Quarry Mar 2021

A Victorian quarry extracts a colloquially famous rock with a fuel-efficient loader

INTEGRATED SYSTEM STABILISES ROCKFACE Fulton Hogan remediates an unstable rockface with the help of precision machine control

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DIGGING FOR WOMBAT ROCK

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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

MARCH 2021

GAINS WITHOUT REINVENTING THE WHEEL An OEM explains why wheeled portable plants are advantageous for quarrying

IN THIS ISSUE MARCH 2021

VOLUME 29, ISSUE 03

FEATURES 24 GAINING THE MOST FROM YOUR EXCAVATORS, HAULERS Why matching your earthmoving gear is vital to lowering your business’s total cost of ownership.

28 LOAD SCALES THAT OFFER A MEASURED APPROACH A recycled aggregates company adopts a forward-thinking on-board weighing system.

33 OEM RINGS THE CHANGES

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WOMBAT ROCK A Victorian quarry is extracting a colloquially famous rock with a fuel-efficient loader.

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INTEGRATED CONTROL Fulton Hogan remediates an unstable rockface with the help of precision machine control.

Multinational OEM Sandvik has announced some important developments in the lead-up to 2021.

36 MODULAR CONSTRUCTION What do Walt Disney, Frank Lloyd Wright and chemistry have in common?

38 COPING WITH EXTREME HEAT As heatwaves become more extreme, which jobs are most at risk?

39 NOMINATIONS OPEN FOR IQA AWARDS 2021 The IQA is now taking nominations for the 2021 IQA Awards, which highlight the industry’s initiatives in education, innovation, safety and creativity.

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TRACTOR-SCRAPER How the tractor-scraper is being repurposed for quarrying applications.

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WHEELED PLANT GAINS An OEM explains why wheeled portable plants are advantageous for quarrying.

EVERY MONTH 06 FROM THE EDITOR

40 IQA NEWS

08 FROM THE PRESIDENT

41 FROM THE IQA CEO

10 NEWS THIS MONTH

42 GEOLOGY TALK

17 PRODUCT FOCUS

Quarry March 2021 3

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EDITORIAL

PASSING ON SAFETY LESSONS – IN THE PIT AND ON THE WATER

I

n my spare time, I’m a sailing enthusiast – with a passion for the America’s Cup, the bluewater trophy Australia famously won. Indeed, as this issue hits desks, the 36th match in the regatta’s 170-year-old history is on in earnest in Auckland, New Zealand.

While Australia hasn’t had a challenger for two decades, our sailors, designers and engineers remain influential. One of those, Jimmy Spithill, who grew up in Pittwater, Sydney, has helmed for a number of international teams and is a two-time Cup winner. In 2021, he is sailing for the Italian Luna Rossa challenge.

The modern America’s Cup boats are a far cry from the wing keeled Australia II – foiling yachts that skim above the water at up to 50 knots (more than 90km per hour). Although fast, they are challenging to sail – and potentially dangerous. Indeed, the US challenger American Magic capsized and was severely damaged in a race on 17 January. Fortunately, none of the 11 crew members were injured – and they had trained for the possibility. America’s Cup sailors wear crash helmets, carry knives and have access to harnesses and oxygen tanks, should the boat crash into the water.

While Spithill in his autobiography describes the high level of risk in the America’s Cup as akin to modern mountaineering – “the participants accept the risk as being part of the adventure” – he discusses safety extensively, including the capsize of Oracle Team USA’s 22m catamaran in training in 2012. The sailors were accounted for and unhurt but the boat was severely damaged.

While quarrying is not as cavalier in its approach to safety, the lessons Spithill took from the incident are applicable.

The capsize did not deter the sailors and shore crew who rallied to salvage and repair the boat, and get their sailing

program back on track. Spithill marveled at the honesty of people about the incident and what they could do to avoid it again.

It was then to Spithill’s dismay that in 2013 the Swedish challenger Artemis capsized in similar fashion, but with a tragic consequence – one of its crew drowned. The upshot of this disaster was that America’s Cup teams would, going forward, “openly share engineering knowledge so that we could create a safer environment for the sailors and learn as a group”.

Sadly, owing to the competitiveness that characterises the Cup, Oracle had not passed on its learnings to the other teams nine months earlier.

This is good reason why the quarrying industry should be collaborative when learning from incidents and mistakes.

Fatal and serious incidents can and do occur. It took several fatalities in Queensland in 2018-19 for the extractive industries there to stop work and evaluate their systems and procedures – and for workers and employers to be upfront and honest with each other.

Hopefully, data about incidents collected

by Australian work safety authorities can also educate the industry of the high risks and the benefits of improved safety.

Quarries and their members should also take advantage of the IQA’s education programs which explore topics such as incident investigation, effective risk management, and disaster learning. Just as sailors have gained from openly sharing knowledge to create a safer on the water experience, so quarries should collaborate more and share ideas and lessons that can not only make the industry safer but stronger as a whole. Collegiality is always preferable to outright competition.

Published by:

IT TOOK SEVERAL FATALITIES IN 2018-19 FOR THE QLD EXTRACTIVE INDUSTRIES TO RE-EVALUATE THEIR SYSTEMS AND PROCEDURES – AND FOR WORKERS AND EMPLOYERS TO BE HONEST WITH EACH OTHER.

11-15 Buckhurst Street South Melbourne VIC 3205 T: 03 9690 8766 www.primecreativemedia.com.au Publisher John Murphy john.murphy@primecreative.com.au

Editor Damian Christie damian.christie@primecreative.com.au

Journalist Nickolas Zakharia nickolas.zakharia@primecreative.com.au

Business Development Manager Les Ilyefalvy les.ilyefalvy@primecreative.com.au

Client Success Co-ordinator Ben Griffiths ben.griffiths@primecreative.com.au

Design Production Manager Michelle Weston michelle.weston@primecreative.com.au

Art Director Blake Storey Subscriptions T: 03 9690 8766 subscriptions@primecreative.com.au Follow Quarry online: Facebook: facebook.com/quarrymagazine Twitter: twitter.com/2021Quarry LinkedIN: linkedin.com/groups/4314906/ Web: quarrymagazine.com The Publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from the advertisers and contributors against damages or liabilities that may arise from material

DAMIAN CHRISTIE Editor

published. © Copyright – No part of this publication may be reproduced, stored in a retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.

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Quarry March 2021

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PRESIDENT’S REPORT

STAYING OPTIMISTIC AND STRIVING FOR POSITIVE MILESTONES IN 2021 The Institute of Quarrying

A

s 2021 starts to take shape, there is hope and expectation that a normal life will eventually return. Mini-outbreaks, if you can call them that, continue to disrupt families reuniting across state borders. As in our case, we were fortunate to be allowed into Western Australia at Christmas, only to be then directed into home quarantine, where we could at least spend time with our daughter and son-in-law whom we hadn’t seen for nearly a year.

The reality is life will continue to be different and it is up to all of us to make the most of the situation in terms of protecting our health and livelihoods.

We need positive leadership from our politicians and community leaders. As parents equally, we must stay positive and supportive to ensure our children stay both physically and mentally healthy. These are very challenging times but we have proven we can get through what was the worst of the pandemic last year in Australia. With confidence, we can look forward to a much brighter future.

We need to look forward to and plan for positive milestones in the year, and to remind ourselves that whatever is happening right now in our lives there will be good times ahead. I wrote last month that one of those milestones is the IQA Conference, to be held in Newcastle, New South Wales in October 2021. What a great way to stay positive and start planning for that road trip or extended stay in NSW.

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Quarry March 2021

Australia

Thank you to everyone who has offered their support behind the proposed IQA Mentoring Program.

There is work underway to develop the structure and process behind this initiative and we hope to have the program fully functioning by year’s end. I am sure once established there will be more industry people who have vast experience that will want to be involved with this program and to give back to the industry by sharing their knowledge, skills and experience with young people who will benefit greatly.

Another positive is the progress of the IQ Connect app which will be launched in the coming weeks. Clayton Hill and Kylie Fahey have been working with the Institute of Quarrying UK to get the app to this stage and we are excited about what this innovation will mean for the global extractive industry and our members. The Presidents of all the IQs have strongly supported this initiative and the strategy is to be able to share education content with any member wherever they are in the world and to help each other by developing instructive materials, eliminating duplication of effort and providing relevant up to date information accessible on a mobile device.

On behalf of the IQA Board and administration, stay healthy, stay safe and be positive.

SHANE BRADDY President Institute of Quarrying Australia

Educating and connecting the extractive and associated industries

quarry.com.au WE HAVE PROVEN WE CAN GET THROUGH WHAT WAS THE WORST OF THE PANDEMIC LAST YEAR IN AUSTRALIA. WITH CONFIDENCE, WE CAN LOOK FORWARD TO A MUCH BRIGHTER FUTURE.

The IQA’s Strategic Plan 2020 to 2025 embodies the following vision, values and strategic priorities: Vision: Educating and connecting the extractive and associated industries.

Values: • A safe and sustainable environment.

• Diversity and inclusion.

• Working development skills, careers and life-long learning.

• Networking, connection, trust and communication.

Strategic Priorities: • Maximise outcomes for industry through education and sustainable practise.

• Increase our relevance.

• A high performing and sustainable organisation.

IQA CONTACTS: Phone: 02 9484 0577 Email: admin@quarry.com.au Chief Executive Officer Kylie Fahey Company Secretary Rod Lester For all education, member and branch inquiries, email: admin@quarry.com.au.

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NEWS

PROPOSED QUARRY TO SUPPLY BASALT IN VICTORIA Conundrum Holdings has submitted an application for its North Central Quarry in Wallan, Victoria to the Mitchell Shire Council.

The proposed quarry will provide high quality basalt and extract about 17 million tonnes of the aggregate.

The quarry is expected to have a lifespan of around 30 years with the site to be undertaken in four phases.

Conundrum Holdings stated that the quarry is situated close to clients, which would cut logistics-related carbon emissions.

The quarry’s basalt resources are expected to supply to Victorian businesses.

According to Conundrum Holdings, each person in Victoria uses between 8 and 10 tonnes of quarry products per year.

“Quarrying is an essential temporary land use to maintain our community’s standard of living,” Conundrum Holdings said in a statement.

“This significant basalt resource offers a choice of supply to local and Victorian small, medium and largescale businesses, while we co-exist with and continue to support the economic growth of our community now and into the future.”

“QUARRYING IS AN ESSENTIAL TEMPORARY LAND USE TO MAINTAIN OUR COMMUNITY’S STANDARD OF LIVING” CONUNDRUM HOLDINGS

The North Central Quarry is set to provide 17 million tonnes of basalt over its lifespan.

Conundrum Holdings is a familyowned and operated Victorian-based business.

The North Central Quarry is expected to provide basalt for railways, asphalt and road sealing projects, concrete plants, buildings, agriculture and land and infrastructure development.

Conundrum Holdings’ website states that the quarry “(blends) into its surrounding landscape” to reduce visual and environmental impacts.

Community members from Mitchell Shire Council have the option of providing feedback to Conundrum Holdings’ submission online. •

APPLICATION FOR LEARMONTH QUARRY EXPANSION Walsh Ballarat Quarries has lodged planning documents with the City of Ballarat, in regional Victoria, for the expansion of the Learmonth Quarry.

The City of Ballarat has received a planning permit application for the Learmonth Quarry expansion.

Learmonth is a basalt site located in the town of Blowhard, Victoria.

The quarry has a total resource estimate of 9.5 million tonnes. Its current open area is 32ha, with the proposal to provide an additional 44.2ha.

This will provide continued extraction of basalt toward the east of the approved area.

According to a Terrock Consulting Engineers blasting impact assessment for the extension , blasting has been conducted at the quarry for more than 30 years. “… the rock structure beneath the

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Quarry March 2021

The proposed expansion of the Learmonth Quarry. Image courtesy of BCA Consulting - Earth Resources.

extension area is not anticipated to present new challenges for shotfirers and blast designers familiar with the regional geology,” the application stated.

The closest house to the extraction area is 410m south of the proposed extraction area.

The rehabilitation plan for the site aims to return it to a “safe, stable and sustainable manner” that blends in with its surroundings.

The proposal to extend the extraction area of the quarry will have an estimated cost of $850,000. •

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NEWS

FEDERAL GOVERNMENT LAUNCHES $600M RECYCLING MODERNISATION FUND The new Recycling Modernisation Fund (RMF) announced by the Federal Government will support recycling infrastructure for sorting, processing and remanufacturing materials.

The RMF aims to combat the waste export ban by futureproofing Australia’s waste and recycling industry, encouraging a circular economy by diverting recycling materials such as glass and plastic into road aggregates.

The Federal Government will invest $190 million into the RMF, with funding also being provided by state and territory governments.

It is expected that more than 10,000 jobs will emerge through the RMF, with over 10 million tonnes of waste to be diverted from landfill.

State and territory governments will be responsible for directing the funding to specific projects.

A total of $8.1 million will be offered in first-round funding for seven glass and plastics projects in Victoria, while there will be an $11 million joint funding agreement for Tasmania’s recycling industry.

The Federal Government will direct $20 million in funding to Western Australia, which is required to be matched or exceeded by industry investment, with combined total investment expected to be more than $60 million.

The Australian Capital Territory’s Material Recovery Facility will also receive a major upgrade through a $21 million partnership between the Federal and ACT Governments. •

The new RMF will see Australia step up in its domestic recycling capabilities.

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Quarry March 2021

ADBRI EXTENDS LIME CONTRACT WITH SOUTH32 TO 2029 “OUR LIME BUSINESS REMAINS UNIQUELY POSITIONED WITH OPERATIONS AND LOGISTICS CAPABILITIES STRATEGICALLY LOCATED TO RELIABLY SUPPLY CUSTOMERS IN WESTERN AUSTRALIA, SOUTH AUSTRALIA AND THE NORTHERN TERRITORY.”

Adbri will exclusively supply lime to South32’s Worsley Alumina refinery in Western Australia for a further five years.

The contract will see the aggregates company extend its supply relationship at the Worsley Alumina refinery to more than 40 years.

Adbri expects that $224 million of revenue will be generated over the term of the contract to 2029.

The contract is a filip to Adbri which in 2020 ended its lime dealings with long-term customer Alcoa, which chose to purchase imported products.

Adbri chief executive officer Nick Miller said the company’s lime business is positioned to continue to supply to its Western Australia, South Australia and Northern Territory customers.

“We are pleased to extend our long-term relationship with South32’s Worsley Alumina refinery,” he said.

“The extension of the contract demonstrates the strength of our Western Australian production and transport infrastructure assets which enable us to deliver a high quality product offering that is competitive

South32 Worsley Alumina operation. Image courtesy of South32.

against imports.

“Our lime business remains uniquely positioned with operations and logistics capabilities strategically located to reliably supply customers in Western Australia, South Australia and the Northern Territory.”

Worsley Alumina is a bauxite mining and alumina refining operation and is one of the largest and lowest cost alumina producers globally.

South32 holds an 86 per cent interest in Worsley Alumina, with Japan Alumina Associates owning 10 per cent and Sojitz Alumina owning four per cent. •

HOUSING CONSTRUCTION TO FLAG BY MID-2021 Deloitte Access Economics (DAE) has predicted housing construction in Australia will decline.

DAE’s quarterly business outlook suggests that while damage on the economy from COVID-19 has eased, the impact will persist in 2021.

However, Australia is one of five nations that will enter 2021 in a strong position due to low COVID-19 cases and the introduction of a vaccine.

DAE’s outlook expects that housing construction will bottom out by mid2021, with about 37,000 housing starts but recover to 50,000 by 2023.

By mid-2023, DAE anticipates the unemployment rate will drop to 5.5 per cent.

“COVID numbers are very low, the vaccine news is excellent, confidence

is rebounding, Victoria is catching up to the recovery already underway, there are heartening developments in job markets, and China’s trade war with Australia has – so far at least – actually added to national income rather than hurt it,” DAE stated.

According to DAE, Victoria will experience the highest economic growth of all states and territories in 2021 at 5.3 per cent.

House prices are rising due to low interest rates and support packages, while construction activity is falling.

Oversupplied markets, high debt and unemployment, and fear about the rollback of government incentives like JobKeeper are adding to the decline in construction activity, DAE said. •

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NEWS

CSIRO ROADMAP ENCOURAGES RECYCLED AGGREGATES

VRX SILICA CLOSES IN ON OFFTAKE PARTNER VRX Silica has received interest in offtake agreements for its Arrowsmith North and Muchea projects.

VRX Silica highlighted that the samples had been sent to eight potential customers, according to an ASX announcement on 31 December, 2020.

VRX managing director Bruce Maluish said COVID-19 had not impacted Asia’s interest in silica.

“VRX is in an enviable position as we continue to engage with potential customers in South Korea, Japan, Philippines, Malaysia and Thailand,” he said.

“Demand is growing for high quality silica sand products across southeast Asia while the supply side continues to be squeezed.

“Despite the inevitable slowdown earlier this year [2020] due to COVID-19, most organisations in southeast Asia we are engaging with have expressed positive sentiment towards stimulus spending and growth in construction in general across the region, and are gearing up their operations for 2021 and beyond.”

Maluish said VRX Silica is moving closer to selecting its first offtake partner and expects to agree terms in 2021.

“VRX has received a tremendous level of interest for offtake from both our Arrowsmith North and Muchea projects, and we are much closer to selecting our first offtake partner to underpin development.

We expect to agree terms in early 2021.” •

A map of VRX’s Arrowsmith North, Central and South projects, about 300km north of Perth, WA. Image courtesy of VRX Silica.

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Quarry March 2021

“SCIENCE CAN TRANSFORM OUR ECONOMY INTO A CIRCULAR ONE ... AND INDEED A VIRTUOUS CIRCLE THAT CREATES BETTER JOBS, NEW TECHNOLOGY, AND PROTECTS THE ENVIRONMENT.”

The CSIRO has outlined strategies to create jobs and build profits through recycled plastic, glass and tyres.

The National Circular Economy Roadmap advocates an increase in market development and demand for recycled materials and nationally consistent governance for supply chains. The CSIRO estimates that increasing the recovery rate by five per cent would add $1 billion to Australia’s GDP. “Australia is among the world’s best in advanced manufacturing and environmental research, and that unique science can turn industry and environment into partners by making sustainability profitable,” CSIRO chief executive Dr Larry Marshall said.

“Science can transform our economy into a circular one that renews and reuses what we previously discarded, and indeed a virtuous circle that creates higher paid jobs, advances new Australian technology, and protects our environment.”

Six elements on the roadmap include retention of materials through use and collection, improved

Australia loses $115 million of paper and $70 million of litter to landfill each year.

recycling technologies, design and manufacturing innovations, development of secondary material markets, nationally consistent governance, and a zero waste culture.

The CSIRO added there would be more incentive for the construction industry to employ recycled glass in construction materials with updated construction material standards.

The roadmap can be viewed at csiro.au/en/Research/Environment/ Circular-Economy/Circular-Economyindividual-products •

VICTORIA KEEPS TOP SPOT FOR CONSTRUCTION WORK DONE CommSec’s State of the States report has revealed construction work in the September 2020 quarter exceeded the decade average in four states.

Construction work in Australia has flourished off the back of big spending from state and federal governments in 2020.

CommSec calculated the real value of residential, commercial and engineering work completed in the September quarter, finding Victoria, Tasmania, New South Wales and South Australia exceeded the decade average of construction work done.

“In four of the states and territories, construction work in the September quarter was higher than the decade average, down from five economies in the previous

quarter,” CommSec stated.

Victoria retained its top position for construction work done at 18.8 per cent, while Tasmania (11.2 per cent), New South Wales (9.6 per cent) and South Australia (7.2 per cent) all scored above the decade average.

The Northern Territory was 65 per cent below the decade average, while Western Australia was down 43.8 per cent.

Tasmania had the best performing economy in Australia for the fourth year in a row. It recorded 23.5 per cent above the decade average for dwelling starts, with home building strengthened through population growth and low house prices. •

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NEWS

NORWEGIAN QUARRY ROLLS OUT AUTONOMOUS VEHICLES

FORMER UK QUARRY BECOMES STAR WARS SET PIECE Local residents have knocked Disney for allowing an abandoned quarry to be transformed into a filmset for the company’s Star Wars: Obi-Wan Kenobi television series.

The former Spade Oak gravel quarry was opened by the Folley Brothers in 1966, before transferring ownership to Lafarge Aggregates in the 1990s.

Wycombe District Council acquired the quarry from an overseas investor in 2019.

Located in the UK town of Little Marlow, Buckinghamshire, the site is situated near Spade Oak Lake.

It could now be used for up to three years for the Star Wars series.

Residents have raised concerns about disturbances to wildlife, traffic and light pollution in the town.

“This is a massive production and a hugely lucrative franchise – but obviously not everyone locally is pleased to see Disney moving in,” a source told The Sun (UK).

“It might generate some jobs, but this is a pretty rural area which has always been quiet and peaceful – the thought of turning it into some sort of intergalactic war zone to make TV shows is horrifying.

“The set is massive, with great big buildings on it alongside loads of heavy duty machinery coming and going – it’s just totally out of keeping with the countryside vibe here and people are up in arms about it.”

Filming for the Star Wars: ObiWan Kenobi series is due to start in March 2021. •

A filmset for a Star Wars TV show has been built at an abandoned quarry.

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Quarry March 2021

“ROMARHEIM IS A VERY FORWARDTHINKING CUSTOMER WHO IS EXCITED TO BE PART OF THIS INNOVATION PROJECT.”

Automation systems specialist Steer Tech will develop technology for an autonomous dump truck fleet at a Norwegian quarry under a new contract.

Quarry company Romarheim has signed the contract to provide more efficient and cost-effective autonomous operations.

The contract is the first time Steer has partnered with a quarry company.

Works at Romarheim’s stone quarry in Osterfjord under the contract will involve loading autonomous trucks with stones to follow a set route into a shaft that leads to the crushing plant for processing and distribution.

Steer co-founder Njål Arne Gjermundshaug said the Osterfjord quarry was a suitable testing ground.

“These are quite repetitive tasks, and this is a perfectly sized project to test our autonomous solution even further,” Gjermundshaug said. “In addition, Romarheim is a very forward-thinking customer who is excited to be part of this innovation project.”

Steer’s autonomous construction equipment has previously been involved in clearing large artillery

A quarry in Norway is looking to improve its efficiency with autonomous haul trucks.

ranges in dangerous areas.

Romarheim has previously focused on improving mass transport systems at its operations, with automation being the next step.

The company hopes automation will prevent personnel from entering hazardous areas to reduce injuries, while boosting efficiency and reducing the equipment’s maintenance costs.

By using Steer’s technology, a wheel loader operator will be able to oversee and direct trucks by using an iPad. The project is set to commence in the first half of 2021. •

HISTORIC GRANITE QUARRY EXHIBITION IN EUROBODALLA A photographic exhibition showing the history of four granite quarries in New South Wales’ Moruya region has been on display at the Eurobodalla Libraries.

The exhibition - Our past in pictures: A closer look at the history of Moruya granite - was on display at the Batemans Bay, Moruya and Narooma libraries.

The four granite quarries supplied granite for structures including the Sydney Harbour Bridge and Sydney Cenotaph.

Eurobodalla Libraries used photographs in the exhibition to document the early days of granite quarrying in the Eurobodalla Shire.

The Eurobodalla granite quarry had a workforce of 250, which included

men of 13 nationalities.

Libraries’ co-ordinator Samantha Fenton said the images provide a unique way for people to connect to the story being told, compared with reading.

“The exhibition of seven photographs shows some landmarks from the quarrying days,” she said.

“The group shots are particularly compelling. There’s something about looking at portraits – you think, ‘What was it like to live like that?’”

The three libraries included enlarged copies of the seven photographs held by the Moruya and District Historical Society along with a take-home fact sheet based on granite quarrying in the region. •

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COST-EFFECTIVE QUARRY KIT To keep operations flowing, the SKF Quarry Kit meets daily bearingrelated maintenance. It features all the quality components for a high performing bearing system, eg a SNH plummer block housing, four-lip seal, a SKF explorer open or sealed spherical roller bearing, automatic single point lubricator, end cover and other accessories. By incorporating these solutions into a handy package, the Quarry Kit enables operations and site managers to order components that would be costly if obtained separately and saves on considerable time and expense researching multiple solutions and reduced inventory. Applied Industrial Technologies is the exclusive distributor for the quarry kit in Australia and New Zealand.

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EXTRA CONTROL WITH C3 CONE The C3 mobile crusher, equipped with its MC300 (223kW) cone, is capable of producing high specification material with increased throughput. With large stockpile capacity and customer-focused features, the C3 cone crusher puts McCloskey at the fore of mobile crushing plants and pushes the boundaries of industry performance.

The C3 crusher provides a high degree of control over the final product, making it an ideal mobile secondary unit.

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Quarry March 2021 17

LOAD & HAUL The Liebherr L 580 XPower in action at Coragulac Quarries, near Colac, in Victoria.

WOMBAT ROCK SITE CEMENTS TWO-DECADE RELATIONSHIP

A Victorian southwest coast quarry has steadily grown its relationship with a major OEM, hailing clever design, fuel efficiency and cost savings as the backbone of their 25-year partnership – and all while extracting a colloquially famous rock.

Q

uarries in regional Victoria are vital to progressing the state’s infrastructure demand which drives the economy and requires huge amounts of crushed aggregates.

Coragulac Quarries is no exception, having operated out of Colac, about 150km southwest of Melbourne and 40km inland from Bass Strait, for more than 50 years.

The site produces between 120,000 and 150,000 tonnes of aggregates per year, which are sourced from three work authorities owned and operate by Coragulac.

Current owners Phil Boyd and Steve Lang have operated the site for the past 25 years and have enjoyed significant growth in the business.

“Phil and I have owned the quarry since 1996,” Lang told Quarry. “In that time it’s grown threefold.”

Coragulac’s key products include crushed rock and crushed concrete, basalt, drainage rock, red gravel, scoria and volcanic tuff rock (locally known as “wombat”).

Coragulac’s “wombat” aggregate is renowned in the Colac region, and is sourced by extracting the rock from an extinct volcano for which the area is renowned. It is mainly used as an alternative to driveway gravel, but can also be used for stones in buildings.

The site is also capable of crushing concrete aggregate for re-use which provides a lower cost alternative construction material.

18

Quarry March 2021

Coragulac’s products are delivered, laid, compacted and rolled for a number of applications, “mainly in construction projects,” according to Lang.

The company offers delivery to surrounding regions, including Geelong, Beech Forest, Apollo Bay, Lavers Hill, Wye River, Cressy, Winchelsea, Lorne, Beeac and Birregurra.

AN EFFICIENT CHOICE Supporting Coragulac’s extensive output of products is a fleet of Liebherr machines that offer a wide range of benefits matching the capabilities of Boyd and Lang’s quarry.

Boyd said Coragulac Quarries currently uses seven Liebherr machines that have proven reliable after the company first purchased a second-hand PR 732 dozer in the late 1990s. It is still used on the site today.

“We actually bought our first new Liebherr machine in 2001,” he said. “It was an L 538 wheel loader. We’ve still got it and it’s been quite reliable.

“We’ve also got two L 580 XPower wheel loaders, a PR 732 dozer, a PR 764 dozer, an R 916 excavator and an R 922 excavator.”

A major factor in Boyd and Lang’s investments has been the competitive price and value of Liebherr’s machines along with their fuel economy.

“Value for money and fuel efficiency leading to lower operating costs are two of the biggest benefits that have kept us coming

back,” Boyd said. “We definitely find that their price point is competitive, offers a high level of reliability and ease of operation.”

As the cost of fuel continues to rise, a fuel-efficient machine such as the Liebherr L 580 XPower wheel loader has had plenty of benefits for the company.

“The big one is fuel economy,” Boyd said.

“You hate to see the profit margins going up the exhaust pipe!”

LOADER’S ‘X FACTOR’ The most recent L 580 XPower wheel loader purchased by Coragulac in 2020 has maximised the company’s fuel savings even further.

“The L 580 XPower is fast, efficient, and a large sized machine ,” Lang said. “The last one we bought was 10 months ago. It has been operating on 12.7 litres per hour. You’d probably expect the fuel consumption to be twice or thrice that amount.”

The XPower driveline brings together the benefits of both hydrostatic and mechanical drives. The interaction between the two different drives is automatically adjusted to suit any application. As a result, the XPower offers optimal efficiency during loading and transport, without noticeable gear shifting or interruption in tractive force. The machine can produce 233kW of power with a tipping load of 19.5 tonnes to 22.2 tonnes while providing significant fuel savings.

“The intake between these two drives is continuously adjusted automatically to basically any given application,” Andreas Holzmueller, the Victorian area sales manager for Liebherr’s earthmoving division, told Quarry.

“As a result, the XPower offers an optimal level of efficiency not only during material loading as well as providing maximum acceleration and performance along all loading cycles – including long routes. All components are also ideally adapted to each other. ‘Power’ stands for maximum efficiency.”

According to Holzmueller, the L 580 has a very well thought out design that enables simpler and safer daily maintenance routines.

“The most important points for daily maintenance can be seen at a glance in the access area of Liebherr XPower wheel loaders,” Holzmueller said.

“All points requiring day-to-day maintenance can be reached comfortably, safely and cleanly. Safety features like anti-slip steps and sturdy handrails provide a high degree of safety “For Coragulac Quarries, the time and cost savings through simple maintenance is a benefit as well.

“The unique positioning of components to the rear of the machine gives optimum weight distribution and excellent maintenance access. As a result of the excellent maintenance access, items requiring servicing are within easy sight and convenient reach.

“The engine hood, which opens up electrically towards the rear, ensures safe, free access to the entire engine compartment with all service points easy to see and reach.

All maintenance work can be carried out comfortably and safely from a level base in the engine hood.

“The modern, ergonomic cab design provides exceptional all-round visibility that allows the operator to work with high concentration without being fatigued – this increases safety and productivity.”

A LONG-LASTING PARTNERSHIP While Liebherr offers quick and reliable service carried out by qualified service specialists, Boyd and Lang have had a hassle-free experience with its fleet.

“We don’t need it,” Lang said. “But Andreas keeps in touch with us all the time.

“He’s been a pleasure to deal with over the years.”

Holzmueller has developed a strong relationship with Boyd and Lang since he first joined Liebherr’s local sales team.

Coragulac Quarries director Steve Lang: “The L 580 XPower is fast and efficient.”

SPECS

LIEBHERR 580 XPOWER WHEEL LOADER

TIPPING LOAD

19.5 – 22.2 tonnes

BUCKET CAPACITY

4.50 - 14m³

SPECIFIC BULK WEIGHT OF MATERIAL

0.45 - 1.80 t/m³

OPERATING WEIGHT

27.6 – 30.1 tonnes (27,650 - 30,100kg)

ENGINE OUTPUT (ISO 9249)

230kW

RATED OUTPUT (ISO 14396)

233kW

EMISSION STAGE

Tier 4f

“When I first started at Liebherr, my first customer was Coragulac Quarries,” he said.

“From the moment I arrived, I could sense the strong bond between Liebherr and Coragulac Quarries. As a Liebherr employee, seeing only Liebherr machines on site gives me a sense of pride.

Apart from reliability, high performance and comfort, Liebherr has built its brand on customer relations.

“Liebherr Australia already has a very strong reputation for customer focus in its after sales activities,” Holzmueller said. “We have a Liebherr team which is structured to respond quickly and effectively to any queries from the customer.”

Holzmueller said what separates Liebherr from its competitors in Australia is its ability to be in daily contact with its European manufacturing plants, to provide next day spare parts supply, on-site repairs or major overhauls in their workshops.

“Liebherr is a global company with a national footprint in Australia and New Zealand. We have facilities that are located

around Australia and are staffed and equipped to support our customers and provide the most appropriate solutions,” he said. “Our products are designed with Liebherr’s customer needs in mind.”

The presence of a local Liebherr team has also led to Boyd and Lang developing a strong bond with Liebherr.

“To Liebherr, you’re not just another number. They bring personal connect to our relationship” For Holzmueller, Liebherr’s customer relations continue to pave the way for its success as a trustworthy and reliable company.

“One of the key factors of success for Liebherr is the strong ties between Liebherr and its customers and I think our 25 years of relationship with Coragulac Quarries is a testimony to that.”

To learn more about the L 580 XPower, visit: liebherr.com/en/aus/products/constructionmachines/earthmoving/wheel-loaders/ details/241928.html. • Source: Liebherr Australia

Quarry March 2021 19

LOAD & HAUL

INTEGRATED MACHINE CONTROL BOLSTERS HAZARDOUS ROCK FACE

When New Zealand contractor Fulton Hogan was awarded a contract to remediate a steep, unstable rock face overlooking the Port of Otago, it faced a number of challenges to deliver the project safely, within a tight budget, and in a highly visible location.

T

he goal of the project, known as the Flagstaff Hill Earthworks, was to stabilise a steep hazardous rock face next to the Port of Otago.

Also known as Observation Point, reclamation of areas of the port during the 1990s had resulted in an unstable rock face, with several slips, as well as rocks and boulders falling to the road below.

For the past 20 years, half the roadway at the foot of the face has been battered off with safety fencing to protect public roads and walkways.

The area is one of outstanding beauty, with views to Otago Harbour’s historic Quarantine and Goat Islands, and across to the Otago Peninsula.

A KiwiRail line for freight and daily passenger services during the cruise ship season runs adjacent to the site, while both locals and tourists use the road and tracks below for recreation.

Over the years, slips have caused closure of the road, while frequent rock falls and boulders have come down the slope.

20

Quarry March 2021

At the turn of this century (circa 2000), Port Otago installed a shipping container wall across half of the road, along with additional safety catch fencing, to minimise risks and protect the public. At the same time, an adjacent log yard storage and handling area was reduced, to allow the public road to use part of the Port’s land for access.

The unstable nature of the face meant daily inspections of the road had to be carried out since the 1990s works. Slips, boulders and rock falls had to be removed on an all too regular basis.

ASSESSING THE FACE Consulting engineers WSP Opus were awarded a design contract to assess the underlying geology and develop a design for a cut slope with benches to remove the risk of further slips and rock falls in the area. The result of the design was the planned removal of 47,735m3 of material.

Fulton Hogan successfully tendered for the works, which commenced in the winter of 2019, completing the project in the four

months to October 2019.

According to Grant Sime, Fulton Hogan’s senior project delivery manager in Dunedin, the contract scope was to work at height on an unstable rock face and strip off more than 47,000m3 of clay and rock, and safely remove all the material from site.

“Before we would work out where and how to start the physical work, the entire site needed to be accurately surveyed,” Sime said. “With existing gradients of 70 per cent and greater, combined with the instability of the ground, putting people on the slope face would have been extremely dangerous.

“Using our own in-house surveying team, and external subcontractor Jared Reeves of Overview Surveying, we carried out a point cloud survey using a drone to understand what we were up against.”

The pre-start drone survey was mapped against the required finished batter of 35 per cent, along with three five-metre wide benches at the top of the slope, so the exact quantities of material to be excavated were known.

Given the safety and operational challenges of excavating on such a steep, unstable slope, Fulton Hogan sought input from excavator operators Ray Te Huna and Kevin Patrick on how best to proceed.

Sime describes Te Huna and Patrick as two of the best operators in the region.

“It’s simple,” Te Huna said. “When you are loading out from a digger, you sit on top of the material and load out while your mound comes down gradually.”

Sime said this response gave Fulton Hogan the basis for how to proceed, knowing the company had full engagement of its expert operators. “Together we developed a plan.”

With the drone survey having provided a highly accurate 3D overview of the existing site, and WSP Opus providing a 3D model of the required final design, making use of an excavator fitted with precision GPS-based machine control was the solution.

PRECISION CONTROL MACHINE Fulton Hogan purchased a Komatsu PC210LCi-10 intelligent Machine Control

Designs can be imported into the PC210LCi-10’s iMC systems and portrayed on the in-cab screen to assist the operator.

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LOAD & HAUL

Fulton Hogan’s Komatsu PC210LCi-10 hydraulic excavator working at the foot of the face.

The excavator was part of an extensive program to strip off more than 47,000m3 of clay and rock.

(iMC) excavator specifically for this project.

Based around Topcon Positioning Systems’ precision machine control capabilities, fully factory-integrated within the machines, iMC allows earthworks to be carried out to millimetre-level accuracy.

“Having intelligent Machine Control on this excavator was magic,” Sime said. “Not having to set out pegs using manual survey methods improved efficiency ten-fold. And because we didn’t have to have a surveyor on

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Quarry March 2021

the ground, it was much safer.

“In that type of environment, we had no option but to start at the top and work down, and there was no going back.

“And the end result was without a doubt the best batter slope I have ever been associated with,” Sime added. “It wasn’t just a simple slope either; it was benched at the top, then battered and curved around to follow the line of the point.”

The designs for the batter were provided to

Fulton Hogan electronically, then downloaded to the iMC excavator, so at all times it was working to the client’s designs.

“In addition, the client accepted the asbuilts coming out of the machine,” Sime said.

“Then, when we completed the 47,000m3 material removal, we were between 80m3 to 100m3 out, compared with the original design. It was so close, the client was just blown away. We are very proud of how close we got; in terms of that volume of material, it was nothing,” Sime said.

When Fulton Hogan was considering which excavator machine control system to use on the project, Sime said the company looked at a number of different makes.

“With the Komatsu system, what really impressed me was the simplicity of the cab layout for the operator. In terms of the operator interface, it’s spot on. I think it offers by far the best operator layout,” he said.

OPERATOR’S VIEW Operator Ray Te Huna, who has been an earthmoving equipment operator for nearly 20 years, with the last 10 years almost exclusively on excavators, said the Komatsu iMC excavator made his job “a hell of a lot easier”.

“It also takes a lot more people off the ground, so it’s much safer and easier not having to work around them,” he said.

“Certainly, it’s heaps faster. I’m probably

50 to 60 per cent quicker doing my work, because I don’t need people to check it all the time. Now we just need the surveyors to come in and check the calibration a couple of times a week, if that.”

Since the Port Chalmers project, Te Huna has been operating the iMC excavator on a range of projects, including a logging yard extension, building pads for a large carpark, drainage works, and on an arterial road project.

“Using designs imported into the machine is so much easier,” he said. “I think I’d probably find it hard going back to a conventional machine after this.”

SURVEYOR’S VIEW Fulton Hogan’s Otago-based surveyor Craig Kenneally also said the Komatsu iMC concept has made his job much easier.

“I like the Topcon operating system, I always have, because you can put your drawing files straight into it, rather than having to use third party software,” he said. “That’s one less step, and it’s easier than loading up terrain models.

“And because the sensors in the Komatsu machine are integrated, the excavator works really well, as you don’t need to worry about them getting knocked. I’ve seen how vulnerable they can be with the bolt-on systems.”

Kenneally said Komatsu’s Smart Construction crew also provided invaluable support. “There’s a feature where they can log into the excavator’s system remotely and help us out where there’s any issues. There was a bit of a training/transition period when we first got the kit, but the support’s always been really good.

“With the Port of Otago, we flew a drone over the job every few weeks to check everything.

But on a nearly 50,000m3 job, to come within one to two truckloads is really good.”

Kenneally worked closely with operator Te Huna setting up project protocols and loading the data. “It’s also really nice that it’s got that feature where I can load the data externally whenever we get a new set of plans to work from.

“At the Port of Otago, we were using the

excavator to quality assure all the time. Ray would go to a known point to check it was calibrated, and it was always consistent, always good.

“We were very happy with the data coming off the excavator, it was always very close to what we were getting off the drone and our other surveying systems,” Kenneally said.

Komatsu’s Smart Construction program consists of five phases – from initial site survey and design, through to machine control management, machine interconnectivity and review of project progress. It builds on industry-leading expertise in machine management through an INSITE fleet management centre, the KOMTRAX remote monitoring service and its iMC offerings, which are currently available in dozers and excavators.

For more information about Komatsu’s Smart Construction program and offerings, visit komatsu.com.au/innovation/ smartconstruction • Source: Komatsu Australia

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LOAD & HAUL

SIZING AND GAINING THE MOST FROM YOUR MINING EXCAVATORS AND HAULERS

The A45G haul truck easily accounts for a winding track.

I

n the extractive industries, it is important to match excavators to your haul trucks to lower your total cost of ownership (TCO).

If they are mismatched, you will be inefficient and burn extra fuel. If you can mitigate that, you will lower your operating costs over time and start realising higher profits as a result.

Below are some tips to help you properly size your haulers and excavators, plus ways to ensure you are getting the most of the construction machines you run each day.

There are tools out there to help you size and pair machines depending on your setup and situations. In most instances, Volvo Construction Equipment’s Site Simulation tool can be adopted to look at the job, the haul roads, the total distance, the time constraints and the material that needs to be moved. That information is used by CJD Equipment to rightsize the truck fleet to the excavator to increase an operator’s efficiency on the job. While many customers already know what they want, they can still be guided in the right direction as CJD talks more about its unique set-up. For example, if a single A60H haul truck can match (or even increase) production over two A45Gs, they can potentially reduce the fleet size, optimise the workforce and so on.

Construction weight and excavator calculators can help producers uncover costs and savings they may not realise up front.

Volvo CE utilises a proprietary sales toolbox with customers alongside its dealers. These

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Quarry March 2021

worksheets calculate TCO on a machine, allow customers to select different specifications for certain machines (eg buckets, boom configuration, etc), calculate fuel consumption, the number of passes to fill a hauler, and more.

It is a handy tool to ensure customer fleets are sized correctly for the type of work at hand.

Once your haulers and excavators are sized correctly, the following tips will help you get the most out of them: • The most efficient way to load a truck — for the fastest cycle times — is side loading.

Don’t waste time, fuel and money backing in and manoeuvring your trucks. If you can set up your site to side load, you will experience faster cycle times and lower operating costs over time.

• When loading the bucket, make sure you have good, heaped loads go in the truck, and utilise the bed as much as possible.

It is best practice to evenly distribute the load across the bed. You want to feather the material into the truck because it won’t have that “splat” effect that usually leads to material sticking to the bed. This is especially true in sticky clay situations.

• Configure your mining excavators appropriately with boom and arm options.

Some customers prefer a longer reach, while others want as big a bucket as possible to load more material, which requires a shorter boom and shorter arm. The most popular compromise between reach and the bigger

bucket approach is a hybrid — a standard boom and short arm. The advantage of a hybrid configuration is that reach is reduced by about one-third of a metre but lifting capacity can be increased by eight per cent or more. Obviously, there’s give and take with different arm and boom configurations, so it is important to configure your excavator for the type of work you are doing, then ensure your haul trucks are appropriately matched.

• Use on-board weighing scales to improve accuracy. Volvo CE offers Haul Assist onboard weighing, which comes standard on A30G through to A60H models. With other manufacturers, the scales aren’t standard equipment. The Haul Assist scales help operators see each loading cycle. The lights on the end of the mirrors on the truck are indicators. Yellow means put more material in the bed, green is perfectly loaded, and red is overloaded. Operators can always tell exactly where they are at in the loading cycle as far as the actual bed capacity. Anywhere from 90 per cent to 110 per cent of the bed capacity is considered a perfect load.

• Working with an OEM and a dealer who have parts and can react quickly is critical.

Your support will be even faster when you use telematics systems to diagnose and take care of problems before they become catastrophic issues.

If your operation moves a lot of material and you’re looking to gain some efficiencies in your cycle times, you might also consider pairing up an EC950E excavator with A60H haulers. You will move more tonnes and keep your haulers moving without burning excessive fuel.

It has been more than 25 years since construction giant Volvo CE partnered with CJD Equipment. This successful partnership has supplied Australia with Volvo’s world-class products, along with after market service and support right across the country.

CJD’s branch and dealer network spans the country, providing 24/7 sales, parts and service support from more than 500 highly experienced staff with knowledge and skills.

For more information on CJD Equipment’s Volvo CE line-up, visit cjd.com.au • Source: CJD Equipment

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LOAD & HAUL

A SCRAPER ADAPTED FOR QUARRYING APPLICATIONS

Primarily used for earthmoving in coal, civil construction or agricultural applications, the wheel tractor-scraper is being adapted for quarrying applications, courtesy of a global OEM.

W

ith a field-proven, twin-power design to boost cycle times, the new Caterpillar 657 wheel tractor-scraper (WTS) elevates productivity and operating efficiency to deliver low cost earthmoving.

The WTS offers a seven per cent increase in fuel efficiency over its predecessor the 657G, meaning more material moved per unit of fuel burned, and improved on-board payload estimating accuracy helps optimise productivity. With a rated load of 46.4 tonnes, the 657 WTS features the largest open bowl scraper in the Caterpillar line-up, and now has a more spacious cab to boost operator comfort and efficiency in high volume earthmoving, highway construction and mining applications.

“This new 657 is the next generation of ultraclass material moving systems,” said John Gerhold, Caterpillar’s wheel tractor-scraper application specialist. “It delivers improved productivity, safety and technology, which our customers can use to strengthen their business today—and it is equipped to grow with them to meet tomorrow’s requirements.”

The 657 features on the go weighing through a payload estimator, allowing the new WTS to achieve 95 per cent load accuracy, so operators more easily reach target load goals. When working in colder climates, the unique auto-stall feature quickly brings the transmission to operating temperature at start-up, so the 657 goes to work faster.

A ground speed control function lowers

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Quarry March 2021

fuel consumption by allowing the operator to set the desired top speed, and enabling the machine to find the gear that works best for the engine and transmission.

The two-engine design includes the Cat C18 powering the tractor and a Cat C15 in the scraper, both meeting stringent US EPA Tier 4 Final/EU Stage V emissions standards.

The Advanced Productivity Electronic Control System (aka APECS) allows the machine to better utilise engine power and torque, resulting in more material moved throughout the shift. The transmission features Electronic Clutch Pressure Control, which improves shift quality and fuel efficiency. New hydraulic disc brakes improve braking performance and reduce maintenance.

COMFORTABLE OPERATION Comprising a 21 per cent larger cab interior than the preceding model, the new 657 improves operator comfort and provides superior visibility to the bail, cutting edge and bowl. The air suspension comfort seat adjusts and rotates 30 degrees to reduce fatigue, while the new Advance Ride Management controls adjust damping to match ground conditions, resulting in a smoother ride for the operator. An automatic HVAC temperature control and defroster come standard for increased operator comfort. The new power access ladder enhances operator safety when entering and exiting the cab.

The new high pressure steering system requires less steering input, bolstering operator efficiency and productivity. An

engine overspeed protection function automatically engages when the machine is in eighth gear, assisting in slowing machine speed when approaching engine limits. A new option on the 657 – Sequence Assist – automates many operator inputs each cycle to simplify machine operation.

INCREASED EFFICIENCY The 657 tractor includes a new hydraulic on-demand fan that increases engine fuel efficiency. The machine also has draft arm overflow guards, which prevent material accumulation between the draft arms and bowl sides. Ground level access for fuel fill and all daily maintenance points increase service efficiency and safety to increase machine uptime.

Integrated Payload Estimator and Cat Product Link technologies provide real time payload, machine location, fuel usage and idle time information as well as diagnostic fault codes—all to significantly increase fleet management efficiency. A collective view of critical machine operating data is accessed via VisionLink® from any internet connection.

My.cat.com links managers directly to their VisionLink® account and offers access to maintenance schedules, parts and service records, and warranty information.

For more information about the Cat 657, visit the Caterpillar Australia and New Zealand website – cat.com/EN_AU – or contact your local Cat distributor. • Source: Caterpillar of Australia

SPECS – CATERPILLAR 657 WHEELED TRACTOR-SCRAPER ENGINE

TRANSMISSION

Tractor engine

Cat C18

Top Speed - Loaded

Scraper engine

Cat C15

1 Forward

5.7 kph

2 Forward

10.5 kph

469kW/353kW

3 Forward

12.5 kph

Gross power (SAE J1995)

475kW

4 Forward

17 kph

Net power (ISO 14396)

469kW

5 Forward

22.8 kph

Net power (SAE J1349/ISO 9249)

436kW

6 Forward

30.9 kph

Displacement

18.1 l

7 Forward

41.4 kph

8 Forward

56.1 kph 10.8 kph

TRACTOR ENGINE Flywheel power (Tractor/Scraper)

SCRAPER ENGINE

56.1 kph

Gross power (SAE J1995)

359kW

Reverse

Net power (ISO 14396)

353kW

DIMENSIONS

Net power (SAE J1349/ISO 9249)

333kW

Width (overall)

4.36m

Displacement

15.2 l

Width (tractor)

3.75m

Width (rear tyre centre lines)

2.81m

SCRAPER BOWL Scraper capacity - heaped

33.6m³

Width - Inside of bowl

3.68m

Rated load

47200kg

Width - Outside bowl - shipping width

3.93m

Capacity - struck

24.5m³

Height - Overall shipping

4.66m

Depth of cut - maximum

417mm

Front of tractor to front axle

4.55m

Wheel base

9.96m

Width - cut - to router bits

3.8m

Hydraulic penetration force - 657G

542 kN

Length - Overall machine

17.97m

Depth of spread - maximum

660mm

Rear Axle - Rear of machine

2.46m

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LOAD & HAUL

The WK-60 enables more accurate and reliable load scaling.

LOAD SCALES

THAT OFFER A MEASURED APPROACH A major recycled aggregates company has adopted a forward-thinking on-board weighing system for more accurate measurements and improved efficiencies.

Q

uarry operations are generally on the lookout for ways to improve their productivity and output.

The value of these materials makes it just as important to ensure each payload transported records the correct weight every time.

Overloading is of particular concern for quarries in Australia – and not just for a loss of capital.

An overloaded haul truck can face serious criminal and financial penalties while also running the risk of a potential crash.

On Board Weighing general manager Jim Eagle told Quarry that the responsibility for preventing overloading falls back on the entire company.

“The chain of responsibility means that everyone from the company, to the manager, to the loader driver, to the truck driver has some responsibility in ensuring trucks are not overloaded,” he said.

“In addition, if an overloaded truck gets to their destination they could be turned around there because of mass management responsibilities and policies at the receival point. Many companies have a zero tolerance policy to overloading.”

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To combat this issue, Kerfab subsidiary On Board Weighing offers the German-designed WK-60 scales.

Designed and manufactured by German company Pfreundt, the WK-60 is a renowned for its accuracy and reliability globally.

The WK-60 scales enable payload weighing directly from the truck which also saves time and prevents the requirement of a weighbridge and operator.

This is made possible by the WK-60’s compact and easy to read touch screen display.

“On Board scales prevent trucks from being overloaded as the loader operator can see exactly how much they’ve loaded into a truck as they are doing it,” Eagle said.

“I always say to our customers if you can use a phone or an iPad you can use a WK-60 scale.

“It is the most advanced system on the market but it’s also the easiest to operate. It’s a simple touchscreen with big clear writing so anyone can clearly see the information they need.”

With the WK-60 being the flagship model offered by On Board Weighing, the WK-60 Smart, WK-60 S, and the smaller 127mm

(5”) WK-60 XS are also available, with all models featuring accurate and reliable load capabilities.

Eagle said underloading is another major issue suffered by operations with inaccurate load scales. Thanks to the WK-60, this can also be avoided.

“The main advantage if it’s legal for trade is that you can ticket a load and make a sale from a certified instrument straight into the truck – this means you can fulfill more orders in a day and could eliminate the need for a weighbridge and operator entirely,” he said.

“It saves time for the trucks as they don’t need to get to the weighbridge before finding out it’s underloaded or overloaded.”

RIGHT FOR THE JOB A significant advantage to installing an onboard weighing system in a quarry is a lower total cost of ownership through its accuracy, reliability and reduced repair requirements.

“The best part though is that WK-60 scales are more reliable and are accurate for longer.

“When we do service or recalibrate them we more often than not find that they are still within an acceptable margin of error so servicing is

quick and easy,” Eagle said.

On Board Weighing has a network of technicians across Australia to make installation, calibrations and servicing more convenient for customers.

Alex Fraser, a leading provider of recycled aggregates in Australia, has adopted On Board Weighing’s WK-60 at its operations.

Group manager for FP & ME Maintenance Andy McManus told Quarry the WK-60 has improved accuracy for sales loading duties, while also reducing truck loading times and maximising truck capacity.

On Board Weighing was also able to diagnose an issue with a machine to further boost payload accuracy.

“The technician’s system knowledge, diagnosis reporting and support of product showed an undiagnosed fault on the machine,” McManus said. “On Board Weighing worked with us to rectify the fault and enabled repairs to be made on the loader, further improving its accuracy.

“Over and underloading negatively impacts truck turnaround times, increases

The WK-60 uses a simple 7” touch screen to provide load measurements directly from the cabin.

product wastage, and increases site congestion,” he added.

Alex Fraser’s operators were given a thorough training demonstration to show the simplicity of the WK-60. The company utilises on-board weighing to minimise truck waiting times and reduce material wastage.

Eagle explained that the WK-60 enables accurate load scaling without the need for a weighbridge, making it an attractive investment for smaller quarries, while also providing value to larger operations.

“Smaller quarries cannot afford or justify a

weighbridge so where a weighbridge may cost $80,000 to $120,000, certified scales are priced from $10,000,” he said. “(The WK-60) can be as simple or as advanced as the company needs. It can be used as anything from a basic scale to advanced scales connected via the internet to the companies’ ticketing software or anything in between.”

For more information about the WK-60 and other scales, visit onboardweighing.com.au • Source: On Board Weighing

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MOBILE PLANT A Guardian mobile plant at work at the Empire Rock Quarry, in Farmington, Minnesota.

PORTABLE PLANT GAINS WITHOUT REINVENTING THE WHEEL

A leading heavy equipment supplier explains why using wheeled portable plants is advantageous for quarrying. Matthew Voigt, of Superior Industries, spoke to Quarry.

I

n a quarry, the convenience of mobile plant and equipment can go a long way to maximising both time and profits on site.

Wheeled portable plants, for instance, offer a simplified but capable alternative to fixed plant and equipment that can be transported from site to site.

Superior Industries offers bespoke portable plant solutions that focus on peak production, reliability and convenient set-up.

The US-based company has a 50-year history of chassis manufacturing and produces approximately 95 per cent of the materials used in its wheeled portable plants, which boast key benefits for crushing, screening, washing and feeding applications.

A key aspect of Superior’s expertise is that the company can provide multiple plant configurations that enable customised solutions.

Superior Industries product manager for

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portable plants Matthew Voigt told Quarry that Superior supplies the majority of its components rather than using original equipment manufacturers (OEM), making it a one-stop-shop for portable wheeled plants.

“When you look at a portable plant, we are one of the few manufacturers that can supply everything – the structure, the idlers, the pulleys, the belting. Everything on there is from Superior, minus a couple of reducers that come from Dodge and some wet motors but everything else would be a full supply of Superior components,” Voigt explained.

Superior is also capable of offering custom solutions that are compatible with other brands of equipment.

“We do custom plants so we have our standard, cookie cutter price designs but we can sit down with a customer and start from a blank slate,” Voigt continued. “You can design anything you want as long as it will

Superior Industries product manager for portable plants Matthew Voigt.

work within the means. We will design any custom plant you want, which also includes mounting competitive equipment.

“We often mount Terex equipment, Deister equipment, Metso equipment, you name it, we’ve probably put it on a chassis at some point.”

Superior Industries originally mounted other companies’ plant and equipment before developing its own but its commitment to its customers has not changed.

“We just want to service our end user customers as much as we possibly can, whether it’s with our gear or not, and give them a solution that they will be happy with,” Voigt said. “Whether it’s a fleet, custom or ground-up design, we’ll do that.”

PERKS OF PORTABILITY Superior Industries has always provided wheeled portable plants rather than tracked machines.

While tracked machines make up a significant portion of the global market, Voigt said wheeled plants are less complex and are easier to move around sites.

“The advantages would be maintenance access, which tends to be a big differentiator. There is a lot more open air to be able to maintain these units,” he said.

“They are less complicated, there is not as much electrical or hydraulic items to worry about. To move them, you don’t need a specialised trailer, you just hook it to the back of a vehicle and then just ‘grab and go’.”

Wheeled portable plants are generally powered by electricity which also lowers carbon emissions and the upkeep associated with machines that only include a diesel engine, Voigt continued.

Superior’s wheeled portable plants can be powered in three separate ways.

“There are three different ways you can look at it,” Voigt said. “There is full on-line power, where they’re obviously hooked up to line power. In many cases, they will bring a full-on big generator, like a big MCC trailer with a big gen-set that powers the entire plant, and then there is an on-board diesel that powers what is on that trailer.”

The most popular portable wheeled plant in Superior’s portfolio is the Aggredry plant. It is capable of washing and drying fine material through a singular portable configuration, and is capable of producing material with a low moisture content.

“It’s the 6’ x 20’ (1.8m x 6m) Guardian

A Superior truck takes a dual screen plant on the road.

A Guardian plant distributed by 888 Screening & Crushing Equipment in an Australian setting.

horizontal screen with a twin 36’ (11m) AggreDry dewatering washer or a twin 44’ (13m) Aggredry washer,” Voigt said.

“That will screen and make three aggregate products, and then make a completely dewatered sand down to eight to 10 per cent moisture, so that’s instantly saleable.

“That unit is a very, very popular one, especially for some of these guys moving around. They don’t have to wait a week or two weeks for their material to dry before they can sell it, they want to get it in there, get it done and get it out. Especially if you’re doing a road project, you don’t want to have to wait two weeks before you can use that sand, you can use it right out of the Aggredry washer.”

Other popular machines include the Patriot cone circuit plants and Liberty jaw plants, Voigt said.

“Our closed circuit cone plant – whether that be with a 200 or a 300 size cone, and a 6’ x 20’ triple-deck screen – is a very popular unit. Being able to have the cone and the screen all on one chassis and deal with a mix of several products in a closed circuit arrangement is a very popular one.”

The Patriot cone plants feature a closed circuit with rear, front and side discharge, while the Liberty jaw plants offer a jaw/ screen combo that is capable of crushing feed up to 1194mm (47”).

“So the Aggedry wash plant, the cone plant and our newer jaw plants are certainly our most popular at the moment,” Voigt said.

Due to the extensive range of options offered by Superior, customers are satisfied with the user-friendliness of the wheeled portable plants, Voigt continued.

“The feedback that we get is that they are

Quarry March 2021 31

MOBILE PLANT

A Liberty jaw crusher at work in the Normal Wells site in Canada’s Northwest Territory.

The most popular portable wheeled plant in Superior’s portfolio is the Aggredry plant.

very user-friendly,” he said. “We don’t try to skimp on maintenance access, walkways, platforms, etc.

“We give them plenty of options that they can have and they are customisable after the fact too. So if they want something else afterwards, there are the options to do that as well. The biggest thing is how easy it is to get at everything. It looks like it’s designed to work together, it all flows how it should.”

Guarding is an area that Superior pays close attention to, which its competitors do not include.

“We tend to go a little bit overboard on guarding,” Voigt added. ‘And we have had many customers who have had said the guarding that we put on as standard tends to exceed those of our competitors.

“They get a unit in and they know they are going to spend a day or two putting in their own guards, whereas they see our plant and know they don’t have to touch that, they can just bring it in and get to work.”

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CONTAINERISED OPTIONS While Superior may be a US company, its presence is recognised throughout the Australian extractive industry.

To save on freight costs to Australia, Superior offers containerised options for its machines rather than shipping them completely assembled.

“We have the same problems that everyone has in getting machinery to Australia – there’s not a lot of manufacturers in Australia, so it’s going to have to come on a boat at some point, so if it comes on a ro-ro (ie roll on/roll off ships that carry wheeled cargo) or in a container,” Voigt said.

“If you can get it into a container, you have a really big advantage there. With our ability to do containerised designs for that market, it has definitely created more interest.”

The company’s Shanghai facility has also been successful in reducing freight costs.

Voigt said Superior’s largest Aggredry plant model has also been purchased in Australia.

Two such machines have been installed in quarrying operations on the Australian east coast.

“We actually sold a 6’ x 20’ Aggredry plant – our biggest Aggredry plant running in Australia – not that long ago,” he said. “The Aggredry washer has been so popular for us because it can dewater your sand right away and have a nice, saleable end product immediately. That is a huge benefit.

“As far as the rest of the equipment is concerned, we can send it to an Australian customer either ro-ro or we have containerised options that can save on freight and the general capital expenditure. It comes shipped in containers versus completely assembled.”

Superior’s equipment arrives with a two-year warranty, while its wheel-mounted chassis have a five-year warranty and its Patriot cone crusher offers a lifetime warranty.

“If you buy a piece of equipment, you’ll know that will be covered for many, many years – not just the crusher or the screen, but on the structure itself – and it’s a full one-stop-shop solution,” Voigt said.

“If anything happens, you have one phone call. You don’t have to call one guy for the vibrating grizzly feeder, or another for the jaw – one single phone call can solve all your problems.”

Superior’s machines are also shipped to comply with Australian safety and road safety regulations.

“We have to customise our lighting packages to match with the Australian standards, for instance, the use of extra amber lights,” Voigt said.

“So we definitely keep that all in mind when we are sending to Australia, that we have to comply with the national codes, transport laws, whether that’s weights per axle, lighting, kingpins and such.”

Superior’s adaptation to compliance laws in different states and territories within Australia is made easy due to the customisable designs of the Superior units.

“We have engineering on just about every single unit,” Voigt added. “For us, it’s not a big deal because that’s what we do. They are all a little custom, so that’s easy for us.”

For more information about Superior Industries’ range of portable wheeled plant and equipment, visit superior-ind.com Superior Industries distributors in Australia include 888 Crushing & Screening Equipment (888cse.com.au), Tricon Equipment (triconequipment.com.au) and Rivergum Industries (rivergumindustries.com.au). •

CRUSHING & SCREENING

OEM RINGS CHANGES IN START TO 2021

M

ultinational OEM Sandvik has announced some important developments in the lead-up to 2021.

Effective from 1 January, 2021, Sandvik has established Sandvik Rock Processing Solutions (SRP), a new business area which comprises the former Crushing and Screening division that belonged to the Sandvik Mining and Rock Technology business area.

Business area Sandvik Mining and Rock Technology will continue to be led by Henrik Ager and as of 1 January 2021 also changed its name to Sandvik Mining and Rock Solutions (SMR).

The structural change is designed to accelerate the profitable growth within the rock processing solutions area, based on the old Crushing and Screening division addressing separate parts of the value chain and facing different competition to the other SMR divisions.

“Sandvik is market leading within rock processing and our Crushing and Screening division is a well performing business with exciting growth opportunities,” Sandvik’s president and CEO Stefan Widing said.

“The business is already operating quite independently from the rest of Sandvik Mining and Rock Solutions, with its own manufacturing, sourcing and aftermarket. By establishing Rock Processing Solutions as a business area we will improve transparency and strengthen our growth ambitions within the area.”

Sandvik also appointed Anders Svensson, president of the Crushing and Screening division since 2016, as president of the new Sandvik Rock Processing Solutions and as a new member of the Sandvik Group Executive Management, as of 1 January, 2021. Svensson joined Sandvik in 2008 and prior to his current position had several different management positions within Sandvik and at Metso.

The crushing and screening business had, as a division within SMR, about SEK7.4 billion ($AUD1.16 billion) in sales and a 15.9 per cent operating profit margin in 2019, with about 2000 employees.

NEW PERTH WORKSHOP Before its change of name, Sandvik Mining and Rock Technology signalled its ongoing commitment to the Australian mining and

From left to right: Andrew Dawson (Sandvik), Ben Lisle (Hesperia), Debora Paula (Sandvik), Brett Kervin (Sandvik) and Judd Dyer (Hesperia) turn the first sods on the new Roe Highway Logistics Park workshop. .

construction equipment market by signing a long-term lease for a new purpose-built workshop at Roe Highway Logistics Park, in Kenwick, Perth.

The 16,000m2 site will include an advanced workshop, modern office and meeting facilities, and testing and training equipment.

Construction is underway, with the workshop scheduled for completion in 2021.

Nathan Cunningham, Sandvik’s business line manager for service in the Asia-Pacific (APAC) region, said Roe Highway Logistics Park is a strategically important location for Sandvik’s customers.

“The strategic location of our new workshop, with its central position, freight rail and RAV7 truck access will enable us to further support our Western Australian customers and the purpose-built design will improve equipment repairs, inspections and our rebuild capability for our equipment offering,” he elaborated.

“The improved layout, increased size, additional bays and design will enable our fully trained service technicians, aftermarket support and technology specialists to work more efficiently.”

The new workshop will be fully accredited and work to OEM standards. “The high quality of our rebuilds allows us to provide full warranties on the machines we strip down and rebuild,” Cunningham said.

Kate Bills, Sandvik’s sustainability, marketing and communications manager for APAC, said the purpose-built facility will align

with Sandvik’s 2030 Sustainable Business goals, which address a circular society, climate change, safety and fair play.

“As part of Sandvik’s sustainability goals, we’re aiming to halve our CO2 footprint by 2030. The new workshop incorporates state of the art design elements to help us achieve this such as solar panels, green concrete and the use of low carbon building materials.”

The site will also include best practice water management, energy efficient lighting, natural ventilation and rainwater harvesting.

“For Sandvik, being a leader in both innovation and sustainability is key in recruiting the right talent, continuing to be our customers’ preferred choice and remaining a company that is attractive to investors,” Bills added.

Judd Dyer, director at Perth-based property developer Hesperia, added that as part of Roe Highway Logistics Park’s commitment to sustainability, a range of initiatives have been implemented across the design and functionality of the site.

“We are on the path to achieving carbon neutrality at Roe Highway Logistics Park and have a heavy focus on energy, recycling, environmental sustainability and water efficiencies,” Dyer said. “Providing brand new, purpose-built facilities for our tenants, such as Sandvik, allows us to incorporate these features and help futureproof their operations.” • Source: Sandvik Mining and Rock Solutions

Quarry March 2021 33

COMPRESSORS

SAND QUARRY SECURES A ‘PEERLESS’ SOLUTION

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collaboration between two suppliers has enabled a quarry in Victoria to introduce a suitable air compressor for its sand washing operations.

Road and infrastructure projects are poised to play a key role in Australia’s economic recovery post-COVID-19. The 2020-21 Federal Budget features significant funding for the infrastructure industry, with a $7.5 billion investment in transport infrastructure around the country envisioned in the Budget.

The increased demand for high quality fine sand and aggregates in the market means it is more and more important for quarries to improve the efficiency of their sand washing operations and reduce losses and operational costs.

BSC, as a major supplier of industrial products to the mining and quarrying industries, is leading in this area by enabling its customers to source high quality and costeffective industrial components for their plants.

An example of this was a recent collaboration between BSC and its long-term partner, Peerless, to assist a major sand quarry in Victoria find a suitable air compressor for its sand washing operations.

“The quarry is investing heavily in expanding its sand washing plants to meet the increased demand from the market,” said Paul White, BSC’s state sales manager for Victoria.

“The quarry managers approached the BSC field service representative looking for a high quality and reliable air compressor to drive the actuators and pinch plates in their two new sand washing machines. We then leveraged our close relationship with Peerless to work out the most suitable compressor for the quarry’s specific requirements,” he added.

The final solution provided by the BSC/ Peerless team was a Peerless HQ-Air 20 HP-8 Bar rotary screw compressor, which is a full feature unit comprising a rotary screw compressor, a refrigerator dryer and a 500-litre tank capable of condensing an air flow of 2400 litres per minute at 116 psi.

Troy Jamieson, national sales and marketing manager at Peerless, said the compressor was

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designed to suit the demands of the Australian market.

“Peerless compressors are designed to handle the hot conditions of Australia. The full feature HQ-Air 20 HP rotary screw compressor uses the German-manufactured Rotorcomp air end, Schneider electrical components and high quality German-made oil/air separators.

The LED colour touch screen takes away the confusion on how your air compressor is operating with all functions displayed. It can also show you the full diagnostics of the machine for easy servicing,” he said.

“With the Peerless rotary screw compressors, we test each model prior to being sent out from our factory for a minimum of six hours.

The quality assurance inspector then runs the unit through our 24-point quality control checklist to make sure the customer receives a fully checked unit. The service label clearly notifies the customer of when the next service is required,” he added.

Jamieson said the partnership between Peerless and BSC works both ways in allowing Peerless to better service the end market.

“We are proud to offer one of the widest ranges of compressors in the Australian market, from the small direct drive compressors to single-phase and threephase belt-driven compressors, dental air compressors, diesel and three-phase rotary screw compressors and more. All BSC field service representatives are fully trained on the complete range of Peerless compressors and they can guide customers on the most suitable compressors for their applications.

“Also, through working with BSC, we can offer custom-build solutions to multiple industries. A lot of our diesel compressors are installed on service trucks and commercial vehicle fleets that service the mining sector. In customising the compressors, we always prioritise space saving and weight reduction. So, for example, we have created a lift pump that goes on the air compressors to feed fuel into the compressor directly from the vehicle’s fuel tank and by doing so, we can help reduce the compressor’s weight.”

The Peerless HQ-Air 20 HP-8 Bar rotary screw compressor.

KEY FEATURES: • Rotorcomp air end with the new EVO technology.

• Schneider electrical components.

• Low power consumption – energy savings.

• German-made oil/air separator.

• Smart motor technology – MEPS approved IP55.

• Low noise.

Jamieson says Peerless is also keen on helping reduce capital expenditure for small to medium businesses by introducing an instalment-based financial program.

“Starting next calendar year [2021], Peerless will be rolling out a plan that enables buyers to purchase air compressors through weekly instalments rather than incurring huge initial capital expenditure. The instalment plan will depend on the value of the compressor being purchased. So, for example, for a small direct drive compressor, the instalment might be as small as $40 per week. This will enable our distributors, including BSC, to offer an additional service to their clientele.”

With years of experience in supplying air compressors to a range of different industries, White said the BSC team can support and advise the customer for any application.

“We can calculate and recommend the correct size and volume of air required to service a site. Our staff are also trained

by Peerless to help our customers with compressor maintenance in accordance with the manufacturer guidelines.” • Source: Motion Asia Pacific

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SMART BUSINESS

COULD MODULAR CONSTRUCTION REVAMP THE SUPPLY CHAIN? What do Walt Disney, Frank Lloyd Wright and chemistry have in common?

Ralph Belperio explains the connection.

A

research chemist posed the question: “If someone came into your house and offered you a cocktail of butanol, isoamyl alcohol, hexanol, phenyl ethanol, tannin, benzyl alcohol, caffeine, geraniol, quercetin, 3-galloyl epicatechin, 3-galloyl epigallocatechin and inorganic salts, would you take it?

“It sounds pretty ghastly,” he qualified. “If instead you were offered a cup of tea, you would probably take it.”1 Tea, the master of chemical diversity, is a complex mixture containing all of the above and the most widely consumed drink in the world. If you know what you’re doing, you only need tiny, standardised building blocks – atoms – to build a universe with everything in it, including tea.

The most complex organisms and spectacular phenomena are created by means of modular design. And if it has nature’s signature on it, you can bet it is a proven, efficient system.

If this is such an elegant approach, then why hasn’t it been fully embraced on the construction site? Why hasn’t prefab construction become mainstream if it has been around for more than a century? Will the restrictions imposed by another little chemical compound – COVID-19 – see to it that projects finally become products with the helping hand of robots, 3D printing and off-site prefabrication?

DISRUPTIVE FORCES The fragmented nature of the supply chain for property development has traditionally limited the industry’s conversion to modular construction. A small building potentially comprising more than one million parts is typically supplied by up to 10,000 suppliers

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Could building structures in the future be as simple as Lego construction?

from 12 to 15 countries. In most instances, there is limited dependency between these suppliers, the parts they produce and the almost infinite permutations and combinations of building design.

However, COVID-19 is now making some countries across the world re-examine their global supply chains and question their nation’s resilience for continuing to build

in the wake of significant supply chain disruption, as evidenced by Australia’s recent commitment to re-energise a manufacturing sector that has been hollowed out for 30 years with a $1.5 billion Modern Manufacturing Strategy.2 The construction industry is notorious for lagging behind in adopting advanced technologies. But post-March 2020, if you

visit a site where only 25 per cent of the workforce is allowed and everyone needs to be 1.5 metres apart, the need for a big overhaul in thinking and behaviour quickly becomes apparent. Modular design is about flexibility, after all. With the 26 letters of the alphabet, we produce endless books. With six Lego bricks, 915 million combinations are possible. Investing in Lego sets used to be more valuable than gold at certain points in time. Not bad for a company born in 1932 out of the need to use old wood from its predecessor – a failed carpentry business.

It’s time to take a leaf out of Lego’s book and turn our own productivity fails into opportunities for evolution. COVID-19 and social distancing rules are responsible for a projected drop in productivity by 30 to 40 per cent3, while tighter immigration controls will worsen the current labour problem. As one contractor describes the ramifications of COVID-19 on construction: the new normal is to “live in suspense every day”4, waiting to see whether materials will arrive, how many workers will make it on site, which building has been put under quarantine, which districts are closed for testing.

LONG TIME COMING Modular construction was supposed to be the building style of the future. It hasn’t always gone to plan – the first Disneyland resort built in 1960 by United States Steel used modular construction to much fanfare but resulted in significant cost and time blow-outs. However much progress has been made since then, with 84 per cent of homes in Sweden now prefabricated using timber elements, compared to 15 per cent in Japan and five per cent in the US, UK. and Australia.

Like Lego, prefab has been around for a long time. Modular construction dates back over a hundred years when Richard Sears developed “kit houses” between 1908 and 1940 that were manufactured and then assembled on site, enabling middle-class families to become homeowners, courtesy of mass production’s cost-saving virtue.

From the 1940s through the 1960s, modular construction enjoyed post-war booms, when speedy reconstruction and social housing were needed in the midst of steel and labour shortages.

Simply put, the pre-conditions haven’t been right to create the disruptive forces that are necessary to change the supply chain across the industry. But this could all be about to change.

We need to be building more than 13,000 buildings each day if we are to house a population of 10 billion people by 2050.5 COVID-19 is basically forcing us to build safer and smarter and let go of outdated techniques. Prefabrication, powered by digital technology and the use of timber, seems to be the answer in mitigating the damage and meeting these demands fast and sustainably. How is building a 57-storey tower in just 19 days for speed?6 This revolution will also require a shift in the mindset of designers. Too many architects focus on creating an individual and bespoke design that will win awards.

This needs to instead shift towards more of a design mindset of addressing a client’s specific needs for functionality and performance by using a limited number of standardised parts and integrating them in a novel, repeatable way.

If we can shift thinking across the industry to one of combining standard parts, the supply chain (might) respond by manufacturing standardised parts.

Realignment of supply chains from global to local will be further supported if designers start their design process with the question: “Where does this part come from and can I source it locally?”

CHEMISTRY OF CHANGE The post-war, cookie-cutter solution for mass housing is what seems to stick in peoples’ minds when they hear the word “prefab”.

However, some companies are changing the perception that modular buildings are cheap, poor quality eyesores.

One of the first architects to have shown the potential of the modular form was Frank Lloyd Wright with his cost-effective Usonian homes after the Great Depression in America. They were built using modular concrete blocks – the very same concrete blocks that were used for his famous Fallingwater house. Stockholm’s 79 & Park modular building, with a cedar-clad façade, resembles a wooded hillside and also proves that low cost housing can be beautiful.

If it is mass-produced doesn’t mean it has to be generic or monotonous. Would you describe Sydney’s 101 George Street as boring, Brisbane’s 25 King Street as uninspiring, or Dubai’s planned Dynamic Tower as a cookie-cutter design?

With a 20 to 50 per cent reduction in construction time, 20 per cent reduction in

costs, increased safety on site, reduced wastage, improved precision and quality, it seems like a no-brainer. Although the assembly-line efficiency and climatecontrolled environment of a factory shave labour costs and shorten project schedules, it is the increased site safety that will be the major drawcard in a pandemic world. Could social distancing, labour shortages and population growth be the drivers for scale and repeatability that modular design needs to finally take off as a mainstream solution?

Following on the heels of mainstream prefabrication will be mass customisation thanks to digitisation. The DFAB House is the world’s first inhabited house which was both digitally planned and built with the help of robots and 3D printers. 3D printing reduces the need for standardisation that burdens traditional automation, leaving room for greater design freedom.

It’s about better quality and a better concept than what we have today. Can we unravel the silver lining around the pandemic black cloud and bring the construction industry up to speed while creating a safe, productive working environment? We have the tools, we have the technology, and now we have even more reason to create a new era modelled on the childhood game that probably inspired many players to take up a career in this industry in the first place – Lego. • Ralph Belperio is the major projects director at Aurecon, based in Adelaide.

REFERENCES & FURTHER READING 1 Oxenham S. Everything is made of chemicals. Big Think, 1 August, 2014. bigthink.com/neurobonkers/everything-ismade-of-chemicals 2 Prime Minister of Australia, Minister for Industry Science and Technology. Transforming Australian manufacturing to rebuild our economy. 1 October, 2020. pm.gov.au/media/ transforming-australian-manufacturing-rebuild-oureconomy 3 Lin F, Howell-Jones M. Here’s how smart construction could transform home-building after COVID-19.

World Economic Forum; 7 August 2020. weforum.org/ agenda/2020/08/here-s-how-smart-construction-couldtransform-home-building-after-covid-19/ 4 Srivastava M. Operational disruption affects construction productivity. MEED; 21 August, 2020. meed.com/ operational-disruption-affects-construction-productivity 5 Bertollin V. Here’s what building the future looks like on a 10-billion-person planet. Redshift by Autodesk; 24 August, 2018. redshift.autodesk.com/building-the-future/ 6 Bernstein P. Future of construction: Your next building won’t be built – it will be manufactured. Redshift by Autodesk; 3 May, 2018. redshift.autodesk.com/future-ofconstruction/

Quarry March 2021 37

SAFETY

AS HEATWAVES BECOME MORE EXTREME, WHICH JOBS ARE RISKIEST?

H

eat is more dangerous than the cold in most Australian regions. About two per cent of deaths in Australia between 2006 and 2017 were associated with the heat, and the estimate increases to more than four per cent in the nation’s northern and central parts.

In fact, Australian death records underestimate the association between heat and mortality at least 50-fold and chronic heat stress is also under-reported.

The risk is higher in some regions but where you live is not the only factor. When it comes to heat, some jobs are more dangerous, and put workers at higher risk of injury.

One study compared workers’ compensation claims in Adelaide from 2003 to 2013. It found workers at higher risk during extremely hot temperatures included: • Animal and horticultural workers.

• Cleaners.

• Food service workers.

• Metal workers.

• Warehouse workers.

The authors noted hot weather “poses a greater problem than cold weather. This is of particular concern as the number of hot days is projected to increase”.

Another study involving many of the same researchers looked at the impact of heatwaves on work-related injuries and illnesses in Melbourne, Perth and Brisbane. It found vulnerable groups included: • Males.

• Workers aged under 34 years.

• Apprentice/trainee workers.

• Labour hire workers.

• Those employed in medium and heavy strength occupations.

• Workers from outdoor and indoor industrial sectors.

A study of work-related injuries in Melbourne between 2002 and 2012 found young workers, male workers and workers engaged in heavy physical work were at increased risk of injury on hot days, and a wider range of worker subgroups were vulnerable to injury after a warm night. This information is important for informing injury prevention strategies.

A study using data for Adelaide between 2001 and 2010 concluded male workers

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In extreme heat, some jobs are more dangerous than others, and put workers at higher risk of injury.

and young workers aged under 24 were at high risk of work-related injuries in hot environments. The link between temperature and daily injury claims was strong for labourers, tradespeople and intermediate production and transport workers (who operate plant, machinery, vehicles and other equipment to transport passengers and goods).

Industries with greater risk included construction, electricity, gas and water.

A systematic review and meta-analysis of 24 studies on the links between heat exposure and occupational injuries found young workers (35 years or younger), male workers and workers in agriculture, forestry or fishing, construction and manufacturing industries were at high risk of occupational injuries during hot temperatures. Further, young workers (ages below 35 years), male workers and those working in electricity, gas and water and manufacturing industries were found to be at high risk of occupational injuries during heatwaves.

That apprentices or trainees had greater heat-related injuries in the workplace may surprise many, as heat tolerance deteriorates with age. Exposure to labour-intensive work, less experience in managing heat stress, and a propensity to avoid acknowledging they’re affected by heat may contribute to the higher risk for younger workers.

A growing body of international research shows extreme heat can cause severe health issues.

Underlying health conditions increase the risk of heat-related illness and death. These health conditions include: • Diabetes.

• High blood pressure.

• Chronic kidney disease.

• Heart conditions.

• Respiratory conditions.

Chronic heat exposure is dangerous and has been linked to serious health problems, including chronic and irreversible kidney injury. A range of studies have linked higher temperatures with increases in suicide rates, emergency department visits for mental illness, and poor mental health.

Most of the studies focused on worker’s compensation claims. That data includes only those injuries for which compensation claims were actually made. In reality, the problem is likely more widespread.

The Australian studies primarily focused on the milder climatic regions of Australia, but the rate of injuries and ill health is greater in hot and humid regions. The dangers may be worse in regional and remote areas, particularly when and where workforces are transient.

We also need more research on the relationship between the length of exposure to higher temperatures (in hours or days) and worker health.

National studies or studies in other regions should assess whether rates of injury differ by occupation, climate zone and remoteness.

Capturing data on all types and severity of workplace injuries (not just those that led to a compensation claim) is crucial to understanding the true extent of the problem.

As the climate changes and heatwaves become more frequent and severe, it’s vital we do more to understand who is most vulnerable and how we can reduce their risk. •

By Thomas Longden, Matt Brearley and Simon Quilty This article first appeared in The Conversation. Visit theconversation.com/as-heatwaves-become-moreextreme-which-jobs-are-riskiest-151841

EDUCATION & TRAINING

NOMINATIONS OPEN FOR IQA AWARDS

T

he Institute of Quarrying Australia (IQA) is now taking nominations for the 2021 IQA Awards, which highlight the industry’s merits in education, innovation, community engagement, environmental management, safety and creativity.

The IQA Awards will be presented as part of the IQA’s National Conference from 5-7 October, 2021.

All current IQA members are permitted for award nominations, while a non-member is permitted to be the nominator.

The IQA’s chief executive officer Kylie Fahey told Quarry the awards represent an opportunity to recognise the achievements of the industry, while setting a positive example for peers to follow.

“Awards are really important for an industry,” Fahey said. “They do a number of things. They recognise the contribution of innovations and good practice to the overall industry.

“Sharing innovation and good practice on safety and environment will only improve the industry as a whole, and if you’re looking at individual awards that’s about individual contribution to an industry and a business.

“Awards really recognise industry sectors and showcase some of that innovation and progress.”

Fahey said that peer recognition from a nomination can also lead to improving work culture and performance.

“There’s a lot of research that points to how recognition of your peers and recognition of your teams within a business can improve culture, performance, morale,” she said.

“Awards are one tool that people can use to do that.

“Just the process of nominating peers can be very powerful. The awards give an opportunity for managers, business to be recognised by their teams and their peers.”

This year’s IQA Awards will showcase how companies have responded to COVID-19related changes to working environments.

“We’re coming off the back of a very interesting period of social connectivity as a result of COVID-19 and I really encourage people to just take time to be nominating people and recognising people,” Fahey said.

“It’s an opportunity for businesses to take stock of what they have been achieving in unusual circumstances and that team and peer recognition is really important.”

in areas including exceptional rehabilitation, a new or improved pollution control method and displaying environmental awareness and leadership. It also includes a framed certificate and an engraved gold plated trophy.

Excellence in Innovation and Community Engagement Recognises an individual’s contribution to excellence and innovation in the industry while demonstrating improvements or measurable outcomes, eg in community engagement and consultation that may show design, production, operations, automation, plant design, and maintenance. Prizes include a framed certificate, trophy and a contribution for an approved professional development activity.

The 2019 IQA Excellence in Innovation Award, sponsored by Trimble and presented to Alasdair Webb.

Nominations will close on Friday 6 August, 2021 at 5.00pm AEST, with the winners to be finalised in September.

The 2021 IQA Awards include:

President’s Medal For an applicant with outstanding and ongoing service to the extractive industry that shows leadership and the advancement of the industry. Prizes include a framed certificate and inscribed medal.

The Alec Northover Award (sponsored by AIQEF) Acknowledges IQA members who have completed study and achieved Certificate III, Certificate IV, Diploma or Advanced Diploma qualifications in surface extractive operations.

Prizes include a framed certificate and an allowance to attend the IQA conference.

Gold Hard Hat Site Safety Award (sponsored by IQA) Recognises a site’s contribution to the advancement of health and safety in the quarry industry. Prizes include a framed certificate and an engraved gold-plated trophy.

Gold Environment Award (sponsored by Groundwork Plus) Presented to a site that has contributed to the advancement of environmental management,

Quarry Manager of the Year <10 FTE (sponsored by Metso Outotec) Highlights an individual quarry manager with demonstrable achievements within the quarrying industry, who has less than 10 FTE employees. Prizes include a framed certificate plus a $3000 contribution to a professional development opportunity.

Quarry Manager of the Year >10 FTE (sponsored by Metso Outotec) Highlights an individual quarry manager with demonstrable achievements within the quarrying industry, who has more than 10 FTE employees. Prizes include a framed certificate plus a $3000 contribution to a professional development opportunity.

Quarry Operator of the Year Recognises a quarry operator with demonstrable achievements in the quarrying industry, including a personal commitment and leadership in occupational health and safety and demonstration of broad industry knowledge. The award is in recognition and memory of Sydenham Hill and his contribution to the extractive industry. Prize includes a framed certificate.

IQA Conference Exhibitor of the Year Awards a supplier/sponsor with the most creative and engaging exhibition and involvement at the IQA 2021 national conference. Prize includes a framed certificate.

For more details about the 2021 IQA Awards, visit the IQA website: quarry.com.au •

Quarry March 2021 39

IQA NEWS IQA CONFERENCE RECOGNISED BY AUSTRADE On 11 September, 2020, the Australian Government announced it would provide $50 million to create the Business Events Grants Program. This initiative aims to support Australian businesses by providing grants between $10,000 and $250,000.

The IQA’s 63rd National Conference in Newcastle in October 2021 has been listed

by Austrade on the Schedule of Approved Business Events. This means eligible businesses can apply for funding under the Business Events Grants Program to cover up to 50 per cent of the costs of participating in the IQA 2021 Conference.

Conference chair James Collings stated the grant was open to priority sectors and the IQA was able to demonstrate that the extractive industry clearly aligned with one or more Australian Government priority sectors.

“Being an Approved Business Event means that conference exhibitors and stakeholders can apply for grants through Austrade from $10,000 to $250,000 per entity,” Collins said.

“The terms and conditions also provide some certainty if the event is postponed or changed due to COVID-19.”

The Newcastle region will host one of the most innovative conferences yet. Delegates and sponsors will experience a program aligned to the theme “Re-source, Re-think, Re-engage”.

Further information about the Business Events Grants Program can be found on the Austrade website.

Landslide management on the east wall of Holcim Dubbo Quarry. Slope stability is again on the list of the IQA’s educational seminars in 2021.

To register for these events, email admin@quarry.com.au or visit the “Networking & Branches” section of the IQA website: quarry.com.au

SPONSORSHIP PROSPECTUS The sponsorship prospectus for the 2021 IQA annual conference has been issued to the industry. Hitachi, Komatsu and Caterpillar have been confirmed as the Platinum sponsors of the event. There is already solid interest in the numerous sponsorship and exhibition opportunities. If you have not received a prospectus you can download it from the conference website: iqa.eventsair.com/conference

Visit austrade.gov.au/Australian/Tourism/ Tourism-and-business/Business-Events

• 16 March - Slope Stability.

• 4 May - Learning From Disasters.

• 8 June - Slope Stability.

• Effective Risk Management (Fully online course).

• Incident Investigation (Fully online course).

IQA 2021 AWARDS

• Gold Hard Hat Site Safety Award.

• Gold Environment Award.

• Excellence in Innovation and Community Engagement.

• Quarry Manager of the Year <10 FTE, • Quarry Manager of the Year >10 FTE.

UPCOMING EVENTS

• IQA Conference Exhibitor of the Year.

• 8 March - Queensland Women In Quarrying (WIQ) #IWD2021 Breakfast, The Treasury, Brisbane.

• President’s Medal.

• 13 March - SA Branch Dinner, Barristers Block Wines, Woodside.

• 19 March - WA Bowls Challenge & Sundowner, South Perth.

Quarry March 2021

• 10 March - Respirable Crystalline Silica.

• Alec Northover Award.

For more information about the IQA National Conference, contact the IQA, tel 02 9484 0577, email admin@quarry.com.au or visit the conference website: iqa.eventsair.com/conference

40

To register for the courses below and/or organise training, email admin@quarry.com.au or visit the “Education” section of the IQA website: quarry.com.au

The 2021 IQA Awards are now open for applications and nominations, and will be presented in the following categories:

Applications for the program close at 5pm (AEDST) on 30 March, 2021 – or earlier if funding is exhausted.

• 11 June - Queensland Quarrying & Mining Safety & Health Conference, Brisbane.

EDUCATION AND PROFESSIONAL DEVELOPMENT COURSES

The IQA Conference prospectus is now available online.

Any member of the IQA can be nominated for an award. A non-member may be the nominator for an award. However, only IQA members can be nominees/recipients of an award. A person may choose to nominate themselves for an award or nominate a third party. The person nominated for the award must be a current member of the IQA. Where

The Institute of Quarrying Australia

ONGOING FOCUS ESSENTIAL TO A HEALTHY WORKFORCE Health and safety is always at the forefront of strategy and actions in our industry.

Analysing data will often drive how we look at, and respond to, health and safety risks and requirements on site and across the business as a whole.

Recently the Health and Safety Index survey for 2020 released some interesting findings.

The top three outcomes that influenced health and well-being were: setting expectations, safe workplace conditions, and the ability to talk with supervisors.

Since the Brady Review in 2020, the IQA has been engaged with industry, looking at ways to help address a number of the findings in the report, especially adequate supervision. The Health and Safety Index survey reported that two of the most correlated factors adversely impacting on health and well-being were bullying and supervisor support.

This data highlights the critical role supervisors play in operations and the health and wellbeing of staff. The ability for supervisors to communicate effectively, and equally talk with teams and individuals, is an increasingly

important part of an appropriate health and safety system.

Effective communication and supervision requires skill. The Health and Safety Index results highlight that while training is important, it alone is often not the silver bullet to improve health and well-being in the organisation. Every organisation will have different needs and these needs constantly change as the organisation adapts to its environment, the current market, customers and other variables.

The Health and Safety Index results conclude the following areas of focus are extremely useful in improving health and well-being: • Values and beliefs – Promoting positive values and beliefs, effectively managing workplace culture.

• Trust in leadership – Leadership coaching and development. This includes effective feedback to reinforce or redirect behaviour.

• Management of change – Effective

the award is site- or company-specific, the site or company must have current IQA members and demonstrate support for the IQA.

The closing date for all award nominations is 5pm (AEST) on Friday, 6 August 2021. The 2021 IQA Award winners will be finalised in September, and the winners announced at the IQA Conference in October.

and genuine consultation, setting clear expectations on change and managing uncertainty.

• Job control – Providing realistic time pressures, expectations, reasonable levels of job autonomy and decision-making freedom.

Managing productive and healthy teams requires constant attention and focus.

KYLIE FAHEY Chief Executive Officer Institute of Quarrying Australia

discussed, including some specialised methods, including polished aggregate friction value and petrology. The Queensland YMN branch is grateful to Groundwork Plus for this opportunity. •

For full details visit the IQA website: quarry.com.au

IQA NEW MEMBERS

YMN SITE TOUR AND NETWORKING Members of the Queensland Young Members Network visited the Groundwork Plus aggregate testing laboratory in Brendale, Brisbane, followed by a debrief and networking session at The Eaton’s Hill Hotel, on 16 December, 2020.

This tour provided attendees with the opportunity to discuss a range of test methods which impact their working days and encouraged a more thorough understanding of laboratory operations.

The Young Members were able to discuss a range of test methods which impact their working days.

Standard aggregate testing was

GRADE NAME ASSOC MIQ MIQ MIQ MIQ TMIQ TMIQ TMIQ TMIQ TMIQ TMIQ TMIQ

Peter Kaarsberg Trent Murray Kate Pemberton Declan Halpin Matt Wall Simon Kitson Chelsea Flood Ben Patrick Christopher Ainslie Andrew Laws Drew Mashford Corey Harris

BRANCH NSW QLD QLD VIC NSW SA NSW QLD QLD QLD NSW NSW

Quarry March 2021 41

GEOLOGY TALK

CUBES: NATURE’S BUILDING BLOCKS

A 4.5m gömböc statue in the Corvin Quarter in Budapest, Hungary – a shape with only one stable balance point.

An electron micrograph scan of dolomite, a mineral with a cube-like structure.

We might not be living in a world made of Lego, but a team of researchers have discovered why rocks and icebergs form cube-like shapes when they are broken down. Nickolas Zakharia reports.

idealised conditions they used.

“But in a statistical averaged sense, rocks are born as something that’s a vague shadow of a cube,” University of Pennsylvania geophysicist and co-author of the research paper Douglas Jerolmack said.

The findings, according to Jerolmack, have the potential for hydrologists to predict fluid flow through cracks in the ground for oil extractions and assist geologists in calculating the sizes of rocks that break off cliff faces.

Anne Voitgtländer, a geologist at the GFZ German Research Centre for Geoscience, told sciencemag.org a different view of the earth surface is needed to understand the study.

“You need to have this abstract theoretical view of earth surface processes to really dig into what this can mean,” she said. “It’s sometimes hard for geologists to understand the value of it, or to see where it applies.” •

T

he discovery was published in Proceedings of the National Academy of Sciences, and drew comparisons to the Greek philosopher Plato, who saw the Earth’s building blocks as cubes.

According to sciencemag.org, the findings were made off the back of earlier work from Budapest University of Technology and Economics’ Gábor Domokos in 2006, who proved the existence of the ‘gömböc’ – a shape that has only one stable balance point.

Domokos’ team discovered pebbles and sand grades erode toward “gömböcish” shape and further research showed that fragmenting an abstract cube into 600,000 fragments using a computer simulation also resembled cubic shapes.

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Quarry March 2021

This prompted the research team to hypothesise cubes might be a common feature of rock fragmentation.

Using an outcrop of mineral dolomite in Budapest, Hungary, the research team discovered that in a real world situation, cracks in a dolomite stone face also formed squarish shapes that resembled a cube – whether they had weathered naturally or been formed by dynamite explosions at the mountain.

They also discovered that breaking down materials under idealised conditions – such as a rock pulled in all directions equally – formed polyhedral pieces (cubelike structures).

The research team noted that many natural objects, such as mica, do not represent cubes as they were not in the

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