Terex has major plans to grow within the North American market.
Features
Melker Jernberg discusses the future of Volvo Construction Equipment in a number of key markets. 28 CONEXPO/CON-AGG
The latest updates from one of North America’s largest trade show.
All
The
An in-depth look at Smiley Monroe’s growth in the US
CDE
for
a
The latest innovations and case studies in the conveying sector.
34 CATERPILLAR 100 YEARS
Caterpillar enjoys its centenary celebrations.
How technology is shaping Astec’s approach to US aggregates. 46 CDE SHOWCASE
38 HAULING
The versatility of hauling equipment is on show in the quarrying sector.
40 CRUSHING AND SCREENING
New crushing and screening equipment has been launched in key markets.
44 LOADING
Case studies showcase innovative loaders.
CDE discusses how it is adapting to an evolving recycled materials sector. 48 SCREENING BUCKETS
Screening buckets are proving versatile additions to quarry sites.
New asphalt plants and asphalt technology has debuted globally.
52 TYRES
BKT shares its ambitious plans for global growth.
PROPRESS™
A new generation of filter press, built to bring proven experience, proficient operation, and progressive ingenuity specifically to the construction and demolition, waste recycling, quarrying, and mining sectors.
ProPress uses a dual feed and plates that are 25% larger, handling more material, producing a dryer cake product, while recycling 95% of its process water.
Find out how CDE ProPress can bring safer operation, reduced costs, and maximized outputs to your plant today.
Contact our US Sales Team on 682-350-0300 or visit cdegroup.com/propress
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 (0) 423 177 966 les.ilyefalvy@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.
PUBLISHED BY
Prime Global Publishing
AGGREGATES BUSINESS USPS: is published six times a year.
A ‘Big Beautiful’ future? GUY WOODFORDEDITOR
The American building materials, construction, building contractor and off-highway equipment manufacturing industries have enthusiastically welcomed the July passage into law of the One Big Beautiful Bill Act (OBBBA). The large legislative package includes tax cuts, spending increases on defence, border and security, as well as cuts to social programmes.
The National Stone, Sand & Gravel Association (NSSGA) believes that the Act, particularly in making permanent the 2017 tax cuts enacted under President Trump, which were set to expire at the end of 2025, will boost manufacturing and create new jobs.
NSSGA interim chief executive of cer Michele Stanley welcomed the nal passage of the OBBBA through Congress.
“NSSGA applauds the passage of the One Big Beautiful Bill Act, which builds upon the positive outcomes of the Tax Cuts and Jobs Act by investing in policies that promote growth, support workers and bene t small businesses,” she said.
“NSSGA appreciates that the OBBBA makes several key business tax provisions permanent, including bonus depreciation for eligible property acquired after January 19, 2025; domestic research expenditures; and small business deductions through quali ed business income (QBI) deductions (Section 199A).
“The OBBBA maintains a higher estate and gift tax exemption, setting it at a $15 million base for single lers starting in 2026 and indexing it for in ation, while also protecting percentage depletion for land and other property when accounting for adjusted nancial statement income. The OBBBA will provide certainty for aggregates operators to make necessary capital investments, create jobs and drive economic growth.”
Associated Builders & Contractors (ABC), comprising 67 chapters that represent more than 23,000 member companies and millions of construction workers across the US, also warmly endorsed the OBBBA.
ABC vice president of government affairs Kristen Swearingen said the reform will bring certainty to the sector.
“ABC celebrates Congress and the White House working together to bring this pro-growth tax reform to reality for the millions of hard-working Americans who build and power our economy. This new law provides long-overdue tax certainty, empowering construction businesses to invest in their workforce, expand operations, and keep America building,” she said.
“Now that this critical legislation has been signed, we urge Congress and the administration to build on this momentum by enacting additional reforms to reduce regulatory burdens on businesses. Smart, targeted regulatory relief will give contractors even greater ability to create jobs, strengthen their communities and drive economic growth nationwide.”
ABC said the new law assures more than 95 per cent of all US businesses that are structured as S corporations, partnerships and sole proprietorships. These pass-through businesses employ 62 per cent of the private sector workforce and form the economic backbone of virtually every community across America.
Association of Equipment Manufacturers (AEM) senior vice president of government and industry relations Kip Eideberg said that with the signing of the OBBBA into law, equipment manufacturers can breathe “a sigh of relief” that the US tax code will continue to incentivise job creation, innovation, and investment in domestic manufacturing.
“Equipment manufacturers are grateful to President Trump and our pro-manufacturing champions in the House of Representatives and Senate for ghting tirelessly for these pro-manufacturing tax provisions, which will strengthen US equipment manufacturers and bolster our global competitiveness,” he said.
“We also thank our members, who bolstered our advocacy efforts and made their voices heard.”
GW guy.woodford@primeglobalpublishing.com
CRH to acquire Eco Material Technologies
The business will operate as Eco Material Technologies, a CRH Company.
CRH, a major provider of building materials, has signed an agreement to acquire Eco Material Technologies (Eco Material), a leading supplier of supplementary cementitious materials (SCMs) in North America, for US$2.1 billion.
The major deal positions CRH to meet the growing demand for cementitious products to modernise North America’s infrastructure. It also secures a long-term supply of critical materials and strengthens CRH’s position as a leading cementitious player in North America. Eco Material further expands CRH’s national distribution network and innovation capabilities to better serve its customers. Furthermore, the acquisition demonstrates CRH’s commitment to accelerating growth through value-creating capital allocation.
“This strategic acquisition further positions CRH as a leading cementitious player in North America with both cement and SCM capabilities,”
CRH chief executive of cer (CEO) Jim Mintern said. “This transaction demonstrates CRH’s disciplined approach to capital allocation, building marketleading positions in higher-growth markets with secular tailwinds and superior returns.
“As we continue to modernise North America’s infrastructure, this transaction secures the longterm supply of critical materials for future growth and puts CRH at the forefront of the transition to next-generation cement and concrete. With more than 1100 Eco Material employees joining the CRH team, our combined operations create a more connected business to better serve our customers.”
Eco Material is headquartered in Utah and operates a national network of fresh and harvested y ash, pozzolans, synthetic
Caterpillar and Luck Stone reach one
Caterpillar and Luck Stone, America’s largest family-ownedand-operated producer of crushed stone, sand and gravel, announced a signi cant milestone in their ongoing collaboration: one million tons autonomously hauled at Luck Stone’s Bull Run Quarry in Chantilly, Virginia.
The achievement marks a rst for Caterpillar in the aggregates industry and underscores the success of its autonomous haulage system in a quarry environment. It also demonstrates the safety and productivity of autonomy in applications beyond traditional large-scale mining.
“This milestone is a powerful demonstration of what’s possible when we collaborate with our customers to deliver solutions for their critical needs,” Caterpillar group president for resource industries Denise Johnson said.
“Reaching one million tons hauled autonomously at Bull Run shows that autonomy isn’t just for mining – it’s scalable, reliable, and ready to transform the aggregates industry.
“This autonomous journey with Caterpillar has been one of the most powerful and transformative projects in our 100-year history.
“Reaching the one-milliontons-hauled milestone has engaged every part of our operation ... proving that this technology can work, and work well, in a quarry environment.”
The collaboration between Caterpillar and Luck Stone began with a shared vision to transform quarry operations through cutting-edge technology. Bull Run became the rst site in the aggregates industry to deploy Caterpillar’s autonomous Cat 777 trucks, supported by a full autonomy technology stack and site integration services.
The collaboration has focused on validating autonomy along with the people and processes in conditions that are typical in quarry operations but distinct from mining.
Reaching this milestone helps to con rm that autonomous haulage can deliver consistent, repeatable performance. It
gypsum and green cement operations distributed across a network of over 125 utility source locations, production facilities and terminals. The company partners with leading electric utilities to process and recycle approximately seven million tons of y ash and three million tons of synthetic gypsum and other materials annually, with signi cant additional capacity currently under construction.
“Eco Material is excited to enter a new phase of growth, partnering with industry leader CRH to enhance our scale and suite of offerings to our utility partners and readymix customers,” Eco Material chairman and CEO Grant Quasha said.
“CRH’s strong industry presence, coupled with its intense focus on safety, innovation and customer service pair perfectly with Eco Material’s key values.”
“The proposed transaction is ... expected to close in 2025. CRH plans to fund the transaction with cash on hand and does not expect any change in its credit ratings.
million
also signals how autonomous solutions will address skilled labour shortages, improve site safety, increase operational ef ciency, and upskill quarry employees to run autonomy.
“At Luck Stone, our mission is to ignite human potential, and this project is an example of what’s possible when people, purpose, and progress come together,” Luck Companies president and chief executive of cer Charlie Luck said.
“We’re grateful to Caterpillar and con dent that operators across the country will have a similar experience.”
Caterpillar and Luck Stone continue to explore opportunities to expand autonomy across additional sites and applications. The success at Bull Run sets a precedent for the broader aggregates industry and reinforces the companies’ commitment to innovation and operational excellence.
CRH CEO Jim Mintern.
Autonomous Cat 777 trucks at work in Luck Stone’s Bull Run quarry
Image:
Caterpillar
Granite Brook success with EvoQuip
EvoQuip, a global manufacturer of compact mobile crushing, screening, shredding and conveying equipment, has played a pivotal role in the evolution of Granite Brook Stone & Landscape Materials, helping the Massachusetts-based business expand from a local landscaping service into a thriving supplier of premium soils and materials across New England.
Founded in 2013 by Mike Leone, Granite Brook was born from over two decades of landscaping experience. Located in Weston, Massachusetts, the company quickly became a go-to destination for mulches, soils, bluestone, granite, pavers, and decorative stones. However, it was in 2017 that Granite Brook took a major step forward by investing in its soil manufacturing capabilities, thanks to the assistance of EvoQuip.
After connecting with Powerscreen New England’s Sean Cli ord, Mike took delivery of one of the first EvoQuip Colt 600 units
HMNA LEADERSHIP ROLE FOR BILL FEDORKA
in North America. The Colt 600 is a compact scalping screen specifically designed for operators who value versatility, manoeuvrability and transportability. Small enough to fit inside a container for transport, it is also strong enough to withstand the toughest of applications.
“Since 2017, the unit now has 5000 hours, and we love it. It’s the most versatile tool in our operation; it handles everything we throw at it and is easy to move,” Leone said.
“We can make several di erent grades of loam, and we even screen compost now.”
Command Alkon acquires Digital Fleet
Command Alkon, a global leader in software and technology solutions for the heavy building materials industry based in the Birmingham, Alabama, has acquired Digital Fleet, an industry-focused innovator in eetmanagement solutions.
This strategic move reinforces Command Alkon’s commitment to delivering purpose-built, modern technologies that enhance operational performance, streamline logistics, and empower business transformation for heavy building materials producers worldwide.
The transaction includes the full Digital Fleet product suite and team. With a strong reputation for responsive service and mobile- rst innovation, Chicago-based Digital Fleet brings deep experience and expertise in serving customers of heavy building materials. The company was previously owned by Ozinga Ventures, a private investment rm of the Ozinga family focused on multiple vertical markets.
“We are delighted to welcome the Digital Fleet team to Command Alkon,” Command Alkon chief executive of cer Martin Willoughby said. “This acquisition exempli es our Command Alkon 3.0
vision – integrating industry-leading products and exceptional talent to deliver innovative, scalable, secure and smart solutions tailored to the needs of the heavy building materials sector.”
Heidelberg Materials North America has appointed Bill Fedorka, P.E., as its senior vice president for fly ash in the south-east region. He succeeds Jim Clayton, who is retiring after 20 years of service with the company.
“Jim’s commitment to building a creative team focused on problem-solving and implementing strategic plans throughout the region has significantly shaped the fly ash industry,” Heidelberg Materials North America president for the south-east region Scott Dickson said Clayton joined the SEFA Group, a predecessor of Heidelberg Materials, in 2005. He served as the director of utility relations until 2011, when he assumed the role of vice president of operations. In 2015, he was promoted to chief operating o cer, overseeing all plant operations, SEFA Transportation, engineering and construction services, business development, safety, and environmental matters. “It has been an honour to work alongside such a talented team,” Clayton said. “I’m proud of what we have accomplished together throughout the years and am excited to see Bill guide our fly ash business into its next phase of growth.” Over the past two decades, Fedorka has held several key leadership positions at the SEFA Group and Heidelberg Materials. In his new role, he will provide technical and strategic direction for fly ash operations and initiatives, focusing on strategic growth, technological innovation, and operational excellence.
Granite Brook’s Mike Leone pictured with Powerscreen New England’s Sean Cli ord.
Image: EvoQuip
Command Alkon’s Ruckit trucking performance app.
Images:
Command Alkon Image/HMNA
Bill Fedorka is Heidelberg Materials North America senior vice president for fly ash.
TERRA CO2 INVESTMENT BOOST
Terra CO2 has secured Series B funding from additional strategic investors to support the build-out of its future commercial facilities.
In addition to its Series B coleads, Breakthrough Energy Ventures, Eagle Materials, GenZero and Just Climate, the new funding features key industry players. This includes Barclays Climate Ventures, as well as Prologis, Cemex, and Siemens Financial Services.
“Terra’s technology o ers a combination of commercial readiness and cost competitiveness. Its ability to support the decarbonisation of a heavy industry such as cement aligns with our commitment to support scalable, near-term solutions in hard-to-abate sectors,” head of Barclays Climate Ventures Steven Poulter said.
Colorado-based Terra CO2 is proceeding with the construction of a commercial processing facility in the Dallas-Fort Worth, Texas, market, which is expected to produce up to 240,000 tonnes per year. The funding will also expand the company’s o ces and industrial facilities, as well as develop commercial projects and new cementitious products.
The company is focusing on supplementary cementitious materials (SCMs). The SCMs are an alternative to Portland cement and fly ash products.
Terra CO2 is using feedstocks from existing aggregate mines and works within existing industry infrastructure.
Terra’s second product, OPUS Zero, is undergoing concrete trials and is designed to serve as a replacement for Portland cement.
“Terra’s mandate is to deliver cementitious material solutions the market would purchase solely based on cost and performance, even if there were no carbon benefit,” Terra CO2 chief executive o cer Bill Yearsley said. “The fact Terra’s cementitious materials also o er significant carbon mitigation is an additional advantage for the built environment.”
Fortera confirms key leadership appointments
Fortera has bolstered its global expansion plans with the appointments of two key leaders to grow its low-carbon cement technology. Sandy Clancy and John Dotson have joined Fortera as chief projects of cer and general counsel, respectively.
“We’re building a company that can revolutionise the way cement and concrete are made around the world,” Fortera chief executive of cer Ryan Gilliam said.
Clancy will focus on Fortera’s project pipeline, including bringing the company’s ReCarb plants online at scale and on time.
Having previously worked at JERA Americas, one of the world’s largest energy producers, provided Clancy with experience in complex energy and industrial builds across the US and Canada, focusing on engineering, execution, and stakeholder alignment.
“Joining the Fortera team is a unique opportunity to deliver technology that creates both environmental and economic value,” Clancy said.
“We’re engineering solutions that work with existing infrastructure while delivering superior performance.
“My focus is on building a project-delivery pipeline that brings cost-effective, scalable cement solutions to market ef ciently and repeatedly, creating value for our partners while meeting the need for cleaner materials.”
Dotson has more than 25 years of legal experience, including senior roles at Chevron and Raytheon. This
included working on international deals, joint ventures, and regulatory frameworks. In his new role, Dotson will focus on legal, regulatory and compliance strategies.
“Fortera offers a rare combination of innovation, proven technology and clear market opportunity,” Dotson said.
“I’m excited to help build the legal foundation for a company that offers a path to modernise a massive market while creating value for all stakeholders.”
Recycl8 secures sought-after
Recycl8 has recently been awarded a patent from the US Government for its R8 Mix binder technology, which repurposes waste material to produce a sustainable, lower-carbon concrete solution.
The rm, which already holds the UK patent, utilises incinerator bottom ash aggregate (IBAA) that is often
destined for land ll, transforming it into a sustainable, lower-carbon component for concrete manufacture. In doing so, the R8 Mix technology addresses the challenge of reducing CO2 emissions in construction while fostering the sustainability of construction materials within a circular economy.
US patent
The US Patent and Trademark Of ce found that Recycl8’s new technology met its stringent criteria for being useful and novel, particularly concerning its application of IBAA, which has different properties compared to the coal ash commonly used in the US.
Recycl8 managing director Mark Gillespie welcomed the news.
“We are pleased to accept the award of this patent in the US; it’s a massive validation of not just our technology and commercial viability but also our ability to reduce the impact of concrete production on climate change,” he said.
“Our R8 Mix not only has a lower embodied carbon than traditional mixes but it also breathes new life into materials that would otherwise be discarded, reducing the reliance on virgin quarried materials.”
Fortera’s new general counsel John Dotson .
Fortera’s chief projects o cer Sandy Clancy.
Recycl8 R8 Mix binder technology in action.
Image:
Recycl8
Images: Fortera
SEPTEMBER 16-19
Collaborating for success
National Stone Sand & Gravel Association senior director of communications Kerry Lynch shares an update on the association’s latest activities in the US.
The National Stone Sand & Gravel Association (NSSGA) serves as the aggregates industry’s strongest voice in the nation’s capital, representing producers, manufacturers, service providers, and the industrial sand division. Our members bene t from having professional, experienced staff represent them in Washington, DC.
Our association also routinely collaborates with other stakeholders in the construction industry who share similar interests. Through coalition efforts and events, we actively participate in opportunities to showcase the value of our industry to members of Congress and their staff, administration of cials and media.
This helps to ensure our voice is united and stands out in the noise of Capitol Hill. Our association collaborates with others by jointly sharing policy priorities in meetings, sending letters to congressional committees, and partnering on member events.
Here are some speci c ways the NSSGA has collaborated with others in Washington, DC to provide education about the vital importance of our industry.
Coalitions
The NSSGA is a member of the Transportation Construction Coalition (TCC), a partnership of 33 national associations and construction unions representing hundreds of thousands of individuals with a direct market interest in federal transportation programs. We actively participate in its annual y-in, which brings industry leaders together in Washington, DC for a two-day meeting and accompanying Capitol Hill visits.
This past May, NSSGA staff and members participated in the policy brie ng and Capitol Hill visits. Attendees heard remarks from the Senate’s Environment and Public Works chair Shelley Moore Capito (WV), the House Transportation and Infrastructure Committee chair Sam Graves (MO), the House Transportation and Infrastructure Committee ranking member Rick Larsen (WA), Federal Highway Administration chief counsel Jay Payne, and the American Society of Civil Engineers executive director Thomas Smith. Attendees then conducted Hill visits to encourage policy interests, such as making the Highway Trust Fund solvent and passing budget reconciliation with the Tax Cuts and Jobs Act provisions.
Celebration of Construction
The NSSGA also promoted the aggregates industry at construction events in Washington, DC by working with the Association of Equipment Manufacturers and participating in the 2025 Celebration of Construction.
We hosted a booth during this landmark event on the National Mall in Washington, DC from May 14–16. The event showcased leading construction equipment manufacturers, technology innovators and workforce development organisations to demonstrate how the industry is building a stronger, safer, more sustainable America.
The Celebration of Construction aimed to educate policymakers, the media, and stakeholders about the construction industry’s vital role in the US economy, public safety, and environmental stewardship. More than 30 industry leaders participated with their own tent space on the National Mall. These featured interactive displays, equipment demonstrations and educational exhibits. The NSSGA staffed a booth promoting the industry, and many of our Manufacturers & Services members participated with their equipment.
The show was free to attend, and visitors included members of Congress, Trump Administration of cials and their staff, as well as the public. Booth participants also held live demonstrations, allowed attendees to speak with company experts and highlighted how innovation drives progress in the construction sector.
Legislative & Policy Forum
Looking to the future, the NSSGA will once again host its Legislative & Policy Forum (LPF) in Washington, DC from September 16–19. We will also be joined by association members of the National Asphalt Pavement Association (NAPA) and the National Ready Mixed Concrete Association (NRMCA) to tell the story of our industries and our shared
During Hill Day, NSSGA members met with Rep. G.T. Thompson (PA) (centre) to share aggregates industry priorities.
legislative goals. Registration is open now through nssga.org
During LPF, attendees will network and meet with other professionals in the aggregates industry, gain a deeper understanding of the sector, and participate in open committee meetings. Many committees are open to all attendees, including Communications, Environment, Engineering & Technical, and Membership. Additionally, everyone is invited to the NSSGA Board of Directors and Membership Meeting on September 19. This is your chance to engage with NSSGA leadership, learn about initiatives and provide input.
We also encourage every NSSGA, NAPA and NRMCA member to participate in Hill Day on September 18. If you’ve never participated, the NSSGA’s team of government relations professionals will walk through the whole process ahead of time. Each meeting will also have a team leader to help navigate the ins and outs, including discussing policy issues, sharing one-pagers, and leading the group to the of ce.
Promoting our industry’s importance is crucial to ensuring its long-term success, and collaboration with others ampli es our voice and strengthens our position. The NSSGA is proud to represent our members and work on their behalf in Washington, DC. AB
For more information about NSSGA and the Legislative & Policy Forum, contact meetings@nssga.org
Image: NSSGA
HAVER & BOECKER invited industry stakeholders and key customers to the event.
Centenary celebrations
HAVER & BOECKER has recognised a major achievement with year-long festivities as its machinery division celebrated 100 years since its establishment.
HAVER & BOECKER’s headquarters in Oelde, Germany, have been the centrepiece of celebration as the company invited customers and industry stakeholders to mark an important milestone.
The company’s machinery division is celebrating 100 years since its establishment, while two of its subsidiaries, IBAU HAMBURG (50 years) and AML Anlagentechnik (25 years), are also marking notable milestones.
If a week is a long time in business, 100 years is an eternity. While HAVER & BOECKER has seen many industrial shifts, some things have remained the same.
“A lot can change in 100 years, but our commitment to our employees, customers and core values, which are masterfully crafted, inspiring and familiar, remain consistent,” HAVER & BOECKER managing partner Florian Festge said.
“Those principles continue to guide us into the future.”
Past and present
Customers and industry partners were welcomed to HAVER & BOECKER’s headquarters for an innovation showcase.
The exclusive event featured realtime demonstrations of the company’s packaging technologies. Attendees gained hands-on experience with the RADIMAT, ROTOPACKER and INTEGRA systems. New technologies, including the RADIMATPATHFINDER for empty bag logistics and AMICUS Depal for empty bag depalletising, also impressed onlookers.
The INTEGRA IVT Seal edition, part of the next-generation IVx series, showcased how arti cial intelligence (AI) capabilities can enhance packing performance.
Its digital solutions, including the QUAT²RO and PROcheck, were demonstrated to the international guests.
The advanced ltration system RPDHiFlow demonstrated a new industrial woven wire innovation.
The company will conduct two more customer events as part of its centenary celebrations on September 4 (which is sold out) and December 3.
“This milestone celebration is a testament to the fact that innovation at HAVER & BOECKER is not merely a response to market trends. It is embedded in our DNA,” Niklas Haver said.
HAVER & BOECKER also celebrated the 125th anniversary of the Haver Academy, which trains apprentices and early-career employees. Academy attendees shared their insights into their early-career development, re ecting the company’s commitment to investing in internal growth.
“We want to express our deep gratitude to our customers for their trust and partnership throughout the years. It is that trust that has truly sustained and inspired us,” Festge said.
“We also thank all the dedicated engineers and the entire team, whose expertise and passion have made this century of innovation possible.”
New innovations
HAVER & BOECKER has launched the RADIMAT PATHFINDER Edition for packing operations especially in the cement and building materials sectors.
The PATHFINDER conveyor system is designed to transfer empty bags from HAVER & BOECKER’s RADIMAT, a fully automatic empty bag separation and application device, to the ROTO-PACKER, a fully automatic packing machine. This enables the packing line to be fully automated while working within space constraints.
“Customer success is at the forefront of our design process at HAVER & BOECKER,” HAVER & BOECKER machinery division’s cement business unit Frank Ormeloh said.
“It’s why we’re so pleased to offer a solution to improve exibility in the packing process while also boosting ef ciency, reducing maintenance and improving worker health and safety.”
The PATHFINDER can work with the full portfolio of HAVER & BOECKER’s automated packing solutions across the full production cycle. The AMICUS Depal depalletises empty bags onto the RADIMAT, the PATHFINDER transfers them to the ROTOPACKER before the AMICUS Pal palletises and prepares the lled bags for shipping.
“For those producers currently applying bags by hand who want to take the journey to automation in phases, the PATHFINDER Edition can also be implement in a simpli ed version without the use of a RADIMAT,” HAVER & BOECKER said.
“Rather than having to place the bag on the actual spout, operators simply feed the bags into the conveying system itself, which then applies the bag to the spout automatically. In this situation, the worker experiences many of the safety bene ts of the fully automatic system.” AB
Image: HAVER & BOECKER
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
Born in Ireland, made in Kentucky
Smiley Monroe is celebrating five years of stateside success.
Five years ago, Northern Irelandborn manufacturer Smiley Monroe expanded its operations stateside when it opened the doors of its rst US plant in Franklin, Kentucky. This strategic move was not just about geographic expansion; it was about bringing the brand’s core value of being “close to our customers” to life on American soil.
Despite being the new kid on the block, Smiley Monroe came to the US with more than 45 years of belting expertise and an established blue-chip customer base in the US, including the likes of Terex, Astec, Wirtgen, McCloskey and Eagle. The decision to invest in a plant across the Atlantic was customer-led from day one.
“Our Kentucky facility was born out of listening to our original equipment manufacturer [OEM] customers across North America who needed faster access to premium, customised, endless conveyor belts and after-market support,” Smiley Monroe Inc vice president Morgan Walker said.
“Five years on, Smiley Monroe Inc [the US-based subsidiary] continues to meet and exceed those needs, and to date has delivered conveyor belts to 48 states and expanded sales into Canada, Mexico and the Caribbean, growing our prestigious customer base in the process.”
The after-market hero
It is not just equipment manufacturers who are bene ting from Smiley Monroe’s move to the US.
The company’s after-market product ZIP CLIP is gaining traction in the market and now accounts for nearly 60 per cent of its total sales. Smiley Monroe Inc estimates that ZIP CLIP is more than 10 times faster than vulcanising and is supplied ready-to- t.
The mechanically fastened belt can be self-installed and run in under one hour without the need for a vulcanising team or specialist service crew. The factory-prepared joint ensures the joint retains the same tensile strength as the belt itself, making ZIP CLIP a more permanent solution than DIY clips. Once tted, Smiley Monroe has said it can be run inde nitely. The fact ZIP CLIP can be tted without removing the conveyor and from ground level makes it a safe installation option on-site, reducing not only downtime but health and safety concerns.
Kenny Harris, superintendent at Kentuckybased limestone quarry Gaddie Shamrock, said ZIP CLIP has slashed downtime from 24–36 hours down to three or less.
Smiley Monroe Inc vice president Moran Walker.
Images: Smiley Monroe Inc
Smiley Monroe Inc is investing heavily in its US operations.
“ZIP CLIP has cut our downtime a lot. In the old days, we relied on a service team coming to vulcanise the belt,” he said.
“Because ZIP CLIP is supplied ready to go with the joint already prepared, it’s a much safer, faster option for us to get back up and running.
“It saves us thousands of dollars in service bills and lost production.”
Smiley Monroe offers ZIP CLIP on a 24-hour turnaround with expedited delivery options, which is proving to be a key selling point in reducing customer downtime, especially in the case of a breakdown scenario.
Smiley Monroe Inc is celebrating five years of US operations.
A
material world
Located just one hour north of Nashville and within a day’s drive of over 70 per cent of the US population, Smiley Monroe’s Franklin facility is well situated to serve America’s materials handling industry.
While shorter lead times and local support have led to growth in the market, the company’s global footprint and extensive supply chain are proving to be a competitive advantage.
“Our extensive stock holding across three global sites alongside our highly developed supply chain means we can offer our customers a large range of material options, including a wide range of chevron or cleated belt pro les,” Walker said.
“We work closely with our customers to help choose the correct material speci cation and pro le for their application, ensuring they achieve maximum conveyor uptime, belt lifespan and material throughput.”
That advantage extends to exible supply options, from off-the-shelf belt rolls and readyto- t ZIP CLIP replacements to customised, hot vulcanised endless belts. These are all manufactured to strict quality standards and supported by Smiley Monroe’s engineering and research, and development teams.
Customers with extreme conveying applications are also bene tting from Smiley Monroe’s premium ToughFlex belt range, which the company said last up to four times longer than standard EP-multiply belts. This heavyduty option is available in a range of widths and pro les and can be customised to suit the customer’s needs. Reinforced with heavy-duty (cut- and impact-resistant) top covers and an additional binder warp, ToughFlex offers a metal-free alternative to RipStop belting.
What’s next?
With a growing customer base, Smiley Monroe will seek to expand its US operations with an eye on new locations and sectors.
ZIP CLIP is already becoming the go-to belt option for tricky waste recycling applications and has found a niche in construction and demolition waste. As the facility grows, Smiley Monroe will also seek to emulate the computer numerical control (CNC) capabilities of its Northern Ireland and India sites, bringing a local supply of cut rubber and plastic parts to the US market. The company is committed to recruiting new talent to deliver the expertise, support and customer-centric service on which its global reputation has been built. AB
Freehaven Materials’ 150tph CDE waste recycling plant in Brookhaven is turning resources that would have been discarded as waste into valuable in-spec sand and aggregates.
Transforming waste into opportunity
CDE showcased its abilities to transform waste materials into valuable revenue at an open house event in Brookhaven.
As available land ll capacity continues to diminish across Long Island, CDE and Freehaven Materials joined forces to deliver a waste recycling plant that can repurpose excavated waste material.
Unveiled at a recent open house event, the 150-tonnes-per-hour (tph) waste recycling plant in Brookhaven is turning resources that would have been discarded into valuable in-spec sand and aggregates.
Attended by more than 160 guests from across the states of New York, New Jersey, Massachusetts, Connecticut and Maryland, and as far as Montreal, the event included a live demonstration of the technology in action and showcased the nal materials produced by the plant, which are crucial to major construction projects in the area.
The majority of sand produced at the facility is used for concrete production in New York City, while much of the aggregate is needed to support major infrastructure projects, such as the Sunrise Wind project and major highway projects.
To mark the occasion, Suffolk County executive Edward Romaine cut the ribbon at the open house event.
“This is a great day for people who can turn dirt into clean sand,” Romaine said. “Sand is needed for construction, so we need this (event) now more than ever. I wish everyone involved tremendous success with this project to make money, help the environment and let’s rebuild America.”
In Long Island, and indeed across the wider state of New York, there is an increased focus on recycling construction and demolition
(C&D) waste and repurposing it in some of the many local infrastructure projects, such as roads, highways and bridges.
With the reduced availability of land lls, topped with the increasing need for in-spec sand and aggregates, the New York Senate is considering a bill that will require contractors in certain large cities to recycle 50 per cent of the waste generated on construction and demolition sites, af rming the state’s dedication to reducing waste and repurposing valuable materials.
Freehaven Materials managing partner Tom Hayes said this plant is allowing them to create materials for critical infrastructure.
“Across Long Island, we’re seeing more land ll sites close, which was limiting the options for how we got rid of this material,” he said. “And that’s where CDE came along.
“We seized the opportunity to transform dirt into dollars, not only giving us a competitive advantage for full-scope heavy civil projects, but in turn contributing
to the circular economy and preserving natural resources.
“We are so proud of this waste recycling plant, and it was an honour to showcase it to industry representatives at the open house event. We look forward to seeing where our partnership with CDE will take us.”
CDE business development manager Joe Teahl said the event was a great showcase of CDE’s capabilities.
“It was a pleasure to highlight our capabilities at this open house event. With increased demand for sand and aggregates across the region, mixed with high disposal costs and virgin material scarcity, Freehaven Materials realised the value in transforming this C&D waste into a resource,” he said.
“With this sustainable solution, Freehaven Materials is recycling products, without compromising on quality, creating material which is vital for local construction projects. By investing in CDE, they’ve invested in the future.”AB
Freehaven Materials is recycling products without compromising on quality.
CDE and Freehaven Materials joined forces to deliver a waste recycling plant that can repurpose excavated waste material.
Images:
CDE
Astec is a proven manufacturer of crushing and screening equipment.
Technology enhances the rock and road
Astec is taking a holistic approach to supporting its customers in the quarrying and aggregates sectors.
In a promotional video at March’s AGG1/World of Asphalt exhibition in St Louis, Missouri, Astec chief executive of cer and president Jaco van der Merwe said the company’s booth demonstrated a “great combination of products and technology”.
“Astec aims to bring industry-changing solutions to the market,” he said.
“We do that by taking the dumb iron and making it smart with the use of technology, and you will see that [technology] integrated into every piece of equipment that we have on display.”
In his ve-and-a-half-minute AGG1/ World of Asphalt video, van der Merwe also highlighted the importance of the on-show Astec DIGITAL platform.
“With it, we can show our customers exactly where their equipment is, how it's running, what their fuel consumption is, and when they started working,” he said. “Our customers have a lot of assets running, and in one place they can see the performance of their whole eet.
Astec group president of material solutions Michael Norris was another senior executive attending AGG1/World of Asphalt. Speaking to Aggregates Business, Norris said Astec, which has headquarters in Chattanooga, Tennessee, is introducing up to 20 new mobile tracked crushing and screening plants over the next 18 months,
the result of a signi cant research and development program involving machine design and engineering teams based in the US, Northern Ireland and South Africa.
Norris said the quarrying and road construction equipment manufacturer’s all-new plant line-up is part of its comprehensive international growth strategy, and has been in uenced by detailed feedback from customer advocacy groups and decades of high-quality in- eld engineering knowledge.
be
“They will be rst in class when it comes to productivity, reliability, cost of ownership and maintenance,” he said. “Our customer advocacy groups comprise customers from various parts of the world, as well as users of other equipment. We talk about what they like, what they don’t like, what’s great about our machines, what’s not great about them, and pain points.
“Our sales are currently around 70 per cent in North America and 30 per cent internationally. We are looking to make that 50 per cent each, as we see international business as the biggest growth driver for us.”
Norris discussed about the signi cance of the $6.5 million 44,000ft² expansion of its Astec Doogary facility, bringing the total
Astec chief executive o cer and president Jaco van der Merwe.
Astec group president of material solutions Michael Norris.
Astec Omagh, Northern Ireland, footprint to 100,000ft². The extension, completed in 2023, took Astec’s total investment since its acquisition of Telestack, a leading mobile dry bulk material handling solutions company, to over $10 million, with the off-highway equipment manufacturer now employing more than 230 people in Northern Ireland.
“Part of the Doogary facility is warehousing dedicated to parts support for the European region, not just for Astec [crushing and screening] models and Telestack, but the wider Astec offer – our asphalt batching plants, our Peterson wood chippers and grinders, and our Roadtec asphalt paving equipment,” Norris said.
Among the new and latest machines showcased by Astec at AGG-1/World of Asphalt under its ‘From Rock to Road’ branding was the new A50 jaw crusher, which van der Merwe said “combines all the best features from products across the Telsmith, JCI and KPI brands”.
The A50 features several unique safety and maintenance bene ts, according to Astec. A patented cheek-plate design joins the upper and lower cheek plates together, allowing them to be easily released as a single piece from the crushing chamber and replaced.
The jaw chamber is offered with a fully hydraulic toggle set-up, ideal for recycling applications, or a new patented mechanical toggle, well-suited to crushing rock. Both are directly interchangeable. The A50’s new frame features a bolted and keyed design, incorporating an anti-vibration mount and a new bolt-on jaw feed, making it a highly exible unit that can be easily integrated into an existing materials processing site footprint.
Attendees at the co-located exhibition had the opportunity to use Astec’s virtual
reality (VR) headset to walk around the A50 jaw crusher and view all its key features. Astec has said the A50’s ease of maintenance increases uptime, resulting in more dollars in the customer’s pocket.
Norris believes Astec’s global reach provides the company with the ability to withstand prolonged challenging market conditions.
“We can make everything that we make in North America in one of our international facilities, so we’re pretty well-positioned,” he said.
According to Norris, the after-market side of Astec is also being signi cantly enhanced to help deliver the company’s global growth plan. This includes hiring more talented machine designers and engineering technicians in a very competitive market.
“We have a pretty good culture and story to tell that enables us to recruit fairly easily,” he said. “I was with Sandvik for 13 years before joining Astec, and we have quite a lot of people with a lot of experience at the likes
Astec has a presence in many key quarrying and aggregates markets.
of Metso and Terex. We have fun here and are part of something that is growing. Despite tough market times, we have continued to invest, knowing that new models were part of a clear global growth plan. It’s exciting times to be at Astec.”
Astec has plans to focus on its wash plant offering in the future.
“Since I’ve been in my current Astec role for the past 12 months, one of the things I’ve been doing is restructuring internally to allow us to put more focus on washing and our packaging around it,” Norris said. “Over the next 12 to 18 months, you can expect to see us producing more things in this area.
“Recycling is also a very attractive space for us and ts into the narrative of what we want to invest in, both organically and inorganically.”
Norris said Astec remains focused on growth opportunities in the North American market, which produces more than 2.4 billion tonnes a year in crushed stone, construction sand and gravel.
“We talked at the NSSGA legislative session [National Stone, Sand & Gravel Association 2025 Annual Convention] about the need to make the next infrastructure bill more roads-and-bridges-focused,” he said.
“The last infrastructure bill, promoted as the biggest ever, contained a lot of spending around non-traditional infrastructure, like telecommunications and EV [electric vehicle] charging, which is nice but doesn’t do much for aggregate demand. We will be conveying the same message at the next NAPA [National Asphalt Pavement Association] event.
“I think there’s more opportunity for us here in the recycled materials space. I think virgin aggregate demand will remain steady, but the consumption of recycled concrete, asphalt or manufactured sand will grow. The economics will drive this.
“When it’s pro table, the market will grow, and it’s getting to be pro table.” AB
L–R: Astec managing director for Europe Damian Power and Astec group president of material solutions Michael Norris at Hillhead 2022.
Image: Astec
Image: Prime Global Publishing
The big advance led by customers and technology
During a press conference at this year’s AGG-1/World of Asphalt in St Louis, Missouri, Terex Materials Processing’s senior management team discussed plans for two of its newest brands, MAGNA and Marco, in the North American market. Aggregates Business looks at its growing customer support o ering in the key regional market, and the global importance of its expanded digital solutions range.
Terex MP president Kieran Hegarty was busy in the days leading up to March’s AGG1/World of Asphalt visiting the Marco business unit in Spring eld, Missouri.
Terex MP is investing heavily in developing the bulk materials handling conveyor business it acquired in 2023, including its 100,000ft2 factory and of ces on a current 15-acre site in Mount Vernon, just over 30 miles west of Spring eld.
In a notable development, Marco recently unveiled a Missouri-manufactured, 150-foot telescopic conveyor designed for North American customers. Hegarty said this is a new area for Marco, which has predominantly focused on bulk handling solutions for the concrete industry, feeding concrete batching plants.
“We bought Marco knowing we wanted to get into the telescopic conveyor market.
While telescopic conveyors are commonly used in the aggregates industry, many also serve as standalone conveyors, feeding ships and barges,” he said.
“They may be conveying not just aggregates, but fertilisers and other agricultural goods. We will also look to leverage Marco’s strength in the concrete batching segment to widen our customer base for telescopics.
“It’s also a big advantage that the Marco factory is speci cally designed for conveyor manufacturing, including big telescopic conveyors. While we build conveyors at our Northern Ireland and India facilities, you have to break them down and containerise them before shipping to customers, which is less cost-effective.”
Hegarty was joined at Terex MP’s AGG1/ World of Asphalt press conference by Terex president and chief executive of cer Simon
Meester and Terex MP vice president of aggregates Pat Brian.
The exhibition was an ideal showcase for Terex MP’s MAGNA brand, which was launched last year to address the demands of large-scale operations in quarrying, mining, construction and recycling industries.
Under the strapline ‘Made for More’, MAGNA is building on Terex MP’s legacy of high-quality, compact and mid-sized equipment solutions from brands including Powerscreen, Finlay and EvoQuip. With MAGNA’s range of robust, high-capacity machinery, tailored to meet the needs of customers requiring larger output and volumes, the business is further enhancing its offerings.
“MAGNA is starting to get healthy traction,” Hegarty said. “Within the aggregates space, you serve everyone from contractors to small sand and gravel
Terex MP has supplemented its digital customer support by opening a state-ofthe-art parts facility in Louisville, Kentucky.
companies to large quarry companies and multinationals with super quarries. While we have served all these segments over the years, this is the rst time we have designed an offering tailored particularly for larger output customers.
“The industry direction of travel in crushing and screening is towards mobile plants.”
Brian this was partly driven by a shift in consumer preferences.
“The in exion point of where you put in a stationary plant instead of a mobile plant is changing as mobile plant production volumes have got bigger,” he said.
“There’s also a speed element to this, as a customer wanting to put in a stationary plant might have to wait three or four years to get their operating permits. With a MAGNA mobile set-up, they could be producing material in days.”
Hegarty said the MAGNA jaw crusher model on show at the exhibition was an example of how Terex MP was adjusting to customers’ demands.
“Twenty years ago, a mobile plant that could produce 200 tonnes an hour can now produce 1500 tonnes an hour,” he said.
“We have mobile plants that can be split into three parts, like a transformer, enabling it to be transported from site to site and set up and operational in six hours.
“If you’ve invested signi cantly in a stationary crushing and screening plant set-up for your quarry, you need to be in the same place for 20 years to get a decent return on your investment.”
Brian said that while MAGNA has some original models in its range, others, such as horizontal screens, have been adapted from larger Powerscreen and Finlay crushers and screeners. He told Aggregates Business that a comprehensive research and development program will, in time, create a full original MAGNA range line-up.
“It’s a similar approach to what we took with EvoQuip, which drew on the smaller Powerscreen and Finlay plants. We plan to add ve new MAGNA plants to our range over the next three years,” he said.
“MAGNA won’t always t all our traditional dealers, and we need to make sure we have the right distribution strategy.”
Hegarty believes MAGNA will enable Terex MP to expand into new market areas.
“Machines of this size could be for customers producing, say, iron ore in Australia, or mining customers in Africa and Central Asia,” he said. “We don’t typically operate in xed mining markets, but MAGNA plants are well-suited for surface mining operations.
“We will be launching a very large MAGNA mobile screen in the next year or so to match up with the very large capacities that MAGNA crushers can process.”
1: An EvoQuip Cobra 230R impact crusher.
2: Some of Powerscreen’s demo area machines at Hillhead 2024.
3: A Finlay C-1550+ Tracked Cone Crusher at work in a quarry.
Just before AGG1/World of Asphalt, MAGNA signed an agreement with GIPO, the Swiss manufacturer of high-quality mobile crushing and processing plants for the quarry, mining, recycling and non-metallic mineral industries, allowing MAGNA to market, sell and support GIPO tracked impact crushers and roller grizzly screens in selected markets, lling a key product gap for the new Terex MP brand.
“That was a relationship essentially formed at Hillhead [2024 exhibition]. GIPO has an exceptional reputation, primarily in Europe, for producing high-quality, large, tracked impactor crushers,” Brian said.
“MAGNA doesn’t have a tracked impactor crusher of that size, and we noted the massive customer loyalty that GIPO generates. This co-branding enhances our product offer and gives GIPO greater access to the North American market through the Terex MP dealer network.
“While we see North America as a key market for MAGNA, we still expect around half of our business to come from elsewhere.”
Showcased in Nashville
A month after AGG1/World of Asphalt, MAGNA had its rst big open house event in North America in Nashville, Tennessee. With more than 100 attendees, the April event showcased a working demonstration of a full eet of MAGNA equipment by Park City Stone, a Kentucky-based Powerscreen Crushing and Screening customer.
Terex Financial Services supported the acquisition of the impressive line-up, and the event showcased the strategic alignment between customer needs, distributor support, and tailored nancing.
AGG-1/World of Asphalt also saw Terex MP promoting its multi-brand digital solutions, which focus on solving real problems and driving business value for customers.
One of the newest support solutions offered by Terex MP is the use of Terex Connect. This tool allows technicians to ‘virtually view’ on-site issues through live video and interact with augmented reality (AR) annotations, providing faster, more accurate diagnostics without needing to send an engineer on-site. The technology was utilised earlier this year to resolve a complex wiring issue on a machine in Italy from a Terex helpdesk in Northern Ireland, demonstrating the effectiveness of remote support and real-time troubleshooting.
“We are making signi cant investments across our digital portfolio, which are primarily focused on customer support,” Hegarty said.
With more than 15,000 connected assets across 145 countries, the MyTerex Customer Fleet app offers customers mobile access to machine information, noti cations, and performance dashboards. The app also brings users closer to the Terex MP parts team and services.
Ask Terex further strengthens service and support. Launched in fourth quarter of 2024, the multilingual arti cial intelligence (AI) platform is trained on Terex documentation and data and designed to deliver intelligent,
rapid responses to customer and product support inquiries. Ask Terex searches Terex MP equipment manuals and provides solutions to questions in an average of just seven seconds.
Available 24–7 and accessible through the Dealer Portal on a computer or laptop, as well as via a dedicated mobile app, Ask Terex is designed to ensure support is available immediately, wherever customers need it.
Terex distributors can purchase annual subscription licenses to Ask Terex through Terex Parts and Solutions, with options available in bundles of three (ASKTEREX3), ve (ASKTEREX5), 10 (ASKTEREX10) or 15 (ASKTEREX15).
“Ask Terex is multilingual and super quick. Someone in Japan can ask a question in Japanese and receive a rapid response. It works in pretty much any language,” Brian said.
“As well as being a great tool for our dealers and customers, we see this as one of the ways we can monetise our digital offering.
“I don’t think it removes the need for our dealers and customers to have good, strong support from humans, but it’s a great supplementary support. What our dealers say is that it will get customers from rst to second base very quickly. The next step for us is connecting all these digital tools to make the customer experience much simpler.”
Leveraging the Terex MP brand machine telematics is the Terex Connected Dealer Inventory (CDI) system, which uses telemetry data to predict the parts required for upcoming service intervals.
This automated system enables Terex MP distributors to maintain optimal inventory levels, helping to ensure customers receive the correct parts when they need them. The CDI tool is also integrated with a ‘Parts Finder’ that enables distributors to easily locate and request stock across different locations, signi cantly speeding up repairs and minimising downtime.
Other support tools offered by Terex MP brands include the Terex eCommerce platform, which allows customers to order parts while accessing up-to-date parts manuals. Users can search for parts by machine model, serial number or through a visual search, where they can capture or upload an image from their device.
Metropolitan Demolition, a customer of Blue Machinery Southern, was impressed with how Ask Terex technology can help when troubleshooting a crusher issue on-site.
Committed to customers
During the hour-long press conference at AGG1/World of Asphalt, Brian said Terex MP has supplemented its digital customer support by opening a new, state-of-the-art parts facility in Louisville, Kentucky.
Operational since the end of 2024, the 134,000ft2 warehouse has consolidated parts for Terex MP brands under one roof, thereby improving operational ef ciency and reducing transportation costs. Equipped with the latest technology, including an automated parts-picking system and a parts photo booth, the facility adheres to the best practices established at the Terex Global Parts Distribution Centre in Northern Ireland, ensuring improved parts availability and quicker response times for customers across North America.
“It’s replicating the Global Parts Distribution Centre in Northern Ireland, but three times the size,” Brian said.
“It’s a key part of how we’re illustrating –not just telling – our support for customers in North America.”
Hegarty said global market trading trends have a major correlation with Terex’s business.
“It’s been tough, particularly in Europe. You’ve some of the biggest country markets, such as Germany, the UK and France, that have seen reduced demand,” he said.
“A signi cant correlation for our business is with general construction, so the substantial infrastructure and factory spending in the US over the last two years has been particularly bene cial to us in this market. Whatever happens under President Trump, America still needs money spent on its infrastructure.”
Brian said Terex MP has an important role to play in supporting the quarrying and aggregates sector.
“You look around in St Louis, the city we’re in, and it still needs aggregates to support its modernisation,” he said. “All cities in Western economies have highways and buildings that are crumbling. We always need to rebuild, and Terex is well placed to bene t and offer real value to its customers.” AB
Battery-electric current a airs
Volvo Construction Equipment is delivering on quarrying-suited machine productivity and e ciency, alternative power solutions, and company- and customer-based sustainability.
President Melker Jernberg spoke to Aggregates Business about the Swedish o -highway equipment manufacturer’s evolution.
Melker Jernberg in front of the Volvo A30 Electric articulated hauler unveiled at bauma 2025.
Melker Jernberg was upbeat as he spoke to Aggregates Business on the afternoon of the second day of bauma 2025 in Munich, Germany, in April. At a well-attended exhibition press conference a couple of hours earlier, the Volvo Construction Equipment (CE) president had delighted in counting down to pressing a button, triggering the fall of a giant curtain to unveil the A30 Electric, one of the world’s rst serial-production battery-electric articulated haulers of its size class. The groundbreaking machine will reach selected European customers in 2026 alongside the new A40 Electric articulated hauler.
Jernberg said the A30 Electric demonstrates Volvo CE’s commitment to sustainable change, further shown by the major off-highway machinery manufacturer’s rst-ever all-electric bauma lineup. The A30 Electric and A40 Electric are ideal machines for quarry and aggregates production sites, and Jernberg is quick to respond when asked how important those customers are to Volvo CE.
“Quarry and aggregates is one of our prime segments. I see more and more a drive towards making quarries more ef cient, not just in the machines used but in the hardware and software used on-site, and in the [after-market] services and digitalised support offered [by equipment manufacturers and their dealer distributors],” he told Aggregates Business
“Each quarry is a company run by a manager and their team. If we see a quarry manager, we know that the quarry, like every quarry, won’t just have Volvo CE machines, so we need to work out how we can help that quarry manager run their quarry more ef ciently.”
Volvo CE enjoyed a busy rst quarter of this year with the rollout of its new-generation articulated haulers, including introducing a brand new A50, alongside several local launches of the latest range of excavators in Asian markets. Delivering on its digitalisation transformation, Volvo CE also partnered with software company Unicontrol to integrate its 3D machine control technology into Volvo excavators.
Another recent range launch was a new generation of wheeled loaders, designed for improved productivity, operator comfort, and safety.
Volvo CE has been at the forefront of wheeled loader technology for 70 years. These innovative new-generation machines are engineered to enhance productivity and ef ciency across various applications, including rehandling, material handling, quarrying, waste and recycling, and earthmoving.
The ve revamped models are the L150, L180, L200 High Lift, L220, and L260. In addition to a fresh design, these hardworking and versatile machines now have even faster cycle times, strong performance, and enhanced operator comfort. They are packed with intelligent solutions designed to help customers maximise productivity and pro tability.
Volvo CE unveiled 80 new or nextgeneration machines in 2024 and the rst quarter of 2025, 40 per cent of its 200-strong product line-up.
“We have launched new excavators, wheeled loaders and haulers,” Jernberg said. “Our dealer distributors can sell one
Jernberg gets a close-up look at Volvo CE battery-electric machines in action.
The new Volvo L220 wheeled loader is said to o er faster cycle times, optimised attachments and the intelligent Load Assist suite of apps.
new Volvo CE machine and then be able to offer other new ones to the same customer. We can meet every quarry and aggregates customer’s needs with our machines and service solutions.”
While Volvo CE has continued to innovate by rolling out new products and services, a market decline affected its rstquarter 2025 earnings.
Global sales dropped eight per cent in the rst quarter of the year, compared to the high levels of the rst quarter in 2024. South America and Asia saw a growth in their markets, but the company said the shortfall was driven by lower volumes in Europe and North America.
Volvo CE managed to maintain a steady performance during this period, while still investing in new technologies for its customers. Though machine sales were down for the rst quarter, the company saw a rise in service sales, which it said demonstrates increasing relevance of service solutions, and an overall increase in orders and deliveries.
Jernberg, who has been Volvo CE president since January 2018, discussed the rst-quarter 2025 trading update.
“As a global company, we are understandably affected by these turbulent times, but we have shown resilience in the face of uncertainty and maintained a solid performance today, while moving in the right direction for tomorrow,” he said.
“Our industry’s transformation may be slower than we would like. However, our commitment remains strong as we continue to invest in building a better world for all, as demonstrated by our pioneering 100 per cent zero-emission line-up at bauma.”
In rst quarter of 2025, Volvo CE’s net sales decreased by eight per cent to SEK 21,117 million (SEK 22,877 million in rst quarter of 2024). When adjusted for currency movements, net sales of machines decreased by 10 per cent, and service sales increased by two per cent.
Compared with rst quarter of 2024, Volvo CE said that a negative brand, market and product mix was partly offset by increased volumes, lower material costs and an improved service business.
Melker
Images:
For the rst quarter, Volvo CE said that the total machine market was at compared to the previous year, with Asia, including China, and South America growing while Europe and North America contracted. Compared to the historically high levels of the rst quarter of 2024, Europe declined 18 per cent, as customer demand remained saturated. North America dropped 14 per cent due to what Volvo CE said was “ eet repositioning and market outlook uncertainty”.
Brazil mainly drove growth in South America (12 per cent) and improved business sentiment in Argentina and Chile. The Chinese market improved by 42 per cent based on governmental policies to stimulate the real estate and construction segments. Outside of China, the market was up slightly (one per cent) in Asia, thanks to the growth in Indonesia and South Korea.
The challenging rst quarter of 2025 for the global off-highway equipment market continued the previous year’s trading environment in several major regions.
“In Europe, 2024 was a tough year. I think the quarry and aggregates segment was down about 25 to 30 per cent,” Jernberg said.
During Volvo CE’s bauma 2025 press conference, Jernberg was joined on stage by Volvo Trucks president Roger Alm and Volvo Penta president Anna Müller. Volvo CE head of corporate communications Bill Law asked the trio whether battery-electric was the “silver bullet” that would one day power all off-highway machinery. Jernberg was clear in his response.
“The answer is clearly, ‘no’,” he said.
“The [sustainability] transformation is underway; unfortunately, it is slower than expected and needed, but we have decided to lead the way regarding sustainable transport, construction and infrastructure solutions.
“To make change happen, we need different technology solutions.”
Jernberg said Volvo CE is committed to investing in alternative machine power solutions.
“We are investing heavily in a number of technology tracts, like battery-electric solutions, including charging. We continue to invest heavily in ICE [internal combustion engine] technology, including optimising ICEs for renewable fuels, as we believe it will continue to play a really big role in our industry.
“We understand all customers are going at different speeds in their transformation journey and we have sustainable solution wherever they are. We are also investing heavily in hydrogen fuel cell technology.”
In April 2024, Aggregates Business reported on the Volvo HX04, the world’s rst prototype hydrogen fuel cell articulated
hauler, being tested in various customer applications as part of Volvo CE’s research and development around hydrogen technology.
The Volvo HX04 has a 20-tonne payload, while its four high-pressure hydrogen tanks (at 700 bars) allow a working time of around four hours. Power to the wheels comes from three electric motors mounted in each of the three axles, which means the truck does away with the need for a torque converter and driveshafts. Instead of a conventional driveline, heavily protected cables run through the articulation joint.
The Volvo HX04 prototype was born out of a research project between 2018 and 2022 funded by FFI, a national collaboration between the Swedish Innovation Agency VINNOVA, the Swedish Energy Agency and the Swedish Transport Administration to support strategic research, innovation and development of sustainable vehicles.
The new A30 Electric articulated hauler is an example of Volvo CE’s commitment to sustainable change.
Volvo CE’s new generation wheeled loaders were unveiled earlier this year.
Much of the development and construction of the six-wheeled Volvo HX04 took place at Volvo CE’s facilities in Braås, Sweden.
Engineers at the Eskilstuna Technology Centre in Sweden contributed software development and knowledge from their fuel cell test laboratory for the project. The results of the Volvo HX04 test phase were expected to generate important information about the possibilities offered by hydrogen and fuel cells as Volvo CE continues its research for future product development programmes.
Jernberg expects the rst hydrogenfuel-cell-powered off-highway machines to appear on job sites by the end of this decade.
“While there is an infrastructure question and issue around [on-highway] hydrogen fuel cell-powered cars and trucks, if we believe we have a good [hydrogen fuel cellpowered, off-highway machine] solution on-site, the supporting infrastructure will be less of an issue,” he said.
“We could do it now from a technology perspective, but the demand from the customer has to be there.”
Diesel-powered loaders and haulers for quarrying and aggregate sector applications remain popular in many regional markets. Jernberg shared his message to customers who prefer them to electric or other alternative-power-based models.
“Buy them,” he said. “We appreciate some countries are at different stages of their development. I will say, we have a task as humans to hand over the planet. We think what we do around electric machines and sustainability will bene t our business over time. We want to take the lead in this area.
“A potential customer talking to one of our dealer distributors may want to buy a new haulier but has not considered an electric version. If they haven’t done a TCO [total cost of ownership] calculation, we will urge them to try an A40 Electric, for instance, and do that calculation.
“Even if a customer wants a combustion engine-powered machine, it doesn’t mean it must be dirty.”
Increased process automation is another big topic in the quarrying industry, and it has been a key area of Volvo CE and wider Volvo Group research and development in recent years.
Volvo CE partnered with Skanska in 2018 to create and run the Vikan Kross Electric Quarry near Gothenburg, Sweden. A key part of the initial 10-week trial to enhance the goal of carbon emission-free quarrying was using eight Volvo HX-02 autonomous, battery-electric load carriers to transport material from the primary mobile crusher to the secondary static crusher.
Jernberg said the successful Vikan Kross Electric Quarry project was the catalyst for
creating a new Volvo Group business, Volvo Autonomous Solutions. Volvo Autonomous Solutions (VAS) and Holcim Switzerland partnered in 2021 to test and develop the use of autonomous electric haulers in a limestone quarry. The two companies emphasised their dedication to seeking safe, ef cient, innovative, and sustainable infrastructure and transport solutions.
“VAS is now testing long-distance, on-highway hub-to-hub driverless trucks in Texas. This is a very interesting development,” Jernberg said.
Given the company’s ongoing product development work and commitment to sustainability, which includes using low-carbon emission steel for serial production of all articulated hauliers built in its Braås facility, Volvo CE is one big and very interesting development. AB
Volvo CE president Melker Jernberg said challenging market conditions have not stopped the manufacturer from continuing to innovate by rolling out new products and services.
A Volvo EC260 crawler excavator is designed for hard work in demanding environments.
Awards go to the next level
The Next Level Awards program for the CONEXPO-CON/AGG 2026 show is set to include two new categories.
CONEXPO-CON/AGG will unveil a suite of new awards as part of its Next Level Awards program for the 2026 show.
The major North American construction trade show will bring back the awards program once again after it debuted in 2023, when Holcim won the Contractors’ Choice Award for its ECOPact Low-Carbon Concrete.
The Next Level Awards program will include two new categories – equipment and technology – for the rst time when the show returns to Las Vegas next year.
“This expansion of the Next Level Awards program exempli es the commitment of CONEXPO-CON/AGG to advance the construction industry by elevating and celebrating its groundbreaking innovations that have an enormous impact on how we build our world,” CONEXPO-CON/AGG show director Dana Wuesthoff said.
“By highlighting the most inventive products, services and technologies, we not only honour the pioneers driving progress but also inspire the entire industry to reach new heights.”
Award nominations will be open from August 19 until December 1 with a panel of industry experts tasked with determining the 10 nalists in each category. CONEXPOCON/AGG attendees can then vote for their favourites in each category throughout the show from March 3 2026, with the winners
unveiled during the ‘Ground Breakers’ keynote stage on March 6. The panel of experts will be announced at a later date.
All award nalists will be showcased in CONEXPO-CON/AGG press releases, social media and other relevant channels during the show. More information on eligibility, application fees, criteria, and the application portal can be accessed via the CONEXPOCON/AGG website.
DESIGN ON EXHIBITION
The Next Level Awards program is not the only event getting a facelift, with a new award design award set to debut in 2026.
The CONEXPO/CON-AGG 2026 Exhibit Design Awards, managed by EXHIBITOR magazine, is set to be awarded for the rst time next year. The award is focused on recognising exhibitors for delivering “exceptional booth design”.
All CONEXPO/CON-AGG 2026 show exhibits will automatically be added to the award and categorised by size. EXHIBITOR magazine staff will be in charge of the rst round of impartial judging and select 10 nalists in each category. A panel of designers and marketers will later judge the winners of each category, as well as an ‘Editor’s Choice’ award.
Winners will receive a trophy and a scholarship to attend EXHIBITORLIVE 2026. They will be announced on the Ground Breakers Stage, alongside the
CONEXPO-CON/AGG will return to Las Vegas in 2026.
winners of the Next Level Awards program, on March 6.
“We’re delighted to partner with CONEXPO-CON/AGG to lead the CONEXPO/ CON-AGG 2026 Exhibit Design Awards,” EXHIBITOR magazine editor Emily Olson said.
“For more than 30 years, EXHIBITOR has recognised compelling and effective trade show design and working with an event that prioritises innovation in exhibit and experiential design is a natural t. Our editorial team and panel of expert judges are eager to see the creativity CONEXPO-CON/ AGG participants will unveil in 2026.”
ABOUT THE SHOW
Held every three years, CONEXPO-CON/AGG has become a “must-attend” industry event. The showcase includes the latest equipment, products, services and technologies for the construction industry and show attendees.
CONEXPO-CON/AGG is owned in partnership with National Ready Mixed Concrete Association (NRMCA), the National Stone, Sand and Gravel Association (NSSGA) and the Association of Equipment Manufacturers (AEM), and managed by AEM. The AEM has been a part of the industry for more than 125 years and serves more than 1100 members and companies across sectors including quarrying, aggregates, mining and construction. AEM provides advocacy, market intelligence and collaboration to support the interests of equipment manufacturers. AB
As the only national quarrying publication and the official journal of the Institute of Quarrying Australia, you’ll always be up to date with the latest developments in industry news, technology and events with Quarry Magazine.
It’s quick and easy to subscribe to our monthly print issues, our annual Suppliers Directory and our weekly eNewsletter. Don’t miss out!
Conveyor vibrancy
It’s a vibrant global market for conveyors serving customers in aggregates and other building materials handling industries.
Telestack has supplied two mobile shiploading systems to DEME, one of the world’s leading marine engineering and offshore energy companies, as part of the Coastal Virginia Offshore Wind (CVOW) project, a landmark initiative in the US’ renewable energy sector.
As the largest offshore wind project in the US, CVOW represents a pivotal step toward clean energy and reducing carbon emissions, with Telestack’s innovative shiploading equipment playing a vital part in its success.
CVOW, developed by Dominion Energy, is designed to deliver 2.6 gigawatts (GW) of renewable energy, enough to power approximately 660,000 homes at peak output. The project involves the construction of 176 wind turbines, three offshore sub-stations, and undersea cables, with onshore infrastructure to channel renewable energy to the grid.
Telestack’s two mobile shiploading systems have integrated into the material handling element of the project, helping to ensure the ef cient loading of large-grade armour rock into exible fall pipe vessels (FFPV).
The company’s shiploading equipment is operating in Bayside, Canada, where it has supplied two AP 1500 D3 wheel-mounted apron steel feeders and two TB52 (170-foot) radial telescopic shiploaders for loading rock material onto DEME’s specialised rock installation vessels at a high loading rate.
The Telestack system included a range of technical features and bene ts that were vital for the long-term handling of these rock grades. The AP 1500 feeders included a heavy-duty steel apron chain, complete with high-grade cast steel ights and bearings, for large rock applications. The feeder allows wheeled loaders to be fed from over three sides, providing ultimate exibility and increased tonnage. The integrated variable speed drive on the feeder is designed to ensure a controlled ow of material to the TB52 Shiploader, key for the large rock. The feeder features a wheel-mounted design,
allowing the operator to move the unit via tow hitch around the quayside as required, aiding the system’s mobility.
The feeder then discharges into the TB52 Radial Telescopic, which also features a number of innovative features, designed to meet the challenges of handling these material grades effectively. The 52m telescopic boom conveyor can load the largest FFPVs, including the DEME’s
Telestack has supplied two mobile shiploading systems to DEME as part of the Coastal Virginia O shore Wind project.
Telestack has installed a TS52 radial stockpiling conveyor for MIBAU Stema
Yellowstone, which is currently the largest FFPV in the world with a 37,000-tonne capacity and free-board/draft height of more than 14m.
The design of the radial and telescopic features enables the operator to place the material easily within the rock hold. At ows the same time, minimising the work required for the vessel’s excavator to move the material within the hold, ultimately increasing the tonnage rate of the entire operation.
The TB52s are tracked, mounted units, which allows them to move off the site when not required, easing their use on multi-cargo berths and jetties. The machines include heavy-duty rollers, belting and skirting, complete with anti-roll-back features to handle large rocks.
The rollers are spaced 600mm apart to minimise the ‘bounce’ of the material when the units stop in operation. This material is further controlled by the variable speed drive on the shiploaders, which works in conjunction with the feeder to ensure full operational control in all scenarios.
This contract has helped to demonstrate Telestack as among the leaders in mobile bulk material handling, largely due to its experience and ability to design and manufacture products that meet the speci c demands of such an instrumental project.
The company’s shiploading solutions are engineered for high throughput, operational ef ciency and exibility achieved through mobility.
“Telestack has a huge portfolio of international projects that demonstrate our expertise,” Telestack international sales manager Carl Donnelly said.
“Our team is experienced in high-pro le projects and values the pre-engineering
stage, which allows the solution to develop through true collaboration, listening to the needs of the operation and leveraging decades of experience.
“This process isn’t just one meeting – it takes time, patience and partnerships, which we pride ourselves on.”
Designed for the toughest applications, Telestack’s heavy-duty equipment is engineered to handle the most demanding materials with durability and ef ciency. Built with reinforced structures and mine-spec componentry, its shiploading solutions help to ensure performance regardless of the application.
The high-capacity loading ability of the Telestack solutions enables the rapid transfer of rock materials, minimising turnaround times for the FFPV. They also assist in delivering to vessels accurately and in compliance with environmental regulations.
Mobile shiploading can signi cantly enhance the operational performance and productivity of a port by offering greater exibility, ef ciency and cost savings compared. These mobile units enable ports to quickly adapt to different vessel sizes and cargo types, thereby reducing vessel turnaround times and increasing throughput. By eliminating the need for extensive infrastructure modi cations, mobile shiploaders can minimise capital expenditures while still providing highcapacity loading rates.
Rapid deployment helps revenue stream begin to ow almost immediately. Unlike
systems that experience downtime due to empty return cycles, mobile solutions enable continuous loading, maximising throughput while reducing operating costs. Designed for simplicity, these machines require minimal training, are easy to maintain, and eliminate complex electrical systems, allowing smooth, uninterrupted operations.
By embracing mobile solutions, companies like DEME and others within the offshore industry can unlock ef ciency, safety, and environmental bene ts in handling their offshore rock.
The CVOW project highlights the crucial role of partnerships and innovative solutions in advancing renewable energy.
Telestack said it is honoured to have collaborated with DEME to devise this shiploading system for a groundbreaking endeavour, which will not only bolster renewable energy capacity but potentially inspire con dence in offshore wind as a reliable and sustainable energy source.
Strategic collaboration
Telestack has successfully installed a TS52 radial stockpiling conveyor for MIBAU Stema UK. This strategic collaboration, facilitated by Telestack’s valued UK ports partner Cooper Specialised Handling, provides a key player in the European aggregates and shipping sector with an ef cient and exible material handling solution.
The Telestack TS52 radial telescopic conveyor is deployed at MIBAU Stema UK’s Sheerness Port terminal.
Image:
Telestack
MIBAU Stema plays a crucial role in supplying aggregates from Norwegian quarries for various applications, including the asphalt, construction, and concrete industries. With an annual production exceeding 20 million tonnes of aggregate, MIBAU Stema ef ciently delivers materials across terminals located around the North Sea and Baltic regions, utilising a eet of self-discharging vessels for swift and seamless supply from quarry to customer.
“We are very happy to have worked with Telestack and Cooper Specialised handling on this high-capacity system from our self-discharge vessels,” MIBAU Stema UK managing director Martin Johansen said.
“The reliable operation of this system is critical to our business, so we had to ensure we had a proven and robust design, which we have received from Telestack and Cooper.
“This is the second high-capacity system we have received from Telestack, and we are happy to work with professional and customer-focused companies such as Telestack and Cooper Specialised Handling.”
The high-speci cation Telestack TS52 radial telescopic conveyor is deployed at MIBAU Stema’s Sheerness Port terminal in the UK where it is designed to enhance the ef cient stockpiling and transfer of the high-volume aggregate directly from the selfdischarge vessel, integrating with discharge process and operation.
The machine offers a versatile and costeffective alternative to handling material from self-discharge vessels, which is typically done via wheel loaders, excavators and material handlers. The fact it takes many of these types of units working simultaneously to handle this tonnage via traditional methods can add signi cant costs to the process and also increase safety concerns due to traf c and multiple movements in the discharge area.
seamlessly integrate with their self-discharging vessels. The ability of our units to handle 2500plus [tonnes per hour] on a consistent basis is a testament to our design, manufacturing, quality and installation and commissioning teams at Telestack.
“It’s fantastic to witness our conveyor technology providing such a signi cant impact on their productivity and operational ow. We look forward to seeing MIBAU Stema reap the bene ts of this investment for years to come.”
The TS52 Stacker boasts a 52m unit, achieving output in excess of 2500 tonnes per hour with its 1400mm (55 inches) wide belt. The unit can discharge material up to 18m (60 feet) and ensures over 100,000 tonnes of aggregates can be stacked from a single position. The unit’s radial and telescopic features also allow for the separation of materials into individual storage bays, depending on the differing grades of materials.
The system also includes variable speed control (VSD) for exibility in operation, along with dual access walkways for maintenance, lights for nighttime operation, radio remote control for all functions, and a specialised 250-micron marine-grade paint nish for operation in the corrosive port environment.
“This is a landmark supply for our business, both in scale and in customer signi cance. MIBAU Stema is a highly respected name in the industry, known for operational excellence and high-volume throughput,” Cooper Specialised Handling sales director Chris Barnes said.
“Being selected to support their UK operations with a Telestack solution is a strong endorsement of our technical capability and our ongoing commitment to delivering engineered solutions for the bulk handling sector.”
Stacks to offer
ProStack, a leading provider of
These new models offer a shorter conveyor length than the existing ProStack range, delivering greater choice without compromising on performance.
The latest additions include the TC 50, TC 60 and TR 60, tracked conveyors measuring 15m (50 feet) and 18m(60 feet), including a radial option. These models are engineered for ef cient stockpiling and are ideal for operations where space, mobility or budget constraints are key considerations.
“This new range allows us to ll a gap in our portfolio with conveyors that are better suited to smaller-scale operations,” ProStack business line director Neil Robinson said.
“They’re compact, competitively priced, and tailored to meet the needs of a wider customer base.”
The new conveyors complement the broader ProStack line-up, which includes tracked feeders, bulk reception feeders, port hoppers, and telescopic conveyors. With this launch, ProStack continues to expand its offering to meet evolving customer demands.
The new range is available globally through ProStack’s distribution network.
“We are incredibly proud to see the Telestack TS52 radial telescopic conveyor successfully commissioned at MIBAU Stema Sheerness terminal. This project truly exempli es the power of collaboration, working closely with our esteemed UK Ports partner, Cooper Specialised Handling, to deliver a highly effective solution for a key player in the UK and European aggregates sector,” Telestack international sales manager Carl Donnelly said.
bulk material handling solutions, has unveiled a new range of tracked conveyors speci cally designed for small-tomedium-sized operations.
Stema’s high-volume operations, offering the exibility and ef ciency they need to
Preventing fugitive material
Most conveyors experience some degree of material loss due to spillage, leakage, dust and carryback, collectively known as fugitive materials. This loss can range from three per cent in poorly operated and maintained systems to less than 0.1 per cent in world-class operations, according to Martin Engineering president emeritus R. Todd Swinderman.
“Although fugitive materials cannot be completely eliminated from bulk material handling conveyors, the issue can be effectively managed, leading to cleaner, safer and more productive operations,” Swinderman said.
“The symptoms of a failure to control fugitive materials include unplanned downtime, excessive cleaning costs, premature equipment failure, regulatory violations and safety incidents. Addressing these symptoms with workable, long-term solutions will enhance performance, housekeeping and safety, and boost pro tability.”
Swinderman said the location and particle sizes of the accumulations indicate
A ProStack TC60 tracked conveyor.
R. Todd Swinderman.
Image: Martin Engineering
the nature of fugitive material problems from any conveyor. Fugitive materials are generally categorised into spillage, leakage, dust and carryback.
“Spillage escapes the belt and collects under the conveyor in both the loading and discharge zones. Piles of spillage accumulate rapidly and occur due to overloaded belts, mis-tracking, and insuf ciently sealed loading and discharge zones. This is best remedied with a skirtboard liner. A wear liner and a canoe liner protect the enclosure from abrasion wear,” Swinderman said.
“Leakage seeps, slowly accumulating in piles. The source of the leakage may not be immediately apparent. Apron-seal dual skirting along the skirt board rides the belt, creating a seal material from dust emissions.
“Dust commonly uses turbulent air to escape at the transfer point. In some studies, working in a dusty environment has been found to reduce worker productivity by as much as 20 per cent. Combustible dust poses re and explosion hazards, as well as health and safety risks. A modular transfer point kit creates a loading zone, a settling zone and a stilling zone, separated by curtains, that control air ow and allow dust to settle back into the material stream.
“Carryback refers to ne material that adheres to the belt surface or gets trapped in imperfections after passing the belt cleaners. At the discharge and along the belt’s return path, this material falls beneath the system, generating dust and accumulating, sometimes encasing the belt and rolling components.”
Swinderman said a common production “upgrade” is to increase the speed of the belt.
Fugitive material problems are roughly proportional to the speed of the conveyor (or tonnage). If the belt speed is doubled, the fugitive material problem and operational costs (clean-up, maintenance, equipment replacement, etc) may also double.
“There’s an old adage: you can’t t ve pounds in a one-pound bag,” Swinderman said. “Careful consideration must be given to capacity calculations, the angle of belt incline, transfer point design, and access for cleaning and maintenance.
“To enhance control of fugitive materials, it is advisable to derate the capacity to 80 to 90 per cent of the theoretical capacity and employ slower belt speeds. Loading at an angle of less than ve degrees and reducing the incline will help minimise ooding and material rollback at the tail.”
Swinderman said designing a longer and taller skirtboard enclosure with dust curtains will help control air ow and dust emissions. Access for cleaning and maintenance can reduce downtime by a third and signi cantly decrease exposure to hazards. If future capacity increases are likely, they should be factored into the initial design.
“A bulk handling operation located near a resort area was facing public outrage due to dust and spillage that were staining the beautiful sandy beaches a deep red. The mill faced daily nes and the risk of closure if the issues were not resolved,” Swinderman said.
“The main focus was on repairing transfer points, replacing idlers and alleviating some of the most signi cant material ow bottlenecks. The bene ts were numerous.
“Spillage decreased from 2.8 per cent to 0.8 per cent of tonnes conveyed, idler life increased by 30 per cent, belt life improved by 25 per cent, and safety incidents and near misses were dramatically reduced,”
Swinderman said. “Operators noticed most complaints shifted to the need to mow grass that grew back underneath the structure.
“However, the most signi cant bene t was the improvement in conveyor availability, enabling a 33 per cent increase in production without expanding the raw material yard’s receiving and storage capacity.”
Swinderman said managing fugitive material is a more economically and operationally sound than merely chalking it up as ‘the cost of doing business’.
“The effect that spillage, dust and carryback have on an operation is a tangible reminder of unnecessary inef ciency,” he said. “By working with experts and installing
1. Example of material spillage.
2. A properly-structured enclosure is slightly elevated, with dust curtains, an external wear liner and adequate skirting.
3. Smiley Monroe said its precision-cut rubber and plastic parts play a vital role in maximising conveyor uptime.
modern solutions to age-old conveyor problems and practising state-of-the-art maintenance, operators can signi cantly improve safety in the workplace and dramatically reduce the cost of operation.”
Cutting it
With over 45 years’ experience in the belt conveying world, Smiley Monroe’s expertise is trusted by the world’s largest manufacturers of mobile and static materials processing equipment. The company, which has its headquarters in Lisburn, Northern Ireland, provides precision-cut rubber and plastic parts that are vital role in maximising conveyor uptime, helping achieve consistent performance and reduced downtime. AB
Smiley Monroe lists ve ways cut rubber and plastic parts work behind the scenes to help keep operations moving seamlessly:
1. Material spillage: Custom-cut rubber skirting seals load zones, preventing material over ow and protecting belt edges from premature wear.
2. Dust seals: Tailored dust seals contain airborne particles, enhancing air quality and safeguarding conveyor components from abrasive dust.
3. Gaskets: Precision-cut rubber gaskets ensure reliable sealing of covers and hatches, dampen vibrations, and resist wear and chemical exposure.
4. Wear liners: Durable wear liners shield high-impact areas like hoppers and chutes from abrasion, reduce material build-up, and minimise operational noise.
5. Ready-to- t kits: Smiley Monroe offers part-numbered, CNC-cut kits that simplify ordering and installation, ensuring consistent quality and t.
Image: Martin Engineering
Image: Smiley Monroe
Image: Martin Engineering
L–R:
Caterpillar senior vice president of global construction and infrastructure
The next 100 years
The next 100 years was the headline theme of a Caterpillar customer panel discussion in front of a large delegations of international construction, quarrying and mining equipment trade press at bauma 2025. Aggregates Business reports on the event.
Caterpillar is marking its 100th anniversary year in 2025, and it was tting that the world’s leading manufacturer of off-highway equipment had such a large presence at bauma 2025, the world’s largest exhibition showcase for construction, quarrying, mining and recycling equipment.
In addition to occupying 9000m² in Hall B6 (more than any other indoor exhibitor) with its new and latest cutting-edge products and linked technology solutions, Caterpillar drew a large crowd to its customer panel discussion at the International Congress Centre Messe München (ICM) on day one.
Caterpillar group president of construction industries segment Tony Fassino and Caterpillar senior vice president of global construction and infrastructure Herwig Peschl set the scene before the main customer panel event, which they co-chaired.
“The last 100 years have been pretty interesting. My grandfather started working at Caterpillar when he was 20 years old; I’m fortunate enough to be here when Caterpillar turns 100 years old. We are built on a legacy of innovation, but more important is the next 100 years,” Fassino said. “We had the product range for connected machines through satellite operations 30 years ago. Fast-forward to today, we’ve got well over a million machines communicating through VisionLink, allowing customers to manage their equipment eet anywhere in the world.
“We have Cat Command now yet, over two decades ago, we had remote control machines, and about two decades ago we had fully electric machines. A lot of the time, the industry isn’t quite ready to take it. From an R&D [research and development] perspective, you’ve always got to be ready.”
Among Caterpillar’s quarrying-suited equipment launched at bauma 2025, held in April in Munich, Germany, were the new 65-tonne-payload Cat 775 off-highway truck, engineered to enable fully autonomous capabilities in the future, and the Cat 395 front shovel (FS) large excavator, Caterpillar’s rst FS con guration for 15 years.
“You will hear about the products, technologies and services that we are integrating to help our customers get the most out of their eet and streamline their operations,” Peschl said at bauma. “You will see an immersive exhibit where our customers will see how we can help them with their most pressing problems.
“Over the last 20 years, we have invested over $30 billion in R&D in our products to help our customers get the most out of them in terms of [lower] fuel burn and technologies.”
Joining Fassino and Peschl on the stage were Lhoist vice president of technical, manufacturing and supply chain for Europe Louis-Florent Sion, Lhoist mining operations manager Dorian Kunert, and EGGERS managing director Leif Nebel.
Founded in 1889 and headquartered in Belgium, Lhoist is a family-owned company and one of the world’s leading producers of lime, dolomite and mineral solutions.
Its products play a key role in daily society’s needs and are essential for various applications that support the energy transition. Lhoist operates in more than 25 countries, employing over 6650 people from more than 70 nationalities. The company has in excess of 135 sites and sells to customers in more than 80 countries across Europe, North America, Latin America, and the AsiaPaci c region.
“Much of our industry is run by multigenerational family businesses, where the children running the businesses today remember their parents or grandparents introducing them to the industry,” Fassino said. “When you think about it, it’s a pretty small world from a construction perspective when you think of the work the likes of these gentlemen do. There’s nobody else who brings the freshwater that we all need, supplies materials to allow us to fertilise the land and produce food and does the mining for raw materials that build our schools, roads and bridges. These folks do that, and it’s a very important part of the story. These are the customers we serve.”
Louis-Florent Sion talked to Aggregates Business about Lhoist’s continuing investment in Cat machines and technologies.
Herwig Peschl and group president of construction industries segment
Tony Fassino at the Caterpillar customer panel event at bauma 2025.
Image: Caterpillar
“Most of our applications are standard load and haul and then jaw crusher processing,” he said. “Our two biggest challenges are safety and cost optimisation.
“When it comes to safety, we have been working on this for many years, focusing on staff training and wellness. We want to take this to the next level and trust that [Caterpillar] technologies are the solution.
“On cost optimisation, when you compare our quarry sites to the average quarry sites in Europe, ours are reasonably big and at each site we tend to extract half a million to one million tonnes a year.
“We aim to optimise costs based on facts and gures, and we look to Cat technologies to help us achieve this. They make access to key machine eet performance data easier and more accessible for each of our quarry managers. It enables them to get the best out of their machines and operator teams.”
EGGERS, a major German company founded by Karl Eggers in Hamburg in 1907, operates across a diverse range of business areas, including earthworks and civil engineering, demolition, environmental technology, explosive ordnance disposal, land ll construction, and road, sewer and pipeline construction.
Since 1991, Karl’s great-grandson Ralf Eggers has been the fourth generation to lead the steadily growing family business. Today, EGGERS employs more than 800 employees from 16 nations.
Available for a wide range of nextgeneration Cat dozers, wheeled loaders and excavators, Cat Command remote control technology is being used in quarry, construction and other industry job sites worldwide. In hazardous materials or unsafe conditions, remote control enables operators to stay at a safe distance from the machine
and its potential dangers. Operators can even work away from the site itself, increasing worker safety while maintaining total control and helping drive bottom-line bene ts.
EGGERS managing director Leif Nebel said the company began exploring the use of remote-control machine operation in 2017 to reduce work-site risk for its employees.
“We got an overview of different market solutions in this area and we talked to Caterpillar about Cat Command, but at the time it was only available in the US,” Nebel said. “We together started to think about how we could bring it to the European region, and we were able to do that.
“It solves numerous problems for us in the highly regulated German market, which has a big focus on safety, as we do as a company.”
Kunert brought a mining perspective to the conversation around the use of Caterpillar work-site technologies.
“Technology implementation can sometimes be challenging, so I see four major ingredients to help overcome that,” he told Aggregates Business
“Firstly, you need very good project preparation. You need key stakeholder involvement. You need the right resources with the proper skills in place. You also need to deploy the latest technologies. In mining, we have a clear roadmap for technology testing, evaluation and implementation.”
Kunert said Lhoist’s mining operations feature regular and transparent communications with workers’ councils, which helps the company quickly implement technological processes.
Cat Command being used to operate a Cat D5 dozer on an EGGERS Group job site.
Image: Caterpillar and EGGERS Group
L–R: Herwig Peschl, Dorian Kunert, Louis-Florent Sion, Leif Nebel and Tony Fassino during the Caterpillar panel discussion.
Image: Caterpillar
“You also need representative machine operators and drivers with enthusiasm for technology to give you feedback and use it to win over hearts and minds,” he said. “This helps build trust around using machine data effectively to improve productivity.”
Nebel said the EGGERS team has embraced the technology.
“The use of Cat Command was, for us, a very big step into the future,” he said.
“Normally, you have a lot of pre-location site surveys to do for sites posing a higher safety risk [the recovery of unexploded ordnance ammunition and other war relics] with employees going around with mine detectors and shovels.
“By using Cat Command, we don’t have to do that. So we can start work earlier and more safely, as no employees are on-site.
The productivity features of VisionLink include a cloud-based platform that gathers and summarises machine telematics and job site data from all of its equipment. Actionable performance data is transmitted to the web platform, allowing users to access it anywhere and anytime via a mobile device, tablet or desktop, on or off the job site.
Kunert said Caterpillar technologies have helped shape Lhoist’s work site and its back of ce functions.
“I mentioned before the importance of having the right resources, and we have got the right people checking the purity of the [machine production] data and recommending ways to get production improvements,” he said.
“We used to have monthly production meetings, but with the productivity features
of VisionLink we can integrate more production data, allowing us to hold weekly meetings via [industrial low-code software] Peakboard to assess performance and results.
“With Caterpillar, we have also developed a tool that provides supervisors and production managers with daily updates on production data, enabling them to act on any issues immediately.
“The next step, which we’ve already tested, is to use a very powerful [application programming interface] to push the data from VisionLink to the tablets in the cabins of the truck drivers.
“All these efforts have led to more cost-effective production and allowed us to assess our costs and develop a competitive advantage.”
Nebel told Aggregates Business that he has seen a similar impact within the business.
“The big change for us is having to look for a new generation of drivers who can use Cat Command and appreciate what VisionLink offers,” he said. “We now have the possibility of a single driver, in effect, stepping from one machine to another from a single Cat Command control station.
“We also have a support team in the back of ce that utilises VisionLink functionality to view machine idle times, which provides us with valuable insights, allowing us to be much more ef cient on-site. We can also look into the heart of the machine if something is identi ed as being wrong.
“These are big steps in making us much more ef cient and a safer company to work at.”
An operator was based on the Caterpillar stand throughout bauma 2025, using Cat Command to operate a machine on a work site many miles from the Munich showground over full working days.
“The operator will be getting their machine to do real work,” Fassino said at the show. “It is not a demonstration, and the operator working the machine will be getting paid. It would be worth taking some time to look at that.”
Kunert said he envisioned off-highway machinery technology evolving over the next 10–20 years.
“It is now normal to have electric-driven mining equipment, and electric drives
The new Cat 395 Front Shovel and Cat 775 o -highway truck side by side at bauma 2025.
Cat VisionLink was showcased at bauma 2025.
will become even more predominant in the mining industry. There will be more disruptive changes with automation technology,” he said.
“I also see an accelerated development of drones, which tends to begin in the military and is then adopted by various industries and impacts our civil world. Having autonomous or manually operated drones can create digital twins of our environment, helping mining equipment, for example, move around autonomously and be operated remotely.”
Nebel shared Kunert’s sentiment regarding the trajectory of the technology within the industry.
“I think the same way [as Kunert],” he said. “I hope to see such advances as soon as possible. We see it in the automotive world, and I think we can use similar automation technologies on our construction sites.”
Fassino said these technological advances present several opportunities to the quarrying and aggregates sector.
“The bottom line is that the products we provide have to offer the lowest cost per tonne and owner-operator cost,” he said. “We have focused heavily on understanding the job site and eliminating waste in processes, including fuel waste, operator motion waste, machine motion waste, and system energy losses.
“One way to limit waste is through the use of autonomous or semi-autonomous functions. Any time a job is performed, if you can eliminate machine motion from that action, you save something.”
“Labour is very hard to nd. Really good labour is very, very hard to nd, so the autonomous or semi-autonomous machine function helps solve part of that. It can also make a good machine operator into a much better one.”
“We are all challenged to work out where AI [arti cial intelligence] ts in our worlds. One of the key ways it ts into our industry is through machine learning, where functions are performed, and AI could be used to present a machine operator with a better and clearer way to do them.”
Peschl said Caterpillar wants to help shape the quarry site of the future through the company’s ability to meet customers’ on-site needs
“We have been active in the [machine] autonomy space for over 20 years. We have applied that knowledge and gained more knowledge,” he said. “We already have Command for Hauling as part of our MineStar suite of technologies, and it’s present throughout the world. We are now applying that technology to meet the speci c needs of the quarry, which are smaller and may not operate 24 hours a day.
“The new Cat 775 truck on the Caterpillar stand at bauma is showcasing our technology around autonomous capabilities. We have planned to introduce Cat 775s with autonomous functions in 2026. It is a 65-tonne unit that will allow quarry customers to apply [autonomous hauling] to their sites.”
Caterpillar has already implemented autonomous hauling for quarry customers with a 90-tonne Cat 777 truck tted with Command for Hauling operating at Luck Stone’s Bull Run Quarry in Chantilly, Virginia, US.
Caterpillar representatives provided details about how alternative fuel or power technologies could be part of the off-highway equipment industry’s long-term future.
“The way we’ve had to answer that is by not picking one, but picking almost all of them,” Fassino said. “You’ll see on the [bauma] show oor some fully-electric machines. But, typically, there will be few customers that will only have one [fuel and power] solution.
“That’s also the case today. You have to spread your research dollars. The energy journey that folks are on and their job sites can be very different. We are looking at engines that burn hydrogen, natural gas, and [fuel] blends.”
Fassino said technology will have its biggest impact in workplace safety. He believes utilising AI-based technology for workforce training will have a signi cant impact on improving industry standards and driving ef ciencies.
“Integrated-technology-based safety tools that improve safety across the whole of the job site will have the biggest impact,” he said. “A simple example of this is a seatbelt monitor. Many incidents have occurred on job sites where machine operators have not been wearing their safety belts. Any way of monitoring and enforcing seat belt use is great. Just like in your car, if a light comes on or a noise goes off while you’re
in the operator’s cabin, reminding you to fasten your seatbelt, that’s a step in the right direction.
“However, only the operator sees or hears that. Integrating a seatbelt monitor into VisionLink would enable an operations manager to track how frequently each machine operator uses their seatbelt. Those managers can spot patterns of seatbelt use over, say, a week or a month. Who keeps forgetting to use their seatbelt, and why? Those operators could then be spoken to and behaviours addressed.”
Sion echoed the sentiment about technology’s capability to support safety and automation.
“We should not be having to tell a machine operator to wear their safety belt, but it can be like this. I like that safetyimproving technology example,“ he said.
“Mining is a big part of our future. We are developing a new mine site in Germany [and] I think the use of autonomous machine systems will be key there, given all the constraints you have when putting a human to work underground.”
Kunert also sees automation technology playing a role in the mining sector.
“Our use of machine automation technologies will continue,” he said.
“We use VisionLink and consistent eetmanagement software. We have RTK-based Leica [Geosystems] visual positioning on our trucks. We have drones and software to measure cut and ll volumes.
“We have also started using passive and active collision control. Active on wheeled loaders, with autonomous emergency braking based on radar detection of rear obstacles, and passive on our trucks, which utilise cameras and LiDAR [light detection and ranging] to differentiate between a person and a vehicle in front.
“We have also begun using a remotecontrolled drill rig, which further enhances employee safety and ef ciency. These technological developments are creating highly skilled and quali ed job pro les, especially in the mining sector, which is leading the way in this area. I will stress that autonomous machines and job sites without people is something I can’t imagine.” AB
The new Cat 775 o -highway truck is engineered to enable future fully autonomous capabilities.
Image:
Caterpillar
The versatility of the hauler
Haulers can come in many di erent sizes, but now they are playing a key role in everything from dust suppression through to fuel savings and sustainability targets in the quarrying and aggregates sector.
Versatility and adaptability are words that can get thrown around when describing machinery in quarrying and aggregates.
But a new venture by Hydex and Hills Machinery has shown why the Rokbak RA30 and RA40 articulated dump trucks (ADTs) embody those traits.
The new joint venture has up tted the Rokbak ADTs with high-performance water tanks, transforming them into serious dustsuppression options for quarries.
The new inclusions include large water tanks (22,712.47L for the RA30 and 34,068.71L for the RA40) and advanced spray and pumping systems with multiple spray bars and nozzles.
Also included is an American-made Elkhart water cannon, which can reach distances in excess of 65m, and operators can adjust the ow rate to suit the application. The rear-mounted electric hose reel, Berkeley hydraulic water pump and optional suction system complete the versatile dust suppression solution.
“This is about using a proven platform to meet a pressing and growing need,” Rokbak director of sales for the Americas Robert Franklin said. “The RA30 and RA40 give
contractors the power, manoeuvrability and durability they need in a base machine. And now, with this adaptation, we’re showing just how far that platform can go.”
The innovation was shaped by industry feedback. Long-time Rokbak dealer Hills Machinery noticed how contractors around North Carolina wanted haulers capable of more than just hauling.
“We work with Rokbak on a daily basis and believe those to be the best two trucks to out t these tanks with,” Hills Machinery and Hydex president Jim Hills said.
“These tanks are serious pieces of equipment in their own right. But what makes them truly effective is the machine underneath – the Rokbak hauler that keeps everything moving and delivers the power, even in the roughest terrain.”
Rokbak has received positive feedback from customers through the real-world demonstrations of its A30 and A40 articulated haulers.
The equipment demonstrations are playing a key role in Rokbak showcasing its solutions in new and emerging markets. These demonstrations enable customers to make an informed decision when it comes to purchasing a new hauler for their eet.
“Demos showcase the best of Rokbak operational features,” Rokbak product manager Scott Pollock said.
“But, most importantly, they allow operators to truly understand how a Rokbak hauler performs where it matters most – on their job site.”
Rokbak provides tailored support around these demonstrations, including operator training and technical guidance. From there, operators and eet managers can test the equipment and verify Rokbak’s claims.
For its part, Rokbak ensures its claims are transparent, veri able and grounded in real-world results, which can be proven in real job-site conditions.
As part of the demonstrations, Rokbak provides customers with the opportunity to experience fully-equipped demo trucks in site conditions. Customers can assess the fuel ef ciency, payload capacity and ease of operation on their own sites in realtime. Rokbak also uses insights from the demonstrations to re ne its approach and better meet customer needs.
The RA30 hauler has been used in a wide range of applications, including quarries, infrastructure developments and commercial construction projects. Customers have
Rokbak
Images: Rokbak
reportedly appreciated the independent front suspension, which comes as standard. The RA40 is a heavier-duty hauler suited to largescale quarry, mine and construction jobs.
This demonstration-based approach also supports customers looking at Rokbak options from an emerging market or region.
“Everything we do is to help customers understand what Rokbak brings to the table,” Pollock said. “It’s about trust, clarity and seeing the difference for yourself.”
Fuelling sustainability
L Lynch Plant Hire has underlined its commitment to sustainability with a major investment in its new articulated dump trucks and dozers.
The investment enabled the UK rental business to equip its new eet additions with the FuelActive clean fuel delivery system. It comes after months of on-site testing to verify the bene ts of FuelActive’s system.
“We had 10 identical ADTs, all doing the same route, being loaded by the same machine, at the same weight. That enabled us to be completely fair,” L Lynch Plant Hire’s head of major projects and innovation James Bardon said.
“We used OEM [original equipment manufacturer] telemetry to compare 960 data points over 5000 operating hours. The machines with the FuelActive system averaged a 3.6 per cent fuel saving. That’s equal to a £9000 [US$11,950] reduction in fuel over a year across the 10 trucks, taking 20 tonnes of CO2 out of the atmosphere.”
“All new ADTs and dozers will have FuelActive installed before they are sent to site. We are also reviewing the installation for excavators and other equipment and expect to install these later this year.”
The UK business estimates it has installed 50 fuel delivery systems so far. The team at L Lynch Plant Hire initially investigated working with FuelActive as a way to negate downtime. Now that the results have proven so successful, it plans to continue adding systems to its rental eet.
“On some projects, for whatever the reason, the fuel has been contaminated with water and the machines now are so sensitive, especially if they are running SCR [selective catalytic reduction]. Any small amount of water can bring that machine to a stop,” Bardon said.
“That leads to downtime for our customer, which is what we are trying to avoid. From the instant that we installed FuelActive, we have never had a case of fuel contamination stopping a machine that is tted with the system from operating.
“However, we also discovered that there was a fuel-saving to be had, as the system is always pulling clean fuel from the tank, allowing the engine to operate more ef ciently, which was an added bonus.
“Sustainability is at the heart of everything we do at Lynch, and we are always striving for marginal gains across the eet. FuelActive has given us the potential to save thousands of pounds for customers and tonnes of CO2
“The beauty of the product is that it works alongside other technologies that we are using to reduce emissions and is very easy to install with a short return on investment.”
Bringing the boom
Develon has unveiled its new parts distribution centre in Belgium, supporting its strategy for the European market.
The company marked the milestone with a ceremony attended by Develon chief executive of cer Seung-Hyun Oh, customers, logistics partners and industry stakeholders.
“The opening of our Belgium PDC [parts distribution centre] represents a critical rst step in our customer- and market-oriented strategy. It is a investment to deliver faster, more stable and more responsive services for our valued European customers,” Oh said.
Develon launched its operations in the European market in 1994. The company also previously operated a parts distribution centre in Germany. The new Belgium facility, located in Boom, features a 24,000m² area and an inventory of 47,000 stock units.
Develon will collaborate with logistics provider Fiege to deliver support to its customer base in the European construction equipment market.
“This achievement is the result of the hard work and dedication of our employees and partners,” Oh said. “We deeply appreciate the trust and support of our European customers, and we will continue to build a better future together based on mutual trust and innovation.” AB
Rokbak haulers have been adapted for dust suppression.
EDGE Innovate’s new SCREENPRO S16 in action.
Priceless precision
Getting aggregate crushing and screening right the first time, every time, is priceless. Aggregates Business looks at some of the new ultra-e cient solutions.
The SCREENPRO S16 is the latest addition to the SCREENPRO range from EDGE Innovate, following the successful launch of the larger SCREENPRO S18 in 2024.
EDGE Innovate has said the new model builds on the performance and robust design of the SCREENPRO S18. The company designed the SCREENPRO S16 to be a more compact solution without compromising on ef ciency or versatility.
Designed to handle feed capacities of up to 600 tonnes per hour (tph), the SCREENPRO S16 is suited to mid-to-large-scale operations, delivering high production rates with precise screening. It features a 14m² screening surface and a wide, oversized discharge conveyor with adjustable angles ranging from 14–20°, helping to ensure high throughput and product quality.
The SCREENPRO S16 features a 4.9x1.5m two-deck screen, equipped with a heavy-duty feed hopper, making it adept at primary and secondary screening across a wide range of materials, including construction debris, aggregates and recycled materials.
The new machine can be equipped with a range of screen media options, including woven mesh, punch plate, nger screens and bofor (grizzly) decks, allowing users to tailor the machine to different feed materials and nal grain sizes.
“During the research phase, we engaged closely with our distribution network to discuss speci cations and the core
requirements for our customers,” EDGE Innovate territory sales manager Steven Conway said.
“I believe we’ve successfully designed and launched the SCREENPRO S16, which we feel is a robust, reliable, ef cient and userfriendly product. It’s also very easy to service, maintain and transport, features that we see as core requirements for any customer in the quarrying and recycling industries.”
To meet the demands of recycling applications, the SCREENPRO S16 can be equipped with over-band magnets and magnetic head drums for the extraction and recovery of ferrous metals.
With a low-level feed hopper, two- or three-way split con guration, hydraulic folding conveyors, and a fully integrated power unit with large service access, the SCREENPRO S16 is engineered for ease of use and maximum operational uptime. The user-friendly control system, featuring sequential start and stop functionality, is designed to enhance performance and safety.
To help ensure minimal downtime, the screenbox features hydraulic lift-up functionality for a quick and ef cient mesh exchange process, supported by full-access walkways on either side of the screen.
The EDGE SCREENPRO S16 also offers added remote functionality for improved operator ef ciency and safety. All major functions on the S16, including tracking, feed conveyor speed adjustment, sequential start-up and hopper jacklegs, can be remotely
operated from a distance of up to 100m or in the comfort of the operator’s cabin.
Powered by either a Caterpillar Tier 4 Final or Stage V engine, the SCREENPRO S16 drive system provides the operator with a reliable, durable and fuel-ef cient screening solution.
In line with EDGE Innovate’s commitment to sustainability, the SCREENPRO S16 and S18 models are available with dual power and electric hybrid drivetrains, enabling emission-free operation.
As the second product in the SCREENPRO range, the S16 offers the same level of reliability and innovation that EDGE Innovate customers have come to expect, now in a more compact form that meets the needs of diverse screening applications.
“EDGE Innovate will continue to widen our product offering through the SCREENPRO range, allowing EDGE to meet the varying applications and budgets of our customers,” Conway said.
“The SCREENPRO S18 and now the newly revealed S16 illustrate our commitment to innovation. Expect to see future editions to this range in 2025 as the EDGE team continues to enhance our SCREENPRO offering.”
MAGNA opus
MAGNA is set to showcase the MT130J mobile jaw crusher at CONEXPO/CON-AGG 2026 in Las Vegas in March.
The largest tracked jaw crusher in the Terex Materials Processing brand’s range, the MT130J has been developed for large-
scale quarry and mining operations. The machine can operate as a standalone primary crusher or be integrated into a mobile or static crushing and screening plant. For easy transportation and movement between locations, the plant can be disassembled and reassembled without requiring on-site heavy crane assistance.
Its electrically-driven power systems can provide signi cant cost advantages and environmental ef ciencies. The large feed width and gape enable the crusher to accept larger and coarser material, reducing the need for hammering of oversized product.
Automatic variable-speed vibrating grizzly feeder (VGF) is designed to ensure continuous choke feeding of the crushing chamber for optimal productivity.
High-powered electric drive allow precise chamber controls and reverse functionality for clearing blockages and assisting in
construction demolition, asphalt and recycling applications. T-Link telematics hardware and software, along with a complimentary seven-year data subscription, are tted and installed as standard.
Ahead of next year’s CONEXPO-CON/ AGG, MAGNA’s business development director Neil McIlwaine spoke to Aggregates Business about the signi cant trends currently shaping the North American market.
“We are seeing a shift across some regions and applications, where customers are looking for higher outputs, with reduced cost per tonne overheads,” he said.
“Customers in this larger segment are looking for trusted, reliable equipment, supported with local knowledge and parts and after-sales support for longer-term projects. In addition to the exibility of fulltracked mobile, customers are also looking for dual-power–hybrid drive concepts for ultimate exibility and reduced production costs with higher operating ef ciencies.”
McIlwaine said notable global cost increases, from building material production to freight, have been keenly felt by MAGNA’s North American customers.
“Clients in North America are also challenged by a reduced talent pipeline and skills in the crushing and screening industry, from plant operators and managers to maintenance and support,” he said. “This puts greater emphasis on the dealer and original equipment manufacturer [OEM] relationship to provide support to the customer, many of whom opt for full service support packages for maintenance at a local level.”
McIlwaine said MAGNA is already identifying key markets for growth potential.
“We see customers in particular industries and markets opting for longerterm solution providers for their operations, from plant selection in this larger segment to assured parts and after-sales support services,” he said.
“The MAGNA range offers the broadest choice in the larger track mobile segment
compared to its competitors, encompassing crushing, screening and conveying products – from traditional diesel-hydraulic to hybrid and full-electric variants. The current product line-up can be con gured for aggregate producers requiring [more than] 1000tph “Our range is also appealing to the mining industry, given the increased production, exibility and robustness of the products.”
McIlwaine provided Aggregates Business with insight into MAGNA’s biggest priorities over the next year.
“Our key priority is to appoint distributors in strategically identi ed regions to market, sell and support the MAGNA product line,” he said. “In alignment with this strategy, we are also working hard to develop and tailor solutions for end-users seeking higher production rates, improved operational ef ciency and reduced operating costs.
“All MAGNA sales and after-sales functions across North America will be channelled through our Terex facility based in Louisville, Kentucky. There are plans to expand our highly skilled sales and aftersales team this year. A key focus of this expansion will be on the after-sales support structure, headquartered in Louisville, which will provide full parts support for critical components and have MAGNA-skilled tech engineers on hand to support both dealer and customer bases.”
In addition to its dealer development expansion plans, McIlwaine said MAGNA has an ambitious product roadmap.
“For example, we recently added the GIPO range of large-scale mobile impact crushers and roller grizzly screens to our range,” he said. “Further adjacencies and products are under investigation, to deliver products and solutions to customers in the large-scale segment across aggregate, mining and recycling industries.
A MAGNA MT130J jaw crusher at a brand event earlier this year in Nashville, US.
Image: MAGNA
Image: EDGE Innovate
A Basic Premium Sandvik describes its new Basic Premium as a “re ned offering” designed to deliver the trusted Sandvik quality in a simpli ed form, speci cally more tailored for the demolition and recycling segments.
The Basic Premium builds offer optimised mobile solutions for the construction industry. Targeted speci cally to meet the needs of the demolition and recycling segment, this offering is built to the same high standard and quality as Sandvik’s premium products, and is capable of reliable performance and high productivity.
The models are designed to be costeffective solutions and entry-level machines in key markets, where Sandvik aims to expand its market share.
“Our ambition with this concept is to offer a solution that bridges performance and affordability and makes Sandvik mobile equipment more widely accessible to a larger market,” Sandvik vice president and product line manager for tracked crushers and screens Mattias Markusson said.
“We’ve re ned the offering to serve two critical needs: the growing demand of the demolition and recycling industries, and the need for high-quality yet simpli ed equipment in emerging markets.”
The four models to be offered in the rst phase of the launch are the QJ341 and QJ241 jaw crushers, QA452 doublescreen and QE342 scalper. More models will be added in the second phase, scheduled to follow later in the year.
The launch underscores a commitment to tailored solutions that empower customers to operate more ef ciently, sustainably and pro tably. Key features include: •Build quality: Built with the same quality and engineering excellence and offered with the same warranty as the original premium lines from Sandvik.
• Built for the industry: Optimised speci cation more for targeted applications.
•Cost-effective performance: A smart investment for early adopters in emerging markets seeking cost ef ciency without sacri cing quality.
•Retro ttable after-market options: Offered with a set of standardised and retro ttable options for added user value.
“Sandvik continues to innovate with customer needs at the forefront, and the Basic Premium is a testament to the company’s commitment to delivering customer-driven solutions with speci c product applications in mind,” the company said in its release.
These models are now available through Sandvik’s authorised distributors and sales partners.
AfriSam chooses Sandvik
AfriSam has enhanced its Rheebok Quarry operation with the installation of a highcapacity Sandvik CH430 cone crusher from Sandvik Rock Processing. The upgrade ensures reliable, safe production with reduced maintenance and a lower carbon footprint.
Located near Malmesbury in the Western Cape province of South Africa, the granite quarry produces a range of materials, including aggregate stone, crusher sand, roadstone and ballast.
Senior engineer for the Western Cape Desmond Jacobs said the investment aligns with AfriSam’s long-term capital strategy.
The decision to install the Sandvik CH430 was driven by key features such as its hydraulic Hydroset system and Automatic Setting Regulation (ASRi) system, both of which are designed to enhance performance and streamline maintenance. The Hydroset system helps to enable precise automated closed-side setting adjustments, while the ASRi system continuously monitors and optimises crusher performance.
“We appreciate how the Sandvik CH430 minimises operator intervention, allowing real-time adjustments to the closed-side setting,” Jacobs said. “This improves product size consistency and quality. The system also tracks key parameters like temperature and pressure, enabling proactive maintenance and reducing unexpected breakdowns.”
Jacobs said the new unit has already demonstrated its impact on product quality by reducing oversized material in the feed stream.
“Our initial assessments showed a dramatic reduction in oversize material being sent for secondary crushing,” he said.
“This allows us to optimise throughput and potentially eliminate redundant processing steps in the future.”
A crucial factor in selecting the Sandvik CH430 was its compact footprint, which closely matched the previous crusher.
“As a brown elds project, we had to work within existing site constraints,” Jacobs said. “Matching the footprint was essential as we had limited time for installation and could not accommodate extensive structural modi cations.”
Sandvik Rock Processing business line manager for crushing solutions PC Kruger said the Sandvik Plant Designer platform helped optimise the model selection process.
In addition, the energy-ef cient crusher, powered by a 132kW motor, aligns well with AfriSam’s speci cation, contributing to lower energy costs and reduced carbon emissions. With a local of ce and warehouse in Cape Town, Sandvik Rock Processing ensures AfriSam receives prompt technical support, spare parts and plant audits whenever required.
Even more connected
Kleemann’s SPECTIVE CONNECT is now available with the company’s mobile classifying and scalping screens. Operators receive all relevant data, such as speed, consumption values, and ll levels, directly on their smartphones.
The ‘stockpile monitoring’ function is particularly useful for screening plants. It displays the current status of material stockpiles. When a prede ned value is reached, operators receive a message instructing them to clear the stockpile as soon as possible. This facilitates internal logistics and increases productivity.
Metso on the Romanian big screen Metso has con rmed plans to expand its presence in Romania with a new screen manufacturing centre.
The Sandvik CH430 cone crusher at AfriSam Rheebok Quarry.
Image: Sandvik
The investment will expand its production capabilities of stationary screens with a new centre in Oradea, Romania. This will allow Metso to support customers in Europe, Central East Asia, and the Middle East with capital screening equipment and the supply of wear and spare parts, including rubber screening media.
Metso expects to employ 70–80 people once the site is fully operational by the end of 2026.
“This investment is a continuation of our regional strategy implementation,” Metso vice president of the screening business line Jouni Mähönen said.
“A new centre in Romania will improve responsiveness to meet customer needs, answer to growing demand in growth markets, and strengthen our ability to deliver tailored screening solutions ef ciently.”
Transport-friendly crushing Finlay has introduced the J-1280 Jaw Crusher, a powerful new addition to its line of tracked mobile crushers.
Designed to bridge the gap between the J-1175 and the larger J-1480, the J-1280 is built to deliver performance in a more transport-friendly package, making it an ideal solution for medium-sized quarries and larger contractors seeking high capacity without the logistical challenges of heavier equipment.
Featuring a large 1200x820mm jaw chamber, the J-1280 offers a wide gape and robust throughput capabilities for hard rock applications. Despite its size, the machine is engineered for easier transport, weighing in less than the J-1480 while maintaining the strength and durability for which Finlay is known.
“This balance of size and mobility has been a direct response to strong feedback from the Finlay distribution network, who emphasised the need for a lighter, more
transportable model yet with the same jaw dimensions [1200x820mm] of our highestselling units in several key regions,” Finlay global sales and marketing director Martin Conway said.
One of the standout features of the J-1280 is its hydrostatic drive system.
Unlike direct drive alternatives, the hydrostatic set-up allows the crusher to operate in reverse continuously.
This functionality is crucial for clearing blockages quickly and safely, eliminating the need to manually lift material from the chamber.
Superior performance
Superior Industries has announced the promotion of Kathy Johnson to vice president of after-market.
Industries.
In her new role, Johnson will continue to lead the company’s after-market services team, which supports dealers and end-users with a range of services, including parts sales, technical documentation and hands-on customer service.
“Kathy has a way of bringing people together to solve problems and make things better,” Superior Industries president Jason Adams said.
“She’s a leader who listens rst, isn’t afraid to get her hands dirty, and never loses sight of what really matters, serving customers.”
Superior Industries said its service and support approach is focused on ‘being there when it matters most’. This means helping customers keep their equipment running smoothly, reducing downtime, and resolving problems quickly.
The team works closely alongside a trusted network of dealers to ensure parts are readily available, support is easily accessible, and help arrives when needed.
Johnson has been with Superior for 13 years, bringing industry experience from her background in technical publications. She has played a key role in shaping the company’s after-market efforts by improving support systems and nding new ways to make life easier for everyone.
Superior is headquartered in Morris, Minnesota, and has approximately one million square feet of manufacturing space and over 100 engineers. It has four additional production facilities in the US, as well as international manufacturing locations in Canada, Brazil and Asia. AB
Finlay has introduced the J-1280 Jaw Crusher.
Kathy Johnson is the new vice president of after-market at Superior
Image: Superior Industries
Image: Finlay
Investment powers loading equipment
Investment continues to push the loading sector forward in the quarrying and aggregates industry. From manufacturers to quarry operators, major investments are shaking up the sector.
Volvo Construction Equipment (Volvo CE) has revealed plans to expand its global excavator crawler production through strategic investment.
The Swedish-headquartered manufacturer has selected three countries in which to invest: South Korea, Sweden and the US . The majority of the 2500 MSEK investment will be directed to the Changwon factory in South Korea.
Volvo CE will reveal the Swedish location, scope of investment and project timing later this year, but it will be key to its crawler excavator production in Europe. The company will also install an excavator assembly line at its Shippensburg facility in the US to expand its production capabilities in North America.
The investment in these facilities will support production in Volvo CE’s key markets, while also reducing long-distance logistics and helping to manage economic and regulatory challenges.
Volvo CE president Melker Jernberg said the strategic approach aims to enhance the company’s presence and operational ef ciency across key regions and markets.
“We understand the need to respond to growing demand and are excited to expand our facilities to serve customers better,” he said.
“This investment underscores our commitment to quality, innovation and competence, allowing us to deliver even greater value. This expansion demonstrates our efforts to respond to customer demand by
investing in our crawler excavator business closer to key markets and customers.”
In other news, Volvo CE also secured a Red Dot award for the design of its Volvo L120 Electric wheeled loader, with the international judging panel praised the machine’s modern look and streamlined design. Volvo CE’s design process was led by its technology and design teams from Jinan, China, as well as Eskilstuna and Gothenburg in Sweden.
The Red Dot is considered one of the most prestigious design awards in the world, which annually recognises leading practices at a ceremony in Essen, Germany.
“I’m happy we won this award, but I’m especially happy that we won it for this machine,” Volvo CE senior chief for advanced design Peter Reuterberg said. “The change from diesel to electric gave us the opportunity to think differently and strive for big impact. Our hope is that this new silhouette will be instantly recognisable as electric.“
Major merger
HD Hyundai Construction Equipment and HD Hyundai Infracore have con rmed a merger, which will lead to the creation of HD Construction Equipment from next year.
The merger was con rmed following separate board meetings by HD Hyundai Construction Equipment and HD Hyundai Infracore on July 1. HD Hyundai Construction Equipment will be the surviving entity and become HD Construction Equipment from January 1, 2026.
The new company will operate the Hyundai and Develon brands with a focus on construction equipment, as well as engines and after-market services. The company is investigating plans to establish a full line-up ranging from compact to ultra-large construction machinery. This will also involve scope for “future growth engines”, including the development of electri ed and smart construction equipment.
“This merger will drive sustainable growth for the construction equipment division of HD Hyundai, helping us strengthen our position in the global market and serving as a signi cant milestone in advancing Korea’s construction equipment industry,” HD Hyundai XiteSolution president and chief executive of cer Cho Young-cheul said.
Backed by investment
Breedon Group has backed the quality of Caterpillar’s machinery after investing in a new Caterpillar 395 excavator for its Hope Cement plant eet.
The UK-based construction materials producer worked with Caterpillar dealer Finning UK & Ireland to nd a machine that would excel in intensive applications. The 395 excavator has so far proven to be a winner, according to Breedon quarries development manager Tim Palmer.
“Straight away, we could see that the Cat 395 was a true powerhouse of a machine,” he said.
“We were impressed with the higher capacity regarding bucket size, which
Volvo CE has made a major investment in its operations.
Image:
for us means greater payloads and faster material movement.
“Durability and productivity are also key to our investment in the Cat 395. The reinforced booms, sticks and frames on this machine go a long way in ensuring reliable performance in very demanding conditions. It is also a highly productive machine thanks to increased swing torque and stick force, which enable faster cycle times and improve material handling.
“We were thrilled to be able to invest in this machine and work with our long-term partners at Finning, who not only supported us throughout the purchase and delivery but also assisted in the acquisition of Sleipner E90 dollies a few years ago to ensure operational ef ciency of the new machine.”
The Caterpillar 395 is the largest excavator in Caterpillar’s Next Generation line-up as a 95-tonne tracked machine.
Finning corporate account manager for mineral products Dean Turner discussed the collaboration between Finning and Sleipner to prepare the machine.
“Finning was thrilled to be able to work with Sleipner on this impressive machine for our long-standing customer Breedon,” he said.
“Sleipner are the experts in transport systems that reduce track wear, fuel consumption and downtime for heavy machinery and we knew this was going to be a vital asset to Breedon to ensure this impressive machine runs at peak performance whilst on site.
“We arranged to have the machine delivered to Breedon to use alongside the Sleipner dollies. The machine was transported on both new and rebuilt Cat 775G off-highway trucks that were on site at Hope Quarry. These are impressive and fuelef cient machines that support the overall sustainability approach.
“The Cat 775G trucks are part of Hope Cement Works Quarry rebuild programme. The fourth truck is currently going through our Chester eld workshop facility, undergoing a Cat-certi ed powertrain and hydraulic rebuild. This programme underlines the company’s commitment to building a circular economy and highlights the ability of Cat machines to be rebuilt as
new, complete with a ve-year powertrain and hydraulic warranty.
“The delivery of the machine and Sleipner dollies truly marked a collaborative effort between Finning, Sleipner and Breedon. We are thrilled to have supported Breedon in the acquisition of this machine that will go on to enhance their operations for many years to come.”
Major milestone celebrated Liebherr was in a celebratory mood as the 10,000th XPower wheeled loader rolled off the production line in Bischofshofen, Austria.
Transmission manufacturer ZF Friedrichshafen AG joined Liebherr to celebrate the milestone, which is the culmination of a remarkable partnership between the two organisations.
The Xpower wheeled loaders feature a power-split travel drive, which is standard on all Xpower models and is produced by ZF Friedrichshafen AG. During the design process, Liebherr drew on its experience in developing wheeled loaders and collaborated with ZF on the power-split transmission, ensuring it could meet the requirements of the XPower travel drive.
The result is the XPower wheeled loaders, which have become a popular choice for customers worldwide. The power-split drive system combines hydrostatic and mechanical drives, which are suited to common operations in a quarrying environment. The hydrostatic is suited to short loading
Representatives from ZF, BERGER Group and Beutlhauser Group help to mark the 10,000th Liebherr XPower wheeled loader.
operations while the mechanical drive can tackle the long loading operations and up-hill driving. The ZF power-split transmission effectively combines the two paths, allowing for variable operation that automatically mixes the ratio of the two drives.
Liebherr’s managing director of technology at the Liebherr plant in Bischofshofen Dr Herbert Pfab said this means XPower wheeled loaders always operate at maximum power and ef ciency.
“This means that the XPower offers the highest ef ciency in material pick-up and transport, as well as optimum acceleration and maximum performance in all loading cycles – even over long distances,” he said.
Head of quality management at the Liebherr plant in Bischofshofen Gerhard Pirnbacher said its development partner, ZF, has been integral to the product’s success.
“The transmission from our partner ZF is a key component of the drivetrain in our XPower wheel loaders,” he said. “With an impressive total of around 64 million operating hours already clocked up by XPower models, this transmission has proven its exceptional robustness.”
Breedon Group has purchased a Caterpillar 395.
The two companies marked the occasion as ZF representatives visited Liebherr’s Bischofshofen facility alongside representatives of the BERGER Group, who purchased the wheeled loader, and representatives of the Beutlhauser Group, who sold the wheeled loader. Pfab presented the new owners with a symbolic key.
The milestone wheeled loader features special decals and a transmission signed by ZF employees. The BERGER Group will utilise the wheeled loader at its BERGER Rohstoffe GmbH quarry in the Bavarian Forest, located near the ZF transmission plant in Passau.
“We value the handling, reliability and relatively low operating costs of our XPower machines,” BERGER Rohstoffe GmbH managing director Matthias Neidhardt said. “We are particularly pleased that a gearbox from our home region of Passau is installed in our new wheel loader.” AB
Image: Liebherr
Image: Caterpillar
CDE has developed solutions in North America.
Seeing opportunities in urban areas
CDE spoke with Aggregates Business about how the company is adjusting to change within the quarrying and aggregates sector, while also pioneering a key part of its future.
When asked what separates CDE Group in a crowded marketplace, the company’s chief engineer Kevin Vallelly is quick to respond.
“We like to think we’re not just an OEM (original equipment manufacturer) selling products; we’re selling solutions,” he told Aggregates Business. “We have a strong product portfolio, but it’s just the building blocks to the solutions we’re trying to provide to the marketplace.
“The really big projects are what differentiates CDE from a lot of our other competitors. Our capability to provide a full turnkey system and collaborate with the customer and key stakeholders enables us to guide them through the entire process.
“Our ability to provide that full end-to-end solution is what differentiates us.”
Quarry and aggregates operators are known for wanting greater ef ciency and higher yields from their materials. But in some key global markets approvals for new quarries have become harder to come by or part of a more drawn-out process. This has presented a new challenge for operators and manufacturers alike: how do you make more material from the existing extractive area? In some cases, customers may need to process ner sand and stickier material while outputting similar materials to before.
The answer itself is not a straightforward one. It can require rigorous planning and, in some cases, upgraded equipment to ensure the material speci cations can be met and the lifespan of the deposit can be prolonged.
“We’re currently undertaking a lot of upgrades, where customers are hitting a very different feedstock. We’ve been able to provide upgrade solutions to help them manage that,” Vallelly said.
“We pride ourselves on taking on those applications. Extending the lifespans of quarries is a no-brainer as opposed to all of the challenges that exist to set up a new deposit,” Vallelly said.
“We’re seeing more and more where there is a broad range of inputs and there needs to be a consistent output. That means we’ve had to design new plants or upgrade existing plants to ensure the customer can maximise the resource for longer.
“As a business, we are dedicated to mitigating our environmental impact both for our customers and ourselves. CDE implements sustainable practices and seeks innovative solutions. Our strategies focus on resource ef ciency, pollution prevention, and promoting circular economy principles.”
With increasing pressure on natural resources, CDE supports quarries in extending the life of their reserves and reducing reliance on virgin materials.
One example that demonstrates this is a long-time customer who had a potential headache. The customer had navigated around its site to extract from areas that avoided the seams of clay on-site. However, these extraction areas were close to exhaustion and presented a problem to the business.
The customer engaged CDE, which was able to upgrade the plant on-site so the operator could process all of the sticky, malleable claybound material into a sellable product for the market.
This solution unlocked an extra decade in the site’s lifespan.
“Extending the lifespan of a quarry is something we look for with customers. It is one of the rst questions we ask, ‘what are your reserves like?’ and from there we can start guring out if there are more reserves there than they think. There might be material there that the customer thought was impossible to wash but we see those challenges as opportunities.”
Demand for sand
As a company with a sprawling global customer base, CDE Group has seen technologies, trends and patterns come and go in the quarrying and aggregates sector.
CDE has long been a key driver for the UK, Europe and American businesses adopting advanced dewatering systems and adapting recycled materials revenue streams, including abilities to make manufactured sand.
While the original product is a byproduct from the crushing process, the processed material has been rising in demand as natural sand reserves decline globally. This came to a head when the United Nations suggested a “sand shortage” was on the horizon in 2022. Operators in some regions have also seen a reduction in their ability to dredge natural sands from nearby rivers.
“In some regions, the cost and availability of natural sand are driving people to look at what they can do with their own waste materials,” Vallelly said. “For some customers who have ready-mix plants, making their sand is easier. In some areas, where they are short of natural sand, making a manufactured sand means they can get a commercial bene t from a waste material.”
Images: CDE
The quarrying and aggregates sector is increasingly shifting to manufactured sand to make up the shortfall, and CDE has played a key role in this development.
The process sees hard rock crusher nes washed and processed to become a sandlike product that can be used in key building materials and cementitious products.
“Historically, it was a waste product which was dormant and there were huge volumes of it sitting on quarry sites,” Vallelly said.
“We’ve got the capabilities to take that material and wash it, re ne it and shape it to make a concrete-sand product. That is something which is growing in the quarrying sector.
“There are a huge number of reasons to do it, but the biggest one we’ve seen is turning a waste product into a commercial product, especially as sustainability has become a bigger focus in the industry.”
Eyes on key markets
CDE nds itself in a similar position as it helps shape the recycled materials sector in the existing and emerging quarrying and aggregates markets. In part, CDE has leaned on its previous experience in other global markets to understand how it can support and grow this emerging sector.
By its estimations, CDE has delivered more than 2000 global projects, ranging from small independents to multinational producers. In 2024, CDE was successful in the tender process for two large recycling plants for a large multi-national public limited company (PLC). The two recycling plants needed to be capable of processing 150 tonnes per hour (tph) and deliver a fully turnkey solution. One plant was recently commissioned, and one is in the installation phase. The plants marked a milestone moment for the company.
“In more recent years, PLC companies have decided to make acquisitions of smaller recycling companies to gain assets and land ll licences. Instead, these are two agship projects because it is the rst of their kind,” he said.
“The customer has taken the initiative to acquire these pieces of equipment speci cally for recycling and processing construction demolition waste. At CDE, we’re not exclusive to recycling plants, but we see huge growth in the recycling markets.”
Europe remains a key market when it comes to sustainable practices and recycling regulations, The European Union’s Critical Raw Materials Act and Extended Producer Responsibility (EPR) framework have been credited with new standards for circular economy practices, encouraging industries to rethink waste and resource management.
CDE has supported a series of agship projects in France, Germany, Sweden and Norway. One of the standout examples is in France, where Entreprise Spiess developed a wet processing facility that recycles over 200,000 tonnes of construction, demolition, and excavation (CD&E) waste annually.
The wash plant incorporates several advanced technologies from CDE, including three EvoWash™ units, a Counter Flow Classi cation Unit (CFCU), ShearClean™ attrition cells, and an organics screen. The system enables maximum nes recovery and contaminant removal, and the ability to produce quality construction sands.
It features a suite of technology that allows operators to monitor performance and optimise production in real-time. This is achieved through CDE SmartTech and CDE OptiMax, which provide Entreprise Spiess with live material data to make informed decisions.
The eco-materials from Entreprise Spiess have been used in civil engineering, infrastructure, and public works projects.
The facility’s natural materials have been proven to meet CE standards for use in concrete production.
These projects are helping to shape how CDE is working with US operators as the country’s recycled materials sector continues to grow, particularly in the north-east. In the past six months, CDE has commissioned two large 250tph plants in Long Island and Philadelphia. But there are always speci c considerations between each region, as the geography and types of CD&E waste differ between each market.
“We’ve got good credibility now; we’ve established almost 50 recycling plants across the UK and Ireland,” Vallelly said. “They’re all scattered over different areas, and they’re all dealing with different types of feed. Some have high sand, some have more clay, some have more organic material, and some have more plastics in the material.
“We believe we can develop a solution for any customer. We have a highly skilled team of engineers that can take the inputs and determine how we can consistently deliver the right output quality that is needed.
“Our systems help divert millions of tonnes of material from land ll each year, contributing to a more sustainable construction supply chain.”
Still, CDE is eyeing the North American market, particularly the US, as a key market where it can support the edgling recycled materials sector. In addition to the Long Island and Philadelphia plants, it has plants commissioned in San Francisco and Maryland in the US, and Calgary in Canada, and one will soon be installed Vancouver, Canada.
“We see that as another growth area for ourselves,” Vallelly said.
“In America, recycling materials is less common, but CDE is seeing greater adoption. We want to demonstrate that it works and that the market is open to taking the material.
“There is going to be a lot of material there … it makes nancial sense for everybody to do it, and [that’s why] we’re planting the seeds and working with the early pioneers to do it.
“It comes down to outlook: where others see problems, we see opportunities.” AB
CDE has successfully delivered tailored solutions.
CDE invests heavily in research and development for its solutions.
Advanced attachments
Some eye-catching new products have hit the global screening buckets and attachments market.
MB Crusher offers two main types of screener attachments: MB-HDS shafts screeners and MB-S screening buckets, both made for hydraulic excavators and other machines.
The Italian company’s quarrying-suited, exible MB-S screening buckets are designed to screen materials directly on the job site, and it said they reduce crushing time by 60 per cent when used before and after crushing of natural materials, including aggregates, pebbles, slag heaps, sand and soils.
MB-HDS shafts screener uses rotating shafts to screen, allowing for on-site material selection and repurposing. Easy to use and maintain, the products come in various sizes and are suited to materials such as demolition debris, soil and organic materials.
In the heart of Indonesia’s coal industry, the MB-HDS323 shafts screener attachment for 22–35-tonne excavators is proving to be the ideal tool for processing material.
Designed for ef ciency, power and simplicity, the MB-HDS line is proving essential to the industry, facilitating the handling, crushing, and screening of coal.
The MB-HDS323, mounted on a CAT320GC excavator, is transforming coal processing in Bandar Lampung, Indonesia. This robust attachment crushes coal from a maximum size of 50cm down to 0–5cm, meeting local and international demand.
Another MB-HDS323 has been successfully deployed with a Kobelco SK203 excavator, delivering the same Indonesian coal-processing results. Smaller coal particles burn more ef ciently in power plants and industrial furnaces, ensuring complete
combustion and reducing waste. Crushed coal is easier to handle, transport and store, reducing logistical costs for local and international markets.
At bauma 2025 in Munich in April, MB Crusher launched a larger version of the MB-HDS323, the MB-HDS533 shafts screener. Designed for use in the coal industry as attachments to excavators weighing 50–80 tonnes or 40–50-tonne wheeled loaders, the 3.8m³ capacity MB-HDS533 is said to be equally effective at screening coal and soil.
“The new MB-HDS533 shafts screener is very good for working in mines and quarries. We received many requests for this type of unit from coal mines in Australia, the United States and other markets,” MB Crusher managing director Guido Azzolin told Aggregates Business
“Such customers want high productivity and need a bigger [shafts screener] model for their excavators. The MB-HDS533 can also work well with [wheeled] loaders.”
Founded in 2001 in Fara Vicentino, a town in the Vicenza province of north-eastern Italy, MB Crusher’s sustained business growth led to the company’s 2015 move to a state-ofthe-art 485,000-square-foot headquarters, where it manages all phases of its operation, including manufacturing, research and development, and sales.
“We continue to grow year-on-year, but it’s not easy, as Europe and the wider world continue to change,” Azzolin said. “Today, it is very dif cult to have a long-term view; however, we will always retain our commitment to do our very best every day.”
Despite challenging global market headwinds, Azzolin said MB Crusher has seen an “unbelievable” increase in its domestic business.
“I don’t know why the Italian market is doing so well. I think the new product we have [MB-HDS533 shafts screener] can do very well there and elsewhere,” he said.
MB Crusher has also developed a crusher and screener bucket performance monitoring telematics solution. The solution is currently only available to Italian customers, and the company plans to make it more widely available after proving its worth domestically.
Asphalt advancement
The new ALLU Asphalt Screening bucket is designed speci cally for screening and crushing cold-milled asphalt and reclaimed asphalt pavement (RAP). It crushes clumps, screens ne material, and separates oversized particles – all in a single pass. The cornerstone of the new ALLU product is its innovative hybrid blade set-up.
Handling the majority of the material directly with the ALLU bucket enables operators to reduce the need for impact crushers. This can result in lower fuel consumption, fewer wear part replacements, and shorter operating hours.
The new MB-HDS533 shafts screener on show at bauma 2025.
This results in savings in time and money, making the process not only more ef cient but more pro table.
ALLU Asphalt Screening bucket is available in four models: the DHA 3-17 for 25–45-tonne excavators and 15–20-tonne wheeled loaders; the DHA 3-23 and DHA 4-17, both for 30–45tonne excavators and 15–25-tonne wheeled loaders; and the DHA 4-23 for 35–45-tonne excavators and 20–30-tonne wheeled loaders.
MRD Plant managing director Tom Chapman said the ALLU bucket has helped handle recycled asphalt while maintaining a eet productive and strong bottom line.
“The ALLU Asphalt Bucket is much more ef cient, productive and less expensive than bringing a mobile crushing plant onto the work site,” he said.
“They are easy to use and much easier to maintain, and they enable us to access restricted sites where we might not be able to bring in a separate crusher unit.”
Exhibitionist
During the rst half of 2025, Steelwrist participated in more than 20 exhibitions around the world, including a successful week at bauma in Munich in April.
Steelwrist returned to CSPI-EXPO in Tokyo, Japan (June 18–21), with an interactive indoor booth. A live demonstration featuring two excavators showcased the ef ciency of the company’s tiltrotator, while the new SQ40 coupler system was also introduced to the Japanese market. With the recent registration of Steelwrist tiltrotators in Japan’s New Technology Information System and a growing local team, Steelwrist has shown its commitment to the local market.
Steelwrist vice president for OEM sales and marketing Karl Serneberg said participating in exhibitions is important for Steelwrist to showcase its extensive product range and interact with existing and new customers.
Local and international exhibitions are part of the company’s tour.
At bauma 2025, Steelwrist launched two new models in its third-generation range of tiltrotators, the XTR15 and XTR23, as well as the SQ40 automatic coupler solution.
“It has been an extremely busy period, with our 20th anniversary event and several successful exhibitions throughout this spring,” Serneberg said.
“Each occasion is an opportunity for the visitor to meet our team members, experience our products in action, and learn about Steelwrist as the leading manufacturer of tiltrotators, quick couplers, and work tools.
“We nish the rst half of 2025 with our most impressive stand ever at CSPI-EXPO in Japan.”
New solution showcased Simex’s family of versatile and low-maintenance VSE screening buckets for excavators is expanding, with a new vestrong TORNADO line complementing the ‘classic’ VSE range.
Designed for heavy excavators, the latest addition to the VSE classic line-up, the VSE 50, is aimed at operators looking for maximum performance when covering underground pipes with the correct output size. With its SAE bucket capacity of 3m³, the VSE 50 is designed for excavators weighing 35–50 tonnes, making it the largest screening bucket in Simex’s classic VSE range.
Now available in eight models for excavators from 1.2–50 tonnes, Simex’s classic VSE screening buckets are speci cally designed for separating different-sized materials directly on-site. The classic VSE products feature the rapid adjustment of output size via instant control in the cabin. This exclusive patent allows the shafts to be instantly distanced and closed, with a maximum travel of 40mm.
Enabling the sustainable recovery and reclamation of soil and aggregates resulting from demolition, Simex classic VSE screening buckets are also helping deliver a circular economy.
Simex’s FIT screening tool technology, another feature of classic VSE screening buckets, remains popular with customers three years after its introduction. The low-maintenance system allows for the easy interchange of every disc or blade without unstrapping shafts. The Italian company said this means 75 per cent lower maintenance costs compared to the previous system.
Multiple con gurations are possible, depending on the materials to be screened. Simex offers users four different set-ups, but many others are possible thanks to the 100-per-cent interchangeable screening elements.
Available from October 2025, Simex’s new VSE TORNADO range of screening buckets is suited to cleaning soil from debris, stones, and gravel, as well as for compost aeration, even in wet and muddy conditions. Designed for mini- and midi-excavators ranging from 1.5–10 tonnes, these buckets are also ideal for pipeline padding and back lling underground utilities and conduits.
The ve VSE TORNADO buckets feature easy replacement of the entire shaft (patented by Simex) or individual elements, allowing for quick adjustments to different particle sizes. This exibility helps to ensure minimal downtime, maximum ef ciency, and optimal performance for a wide range of applications.
VSE TORNADO buckets can be tted with polyurethane or steel tools, depending on the type of application. The line’s new threeshaft con guration, featuring star-shaped discs, enhances the vortex of the processed material, improving performance and increasing pro tability on the job site. AB
1. The Steelwrist booth at the CSPI-EXPO in Tokyo. 2. Simex’s VSE 50 screening bucket attached to an excavator at work in a quarry.
Image:
Steelwrist
Image:
Simex
Burning demand for asphalt
Demand within the asphalt sector is driving breakthroughs in productivity, e ciency and sustainability from manufacturers.
Global asphalt demand remains at a consistent level as customers and manufacturers alike consider the age-old question: how do you develop more at a lower cost per tonne? That fundamental question is worth considering, given that market analysts expect global demand for asphalt to rise in the not-too-distant future.
According to the Global Asphalt Market Report 2024–2029 by Freedonia Group, demand for primary asphalt was estimated to be 128 million tonnes in 2024 and is projected to reach around 150 million tonnes by 2029, a 3.2 per cent annual growth rate. Other analysts, including the IMARC Group, have predicted the market will grow to US$397 million by 2033, up from US$259 million in 2024, a 4.9 per cent growth rate.
A key driver, as seen in much of the global construction materials sector, comes down to advancements in technology, materials and applications.
“This drive towards sustainability not only aligns with regulatory initiatives but also caters to the preferences of environmentally conscious consumers,” IMARC Group stated.
“As a result, sustainable practices and innovative asphalt technologies are emerging as crucial drivers, shaping the future of the global asphalt market.”
Aggregates Business examines some of the latest technology and equipment helping to shape the future of the sector.
Ammann delivers results
The Ammann ABP HRT 320 Asphalt-Mixing Plant in Nijkerk, Netherlands, is held in high regard not only for its results but for its grand inauguration by King Willem-Alexander.
Owned by Van Gelder Groep and operated by Asfalt Productie Midden Nederland (APMN), the plant has been regarded as a “game-changer” in terms of sustainable infrastructure.
“The plant represents a new standard in environmentally responsible asphalt production,” an Ammann spokesperson said. “Its innovative technology and commitment to sustainability have already begun to reshape the industry.”
The Ammann ABP HRT 320 AsphaltMixing Plant has been operational for more than six months, with its RAH-100 recycling technology achieving recycling rates of up to 100 per cent. In this time, Van Gelder has achieved certi cation to produce top layers with up to 65 per cent of recycled materials. Ammann estimates this could translate into up to a 40 per cent reduction in CO2 Its modular design means the Ammann ABP HRT 320 Asphalt-Mixing Plant can
adapt to sustainable fuels in the future. The production process, which includes Ammann Foam, allows operators to produce asphalt at a lower temperature of 130°–140°C instead of the usual 180°C. This enables Van Gelder and APMN to save energy and reduce emissions.
“This marks another major step toward reducing waste and emissions in infrastructure projects,” the Ammann spokesperson said.
The plant is equipped with a 1000tonne ready-mix storage capacity. This is divided into 10 chambers with double-loading doors that eliminate the need for truck repositioning during loading. The plant is also designed with an enclosed mixing tower and covered storage for processed asphalt granulate. The aggregate storage siloes are also heavily insulated, which helps to ensure materials remain at the correct temperature for longer periods.
The latest technology allows operations to access real-time information, which can support maximum productivity.
The plant features the Ammann as1 Laboratory workstation and Ammann as1 control system. The latter is enhanced with automation tools, including energy monitoring, recycling adjustments and predictive load management.
The new Nijkerk project will support sustainable construction.
“The Nijkerk plant is poised for even greater advancements in sustainable asphalt production,” the Ammann spokesperson said. “Plans to install 3000 solar panels on-site will further reduce the facility’s carbon footprint, reinforcing Van Gelder’s long-term commitment to green energy solutions.
“With an annual production capacity of up to 450,000 tonnes of asphalt, the plant has exceeded expectations in its rst six months, proving itself as a model for futureready, sustainable asphalt production. With its ongoing innovations, Van Gelder Groep is not just shaping the present but pioneering the future of sustainable infrastructure.”
Ammann continues to invest heavily in its facilities to ensure customers have technical and after-sales support close by when required.
Earlier this year, the company unveiled its Scandinavian of ce in Viborg, Denmark. The new of ce offers Scandinavian and Baltic customers servicing, retro t solutions, spare parts, and support for new installations.
The existing Ammann team from Germany was transitioned to the new Scandinavian team alongside asphalt industry experts Dennis Pedersen, Jamie Throndal and Casimir Casivi.
Ammann Scandinavia managing director Tim Stolzenberg said the new of ce will have
a strong focus on sustainability projects in the local market.
“I am excited about the new tasks, projects, and customers we will engage with in Scandinavia,” he said.
“Our commitment is to provide exceptional value by being quicker and more responsive to the needs of our customers.
“We are introducing a robust retro t service that caters to all types of plants, including unique, customised solutions, positioning us as the rst choice for modi cations and upgrades in the market.
“This new location is just the beginning. We’re here to grow sustainably with our clients and become the go-to partner for plant modi cations in Scandinavia.”
Benninghoven goes next gen Benninghoven has given customers a glimpse into the future with the release of its new burner generation.
The latest burners are capable of using up to four different fuels, including
Benninghoven has released its new MULTI JET solution.
solid, liquid or gaseous. The design of the new burner generation means the fuels can be used regardless of their physical state, which means the innovation from Benninghoven is capable of using hydrogen as a fuel source.
The MULTI JET burners feature separately positioned nozzles. This enables operators to switch fuels in real-time without the need to shut down the plant and endure downtime. The new system provides businesses and operators greater exibility when it comes to choosing the most cost-effective and available fuels to suit their applications.
Benninghoven head of development and design engineering Steven Mac Nelly said the MULTI JET burners provide several sustainability bene ts.
“Countries such as the Scandinavian nations and Switzerland are already feeling the impact of stricter CO2 pricing for fossil fuels,” he said.
“Noise emissions of the new burner generation were reduced by 5dB(A), which corresponds to cutting the perceived noise level in half. Furthermore, the electrical power consumption was reduced by 20 per cent while maintaining the same feed capacity.”
In many jurisdictions, the use of hydrogen as a fuel source requires a proven safety concept to be designed and implemented. Benninghoven’s expert team can work with customers on this to help ensure their operation is complaint.
The new burner generation can be included in new Benninghoven plants, as well as retro tted onto existing plants from other manufacturers.
“The burner can be integrated into existing plants regardless of their origin, ensuring virtually emissions-free asphalt production,” Mac Nelly said.
“Thanks to the exible options –depending on the availability of the fuels, location or application – the production processes can be sustainably optimised already today, as the MULTI JET burner is now available to plant owners as a standard product.” AB
The Ammann ABP HRT 320 Asphalt-Mixing Plant is operational at Nijkerk, Netherlands.
Image: Benninghoven
Image: Ammann
Taking a global view
The rubber is hitting the road as BKT plans to expand its operations globally. Aggregates Business examines the role the quarrying and aggregates sector will play.
One of the leading tyre manufacturers in the off-highway sector, BKT (Balkrishna Industries Ltd), is thinking big when it comes to the off-highway machine sector as it charts a path to global expansion.
In the 2024–25 nancial year, BKT announced it had achieved revenues of INR 10,615 Crores (US$1.28 billion), up 13 per cent on the previous period. While some businesses might be tempted to rest on their laurels, BKT is using this as a foundation to expand further in the global market.
The India-based company has announced its ve-year strategic plan, with the main goal of reaching total revenues of INR 23,000 Crores (around US$2.6 billion) by 2030. To reach this lofty goal, the company plans to focus on three key pillars to turbocharge its growth: the off-highway sector, expanding its carbon black business, and launching products in new tyre categories in the Indian market.
The plan was agreed at the BKT board of directors meeting in May. The board approved total investments of INR 3,500 Crores (approximately US$400 million), primarily funded internally, to support its key strategic plans.
BKT joint managing director Rajiv Poddar said the company is taking a united approach to achieving its targets.
“To consolidate our position, while achieving such important growth, as announced in our ve-year strategic plan, the board has approved the expansion of the dedicated production facility, expected to be operational in the second half of 2026,” he said.
“In parallel, BKT will continue to develop its mining range, supported by its proprietary All-Steel Radial technology up to 57 inches, complementing the existing Bias range.
“This strategic decision is driven by the strategic role of the quarrying and aggregates sectors, as they represent a high-demand and high-stress application area for the off-highway tire market.”
The quarrying, aggregates, mining, industrial and construction sectors shape the key foundations of BKT Tires’ approach to the off-highway segment.
As part of its approach to enhancing its market share, BKT has gone to the drawing board and identi ed its key markets.
The company has its sights set on the major markets of the Americas, India, and select international markets.
Poddar shared further details about the key markets in which BKT plans to expand its offering.
“North and South America are two core growth pillars, where BKT has ramped up investment and distribution efforts to increase the market share of global tyre sales,” he told Aggregates Business
“In second place is BKT’s domestic market, India, where the focus will be on entering new business sectors. In fact, this country represents the launch market for truck and bus radial [TBR] and passenger car radial [PCR] tyres.
“India’s vehicle parc is rapidly expanding, and the country is projected to become the third-largest passenger vehicle market globally, up from fourth position today. This dynamic context opens up signi cant opportunities to deliver value, especially in segments that demand long-term performance and consistent quality.
“A steady presence in Europe will be maintained, as this geographic area remains a stable and signi cant market, where BKT reaches a consistent percentage of sales and has an established presence in all major
BKT joint managing director Rajiv Poddar.
Images: BKT
countries. The company will consolidate its leadership position in Europe while maintaining a close relationship with OEMs [original equipment manufacturers] and leveraging replacement partnerships.
“A key role will be that of high-potential emerging markets. In line with its growth strategy, BKT is directing capacity expansion in those markets where mining, construction, and rubber tracks have strong potential for future growth.”
The future is carbon black
Carbon black is one of the jewels in the BKT crown. The product segment is supported by a state-of-the-art research and development centre, equipped with advanced equipment and a team of experts with decades of industry experience.
The Poddar family, including Rajiv and Arvind Poddar, provides family-based management to the specialty segment.
In an industrial setting, carbon black is used as a reinforcement ller in tyres and rubber products. In a broader sense, it also has applications in plastics, inks, coatings and many working environments. Known for its strikingly deep black colour, carbon black contains more than 99 per cent pure carbon.
While BKT is known for its capabilities as a tyre manufacturer, it is targeting the non-tyre segment with its carbon black business.
“BKT has built a solid and reliable foundation over the past three years, positioning itself as a strategic partner for major tyre manufacturers both in India and internationally,” Rajiv Poddar said
“This is why the company is strengthening its presence in the specialty carbon black segment, targeting high-performance non-tyre applications.”
“This non-tyre segment, which includes both specialty and advanced carbon black grades, is expected to become a key pillar of growth in BKT’s carbon black business.
“To support this trajectory, the board has approved an expansion of production capacity from 200,000 to 360,000 metric tonnes per year, which includes the development of advanced carbon black. The project is scheduled for completion by early 2026.”
Poddar is excited for BKT’s future in the coming years as it executes its ambitious plans.
“This roadmap demonstrates the ambitious vision of BKT for the future, setting clear goals and standards of growth and innovation,” he said.
“This is demonstrated by the entering new product categories, thus opening a new phase of growth, while consolidating the company’s position in high-value segments and expanding BKT’s presence across strategic global markets.
“With a clear and strategic roadmap, targeted investments and a modular approach to expansion, BKT is positioning itself to lead across diverse segments while staying true to its core values of reliability, performance, and long-term partnerships.
“Despite a global scenario of uncertainty and characterised by several geopolitical and macro-economic factors, BKT has shown strong operational resilience, leveraging its technological and manufacturing excellence, thus remaining committed to the company’s long-term growth strategy.”AB
BKT has a global presence as a leading tyre manufacturer.
BKT has identified its key markets to boost its market share.
SEPTEMBER 2025
23–25
Asia-Pacific’s International Mining Exhibition (AIMEX)
Organiser: Prime Creative Media
Tel: +61 3 9690 8766
16–19
NSSGA Legislative and Policy Forum 2025
Organiser: National Stone, Sand and Gravel Association (NSSGA)
Tel: (703) 525-8788
OCTOBER 2025
14–15
BULKEX 2025
Organiser: Materials Handling Engineers Association
Tel: +44 1257 412635
MARCH 2026
3–7
CONEXPO CON/AGG
Show producer: Association of Equipment Manufacturers
Show owners: Association of Equipment Manufacturers, NSSGA, National Ready Mixed Concrete Association
