NexGen polyurethane panels means the company is able to run a smaller ligament that can provide more open area. A higher percentage of open area in screening panels improves efficiency and material throughput because it gives particles more opportunities to pass through the screen.

In several trials conducted during the test period, the NexGen polyurethane proved to be in a league of its own in terms of wear life. For example, at a major iron ore mine in South Africa’s Northern Cape, the NexGen polyurethane increased wear life by at least six times compared with standard thermoplastic polyurethane (TPU) injection-moulded panels, injection-moulded rubber, and other open-cast polyurethane options.

In a coal application, the NexGen polyurethane panels survived for 10 weeks, compared to the five weeks most of the standard polyurethane panels lasted.

“Doubling the screen media wear life lowered maintenance time and media costs while increasing safety and productivity,” Currie said.

McLanahan director of sales in the UK and Ireland Donal McNicholl said the choice of screen media is influenced by material throughput, product quality, and operational costs.

“Understanding the various types of screen media and their applications is essential for plant operators aiming to enhance performance and profitability,” he said.

Screen media is primarily available as woven wire cloth, perforated and punch plate, synthetic media, including polyurethane and rubber, and self-cleaning screen media.

Each has various advantages depending on the application of the aggregate plant in which it is used, which is where businesses should consider the material characteristics, open area percentage, operating conditions, durability, and wear life in their operations.

Many operations need to consider balancing open area percentage, which facilitates greater material flow, against durability, which extends the wear life of the screen media. This balance is primarily determined by the operational priorities of the business, as well as the material characteristics of the application.

By considering all of these factors, businesses will be able to exert a greater influence on the long-term economic impact their screen media will have on the business, including maintenance and replacement costs.

“Selecting the right screen media is a multifaceted decision that significantly impacts the efficiency, cost-effectiveness, and overall success of aggregate processing operations,” McNicholl said.

“By thoroughly evaluating material characteristics, operational conditions, and economic factors, operators can make informed choices that align with their specific needs and objectives.

“Collaborating with experienced manufacturers and conducting regular performance assessments further ensures that the chosen screen media continues to meet the evolving demands of the industry.” AB

Image: McLanahan

McLanahan has a wide range of screening media.

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Image: CDE

WASHING – 1

Awash with quality and consistency Premium aggregate and recycling wash plant solutions deliver significant quality and sustainability gains for customers worldwide.

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ith high-quality silica sand resources scarce around the world, Fife Silica Sands has partnered with CDE to commission a 210-tonne-perhour (tph) silica glass sand plant to meet the market’s growing demands.

Fife Silica Sands, located at Burrowine Moor Quarry in the central lowlands of Scotland, is owned and operated by Paterson Quarries.

Founded more than 50 years ago, Paterson Quarries operates five sites throughout Scotland. It supplies a range of materials, including concrete, specialist sand and recycled aggregates, across the UK. Paterson Quarries is now a third-generation family firm that acquired Fife Silica Sands in 2002.

Passionate about delivering high quality across its operations, Paterson Quarries has provided sand to prestigious golf resorts across the UK and Ireland, including Loch Lomond and Ardare Manor, as well as for professional football and rugby facilities.

CDE, a leading provider of wet processing solutions for the natural and waste recycling sectors, has been working with Paterson

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Quarries for more than 15 years, with the two companies first partnering on a modular sand-washing plant in 2011.

Having developed a strong working relationship, the team at Paterson Quarries knew CDE would be the right partner to work with Fife Silica Sands to meet market demands.

Showcasing its capabilities in providing solutions for silica sand, CDE welcomed Fife Silica Sands to its manufacturing facility in Northern Ireland, taking the team to reference sites across the UK so they could see the technology in action.

“From previous projects and years of experience working together, we knew that CDE would be the right choice. Our ultimate goal was to deliver top-quality silica sand to customers across the UK and Ireland,” Paterson Quarries managing director Tom Paterson said.

“CDE’s team meticulously tested material in their lab to understand our expectations and the materials we wanted to produce so that they could design the right plant for us.”

CDE director of customer solutions Chris McKeown believes such good relationships are important because, in the

An overview of the CDE plant for Fife Silica Sands. case of all the projects CDE has delivered for Paterson Quarries, “the customer’s input has been critical within this process, and we try to incorporate all the requests into the plant design”.

“This included visiting multiple reference sites, testing the material in our lab, and flying over for inward visits with our design team in-house,” McKeown said.

The glass industry is the largest end-user of silica sand production, accounting for more than a third of the global market.

This is followed by sands for foundry, hydraulic fracturing, filtration and abrasives applications.

The construction market, rising automotive production and technological advancements such as smartphones, televisions, solar control glazing for automotive and building glasses, lightweight glazing glass, and advanced nanotechnology in flat glass are all increasing the demand for high-grade silica.

Consistency is critical with silica sands.

To deliver dependable products that meet market specifications, CDE designed and engineered the 210tph sand-washing solution, which was commissioned in February 2024.

The solution comprises of the CDE P2-108 prograde screen that takes in the material, conditions it and prepares it for the

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downstream processes. The prograde screen generates three products: +7mm, 3–7mm and a 0–3mm.

CDE added five F1-64 Infinity fine screens for the high-efficiency separation of the -0.6mm material from the 0–3mm generated by the prograde screen. The F1-64 side tensioned media pack provides a high open area for optimum throughput, and the lower section of the screen provides superior dewatering of the 0.6–3mm material.

The plant is also equipped with ShearClean attrition cells, spiral separators, and two counterflow classification units (CFCU), three key steps in the production of silica sands.

The paddle design of the ShearClean attrition cells ensures consistent scrubbing of all material, liberating impurities for efficient contamination removal and delivery of highquality in-spec sand products.

The spiral separators facilitate the removal of heavy contaminants from the sand stream, and the two CFCU units, used for two different grades of glass sand output, remove lightweight material and the 0–150-micron fine sand.

CDE incorporated multiple sets of highintensity magnetic filters into the process to reduce ferrous contaminants from the feed stream. The magnets were supplied by a specialist provider and seamlessly integrated into the CDE solution, ensuring minimum downtime.

Three EvoWash sand-washing systems are used for desliming and dewatering the sand: one for high-grade glass sand, one for low-grade glass sand, and one for fines.

These three systems contain modular hydrocyclone technology to allow for control of silt cut points, ensuring that Fife Silica Sands can provide a consistent, in-spec product to meet the market’s needs.

The process water is recycled by the CDE AquaCycle, a highly efficient water management solution that helps to minimise costly water consumption and allows Fife Silica Sands to recover 90 per cent of the process water for immediate recirculation.

The separated water from the AquaCycle is passed over a static screen, capturing lightweight debris before it is recirculated via the AquaStore to the wash plant.

The AquaStore receives recycled water from the AquaCycle, which is then recirculated to reduce the freshwater required to feed the washing plant.

“From an environmental point of view, this plant is a real win for us, as there is less waste and we’re recovering more,” Paterson said. “We have a direct wire to a wind turbine, so we have all the needs for this plant from renewable energy when the wind blows.”

Fife Silica Sands’ wash plant operates 24 hours a day, from Monday to Friday, to keep up with the industry’s supply needs.

To ensure this operation runs around the clock, CDE installed its SmartTech plant management app, which enables Fife Silica Sands to understand its plant

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performance, schedule maintenance, and easily order parts.

Sensors fitted to the plant provide up to 300 precise data points and continuously stream real-time, in-depth performance reports. This live feed provides a full and transparent overview of a plant’s health and is accessible 24–7 through a mobile app.

This technology allows Fife Silica Sands to remotely monitor input feed rates, hopper speeds, thickener levels, and water tank levels.

“With CDE SmartTech, we can track the performance, we can see the settings, and we can look back and view what changes have been made through the plant and how it has affected the quality or yield of the end product,” Paterson said.

“Whilst this is a complex plant, SmartTech allows us to easily analyse the overall performance of the solution.”

Fife Silica Sands quarry manager Kenny Mitchell has been very happy with the relationship with CDE. “From install right through commissioning and into aftercare, CDE has always been very proactive and helpful with enquiries,” he said. “If we need any products, spare parts, or issues that we’ve had, we’ve been able to raise them with the CustomCare team, and they have been able to resolve them either remotely with the aid of SmartTech or by having engineers visit our site.”

With this sand-washing solution, Fife Silica Sands is able to produce seven products to supply the market. The two glass sand products are the plant’s main outputs, and a number of other fractions are produced, which are used for a range of applications, including sports sands and construction aggregates.

McKeown believes consistency is key to glass sand production.

“The output products from Fife Silica Sands will go into numerous applications in the glass industry,” he said. “Product quality

is key, and we were determined to provide a solution that could deliver consistent, highquality products. And that’s what we’re able to track and deliver with the plant.”

Paterson has been delighted to see the plant exceeding expectations.

“We’re supplying thousands of tonnes of specialist sand weekly to large glass manufacturers across the UK, who are producing the highest quality glass, as well as supplying construction markets and providing feedstock for asphalt production, render sands and ready-mixed concrete, high-quality USGA [United States Golf Association] sands for top dressing, golf course construction and bunker sand, along with horse riding arenas,” he said.

“This is a new and different approach for us and we’re getting a much higher yield from every tonne of product, far in excess of our expectations. We have one glass customer who has signed up to work with us for 20 years, which is a testament to the quality of the products we’re supplying.

“At Paterson Quarries, we pride ourselves in what we do and we live by our ethos in providing quality products at competitive prices, combined with delivering reliable service and friendly, knowledgeable staff, and CDE’s technology has allowed us to continue this with our latest investment.”

McKeown, who has been involved with the project “from the early sales stage, through the engineering process, the installation, and now into the fully operational phase”, is very happy to see the plant in its current state.

“Across our industry, tonnes per hour is a common metric used to describe the performance of a plant,” he said. “Ultimately, the return on investment of a plant like this is built on achieving that tonnage over an extended time. So, in CDE, the key metrics for us is tonnes per week, tonnes per month, tonnes per year, over many years.”

Fife Silica Sands’ Kenny Mitchell (right) chatting to CDE’s Chris McKeown.

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Final sand product deposited beneath the TWS FM120C radial conveyor.

Duo collaborated with the client’s civil contractor throughout the project to support site development work.

The new sand-washing system for Northumbrian Water removes contamination from the sand recovered from filtration beds in a single pass, allowing the sand to be reinstated and reused.

The site uses dump trucks to feed the sand into the H12 feeder, which transfers material onto a series of conveyors to the double-deck screen, providing initial rinsing and removing oversized materials and debris. The sand slurry is then captured in the pre-wash tank.

At this point, the upward current helps remove any organics before the sand slurry is pumped to the first pre-wash cyclone and discharged into the FM120C tank.

The sand slurry is then pumped through a final cyclone, discharging onto a high-frequency dewatering screen, ensuring minimal residual moisture in the final product.

Image: TWS

Awash with success A Terex Washing Systems (TWS) FM120C and on-board pre-wash sand-washing system is ensuring the highest efficiency in filter media processing for Northumbrian Water at its Layer Water Treatment Works near Abberton Reservoir, just outside Colchester in Essex in southeast England.

In partnership with Duo Group, TWS installed its solution in January 2025. To ensure a sustainable and resilient water supply for more than 300,000 residents in Essex, the Layer Water Treatment Works is undergoing a significant upgrade.

This includes the construction of a new 9000-square-metre sand-washing yard with an upgraded filter sand washing system.

The solution provided by TWS and Duo includes an H12 feeder, a 12x5 double-deck modular rinsing screen, an FM120C compact sand plant with an on-board pre-wash system, and a radial product conveyor utilised to stack the finished product.

Primary and back-up pumps are also provided for the clean water supply and wastewater removal.

The double attrition provides efficient cleaning of the sand and an in-spec product with minimal handling.

The TWS solution is solving some key issues for Northumbrian Water. The company’s existing sand-washing system at the Layer Treatment Works had served its time. An outdated process design needed regular repair and often required the site to process the sand through the system twice to achieve effective cleaning.

TWS and Duo have supplied an efficient system that will provide effective sand cleaning in a single pass, while remaining compact, reliable and easy to operate. This has resulted in a significant reduction in cycle time to wash each batch of filter sand, provided operational efficiency, and reduced vehicle movements on-site, all of which has contributed to improving sustainability and reducing maintenance costs.

The Layer Water Treatment Works upgrade sets a new benchmark in sustainable water filtration. By integrating advanced TWS technology and innovative engineering solutions from Duo Group, the project enhances water quality, supports climate resilience, and improves long-term operational efficiency.

Conserving resources Following a major restructuring, CFlo has entered a transformative phase, positioning itself as a leading force in modular wet processing technology.

As part of its global growth strategy, the company attended the recent bauma 2025 exhibition in Munich.

Previously focusing only on the Indian subcontinent and Southeast Asia, CFlo has an installation base of approximately 500 projects across 20 countries, which have been delivered over the past 19 years.

The business employs approximately 250 people, all of whom are focused on its purpose of ‘Conserving resources and creating waste-free cities’.

CFlo co-founder and director of global sales Enda Ivanoff told Aggregates Business that recent restructuring allows CFlo to take its technology worldwide.

“Our globally experienced team will build and align the business growth with market demand, and we are building strong relationships and partnerships in various regions,” he said.

“We believe strongly in being close to the customer and will invest in our strategic regions as required with office, service centres and personnel.

“Our initial focus will be the Middle East Africa [MEA], Australia, New Zealand [Oceania], and Southeast Asia. We are currently finalising a strategic partnership for the mining sector in Australia with a huge global business.”

CFlo is bringing innovative solutions to four main industry segments: construction sand and aggregate washing; waste recycling; ore beneficiation; and critical mineral recovery.

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Image: CFlo

A CFlo Combo Mega 350tph plant processing limestone fines material.

“CFlo is committed to delivering cuttingedge solutions that redefine the processing of aggregates and quarrying materials,” Ivanoff said.

“Retaining its extensive portfolio of patented technologies and a globally experienced team, CFlo is now better equipped to expand its footprint and enhance value for quarry operators worldwide while attaining its vision to replace natural sand in 100 countries.

“The revolutionary Combo platform has become the industry benchmark in modular processing.”

CFlo offers a suite of advanced processing technologies tailored for quarry operators seeking to optimise resource recovery, reduce waste and improve environmental impact.

“Our high-efficiency washing systems and water management technologies are designed to address key industry challenges, including excessive fines, inconsistent material quality and water scarcity,” Ivanoff said.

Ivanoff said CFlo’s technology for the aggregates sector feature a number of key benefits: • Maximising yield – advanced washing and classification systems recover valuable fractions that would otherwise be lost, increasing overall product yield • Sustainability and compliance – CFlo plants are engineered to minimise freshwater usage and reduce environmental impact, aligning with regulatory standards and sustainability goals • Operational efficiency – modular and

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scalable solutions ensure reduced downtime, lower operating costs, and faster return on investment The company is setting up CFlo Middle East as a group company to service the MEA region. Ivanoff believes the office has the potential to serve as a global hub for service and a large project management centre of excellence.

“MEA is a rapidly expanding market for infrastructure and construction, driving strong demand for high-quality aggregates,” he said.

“However, water scarcity, inconsistent raw material quality, and strict environmental regulations necessitate more efficient processing technologies – precisely what CFlo delivers.”

CFlo’s growth strategy in MEA revolves around specific factors: • Strategic partnerships – collaborating with key players in quarrying and construction to drive technological adoption • Localised solutions – customising technology to meet each region’s unique geological and regulatory needs • Sustainability leadership – promoting water recycling and sustainable aggregate processing to align with regional environmental policies CFlo’s solutions are already making a difference in the MEA region. One standout project is Power International’s limestone quarry in Fujairah, United Araba Emirates (UAE).

The Combo Mega E5 installation has optimised this process by transforming the -10mm feedstock into high-quality

construction sand and recovering valuable 5–10mm particles as low-silica limestone.

This is an efficient solution that enhances resource recovery and provides a new revenue stream through construction sand sales catering to the high-demand markets in Abu Dhabi and in other regions.

Beyond the UAE, CFlo has delivered highperformance wet processing solutions in 20 countries.

“With its recent restructuring, CFlo is poised to expand to newer markets, revolutionising the aggregates and quarrying industry with smarter, more sustainable processing solutions,” Ivanoff said.

“As demand for high-quality materials rises, CFlo remains committed to driving innovation and efficiency in the sector.

“For quarry operators looking to futureproof their operations, CFlo is the partner of choice. It delivers world-class solutions that redefine aggregates processing for a more sustainable future.”

Ivanoff believes CFlo’s patented Combo platform is the world’s most water and power-efficient system for processing various materials.

“Originally pioneered for producing manufactured sand from crushed rock fines, it has been developed further for use across all four industrial sectors,” he said.

“It is innovative in its use of water recirculation and a combination of processing technologies, based all on one singular platform, which provides huge flexibility for the end user in terms of adaption to site-specific materials and mobility.” AB © AGGREGATES BUSINESS March/April 2025

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Topcon technology is being used at Minas de Ríotinto in Spain, one of Europe’s largest mining operations.

The critical task of weighing extracted material during quarrying has benefited from the industry’s continuing embrace of digitalised solutions.

A

ccording to Topcon Positioning Systems vice president of OEM sales – APAC and EMEA Nick Townsend, the aggregates industry is under increasing pressure to meet the growing demands of global construction.

“Rapid urbanisation, large infrastructure projects and economic development are driving a surge in demand for materials like sand, gravel and crushed stone,” he said.

“As construction projects expand, so does the need for aggregates to support roads, buildings and critical infrastructure, making the sector a key player in modern development.”

Digitalisation and automation are emerging tools in efforts to improve efficiency, reduce waste and ensure regulatory compliance. But the industry faces challenges in areas such as rising fuel costs, supply chain disruptions, and a skills gap.

“Labour shortages, especially in attracting skilled workers for advanced machinery, complicate the adoption of new technologies,” Townsend said. “The industry needs solutions that streamline operations, boost productivity and simplify

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workflows without adding complexity to stay competitive.”

Townsend believes customer feedback is essential to addressing these challenges, helping to identify ‘pinch points’ where technology can drive efficiency and seamlessly integrate into existing systems.

“Operators seek solutions that provide real-time feedback, enhance safety, and improve site visibility,” he said. “Operational disruptions – such as unexpected downtime, equipment failure and delays in material handling – remain a critical issue. Without real-time insights, site managers struggle to prevent costly standstills.

“Digital workflows like Sitelink3D by Topcon bridge communication gaps between on-site teams and control rooms, improving decision-making and coordination.”

When it comes to fuel consumption, trucks moving around sites, idling engines and inefficient hauling routes significantly increase costs and emissions. Topcon’s connective software solution Sitelink3D Haul Truck app offers real-time data on vehicle movements and material flow, helping to eradicate inefficiencies, cut costs and reduce environmental impact.

Image: Topcon

A digital approach However, skilled operators are essential to achieving these improved efficiencies.

“With many experienced professionals retiring, a growing skills gap exists, especially in using complex machinery,” Townsend said. “Machine control solutions, like Topcon’s MC-X excavator machine control system, use automated guidance to assist less experienced operators in performing precision work. This is essential for boosting efficiencies and ensuring best practices.”

Safety is vital in an industry where precision is critical. Operators must ensure compliance with stringent regulations while meeting tight deadlines. Digital solutions that provide visibility across sites and monitor equipment performance help businesses stay ahead of regulatory requirements without compromising productivity.

“Technology is reshaping aggregates operations by addressing interconnected challenges – downtime, fuel inefficiency, communication barriers and safety – and this transformation is already happening on job sites,” Townsend said.

Navigating challenges requires cuttingedge solutions that streamline operations and maximise efficiency.

“Innovations include on-board weighing systems for excavators, front loaders and material handlers, like Topcon’s LX-100 and LM-100,” Townsend said. “These provide real-time load data to ensure accurate measurements and prevent overloading.

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“Beyond improving productivity, precision technology enhances safety. Real-time data helps reduce human error, prevent over-excavation and minimise unstable surfaces, creating a controlled, efficient work environment that reduces downtime and protects operators.”

Digital workflows and fleet management systems like Sitelink3D help to tie such technologies together. These systems integrate with global navigation satellite system (GNSS) machine control technology to improve the accuracy of digging operations, reduce rework and streamline material movement across the site.

This technology is already in action at Minas de Ríotinto in Spain, one of Europe’s largest and most historic mining operations.

“Automated construction technology has increased productivity by 30 per cent,” Townsend said. “Operators have optimised haulage routes using real-time data, reducing fuel consumption and improving site safety.

Rapid transportation of materials is key to increasing production, and hauling routes need to be as smooth as possible. Rough surfaces can lead to materials wearing out, increased maintenance costs, and potential safety risks for workers and operators.

“To level the grounds at Minas de Ríotinto, contractor Sanchez y Lago paired the Sitelink3D site management system with an MC-X excavator,” Townsend said.

“Since the track and surface designs are automatically imported and processed, operators don’t have to manually check the different layers with a level, keeping them safer within the cab, reducing wear and tear, and improving operations.”

OUTSET’s T1 LOADER LFT is a new weighing system for wheeled loaders that is certified for third-party sales with MID OILM R51 certification.

Image: OUTSET

Digital transformation with OUTSET Interconnected data and cloud integration are revolutionising aggregates extraction.

Analytics driven by artificial intelligence (AI) allows machines to provide real-time operational insights, optimising efficiency and reducing costs.

The concept of a synchronised and interconnected quarry represents the future of the extraction sector. All vehicles – loaders, excavators, dumpers and trucks – work in synergy thanks to real-time data sharing. This enables better coordination of extraction, loading, and transport operations, optimises material distribution by reducing waiting times and energy consumption, ensures intelligent resource management, and improves productivity and operational sustainability.

Implementing these technologies brings economic benefits and lays the foundation for a more competitive, safe and efficient sector.

OUTSET helps drive this transformation with systems that manage the entire production cycle. Real-time data connects operations, empowering informed decisions. Intuitive interfaces and comprehensive oversight optimise resources and safety.

The company projects itself towards the future, consolidating its global leadership.

With a strong presence in South America,

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Image: Topcon

SCALES AND WEIGHING

Topcon’s LX-100 on-board weighing system. and supported by a network of distributors, the company expands its influence in Europe and lays the foundations for significant growth in Southeast Asia and Oceania.

It was with this spirit of leadership and innovation that OUTSET participated in bauma 2025 in Munich in April, presenting cutting-edge solutions to enhance efficiency and productivity for industry professionals.

Some of the key innovations unveiled at bauma 2025 : • T1 LOADER LFT – a new weighing system for wheeled loaders that is certified for third-party sales with MID OILM R51 certification, ensuring the highest levels of precision and reliability • T1 DIGGER – an advanced technology for excavators, with the introduction of a system with four next-generation inclinometers, designed to precisely compensate and manage surface, excavator arms and bucket • AI-powered algorithms – to accelerate weighing operations and compensate readings, even in adverse positions, ensuring accurate real-time data • Next-generation wireless technology – when used with automotive long-range Bluetooth modules, this helps eliminate the need for complex wiring and improves system reliability • Zero maintenance and ease of use – as a result of innovative diagnostic data analysis, OUTSET systems provide consistent performance without the need for frequent interventions • Direct interconnection to the cloud and customers’ enterprise resource planning systems – a solution that eliminates the need for external hardware, ensuring seamless integration with workflows OUTSET has reaffirmed its commitment to innovation, offering increasingly intelligent and connected solutions designed to optimise operations and reduce costs. AB © AGGREGATES BUSINESS March/April 2025

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SUSTAINABLE POWER

Rising to the sustainable power challenge Technical writer and power expert Steve Nendick examines how fleet managers can be empowered while meeting the sustainable off-highway machinery power challenge.

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leet managers continue to juggle pressures to minimise costs while maximising productivity and returns for their businesses. They are also facing increased pressure from shareholders to be more sustainable and look towards a zero-carbon future.

Emissions regulations have been around for over 25 years, pushing the industry to invest in technology to reduce particulate and oxides of nitrogen emissions. The progression from EU Stage I to Stage V has brought these exhaust constituents to nearzero levels.

However, CO2 emissions have never been included in these regulations. It is expected that CO2 limits could be included in the potential Stage VI regulations, but these are not anticipated until the end of the decade.

So with no official push to move to lower carbon solutions, what should fleet managers do?

There are several options available that would result in minimal changes to current operating processes.

Machinery with the latest Stage V engines Today’s products that meet EU Stage V emissions are light years ahead of their predecessors in technology and capability.

Significant improvements can be made by replacing older machines with Stage V engine machines, which are cleaner, more efficient and more reliable.

The latest units are clean for urban sites with no visible smoke, helped by the latest exhaust aftertreatment technology.

Engine noise is substantially reduced, while power density has increased, meaning smaller machines can potentially do the job of larger machines, positively impacting operating costs.

Improved fuel efficiency helps to not only reduce running costs, but also CO2 emissions too.

And longer service intervals reduce oil and filter usage, lowering maintenance costs and the environmental impact.

Hydrogen tanks and fuelling equipment.

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SUSTAINABLE POWER

period have prevented any major industrial adoption of compressed natural gas (CNG) or liquified natural gas (LNG).

Manage fleets more proactively with available technology Many of the latest electronic engines have features like stop–start or idle shut-off.

Machines are often left idling for lengthy periods between jobs, and adopting these features saves fuel, protects the engine’s durability, and reduces site emissions and noise.

Many of the latest machines have integrated telematic systems, and retrofit options are available for those that don’t.

The latest fully electronic engines, equipped with an array of sensors that monitor and protect, are compatible with these solutions. They enable fleet managers to connect remotely and look after their valuable assets.

Using telematic systems does come at a cost to the business, from the initial installation, monthly subscription and software integration to the resource for monitoring the output.

However, return on investment can be justified in a number of ways: • Data analysis helps to optimise operations, ensuring fleets match production needs and haul trucks are loaded with the correct payloads • Reducing idle time cuts fuel consumption, cost and emissions • Detecting potential service problems in advance reduces repair costs and unnecessary downtime • Enabling predictive maintenance schedules allows for extended service intervals without affecting durability • Technicians being able to arrive on-site with the correct parts and tools on the first trip improving service efficiency • Overall equipment utilisation is enhanced by extending life and avoiding acquiring unnecessary machinery

Train the operators Having trained people who can operate machinery at their optimal levels will maximise fuel efficiency and reduce potential damage to the unit. Inexperienced people are more likely to use machinery in such a way that increases fuel consumption, cost and emissions. Using telematics to gather data could help improve operator training.

There will come a time when low- and zero-carbon solutions will become more

Image: scharfsinn86/stock.adobe.com

Renewable fuels across the fleet Renewable fuels such as HVO100 – hydrotreated vegetable oil – can lower emissions by up to 90 per cent compared to diesel ‘from well-to-wheel’. For every 1000 litres of fuel, operators could save on average of over 2200kg of net CO2 from switching to HVO, which is fossil-free, sulphur-free and oxygen-free, and requires no engine modifications to use. As a cleaner-burning fuel, fewer filter changes are needed, lowering maintenance costs.

HVO100 can be supplied through the same infrastructure as conventional diesel.

However, it does cost more to produce, given it is made from renewable sources such as vegetable oils or animal fats, which require more complex processing.

In Europe, this price difference is 10–15 per cent higher depending on the region. It is more prevalent in countries with a stronger renewable focus (eg Scandinavia, Netherlands).

While more expensive, the lower maintenance costs could offset the upfront cost, making it attractive for organisations looking to reduce their carbon footprint and emissions without investing in new vehicles or machinery.

Other renewable fuels, such as natural gas, could become a solution. To date, the additional installation costs and long payback

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SUSTAINABLE POWER

prevalent in the market, but this will take some time. Until that time, fleet managers have several options available to them to improve the sustainability of their operations without affecting productivity.

Currently, no solution can match clean diesel’s flexibility and range capability so it will likely remain the power of choice for the foreseeable. It will take time, patience and investment, but, low- and zero-carbon power will eventually grow its share in industrial fleets.

So what does the future look like? What will be the most appropriate power source for quarries and construction site machines?

The main zero-carbon fuel choices are battery electric or hydrogen, provided the hydrogen is produced using clean energy.

Which is the most suitable, and why?

Battery-electric Electric industrial equipment will deliver zero emissions with substantially reduced noise pollution for quarries and construction sites.

If you include electricity-generated emissions to power electric vehicles (EVs), they will still have a significantly smaller lifetime carbon footprint than today’s machines.

For companies that value sustainability, the environmental benefits could justify the higher initial investment, provided the charging infrastructure aligns with the operational needs.

Diesel-powered machinery is traditionally less expensive to purchase upfront compared with battery-electric power. Due to the battery technology installed, the cost of electric equipment can be 20–40 per cent higher than diesel, depending on the type and size of the machine.

While electric equipment has a higher initial cost, the total cost of ownership over several years can be lower than diesel, thanks to reduced fuel and maintenance costs. The break-even period depends on the machine’s usage but typically ranges from

Cummins’ B6.7H hydrogen engine. three–five years for highutilisation equipment.

Using electric power is generally less expensive than diesel fuel, providing potential savings of up to 50–75 per cent in fuel costs over the machinery’s life. So an electric excavator's fuel cost per hour can be significantly lower than a diesel equivalent.

Electric machines have fewer moving parts, so they should in turn require less maintenance. For example, items such as oil changes and fuel filters should not be required, potentially reducing service costs by 25–50 per cnt compared to traditional machines.

The range of battery-electric machines

with a single charge is lower than that of a tank of diesel fuel. The packaging of the battery system in traditional machine designs is also a challenge for manufacturers when considering weight, mobility and sightlines. This technology seems more suited to smaller, more compact machinery particularly operating in urban areas.

Operationally, the balance between charging infrastructure, machine range, and charging speed needs to be calculated carefully. Site location, access to the grid and required charging capacity are critical to success.

Renewable power generated from solar or wind could enable machines to charge

Image: Anoo/stock.adobe.com

Quarries provide key building materials.

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SUSTAINABLE POWER

Biofuels like biodiesel are growing in demand. independently from the grid, perhaps to reduce the draw from the grid during peak periods. Portable battery-changing systems coupled with charging during scheduled downtime would further extend the operating range of electric machines.

Hydrogen fuel Combustion engines and fuel cells are two ways to use hydrogen as a fuel for construction and quarrying equipment.

Combustion engines Hydrogen combustion engines are updated versions of today’s internal combustion engines, which burn hydrogen instead of diesel. They function similarly to a conventional diesel but are spark-ignited rather than compression-ignited. Their combustion process has no carbon emissions, only water vapour and minimal oxides of nitrogen emissions due to high combustion temperatures. Aftertreatment systems can be used to manage these oxides of nitrogen emissions. The real advantage of using hydrogen combustion engines is that they can deliver similar levels of power and torque to diesel but have zero carbon emissions using green hydrogen. This makes them suitable for heavy-duty applications like construction and quarrying, where highpower output is essential.

In addition, the fact their design is so similar close to traditional engines means they fit in the same machine installations and be maintained by the same service networks and technicians.

Hydrogen combustion engines are also less expensive to produce and install than fuel cells, as they can be adapted from existing engine technology, making them a simpler and more affordable option for companies transitioning from diesel.

Fuel cells Fuel cells convert hydrogen into electricity through an electrochemical reaction.

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This electricity goes into a battery that powers electric motors, which move the machine. They operate as a hybrid system, using the batteries for instant torque and peak power demands.

With only water and heat as byproducts, fuel cells are cleaner and more efficient than combustion engines, with 40–60 per cent efficiency rates.

Fuel cells make better use of each hydrogen unit, lowering fuel consumption and total operating costs.

Fuel cells have fewer moving parts, although they do need componentry for controls, air handling, and cooling systems as a package.

From a maintenance perspective, fuel cells have membranes that will degrade over time and need to be replaced. The harder the cells work, the more rapid the degradation of the membranes. They are also susceptible to damage from dust and vibration.

Fuel cells are currently more expensive than hydrogen combustion due to their complex technology and limited production numbers. However, costs are expected to decrease over time as production scales up and the technology becomes more mainstream.

Fuel cells and hydrogen combustion engines benefit from fast refuelling times compared to diesel. This is a significant advantage over battery-electric machines.

Hydrogen management Like battery-electric, infrastructure investment is required to keep the fleet fuelled. Hydrogen delivery, storage and handling on-site need to be managed safely and efficiently. This means being located close to a hydrogen hub would be advantageous. Centralised hubs close to production sites are being set up to minimise transportation needs, reduce costs and minimise safety risks.

Hydrogen is not an easy fuel to manage. It needs to be stored in tanks as a compressed gas under high pressure, and the pressure

and temperature need to be closely monitored. Staff members overseeing the hydrogen need specific training on its unique properties and emergency protocols to manage leaks and fires.

The small size of hydrogen molecules also means they can easily leak, forming potentially explosive mixtures in the air.

Since hydrogen has no smell or colour, specialised sensor equipment is needed to detect leaks. Adequate ventilation is required in facilities to help disperse any leaks and prevent dangerous gas buildup.

Hydrogen will also impact certain metals, making them brittle, so pipes and containers need to be specified with this in mind.

Any business’s chosen carbon-reduction solution is likely to be defined by connecting to the most appropriate, cost-effective and accessible infrastructure. Electric and hydrogen supply create challenges that must be safely and efficiently managed to maximise productivity and environmental benefits.

In the case of machines, battery-electric power is better suited to smaller, more compact machinery with lower duty cycles, especially for construction in urban sites.

Hydrogen combustion engines are better suited to heavy-duty quarrying machinery, where strong power and torque are needed.

The remote nature of quarry operations means they are beneficial where operators and their maintenance staff are already familiar with traditional engine servicing and maintenance.

Hydrogen fuel cells are more suitable for applications where zero emissions and lower noise are prioritised, and noise and vibration can be minimised, such as enclosed areas and environmentally sensitive locations with tighter emissions and noise restrictions.

Due to the focus of major cities on delivering air quality improvements through zero-emissions vehicles, we will likely see these solutions implemented in on-road applications before volume off-road use. AB © AGGREGATES BUSINESS March/April 2025

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

MAY

JULY

SEPTEMBER–OCTOBER

7–9 UK Construction Week – London Organiser: Media 10 Tel: +44 (0)20 3225 5217 ukconstructionweek.com

9–11 QuarryNZ Conference 2025 Organiser: Institute of Quarrying New Zealand and Aggregate & Quarry Association of NZ Tel: 027 664 3080 quarrynz.com

September 30 – October 2 UK Construction Week – Birmingham Organiser: Media 10 Tel: +44 (0)20 3225 5217 ukconstructionweek.com

JULY

JUNE 2026

2–3 PNG Mining Expo Organiser: Prime Creative Media Tel: +61 466 602 893 pngexpo.com

SEPTEMBER

23–25 Hillhead 2026 Organiser: The QMJ Group Tel: +44 (0)115 945 4367 hillhead.com

23–25 AIMEX Organiser: Prime Creative Media Tel: +61 03 9690 8766 aimex.com.au

A LONG WAY

TOGETHER

EARTHMAX SR 41 No matter how challenging your needs, EARTHMAX SR 41 is your best ally when it comes to operations that require extraordinary traction. Thanks to its All Steel radial structure and the special block pattern, EARTHMAX SR 41 provides excellent resistance against punctures and an extended service life. In addition to long working hours without downtime, the tyre ensures extraordinary comfort.

EARTHMAX SR 41 is BKT’s response to withstand the toughest operating conditions in haulage, loading and dozing applications.

Discover the BKT Range

For info: europe@bkt-tires.com

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THE AGGREGATES BUSINESS WEBSITE BRINGS YOU THE LATEST IN FUNCTIONALITY, WITH UP-TO-DATE CONTENT RELATING TO THE QUARRYING INDUSTRY.

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