Quarry October 2021

How a new fleet management tool can offer an optimised visualisation of any quarry site

RENTAL PLANT GIVES BUSY SITE EXTRA MUSCLE

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‘AT A GLANCE’ VISUALISATION

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OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

A Hanson quarry calls on reinforcements to assist its core earthmoving fleet

OCTOBER 2021

NEW JEWEL IN THE FAMILY BUSINESS CROWN A South Australian family business takes delivery of a full turnkey crushing plant

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IN THIS ISSUE OCTOBER 2021

VOLUME 29, ISSUE 10

FEATURES 20 MEDIUM SIZE LOADERS OFFER HIGH PERFORMANCE Caterpillar’s 980 and 982 medium wheel loaders offer up to 10 per cent more productivity.

22 SANDS PRODUCER BOOSTED BY UPGRADE A Far North Queensland sand producer is well positioned to supply his customers following the purchase of a new fuel-efficient excavator.

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‘AT A GLANCE’ A new fleet management tool can offer an optimised visualisation of any quarry site.

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EXTRA MUSCLE, RELIEF A Hanson quarry has called on reinforcements to assist its core earthmoving fleet.

24 LOADERS BOOSTED BY QUICK COUPLER SYSTEM Liebherr has expanded the application of its quick coupler system to most of its XPower large wheel loader range.

30 LARGE LOADER PROMISES MORE PRODUCTIVITY The largest loader capable of working in a quarry is packed with innovative technology features.

36 CRUSHING OPERATION ACQUIRES MOBILE COMBO Cooper Civil & Crushing is taking advantage of industry growth postCOVID-19.

40 HOMEGROWN CONTRACTOR SHINES

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NEW FAMILY JEWEL A South Australian family business has taken delivery of a full turnkey plant.

OCTOBER 2021

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

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RENTAL PLANT GIVES BUSY SITE EXTRA MUSCLE

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QUARRY

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www.quarrymagazine.com

How a new fleet management tool can offer an optimised visualisation of any quarry site

A Hanson quarry calls on reinforcements to assist its core earthmoving fleet

Why do predictions in drill and blast scenarios remain as uncertain as ever?

OCTOBER 2021

COVER ADVERTISER: Komatsu’s new iSite program provides an unparalleled opportunity to monitor and optimise an entire quarry fleet’s operation.

‘AT A GLANCE’ VISUALISATION

VIBRATION PREDICTION

An Indigenous-owned contractor purchases eight new mobile units after going to work on a quarry project in its own backyard.

NEW JEWEL IN THE FAMILY BUSINESS CROWN A South Australian family business takes delivery of a full turnkey crushing plant

EVERY MONTH 04 FROM THE EDITOR

56 IQA NEWS

06 FROM THE PRESIDENT

57 FROM THE IQA CEO

08 NEWS THIS MONTH

58 GEOLOGY TALK

16 PRODUCT FOCUS

Turn to page 18 or visit komatsu.com.au

Quarry October 2021 3

EDITORIAL

AN IDEAL TIME FOR SMALLER QUARRIES TO EMBRACE SAFETY MESSAGE

O

ctober is National Safe Work Month, as promoted by Safe Work Australia (SWA). Since 2009, SWA has run this campaign every October to encourage businesses to promote and commit to strengthened workplace health and safety (WHS). The SWA website – safeworkaustralia.gov.au – provides numerous resources and campaign kits that businesses can download and customise to suit their workplaces.

SWA’s latest initiative is the Clean Air. Clear Lungs. campaign about occupational lung disease in dusty workplaces. While it is designed more for the engineered stone segment, there are useful resources and guidance materials (safeworkaustralia.gov.au/cleanlungs) which quarries can adopt. Clean Air. Clear Lungs. is particularly relevant given most jurisdictions in the past two years have adopted revised exposure standards for respirable crystalline silica (RCS) – at the eight-hour time-weighted average (TWA) of 0.05mg/m3 under the Work Health and Safety Regulations 2011.

Indeed, WHS statutory authorities are mounting action against some quarries and mines for alleged non-compliance when RCS exposure standards were at the old TWA of 0.1mg/m3. Even complying with new rules today won’t protect you if you weren’t abiding by yesteryear’s rules.

Unfortunately, punitive action doesn’t promote safety to quarries in a positive light. Such are the pressures today to keep up with regulatory updates while controlling risks, quarrying supervisors could be forgiven for feeling that safety prowls their unwary operations, waiting to pounce on the tiniest of procedural errors.

Safety shouldn’t be a bureaucratic “beast”. National Work Safe Month is a chance for smaller quarrying producers to reach out to SWA and other regulators for advice about improving safety.

Indeed the New South Wales Resources Regulator’s quarterly safety report for the period April to June 2021 indicates that smaller operations are at a significant

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disadvantage to larger, better resourced quarries. The regulator noted in its report of the smaller mines and quarries segment: “Comparatively, the number of incidents notified by the sector is substantially lower than [the large mines and quarries sector].”

This conclusion echoes a similar point in the Brady Review conducted for the Queensland Government in 201920 – that quarries make fewer incident notifications than mines.

This under-reporting of safety incidents suggests smaller quarrying producers need more guidance and assistance.

Given larger operations can be caught out for inadvertent non-compliance, what chance does the smaller producer have, when its WHS officer may be the site manager or even the owner/operator with broader responsibilities to consider?

It seems online kits for incident notifications should be developed for smaller, less resourced operations, with easy to read fact sheets, templates and reduced paperwork that can capture the essential details (subject to investigation).

Perhaps SWA could take the lead here, developing paperwork that will be accepted across most of the jurisdictions.

At the very least, it should be trialled as a means of encouraging an increase in reporting of incident notifications.

More transparency between quarry producers and WHS authorities is likely if the administrative burden can be reduced. But smaller producers should not wait for WHS authorities to act.

They should use National Safe Work Month to utilise the resources SWA and other educational providers like the IQA have to offer. After all, what’s better?

An approach to the WHS authority for advice and guidance now, or a visit by a regulator later that is unplanned or, worse, preceded by an on-site accident?

Published by:

SUCH ARE THE PRESSURES TODAY, SUPERVISORS COULD BE FORGIVEN FOR FEELING SAFETY PROWLS THEIR UNWARY OPERATIONS, WAITING TO POUNCE ON THE TINIEST OF PROCEDURAL ERRORS

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

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

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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 published. © Copyright – No part of this publication may be reproduced, stored in a

DAMIAN CHRISTIE Editor

retrieval system or transmitted in any means electronic, mechanical, photocopying, recording or otherwise without the permission of the publisher.

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PRESIDENT’S REPORT

NEW BLOOD OFFERS EXCITING PATH OUT OF PANDEMIC GLOOM The Institute of Quarrying

T

his month is the second anniversary of my presidency, with one more year left in my tenure. Thanks to the pandemic, it’s been a rollercoaster ride.

The restrictions on travel and the lockdowns along the east coast have made it difficult for me and other IQA Board directors to attend branch events and to network with members.

No doubt it’s been dispiriting for members, particularly in New South Wales, Victoria and the ACT, that we haven’t been able to participate face to face in the IQA’s social activities and professional development programs.

Nonetheless, I am heartened by the levels of activity in the IQA branches and sub-branches, many of which have held annual general meetings in the past month and finalised their committees for 2021-22. It’s pleasing that so many people volunteered for committee and leadership positions, as it ensures the branches remain active to progress the Institute’s goals.

Whether we’re involved as IQA decision-makers or working in the industry, it’s important that we maintain our members’ enthusiasm ahead of the lifting of COVID-19 restrictions. As leaders, we should be positive and progressive and encourage others to look for the positives, to support each other, and focus on a brighter future.

Part of being an effective leader is being progressive in your thinking about your education and that of your team. As we move into uncertain times we should seek to improve ourselves and enhance the industry’s knowledge. The best way to do that is through the IQA; the Institute can work with individuals and teams on suitable professional development programs (virtual or face to face). The more we can learn and share with others, the more they will be inspired to participate. That is part of the

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Australia

undertone of leadership.

I’m proud to lead the IQA in difficult times. It’s been a challenging two years but the IQA has withstood the downturn and is in a sound financial position. Our decision to move the IQA conference in Newcastle from this month to late March 2022 gives the event the best possible chance of success. Australia should have exceeded its vaccination targets by then, so we will be able to host the conference more competently and safely.

We’re also working with Cement Concrete Aggregates Australia’s leadership at syncing future Construction Materials Industry Conferences (CMIC) and IQA conferences. CMIC will be held in March 2023.

The IQA Board is also committed towards the Institute’s growth and transformation, as outlined in our 2020 strategic plan. We’re making great inroads with the plan and I’m looking forward to advancing the IQA’s course and cause in the final year of my presidency.

In closing, I acknowledge two IQA stalwarts whose service at national and state levels is exceptional. Andrew Wilson has served the maximum time allowed for a Board director and departs after a decade of tireless work (he will continue as chair of the South Australian branch committee). Mike Cooper is also retiring after 35 years of volunteering in various leadership positions at the national level and on the Queensland branch committee.

Good people like Andrew and Mike are hard to find but the recent influx of new blood on the branch committees is reassuring for the future.

SHANE BRADDY President Institute of Quarrying Australia

Educating and connecting the extractive and associated industries

quarry.com.au PART OF BEING AN EFFECTIVE LEADER IS BEING PROGRESSIVE IN YOUR THINKING ABOUT YOUR EDUCATION AND THAT OF YOUR TEAM

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 enquires please email: admin@quarry.com.au.

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NEWS

LOCKDOWN LOSSES CONTINUE TO BITE, BORAL SAYS Boral has turned difficult economic circumstances into a positive for its balance sheet, after sales of USG Boral and Midland Brick in FY2021 contributed to a profit of $640 million.

The profit was reversal of the previous year’s $1.145 billion loss, which included impairment charges in part incurred because of construction declines as COVID-19 took hold.

Boral’s underlying profit after tax of $251 million, excluding significant items of divestment profits this year and impairments in the prior year, was up 44 per cent.

Boral chief executive officer and managing director Zlatko Todorcevski said the company’s plan to reshape the business and focus on the core Australian construction materials business was on track.

Earnings from the core Australian business, excluding property, of $157m was up 11 per cent, despite revenue being down six per cent.

“We have made substantial progress in our strategy to transform Boral into a stronger, better performing, more customer-focused organisation, with a core portfolio of businesses that deliver value throughout the cycle,” Todorcevski said.

“In the past year, we have progressed the divestments of several non-core assets, including USG Boral and announcing the sale of North

Boral CEO Zlatko Todorcevski says ongoing COVID-19 lockdowns will continue to wreak havoc on the construction materials industry.

‘WE HAVE MADE SUBSTANTIAL PROGRESS IN OUR BID TO TRANSFORM BORAL INTO A BETTER PERFORMING, MORE CUSTOMERFOCUSED ORGANISATION’

America Building Products, achieving sale prices well above expectation.”

ZLATKO

Despite this positive ground – Boral reduced its net debt to $899 million, down from $2.58 billion at 30 June, 2020 – Todorcevski said ongoing COVID-19 lockdowns continued to wreak havoc on the construction materials industry.

BORAL CEO

TODORCEVSKI

“Where we can, we are taking actions to minimise the financial impacts of COVID-related measures, including short-term cost measures,” he said. “We expect FY2022 market conditions will be mixed. Infrastructure activity, particularly road construction, is expected to improve in the second half of FY2022 and into FY2023.

“Overall, our turnaround strategy is delivering results at a time of major challenges not just for Boral but the construction sector and the broader economy.”

The Boral CEO said the September quarter of 2021 would likely see a $50 million EBIT impact for Boral as a result of COVID lockdowns and restrictions, while the July quarter had already cost about $16 million.

“It’s always easy to turn off the tap of construction, but it’s a very, very slow ramp-up once you re-open that gatel,” he told the Australian Financial Review about ongoing lockdowns In better news for Boral, Moody’s Investor’s Service affirmed Boral’s investment credit rating at the end of August.

Boral Limited has a rating of ‘Baa2’ with a stable outlook, after the increased shareholding interest of Seven Group Holdings.

Moody’s stated that the affirmation of the ratings reflected the strength of Boral’s balance sheet, financial strategy and risk management policies, its prominence in the Australian construction materials industry and expectations the company will benefit from government stimulus measures.

“We welcome the decision by Moody’s to affirm its investment grade credit rating and stable outlook for Boral, recognising the strength of Boral’s financial framework and our disciplined approach to managing Boral’s balance sheet,” Boral’s chief finance and strategy officer Tino La Spina said in a statement. •

AUSTRALIAN PCI FREE FALLS FROM LOCKDOWNS The Australian Performance of Construction Index from Ai Group and the Housing Industry Association has recorded the worst results in a year after all construction segments fell into decline.

The negative response came in the wake of strict COVID-19 restrictions for the Victorian and New South Wales construction sectors, also hampering confidence in sales and delivery around the nation.

Ai Group’s chief policy advisor Peter Burn said the results were a stark contrast to the beginning of 2021.

“Australia’s construction sector has

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shifted from healthy expansion to steep contraction in a flash as restrictions in the face of COVID-19 outbreaks have closed sites and disrupted supply chains,” Burn said.

The PCI fell 10.3 points to 38.4, seasonally adjusted – where scores below 50 indicate a decline in growth.

The three metrics of activity, employment and new orders all fell significantly, with new orders the biggest drop – down 13.1 points to 36.4.

Housing Industry Association chief economist Tim Reardon said even the usual sources of growth were struggling against the restrictions.

“Lockdowns have brought the industry to a standstill and are eroding builders’ confidence,” he said.

“Even activity in home building specifically started going backwards in August for the first time in almost a year.”

Reardon said these lockdowns were unlike others where the construction sector was exempt from restrictions.

“The industry was not permitted to operate like it did during previous lockdowns, despite its exceptional record of operating safely throughout the pandemic, consistent with COVID safety measures,” he said.•

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NEWS

FIVE LOCAL QUARRIES TO SUPPLY WIND FARM PROJECT

VICTORIA’S BIG BUILD SUPPORTED BY PRIORITY RESOURCES Cement Concrete & Aggregates Australia (CCAA) has welcomed the Victorian Government’s prioritisation of quarry resources in South Gippsland and Wyndham local government areas.

The identification of these Strategic Extractive Resource Areas (SERAs) will allow future developments – both industrial and residential – to work around each other as both continue to grow in Victoria.

The CCAA’s state director for Victoria and Tasmania Brian Hauser said the organisation had supported such strategies for a long time.

‘ON AND NEAR SITE QUARRIES CAN DELIVER A RANGE OF BENEFITS TO THE PROJECT AND SURROUNDING COMMUNITY’ DR JUSTIN MELEO ARDG DIRECTOR

“CCAA’s advocacy over many years has been key to securing these planning reforms,” Hauser said. “They are a significant step forward in Victoria taking a strategic and long-term view around protection of critical sand and stone resources for our future.”

More information about the SERAs can be found at earthresources.vic.gov.au •

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The five quarries will support the Rye Park Wind Farm project (RPWF) to create renewable energy. The sites were selected for their proximity to the wind farm and will reduce the need for trucks to haul material from hundreds of kilometres away.

ARDG undertakes exploratory drilling at one of its short-term quarry sites. The quarries will supply construction materials for a 66-turbine wind farm in NSW. Image: ARDG.

The approval of the Rye Park quarries project will allow for a 60 to 99 per cent reduction in truck movements across the local and regional road network.

Dr Meleo said the development hasn’t come without challenges but it would be all worth it once the quarries commence operations later this year and the RPWF Project commences construction.

“ARDG is pleased to be able to support the renewable energy sector by utilising our in-house extractive industries expertise to reduce the project’s construction footprint, and its carbon footprint,” he said. •

ADBRI RESULTS WARN OF FALL IN CONCRETE CONFIDENCE

Hauser said the approvals process for quarries to supply resources to these projects still needs to be addressed.

“The construction sector, supported by a viable supply of quarry materials provides the engine for a construction-led recovery to the COVID pandemic.

These materials in ever stronger demand are the life blood of the recovery.”

Australian Resource Development Group (ARDG) has spent two years developing the proposal and received approval from Hilltops Council and Yass Valley Council.

“Based on our experience with similar projects, we identified an opportunity to source construction materials from greenfield sites within and close to the RPWF project,” ARDG’s director for planning and development Dr Justin Meleo told Quarry. “On and near-site quarries have the potential to deliver a range of benefits to the project and surrounding local community.”

The new SERAs will look to secure the future of the State Government’s Big Build infrastructure program which includes the Metro Tunnel, the removal of 85 level crossings, the West Gate Tunnel, and the Melbourne Airport Rail project.

“Unfortunately, Government approvals for new or expanding quarries are slow, expensive and uncertain and significant reform of the process is required to replenish the resources we’re all using to meet the increasing demand,” he said.

A resource development business in New South Wales has received council approval to operate five, short-term quarries to supply materials for the construction of a 66-turbine wind farm.

Adbri has achieved strong results in the first half of 2021, but anticipates the second half results will be impacted by reduced production, increased industry competition and COVID-19 restrictions.

Adbri chief executive officer Nick Miller warns that Adbri’s second half-year results may not be encouraging.

Adbri secured three-year contracts in the first half of 2021 for the supply of lime to Northern Star and Newmont.

In addition, Adbri is talking with Alcoa to supply the Wagerup facility in Western Australia until the end of January 2022.

However, chief executive officer Nick Miller made clear the obstacles ahead in FY2021-22.

“Sales volumes in July and August have been in line with or ahead of expectations across all markets, except New South Wales and South

Australia, due to lockdowns,” Miller said. “However, earnings in the second half will be impacted by a reduction in lime volumes to Alcoa, the anticipated commencement of a competing cement import terminal in NSW and COVID-19 impacts, including limitations on construction activity.”

Miller said in the long-term, Adbri would find a way to capitalise, as long as State and Federal Governments played their part in the recovery.

“We remain well positioned to benefit from increasing construction activity as a result of ongoing government stimulus, while navigating continued uncertainty from the Delta strain of COVID-19,” Miller said. •

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NEWS

ALEX FRASER RAISES BAR IN RECYCLING Alex Fraser Group has been awarded a Quarry Registration Certificate from Queensland’s Department of Transport and Main Roads (TMR) for its Archerfield and Nudgee recycling facilities.

The acknowledgement came as TMR attempts to improve the state’s sustainability in road and rail projects by supporting the recycling of construction materials.

Alex Fraser Group’s recycling general manager Sean McCormick agreed with TMR’s initiative.

“There’s been a lot of talk around increasing the use of recycled products – TMR has taken real action by awarding this Quarry Registration

Certificate to Alex Fraser. It’s an exciting time to be in recycling and construction in Queensland,” he said.

Since mid-2020, regulations have been rewritten to include recycled materials alongside virgin quarried materials, allowing businesses like Alex Fraser to become more sustainable.

The stringent regulation around the new standards ensures customers can be assured no quality is forfeited in the name of sustainability.

‘OUR CUSTOMERS CONSIDER OUR GREEN ROADS PRODUCTS TO BE AS GOOD AS QUARRIED PRODUCTS’ SEAN MCCORMICK ALEX FRASER GROUP RECYCLING GM

“We have been manufacturing highspec, recycled construction materials for use in major infrastructure for decades; many of our customers consider our Green Roads products

to be equal to, if not better performing than their quarried counterparts,” McCormick said.

“To maintain certification, our products are tested regularly to ensure they are consistent and conform to the same standards as virgin material.

“This gives our customers peace of mind, knowing that they’ll never have to compromise on quality to achieve sustainability.”

As a result of the Certificate, more than one million tonnes of construction and demolition waste has gone through the Archerfield and Nudgee recycling facilities for processing, reducing carbon emissions by up to 65 per cent.•

ARTICULATED HAULERS ARE REBRANDED WITH SCOTTISH FLAIR Rokbak – the rebranded articulated hauler – has been launched at its historic manufacturing base in Motherwell, Scotland, amid much Scottish pomp and ceremony – and broadcast to a virtual global audience.

Rokbak is being produced by the former Terex Trucks division of Volvo Construction Equipment. Since the Volvo CE acquisition in 2014, the articulated haulers have continued to be produced out of the old Terex Trucks company’s manufacturing facilities in Motherwell.

The Motherwell factory has been operating since 1950, first under the auspices of Euclid Great Britain, then as Terex from 1968. In 1982, engineers at Motherwell designed Terex’s first articulated dump truck. The TA articulated truck range has been in circulation since 1998 and a dozen generations of the TA trucks have been sold globally in the past two decades.

“Our company has an incredible history and a proud heritage,” Rokbak’s managing director Paul Douglas said.

“Seven years ago, we became a member of the Volvo Group, which allowed us to make major improvements in every part of our business. Millions of pounds have been invested in improving our products, modernising our facilities, expanding our network, and developing

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our people. It has been a process of continual evolution.

“That’s why we feel it’s right to recognise this evolution with a new brand name to launch an exciting new chapter in our history. And we’ll keep investing to further improve our machines for our customers.”

In line with the new branding, the 28-tonne payload TA300 and 38-tonne payload TA400 articulated haulers have been recast as the RA30 and the RA40 respectively. In addition to the Rokbak colours and livery – which are a sand colour to the white of the old TA trucks – the new articulated haulers feature new transmissions, a move to environmentally friendlier, lower emission Stage V (European standards) engines and the introduction of Haul Tracks telematics.

The new transmissions and engines are expected to make this latest generation of trucks seven per cent more fuel-efficient.

Douglas said the Rokbak trucks will have an important part in the Volvo Group of Companies’ overall ambition to reduce the total emissions of Volvo products by 35 to 45 per cent by 2030 and achieve zero emissions by 2040.

The first generation Rokbaks introduced to Australia are likely to feature Tier 2 or Tier 3 engines in compliance with Australian diesel fuel regulations for nonroad vehicles. However, customers also

A Rokbak RA30 is roadtested in a Scottish quarry.

have a choice of US EPA Tier 4F or EU Stage V engines, should they so wish.

The first Rokbaks could arrive in Australia towards the end of October.

Porter Group CE has been the Australian and New Zealand distributor of Terex Trucks since 2017, and will continue to be the distributor for the new Rokbak brand.

As part of the virtual launch program, Porter Equipment Australia’s national sales manager Michael Carter said he was looking forward to building on that experience with Rokbak.

“The Terex brand has had a reasonably chequered history in Australia prior to our appointment and because of that we are excited for the change of brand and we are looking forward to the future with Rokbak,” Carter said.

For more information on the rebrand, visit the Rokbak website: rokbak.com •

NEWS

SAND BUBBLES COULD UNLOCK SCREENING EFFICIENCY Scientists from the University of Columbia have been the first to demonstrate that “bubbles” of lighter sand can form and rise through heavier sand when subjected to vibrations and gas flow.

Assistant professor of chemical engineering at Columbia Engineering Chris Boyce said the findings could be “transformational” for a number of applications.

“We have found a granular analogue of one of the last major fluid mechanical instabilities,” Boyce said.

“Our findings could not only explain geological formations and processes that underlie mineral deposits but could also be used in powder-processing technologies in the energy, construction, and pharmaceuticals industries.”

The phenomenon is initiated by the channelling of gas upwards through sand deposits, causing clusters of lighter, larger particles to rise past smaller, heavier ones.

The study was published in the Proceedings of the National Academy of Sciences, in collaboration with a group at Swiss University ETH Zurich.

Boyce said the team was equally intrigued about what this discovery means for the geological community.

“We are especially excited about the potential impact of our findings on the geological sciences—these instabilities can help us understand how structures have formed over the long history of the Earth and predict how others may form in the future,” Boyce said. •

A FRIENDLY CONCRETE CHOICE FOR QUEENSLAND HOMES ‘WE AIM TO HAVE A POSITIVE IMPACT ON THE ENVIRONMENT WHILE SUPPLYING OUR CUSTOMERS WITH AN EXCELLENT PRODUCT’ JASON ZAFIRIADIS WAGNERS EFC GM

Wagners EFC general manager Jason Zafiriadis said the company couldn’t pass up an opportunity to support a respectable business like Gibson Homes.

Wagners’ EFC has been used to build 15 new homes in Queensland’s Darling Downs region.

Wagners has helped Geoff Gibson Homes build 15 houses in Queensland’s Darling Downs region with its Earth Friendly Concrete, saving more than 103.5 tonnes of carbon emissions.

Geoff Gibson Homes aims to increase its homes’ energy efficiency by 80 per cent for a 10 per cent capital input cost, upholding the business’s 30-year legacy of energyefficient construction.

For this reason, Geoff Gibson Homes chose the Wagner Group’s Earth Friendly Concrete (EFC) because it can save 250 kilograms of carbon emissions for every cubic metre poured.

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“We are aiming to have a positive impact on the environment, all while supplying our customers with an excellent product that has improved durability, lower shrinkage and higher flexural tensile strength.”

Geoff Gibson Homes has constructed 860 homes across the Darling Downs region in its 30-year history, with the last 12 focused on optimising their energy consumption.

Geoff Gibson Homes’ namesake director said it had been an extensive process to find the right material to fit his business’s standards. “when it comes to reducing the embodied carbon in constructions materials nothing compares to Earth Friendly Concrete by Wagners. It is superior and cement-free,” Gibson said. •

UK QUARRY IN FOCUS FOR LATEST MISSION: IMPOSSIBLE MOVIE dozens of metres to the quarry floor.

A local photographer – Instagram handle, villagerjim– captured the shot after months of patience.

The image captured by local photographer Villager Jim was seen in local newspapers and on BBC news. Image: @villagerjim.

A Derbyshire quarry in the United Kingdom has taken centre stage for the new Mission: Impossible film, providing a backdrop for a train derailment scene.

A ‘bubble’ of lighter sand (blue) forming beneath heavier sand (white).

“This was an opportunity for us to demonstrate the effectiveness and functional application of Earth Friendly Concrete in homes,” Zafiriadis said.

Teams had been building the set at Darlton Quarry for months before Hollywood star Tom Cruise and the rest of the film crew watched a black steam train plummet off a cliff, falling

“Waited five months for this shot … of the train in the new mission impossible movie going off the cliff!!

Tom was there too, amazing day!!!” he posted.

In a Facebook comment, Villager Jim added it was a tense moment as the locomotive made the leap.

“Five blooming months with so many worries that I would miss it …

I punched the air the moment the train disappeared,” he said.

The movie – quarry included – will be the seventh chapter in the Mission: Impossible film franchise and is set for release in May 2022. •

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CAPABLE CONTRACTOR SCREEN ENABLES EASY SCREENING The Precisionscreen Contractor 604 mobile screen has been designed for the busy operator with a growing business that calls for a diverse range of screening jobs. The Contractor is easy to set up and very portable to get from site to site. With a one-metre-wide feed belt, the 604 can screen sand, pebble, soil mixes and roadbase. The Contractor gets the job done with a throughout of 100 tonnes per hour using a two-bearing, fully floating, two-deck, 2m x 1.2m′screenbox.

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SCALE INSTALLATION, CALIBRATION AND SERVICING Intelligent positioning solutions provider Position Partners has announced a new scale calibration service for the quarrying and extractive industries. With a fleet of new trucks across New South Wales, Victoria, Queensland and Western Australia, the company will provide nationwide installations, servicing, and calibrations for on-board payload systems fitted to loaders and excavators, among other industrial machines. On-board scales assist in reducing wasted material, optimising the loading of road and earthmoving trucks, increasing safety and eliminating rework.

For more information: Position Partners, positionpartners.com.au

RIMEX – DGS AND IGLR WHEELS THE IDEAL SOLUTION RIMEX has introduced the Double Gutter Service (DGS) Series and Integral Gutter Lock Ring (IGLR) Series wheels to reduce technician labour and decrease vehicle downtime. On dump trucks, DGS wheels are fitted to the outer dual positions and IGLR wheels take the front and inside dual positions. These additions allow the tyres to guide over the wheelbase, making change-outs easier than ever. These wheels also improve safety for technicians as the use of an impact wrench is removed and the two-piece lock ring system is lighter and easier to handle.

For more information: RIMEX, rimex.com.au

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Quarry October 2021

LOAD & HAUL

FLEET SOLUTION

PROVIDES ‘AT A GLANCE’ VISUALISATION Developed on-shore by Komatsu Australia, the new iSite fleet management solution is now available to the Australian market. The OEM is keen to promote it to every quarry operation – large or small – across Australia and New Zealand.

K

omatsu Australia has launched a complete fleet management solution that focuses on five key areas: site management, production, machine health, maintenance, and safety for quarry operations and large civil construction projects.

Komatsu’s new iSite V1.1 offering provides site and project management personnel with an “at a glance” production visualisation of any quarry or major civil construction site. iSite V1.1 gives the user a real time animated overview of every movement of production machines – and the material they are extracting, shifting or placing.

Developed by Komatsu in Australia, iSite has been designed from the ground up as a “brand agnostic” holistic visualisation

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Quarry October 2021

solution. It allows all levels of site management to have an ongoing real time overview of every machine movement – and machine condition. iSite uses cloud technology to allow users to monitor an entire site – or multiple sites – whether on premises or remotely.

As a fully “OEM agnostic” solution, iSite is able to work with multiple machine brands and models – so it is not restricted to Komatsu-only fleets and operations.

According to Komatsu’s national product and solutions manager Aaron Marsh, iSite uses data provided by a site’s mobile equipment to give site management a complete view of all machines on a site – including their payloads and production rates.

It predominantly applies to the following equipment types: • Trucks.

• Loaders.

• Excavators.

• Graders and dozers.

Data from a machine’s standard equipment monitoring system – eg Komtrax or Komtrax Plus for Komatsu equipment – is captured with a “plug-in” on-board dashboard device that then transmits the data to a centralised cloud, giving complete site visualisation to the operator and management.

The data captured includes payload, payload opportunity and bucketload information, as well as operating parameters such as machine travel speed and fuel consumption, along with any potential

iSite V1.1 gives the user a real time animated overview of every movement of production machines – and the material they are extracting or shifting.

machine health issues like overheating or excessive oil or fuel consumption.

Up to 50 machine operating parameters can be captured by the iSite dashboard device.

SHARED DATA For machine brands that do not have Komtrax-level monitoring capabilities, the iSite dashboard device can capture required data via a CANbus connection.

“All the data captured by iSite is centralised, so it can be viewed by all key site and management personnel – from operators through to site managers to senior management – through real time visualisation and reporting,” Marsh said.

In addition to being uploaded to the cloud, data can be shared between machines using a peer-to-peer connected mesh network. This means that if a machine is in an area without connectivity, data shared on the mesh network is automatically uploaded when one of the mobile machines is back in range.

“This mesh network facility allows iSite to measure load and dump production on a constant 24/7 basis,” Marsh said.

“It includes automatic truck payload capture, automatic truck to loader pairing, and true vehicle ground speeds.

“In our current V1.1, iSite determines payload from the truck’s payload measuring

system.

“In Version 1.2, due for release in 2022, it integrates to payload systems fitted on loading tools, such as loaders and excavators, for instances where production trucks don’t have their own telematic payload measuring system,” he said.

“Material types can also be set up automatically – for example, in stockpile operations – or selected and changed by operators as they move to different areas of the site.

“And so long as iSite is installed on both trucks and loading tools, and the trucks are fitted with payload measuring systems, loader production can be linked to each truck.”

Marsh said production visualisation is a major step forward in quarry and project management. “iSite makes use of industry-leading dashboards, so easy access to real time data is now a reality,” he said.

“This allows site supervisors and managers to make real time decisions across all aspects of a quarry or project.”

“As a result, key stakeholders can see immediately at a glance just what’s happening across their site, and have the option of immediately diving deeper if they need to.

“This gives an unrivalled opportunity to increase production, and reduce operating costs, by quickly identifying issues and bottlenecks, or where there may be a need to divert resources.”

MACHINE HEALTH, SERVICING iSite V1.1 also provides integrated machine health and maintenance reporting across an entire fleet, no matter how many different brands it may include. Features of this include: • Daily electronic pre-start, linked to operator IDs, and including auto-reporting functions.

• Fault events linked to OEM controllers.

• Fuel consumption on fleet and individual machines.

• Automatic service meter readings (SMRs).

• Automatic machine utilisation measuring.

• Idle analysis.

• Access through the myKomatsu online customer parts portal for parts and service kits, as well as oil analysis kits and reports.

Marsh said iSite’s inclusion of the operator pre-start ensured that all machine pre-starts are completed, with easy reporting and reviewing.

“Because it’s tied to operator ID, it ensures that pre-starts are correctly carried out, every day,” he said.

“In addition, iSite pre-start’s auto-reporting capability – specific to each machine – alerts key site personnel by email and SMS if an unserviceable item is detected, allowing for immediate action on any shift – and it’s based on severity.”

This reporting function also allows for auditing and maintenance review at any time. iSite can also be a significant contributor to improved site and operator safety, Marsh said.

“For example, it can provide in-cab alerts to operators on overspeed and overload events.”

This information is also provided to site supervisors to help monitor and maintain site safety procedures.

“And if an incident occurs, iSite can replay all machine movements leading up to the incident, allowing site management to cycle back and review and audit events, and the potential causes leading up to it,” Marsh said. “iSite has applications in any quarry site that uses more than two or three production units, as well as any fairly large civil construction project with significant production components.

“It’s been specifically designed as a fleet management system for quarry operations and large civil construction projects where there’s a lot of production work going on – and it’s been developed in Australia to meet the needs of these industry sectors,” Marsh added.

“We’ll be fully releasing iSite V1.1 in September 2021, ready for commercial applications in October. And we’ll be targeting every quarry operation – large or small – across Australia and New Zealand with this product.

“We believe it has the potential to make a huge contribution to any quarry’s bottom line, production rates and cost reductions.”

Once it has rolled iSite out in Australia and New Zealand, Komatsu will be looking to offer it to quarry operations around the world.

“Ultimately, we’ll be offering iSite as a package with Komatsu machines going into quarrying and other production applications,” Marsh said. “It’ll be available as a selectable first-fit for new production machines, as well as an aftermarket option.”• For more information about Komatsu iSite and other products, visit komatsu.com.au

Quarry October 2021 19

LOAD & HAUL

MEDIUM SIZE WHEEL LOADERS OFFER EXCEPTIONAL PERFORMANCE

P

art of Caterpillar’s nine- to 11-tonne wheel loader class, the 980 and 982 medium wheel loaders can be up to 10 per cent more productive and lower maintenance costs by up to 20 per cent, compared to the previous 980M and 982M models. These new loaders include an expanded technology platform to increase machine performance and improve efficiency.

The loader combines modern technology with real time actionable information. The standard Cat Payload with Assist provides accurate weighing of bucket payloads and includes low-lift-weigh and manual tipoff functions. The optional Cat Advanced Payload expands the system’s functionality with lists management, multitask- and manual-add modes and tip-off assist.

Compatible with third-party scale house software, it can wirelessly integrate the machine in the scale-house process with Dispatch-for-Loading (subscription required).

The new Cat Autodig with Auto Set Tyres promotes a loading technique to reduce tyre slip and load time. It can automate the complete bucket loading cycle to deliver high bucket fill factors for up to 10 per cent more productivity.

Standard along with Autodig and Auto Set Tyres, the new models introduce application profiles, in which the press of one button sets multiple machine parameters to optimise settings for the application at hand. Customised profiles can be created to fit customer-specific cases. Selectable on-screen job aids, along with a streamlined control layout, promotes ease of operation to help all operators be more productive.

Access to the operator’s cab is easy, thanks to a wide door, stair-like steps and grabrails for stability. Seat belts are now monitored, and the system can be completed with an exterior beacon for supervisors to enhance job site safety. Taller operators have increased legroom inside the cab, while sound suppression, seals and viscous cab mounts lower noise and vibration levels for a quiet work environment. The next generation ride control acts as a shock absorber to improve ride comfort over rough terrain.

The loaders’ dashboards and high

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Quarry October 2021

The 982 loader combines modern technology with real time actionable information.

resolution touchscreens provide intuitive, user-friendly control for enhanced performance. The seat-mounted electrohydraulic joystick steering system provides precise control over the 980 and 982 series models with minimal arm movements to increase comfort and loading accuracy. An automated air conditioning system keeps the cab as cool as desired.

The loaders feature a push-to-start system requiring a valid Operator ID to crank the engine. Operator ID works with a passcode input on the display or with optional Cat Bluetooth key. It acts as a security system with programmable operating restriction.

The floor to ceiling windshield improves forward visibility of the work area, while the standard rear vision camera and convex and spot mirrors enhance visibility around the machine. The Cat Detect radar can alert operators to hazards and an optional multiview, 360-degree vision system provides an extra monitoring level to advance safety.

All maintenance intervals are scheduled in 1000-hour increments, eliminating service downtime every 500 hours. All models offer convenient access to hydraulic and electrical service centres and grouped lube points for fast and easy servicing.

Remote services technologies on the Cat medium wheel loaders can save service trips to the job site and ensure the machine

operates at peak performance. Remote Troubleshoot connects the machine to the dealer’s service department over the air to quickly diagnose fault codes without onmachine cable connection.

Remote Flash ensures the wheel loaders operate with up to date software while working around the production schedule.

Updated files are pushed to the machine in the background and installation can be initiated from the Cat Remote Services Web Portal by the customer in a safe manner, reducing impact on production schedules.

Helping to manage fleet loader location, hours and maintenance schedules, the web portal connects fleet managers to the machine and allows dealer service requests to be made from a mobile device.

Cat Performance Series buckets balance bucket shape against the machine’s linkage for higher fill factors and better material retention. Cat Work tools are an integral part of the complete machine design and contribute to performance and efficiency.

The Cat 980 can be equipped with the optional Fusion Quick Coupler, delivering quick bucket changes. Contractors can also choose from purpose-built configurations to optimise loader performance and durability in tough applications.• For more information about the Cat 980 and 982 series medium wheel loaders, visit cat.com

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LOAD & HAUL

MAREEBA SANDS BOOSTED BY EXCAVATOR UPGRADE

M

areeba Sands has been working away in far north Queensland for 12 years, sourcing sand and hauling it across the region. But as owner Ron Petersen told Quarry, a quality service like Mareeba relies on quality products from CJD Equipment.

“About 12 years ago we kicked off the business,” Petersen said. “I used to work for other quarries nearby and I was doing a job in the area we are now when I noticed there was plenty of sand lying about. So, I made an offer to the landowner saying we should be selling this stuff.

“He and I went into business, started off quite shakily and we progressed from there.”

The small business has cemented itself as a stalwart of the community, treating each customer like a friend or neighbour.

Petersen said his local reputation of more than three decades was a great help in getting the business off the ground at first, but the struggles of small business didn’t avoid Mareeba Sands.

“Because I’ve been working in earthmoving and quarrying for a long time in the area, people already knew who I was when I entered this business,” Petersen said.

“But the biggest challenge was still trying to win everybody over, even though people knew me and what I’d done. Also, with all of our permits, managing the landscape was

another challenge as we tried to work within the guidelines.”

The Mareeba Sands site covers four different blocks, an hour west of Cairns, varying from 12 hectares (ha) up to 40ha.

Digging no further than three and a half metres deep, Mareeba Sands has been able to supply washed coarse sand, fill sand, fine sand, clay, and concrete pre-mix to customers across the region.

Using Petersen’s own truck and dog combo, plus some “subby” fleets on bigger jobs, Mareeba Sands has proudly developed a portfolio of happy customers.

“The biggest, most constant job would be sand for the previously done sewerage works for the Mareeba Shire Council. That was quite an extensive job for them,” Petersen said.

Other Mareeba Sands jobs have been in Chillagoe and Georgetown, up to 400 kilometres away.

Of course, none of this would have been possible without the service and support of CJD Equipment, of which Petersen couldn’t speak highly enough.

“It’s been good dealing with CJD,” Petersen said. “When you first start with ordering something, you change your mind, you go home, you change your mind again.

“But the financing with CJD was brilliant, professional, and super quick to deal with. We

The Volvo EC220D excavator works in tandem with owner Ron Petersen’s truck fleet on sand deliveries.

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Quarry October 2021

changed our mind on something at lunchtime and got an email back in the afternoon saying we were good to go – try that with a bank!”

Petersen had been running an older Volvo EC210 excavator for about eight years at Mareeba Sands. The machine had totalled nearly 11,500 hours of operation.

After a more than serviceable stint from the old machine, Petersen decided it would be more cost-effective to look into an upgrade, instead of forking out more cash on repairs.

So, in rolled the EC220D excavator and Petersen couldn’t have been happier with his decision.

“The EC210 was a reliable machine with brilliant fuel economy. We were extremely happy with its stability and performance. But the new EC220D is even better,” Petersen said.

The EC220D comes with a range of extras on the previous model which pleasantly surprised Petersen. They included an auto-greaser, seat covers, UHF radio, flashing light, windscreen guards, fall protection guards, handrails, reversing camera and a heavier counterweight.

In effect, Mareeba Sands has been allowed to run at full throttle, while saving a bit of cash on repairs and fuel.

“It’s doing everything I expected of it and that’s why I went with a Volvo once again,” Petersen said.

“The other reason is their fuel economy is like no other machine I’ve used. It would average between 14 and 16 litres per hour, depending on the application.”

And while all the trimmings can help a small business like Mareeba to excel for its community, sometimes a little bit of extra care and respect is all that’s needed to maintain a strong partnership.

Petersen attested to this and praised CJD Equipment and Volvo Construction Equipment for their ability to treat “little old Mareeba” as an equal.

“I was pretty impressed because, being a small operator, you’d think they’d hardly even see you,” Petersen said.

“You can imagine, they’ve got clients who’ve got 30 or 40 machines. So, for them to look after a small operator so well is something they can take their hat off to.” • For more information about Volvo CE equipment, visit the CJD Equipment website: cjd.com.au

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LOAD & HAUL Liebherr’s XPower wheel loader range can now take advantage of LIKUFIX.

LOADERS BOOSTED BY QUICK COUPLER SYSTEM

L

iebherr has expanded the application of its quick coupler system LIKUFIX to most of its XPower large wheel loader range.

The automatic, hydraulic coupling system was designed to increase efficiency and productivity, making operators’ jobs easier by keeping attachments connected.

Not even a hydraulic line or a misaligned bucket could give an operator cause now to leave their seat, as LIKUFIX separates and reengages attachments fully automatically.

With the press of a button and the turn of a joystick, wheel loaders can become forklifts or sweepers or grapplers in seconds.

From 2021, this capacity has been made available to an even wider range of vehicles.

XPower large wheel loaders up to the L 580 will now benefit from the technology.

Liebherr Australia and New Zealand’s earthmoving division national sales manager Noel Tosolini said the expansion met every expectation – for now.

“The customer requirements were and are that wheel loaders can change tools fully hydraulically and automatically,” Tosolini told Quarry. “We can now meet this requirement completely. This means that Liebherr has exhausted the potential for this product – but the company is watching the market and, as with any other product, will continue to develop and generate maximum customer benefit.”

LIKUFIX can even be fitted to other manufacturers’ hydraulic excavators, meaning

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Quarry October 2021

there’s no corner of Australia’s extractive industry that the system can’t touch.

The technology builds on the preceding capabilities of Liebherr’s mechanical coupling system and the hydraulic coupling system – both borne of the ethos that swapping attachments can save time and money.

Tosolini explained the applications where LIKUFIX might be used to save time.

“In civil engineering or at sewer or road construction job sites, larger wheel loaders might work with high dump buckets, screener crusher buckets, pipe grabbers or concrete mixer buckets,” he said. “In recycling yards, changing between high dump buckets and hydraulic forks on a regular basis might be necessary. In all these applications, LIKUFIX can save time and reduce risk.”

Not only can the LIKUFIX save money in uptime but through the purchases of fewer vehicles for any given job.

“Several customers in Europe have given us the feedback that thanks to LIKUFIX, a Liebherr wheel loader or excavator can complete the work of two machines in one,” Tosolini said.

For minimal maintenance on the coupling system and sustainable practices, Liebherr has produced a tight and reliable design.

Tosolini dived into the ins and outs of what makes the system so effective.

“The LIKUFIX system is designed for tough construction operations,” he said. “The coupling block is spring-mounted. Therefore,

the forces acting on the hydraulic quick hitch do not transfer to the coupling system.

“Even on long operations, the connections between the hydraulic circuits are completely sealed. No dirt can penetrate the system and no oil can leave the hydraulic system.

“To make maintenance easier, all individual moving parts on the LIKUFIX coupling system are easily accessible.

“Customers are able to easily complete cleaning and simple maintenance activities themselves, such as changing a seal.”

Since 1954, Liebherr has been developing its excavation technology to reach this point, when simplicity and productivity can combine.

LIKUFIX has peaked – for now – and met the needs of the industry. But Tosolini said his company will be ready for the next step in technological advancement when the time comes.

“Depending on customer requirements, addon features can certainly be investigated and, if necessary, developed,” he said. “Liebherr has the advantage here that a great deal of knowhow has already been acquired in the field of quick coupling systems over the last 20 years and synergies can certainly be used here. The primary goal is always to maximise customer benefit.”• Further information about the LIKUFIX can be found on the Liebherr website: liebherr.com/en/aus/ products/attachments/quick-couplers/likufix/likufix. html

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LOAD & HAUL

On loan: Delta’s Hitachi ZX690LCH-5 excavator fills the back of the Caterpillar 773 dump truck.

RENTAL PLANT GIVES

BUSY SITE EXTRA MUSCLE, RELIEF A Hanson Australia extractive operation has never been busier. Fortunately, there has been extra support to assist the quarry’s core earthmoving fleet as it transfers aggregate from the face to the crushing circuit and out the gate.

H

anson Australia’s Kulnura Quarry is located off the New South Wales Central Coast, about 25km from Gosford and about 90km northwest of Sydney. Kulnura Quarry is extracting a columnar basalt deposit and under the current extraction plan, there is about 10 to 15 years of resources left in the quarry.

There are 48 personnel at the site which runs on day and night shifts. The workforce includes operators and maintainers, including boiler makers, heavy vehicle mechanics, diesel fitters and technicians.

Hanson’s annual output at Kulnura is between 1.5 and 1.7 million tonnes per annum. As quarry manager Greg Dressler told Quarry, many of Kulnura’s end products comprise concrete aggregates, 10mm to 20mm and 20mm graded roadbase products, and washed and unwashed manufactured sands.

“We mainly produce aggregates,” he said, “but we also supply the construction market with drainage rock, small gabion rock and specified and unspecified roadbases for the quarry materials market. We satisfy most of the quarry materials markets.

“We supply both to the Central Coast and Sydney for concrete aggregates, and civil construction markets as well. Our concrete plants are feeding into major infrastructure projects in the Sydney market. We supply

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Quarry October 2021

locally to a number of housing developments, so again, civil construction materials, drainage materials, specified and unspecified roadbase products.”

HIRED ‘MUSCLE’ To be extracting and then moving up to two million tonnes of aggregates per year on-site, you require an extensive and reliable earthmoving fleet.

“In our load and haul fleet, we have a fleet of Cat 775G dump trucks, a Cat 990 face loader, a Komatsu WA700 loader, a Cat D9 dozer, a Cat 769 dump truck for stockpiling work, three Volvo sales loaders – two L250s and a L260 – plus ancillary equipment with Bobcats, mini-excavators, telehandlers and elevated work platforms,” Dressler said.

However, even with such an impressive inventory, the demands on Hanson Kulnura Quarry from the Central Coast and Sydney markets means the operation must periodically lease more equipment. It is also necessary to bring in more “muscle” if a regular member of the fleet is also indisposed.

Enter Delta Group whose hire division offers quarries and mines heavy late model plant and equipment nationwide, both for shortand long-term purposes. Hanson Australia has worked with Delta for more than a decade on the supply of rental equipment to its quarrying operations nationwide.

At Kulnura, Delta has most recently supplied Hanson with a Komatsu WA500-7 wheel loader, a large Caterpillar 773 haul truck and two Hitachi excavators – a ZX290LC-5 and a ZX690LCH-5.

“The 773 is an additional dump truck to cover our stockpile requirements,” Dressler explained. “It supplements our Cat 769 from a stockpiling/finished product perspective. The WA500 enables us to stand down a couple of our loaders for major mid-life rebuilds.

“The ZX690 excavator is used for a combination of overburden removal and it also supplements as a face-holding tool for our load and haul fleet. The ZX290, which is the smaller excavator, is used for general housekeeping works and tasks, a little bit of stockpile management, and we also use it for feeding some mobile crushing and screening equipment that we hire in from time to time.”

ACCEPTANCE OF SITE Dressler, who has more than 35 years’ experience in the quarrying industry and worked across a range of extractive companies, was already familiar with Delta Group’s reputation and expertise prior to joining Hanson Kulnura earlier this year.

“Most of the Delta Rent equipment is low hour, late model machines,” he said. “Delta’s gear is well maintained. Our earthmoving fleet is quite diverse because it is Cat, Volvo,

Hitachi and Komatsu. The operators are very happy. When the guys jump out of one brand of excavator into another brand of excavator, the excavator operations remain the same, it’s just becoming familiar with the new machines.

“We do a familiarisation with our people.

We also do an acceptance of site for hired equipment to ensure that it meets our minimum site requirements around MDG15, from a safety perspective. Generally, the machines are well and truly up to spec but it is one of our processes that we have to follow to meet site requirements.”

The flexibility, Dressler said, to lease the plant from Delta Rent enables Hanson Kulnura to stand its machines down for “mid-life rebuilds or major repairs”.

“Having our own core fleet is what we maintain but we use Delta Rent to supplement equipment for peaks in the market and mobile crushing and screening operations or any other projects on-site with overburden removal and the like,” he added.

Dressler added that by hiring equipment on a supplemental basis, quarries also stand to make capital savings. “There are some operations that may not have the capital available, so rental is a good option. The market goes up and down, so it makes little sense to purchase machines of your own that you don’t end up utilising – that ends up being a lot of money wasted with none of the benefits.

Having a core fleet means you can supplement it with rental equipment based on demand.”

FLEET DATA Core fleets, particularly in larger quarries, will inevitably utilise fleet management solutions to monitor machine and operator performance.

Dressler explained that Hanson Kulnura uses the SAP software platform which “helps us in and around our scheduled maintenance and financial tracking of our mobile fleet.

Internally, we also have some very good visibility of the efficiencies of our mobile fleet, whereby we monitor idle times and the fuel factors of our haul trucks. It’s good data to have to optimise the efficiency of your operations.

“With the hired-in equipment from Delta, we don’t use SAP. Delta maintains the gear well in terms of scheduled servicing but if there is data we need, we can recover it from Delta.”

Damien Gramola, the national sales manager for Delta Rent, told Quarry that operator and machine performance is readily

available for quarrying clients to add to their own fleet data.

“We can provide any customer with operator and machine telematics,” he said.

“This is derived from the OEM telematics programs which Delta Rent use on a regular basis to monitor machines and their performance.

“It is also used to provide hours for servicing and maintenance to ensure the machines are maintained at their peak performance.”

Gramola said the company’s approach to leasing its equipment to quarrying clients applied across the spectrum, whether it was large, medium or small producers. He said the appeal of Delta to larger producers with large earthmoving fleets like Hanson was that they could hire equipment to support their operations with few restrictions and at relatively short notice.

“For the big producers, it’s about flexilbility and responsiveness to demand,” Gramola explained. “If they have a breakdown we can mobilise equipment quickly to reduce the impact of the breakdown, plus when the unit is no longer needed it is simply off hired and returned. We can hire equipment out for one day, one week, one month or years, it’s really up to the customer.”

In this time of COVID-19 uncertainty, it is a brave man who can organise delivery of heavy-duty plant and equipment at short notice but nonetheless Gramola said that the turnaround times on Delta’s hire gear is reliable. “It depends on when the request is

made, but usually within 24 hours we can have a replacement machine on-site and ready to work.”

Gramola added that the scalability and costs of renting are also more attractive for quarrying producers than “trying and buying gear” from OEMs/dealers or buying low hour machines from auctioneers.

“When demand for product increases or they need to start stripping, they can bring in equipment to satisfy the need, then when demand falls away or the stripping finishes, they can simply off hire and return the unit,” Gramola said.

“It allows customers to forecast costs and output based on equipment required and the amount of time needed to complete a project.

It also prevents them having to deal with any servicing or breakdowns because we take care of all maintenance and servicing.”

Greg Dressler has liaised with Paul Ryan, Delta’s heavy earthmoving rental equipment specialist in NSW, and described his overall experience with Delta – both before and since joining Hanson – as positive.

“They’re a very professional company to deal with, very responsive and very costcompetitive,” he said. “They can cover our needs quite quickly. They have a large fleet across the eastern seaboard and it’s a reasonable range that is available at very short notice.”• For more information about Delta Group’s rental service, visit deltagroup.com.au/rent

The hired ZX290LC-5 excavator is employed at Hanson Kulnura Quarry for general housekeeping works and tasks, including stockpile management.

Quarry October 2021 27

LOAD & HAUL

BIODEGRADABLE TOOL GREASE IDEAL FOR SUSTAINABLE CONTRACTOR

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HT Contracting founding director Mike Heddon has had a relationship with Rammer that stretches back into the mid-1990s. Upon these foundations, his company now trusts the experts at Rammer to develop a range of reliable products including its BIO Tool Grease – a biodegradable grease for hydraulic rockbreakers.

RHT formed in mid-2018 as Heddon returned from time away from the extractive industry to realise there was still plenty of work to be done across Western Australia.

RHT runs with a focus on safety and sustainability, owing to Heddon and his colleagues’ extensive history of mine and mill management.

The company has even grown to be responsible for the largest central discharge dam in the southern hemisphere.

Naturally, this ethos calls for investment in the best products available which can enable safe operations for RHT and its clients.

One such investment is Rammer’s BIO Tool Grease for hydraulic rockbreakers which has been developed in collaboration with customers across the extractive industries.

Heddon said he didn’t hesitate to switch out the old Rammer tool grease for the new biodegradable option.

“When it came out, they rang me straight away and said Rammer would be trialling it and asked if I wanted to try it. I said absolutely we do,” Heddon told Quarry.

Heddon’s extensive relationship with Rammer has kept him among Rammer’s first ports of call to experience new products.

His contact knew RHT would be keen on the grease, so long as it could tick one simple box.

“We run world’s best practice equipment,” Heddon said. “We keep up to date with the best available to us and if something comes out, we ask ‘will this make the job better?’

“We have a philosophy of constant improvement while always looking outside the square, no matter what we do for our clients. They then reward us in repeat work and longer contracts.”

RHT has reported no noticeable difference

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Quarry October 2021

in the BIO tool grease compared to its non-biodegradable predecessor – just the same reliability the contractor has become accustomed to in Rammer products.

Competing bidegradable greases have seen high temperatures limit their effectiveness, which is important in hydraulic rockbreakers which can reach up to 1100°C. Rammer’s BIO grease, however, manages to combat both high and low temperatures using a specially formulated lithium complex thickener.

Heddon said he trusted Rammer after visiting its facilities in northern Europe and witnessing the work that goes into the products.

“A big eye-opener for me was when I went to Rammer in Finland and saw how passionate they were about everything they do, and how serious they were about their environmental practices,” Heddon said.

“So, there was no hesitation about the product’s quality. If it’s got the tick of approval from a place like Finland, you know it’s good.”

The biodegradable nature of the tool grease allows for stress-free use in areas with strict regulations such as cities, underwater and where groundwater may present a risk of spreading any spills.

Heddon said the extra peace of mind that comes with being environmentally friendly is a bonus.

“Rockbreakers obviously run down and wear out eventually, which can lead to breakages or oil spillages in worst case scenarios,” Heddon said.

“But it’s just great to know that if there is ever an oil spill of any kind, there’s less worry as to how it might contaminate the environment.”

This responsible state of mind extends to every task undertaken by RHT. Whether it’s tailings dams, rehabilitation, crushing and screening or any of the company’s other services, safety and sustainability are both no-brainers.

Heddon said in this day and age there’s no reason these pillars of operation shouldn’t be front of mind.

“Sustainability is just like safety in our

Rammer’s biodegradable grease has been specially formulated with a lithium complex thickener.

eyes,” Heddon said. “If we find ourselves working in an unsafe environment, we basically leave. It’s the same with sustainability.

“If you don’t move with the times, clients will move away from you, so it’s just another box to tick because it’s the right thing to do. Just like you look after your health and safety, you look after the environment.”

Rammer BIO Tool Grease became available in Australia from the last quarter of 2021 via the Australian authorised Rammer dealer network.

Rammer has several dealers across Australia. These include GroundTec (New South Wales), Walkers Hammers (Victoria and Tasmania), QLD Rockbreakers (Queensland), Renex Equipment (South Australia and the Northern Territory), and Total Rockbreaking Solutions (WA).•

ENGINEERED FOR RESULTS Our expert engineers design customised solutions that transforms natural sand and crushed rock reserves into high-value products for an exceptional return on investment. An integrated water management system recycles up to 90% of process water for immediate re-use in the system, significantly reducing footprint and maintenance of settling ponds.

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LOAD & HAUL

LARGE LOADER OFFERS

HIGHER PRODUCTIVITY, LOWER COSTS Komatsu Mining, the mining division of Komatsu Australia, has released an upgraded version of its 11m3 to 13m3 class mining loader: the WA900-8R. It incorporates innovative technology features that deliver increased productivity and ease of operation, while reducing operating costs.

T

he WA900-8R loader, the largest that can be operated in a quarry, incorporates Komatsu’s SmartLoader Logic technology to provide the engine with the precise torque for each part of the duty cycle.

Komatsu’s national product manager Mark Summerville said SmartLoader Logic can improve the WA900-8R’s fuel economy by up to 10 per cent compared with the previous WA9003E0, while also increasing productivity. Other productivity improvements include a modulation clutch for controlling speed and torque, along with faster boom raise speeds for faster cycle times.

“These features combined with automatic dig and a semi-automatic approach and dump system means the WA900-8R can improve an average operator’s efficiency,” Summerville said.

The new loader includes a Komvision obstacle detection system that uses radar and 360-degree cameras to alert the operator if a person, vehicle or obstacle is detected. This greatly improves personnel safety in and around the machine.

The WA900-8R, powered by a 671kW Komatsu engine, has an operating weight of 116.4 tonnes. It is matched for loading 90-tonne dump trucks (Komatsu HD785 size) in standard configuration, and up to 140-tonne trucks (Komatsu HD1500) in high-lift spec.

PRODUCTIVITY AND ECONOMY FEATURES Komatsu Mining has listed numerous features that can increase the loader’s productivity while reducing operating costs, including: • SmartLoader Logic system for improved fuel economy.

• A large capacity torque converter.

• A tyre slip control system.

• Increased boom speed and breakout force.

SmartLoader Logic optimises the engine torque across all applications to minimise fuel consumption while giving the loader the torque and digging power it needs.

“This system functions automatically and doesn’t interfere with operation, saving fuel without decreasing production,” Summerville said.

The system is matched to the loader’s automatic transmission, with an electronically controlled modulation (ECM) valve that automatically selects the correct gear speed based on travel speed, engine speed, and other travel conditions.

“This ECM system also engages the clutch smoothly to prevent lags and shocks when shifting,” Summerville said.

The WA900-8R’s powertrain has a large capacity torque converter designed to ensure optimum efficiency.

“This ensures greater productivity in

‘V-shape’ loading applications because the torque converter’s increased tractive effort means it doesn’t require full throttle,” Summerville said. “It also allows the loader to achieve higher gear ranges and maintain higher travel speeds when working in load and carry applications.”

The loader’s hydraulics are designed around Komatsu’s closed-centre load sensing system (CLSS) technology. “This uses a variable displacement piston pump combined with CLSS to deliver hydraulic flow exactly when the task requires it, preventing wasted hydraulic flow, which contributes to better fuel economy,” Summerville explained.

Another feature is a tyre slip control system.

When it senses tyre slip, the control system applies the modulated clutch to control the torque converter and minimise tyre slip.

“All these features combine to reduce fuel consumption by up to 10 per cent – while also increasing productivity – compared with the WA900-3E0,” Summerville said.

The WA900-8R features Komatsu’s latest generation cab to improve operator comfort and safety. It includes the addition of a trainer seat, shockless stop cylinders, climate control air conditioning and modulated clutch.

These features, combined with ergonomic improvements, all contribute to higher operator productivity, easier and safer operation, and

The WA900-8R large loader is matched for loading 90-tonne dump trucks in standard configuration, and up to 140-tonne trucks in high-lift spec.

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reduced fatigue. The cab also includes: • A new automatic digging system.

• A semi-automatic approach and dump system.

• A redesigned large operator cabin seat, incorporating low effort control levers and an advanced joystick steering system.

• An electronically controlled suspension system (ECSS).

“Our new automatic digging system actuates the bucket tilt and lifting operations by detecting the sensing pressure applied to the equipment,” said Summerville. “It’s designed to significantly reduce operator fatigue and improve efficiency, ensuring optimum bucket fill every time the machine enters the pile, whether in rock or in loose materials.”

The digging system works in conjunction with the semi-auto approach and dump system.

“This automates boom lift and bucket dumping when approaching a dump truck, particularly in ‘V-shape’ loading operations,” Summerville said. “Combining this with our

automatic digging system, loading operations from stockpile to dump truck are made easier, and operator effort and fatigue greatly reduced.”

The operator’s compartment – a large, pillarless ROPS/FOPS cab – features a new air suspension seat that provides enhanced support on rough roads and dampens machine vibrations. “Integrated within the seat is an electronic pilot control lever console and a joystick steering lever,” Summerville said.

With WA900-8R loaders used in load and carry applications, Komatsu has standardised the ECSS to reduce pitching and bouncing on uneven surfaces. “This ensures better travel performance, reduced operator fatigue and less material spillage, while delivering a smooth ride, even at high travel speeds,” Summerville said.

SERVICEABILITY Maintenance and serviceability have been optimised through a high resolution in-cab

monitoring system, which works in conjunction with Komatsu’s Komtrax Plus remote system.

Maintenance is also simplified through sideopening engine doors, an accessible engine compartment with dual-side engine bay access ladders, along with a swing-out reverse cooling fan and wide-core radiator (with modular core).

An adjustment-free braking system, along with service brakes mounted in-board from the final drives and brake on the sun gear, ensure increased brake life.

Improved loader linkage and upgraded structures for the front and rear frame provide a longer structure life. The machine is also fitted with nine lanyard anchorage points, providing safer maintenance access in difficult areas.

“With our new WA900-8R loader, Komatsu has developed a best in class loader, while delivering significantly higher productivity and operating efficiency, combined with lower fuel consumption and reduced operating costs,” Summerville said.• For more information about the WA900-8R and other products, visit komatsu.com.au

Our vision is to connect people, processes and products, advancing innovative solutions from rock to road as OneAstec.

FIXED • TRACK • RECYCLING • WASHING • MODULAR • MATERIALS HANDLING

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BUILT TO CONNECT

CRUSHING & SCREENING

FULL TURNKEY PLANT LATEST JEWEL IN FAMILY CROWN

A South Australian family business with Victorian quarrying interests has taken delivery of a full turnkey plant – while overcoming a few pandemic curveballs during installation.

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EM Group Holdings is a family-owned business that was commenced by owner/director Ian Sutherland in 1959 and has specialised in earthmoving, civil construction and quarrying projects for 62 years.

The group’s headquarters is in Mount Gambier, South Australia. It has 127 staff, each with a range of specialised skills and abilities. The group covers all aspects of civil construction from the supply of quarry materials such as Telfords Quarry rubble for road making and agricultural lime through to roading sealing and a state of the art asphalt plant. Gambier Stone, another member of the group, provides dimension stone to the building industry, while Martes Quarry supplies agricultural dolomite to the farmers. Gambier Earth Movers also operate the Mount Graham Quarry bluestone site at Mount Burr, SA. The company also operates Moree Quarries, in Harrow, in central western Victoria, about 150km northeast of Mount Gambier. GEM Group covers a radius of 200km in terms of clients and projects.

In addition to these sites, GEM Group’s managing director and civil project works supervisor Glen Sutherland (son of founder Ian) told Quarry that the combined companies’ overall output is 500,000 tonnes per annum.

“We have mobile units that crush in other quarries,” he said. “We have 14 leases in South Australia to our name. Our mobile crushers also do work for local councils as well.”

Sutherland divides his time between working daily at GEM’s HQ in Mount Gambier and working at least one day per week at Moree Quarries, which the GEM Group has operated for 35 years. The site is anticipated to have more than 20 years of reserves of a bluestone/ basalt deposit. Sutherland said the quarry is producing Class A sealing aggregates, asphalt aggregates, concrete aggregates, ballast and Class 1 to 4 crushed rock and scalps. “We also have pre-coated sealing aggregates on-site, which are being used for roadwork and asphalt

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The new Moree Quarries full turnkey crushing and screening plant has been operating since May 2021.

works,” he added.

The end use of these products can be found in roads, concrete paths, farms, and asphalt and sealing operations throughout regional Victoria and SA. Moree Quarries has for 25 years operated a crushing plant that included a Jaques single toggle jaw crusher and a Canica model 90 VSI crusher. “That last plant simply couldn’t keep up with demand,” Sutherland said. “It was doing about 80 tonnes per hour (tph).”

Consequently, GEM Group put out a tender for a supplier to provide a new crushing and screening plant for the Moree site. “We wanted a plant that would be capable of producing up to 400 tph and could provide a quality shape and cleanliness in our aggregates,” Sutherland added. “We wanted the plant to be fully automated and QME answered the call.”

PLANT INSTALLATION QME – Quarry & Mining Engineering – is involved in the fabrication and installation of full turnkey plant and equipment in mines and quarries throughout Australia. The company, which has been headquartered in Bendigo since its inception in 1980, is aided on all its projects by support services and contractors.

It counts Terex Jaques, Sumitomo and Indeco among its network partners.

Ian Rowan, the managing director of QME, told Quarry that GEM Group first approached him in 2019 about establishing a new crushing and screening plant at Moree Quarries. After being briefed by Sutherland about the key requirements of the new plant, Rowan and the QME team recommended a new plant on a hectare-sized footprint that would incorporate Terex Jaques equipment.

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Our improved Centra™ Gold formula combined with our industry-leading service gives your quarry the results you are looking for.

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CRUSHING & SCREENING

Sutherland was entirely comfortable with the recommendation. “Based on our history with Jaques and QME, we went with Jaques. We had some Terex Jaques machinery at Moree and our previous company Mount Schank Metals had Terex Jaques products as well.”

The new Moree Quarries circuit, which has been operating since May 2021, consists of a Terex Simplicity 5124 vibrating pan feeder, a Jaques ST48 jaw crusher, a Cedarapids TSV6203 medium scalper vibrating screen, two Cedarapids MVP450X cone crushers, a Canica 100 rock-on-rock (ROR) vertical shaft impact (VSI) crusher, and three triple-deck Cedarapids TSV8203 vibrating screens.

A Supervisory Control and Data Acquisition (SCADA) operating system manages the plant processes via a programmable logic controller (PLC); the PLC reports data to and communicates with the SCADA system. The plant operation and status is communicated to the plant operator via a 660mm touchscreen Human-Machine Interface (HMI) monitor (SCADA or Panelview system) in a deskmounted console.

FIXED CIRCUIT All the machines were statically mounted and designed to operate in a fixed system. Rowan and John Flynn, the Australian and New Zealand business manager for Terex Jaques, stated there was customisation to allow for the processing of different materials.

“All crushers have some configuration options,” Flynn told Quarry. “There has been no unique customisation but the machines are configured to best operate as a complete system per Moree Quarries’ requirements.”

The Cedarapids MVP450X cone crusher (centre) features a roller bearing design, a 10mm to 51mm CSS setting, a 300kW motor and a hydropneumatic tramp iron relief system.

Flynn said the 1295mm x 13m long Simplicity 5124 features a full length pan suitable for accepting a large primary feed. It is equipped with an oscillating twin-shaft drive arrangement that moves material efficiently and effectively.

As part of the new Moree Quarries circuit, the Simplicity 5124 feeds material to the Jaques ST48 single toggle jaw crusher which is renowned for its large gape feed opening (1067mm x 1219mm) and hydraulic closed side setting (CSS) adjustment. The primary feed from the ST48 is then transferred to the double-deck Cedarapids TSV6203 which, Flynn said, “is installed at a five-degree angle to best handle coarse jaw crusher product and resisting pegging in the large scalping apertures of the top deck”. The variable slope capability of these screens allows installation from a zero- to 10-degree angle to best suit the application. The TSV6203 is the latest generation El-Jay horizontal screen which can handle a broad range of applications.

The Cedarapids MVP450X cone crushers are the next links in Moree Quarries’ crushing and screening chain. They each feature a roller bearing design, a 10mm to 51mm CSS setting,

The Terex Cedarapids TSV6203 is the latest generation El-Jay horizontal screen which can handle a broad range of applications.

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a 300kW motor and a hydropneumatic tramp iron relief system. They can process sand and gravel, shot rock and recycled materials, with a throughput of up to 500 tph.

The secondary feed from the MVP450X is then passed to the 220kW Canica 100 VSI crusher, which has a maximum feed size of 125mm and a throughput of 400 tph. “The configuration of the Canica VSI can be set up with primary aim to crush, shape product or a combination of both,” Flynn said. “The Canica Model 100 ROR at GEM Moree has a rotor and rock box configuration. Its primary aim is to shape material already reduced by the cone crushers to a cubical final product.”

Feed from the Canica VSI is passed to the three Cedarapids TSV8203 triple-deck horizontal screens. Flynn said the TSV8203 is built for durability and its patented lubrication system, coupled with high tolerance machined components, enables efficiency and a long bearing life in the final screening duties at Moree Quarries. “A high G-force operation ensures that required specifications can be met through highly efficient screening.”

PANDEMIC DELAYS Due to COVID-19 lockdowns and border closures in the past 20 months, Glen Sutherland has secured a border permit to cross from SA to Victoria and back regularly.

The border closures had some impact on operations at Moree Quarries.

“From start to finish, installation was just over 12 months,” Sutherland said. “There was a delay because we couldn’t get across the [SA/ Victorian] border to do the earthworks. QME had the plant completed within the time that was promised. However, once the borders opened up and we completed the earthworks, the plant was delivered and installed.

Throughout the process, there were phone calls between myself, Ian and Sue [QME’s project manager] but overall it ran smoothly.”

Sutherland’s impressions of the new plant over the past five months of operations are

An aerial view of the new Moree Quarries circuit, which was a collaboration between GEM Group Holdings, QME and Terex Jaques.

positive. “From the time the first rock went through the plant, we’ve been impressed with the output and the cleanliness of the aggregates,” he said, “particularly as there has been a lot of rain in the past few months and conditions have been a bit dirtier than normal.

The cleanliness of the rock coming out of the plant has been really impressive.”

Ian Rowan, of QME, agreed that the new plant has shown potential but has not had the opportunity to perform to its absolute

best because it has “not had the consistent quality feed and the raw material has been very wet”. He was optimistic that as the spring season commenced and with drier rock conditions, the plant’s capabilities “would come to the fore”.

Nonetheless, Sutherland said he and the GEM Group are pleased with the new plant’s early results and praised QME and Terex Jaques for their work. “From the first initial catch-up in January 2019 through to commissioning, QME

has been fantastic,” he said.

“Day or night, Ian and Sue from QME have been available and had our best interests at the forefront. QME have handled the whole turnkey operation at a high level.

The commissioning and handover between QME and Terex Jaques was smooth and I recommend both companies to anyone who is in the market for an upgrade to an existing plant or for a full turnkey plant.”

Sutherland anticipates that QME and Jaques will have a hand in the aftermarket support of the plant. “I’ll definitely talk to Ian quite closely about that, and we’ll talk to Terex Jaques as well. Communication is the key and we’ll work it out between all three parties.” • To view the specs for Terex Jaques plant, visit terex.com/mps/en-au For more information about GEM Group Holdings, visit gem-group.com.au To learn more about Quarry & Mining Engineering, visit qmebendigo.com

CONTACT US TODAY ON

1300 793 071

DELTA RENT IS THE HEAVY PLANT RENTAL DIVISION OF DELTA GROUP - ONE OF THE LARGEST DIVERSIFIED CONTRACTORS IN THE WORLD TODAY.

We have the financial, operational and organisational capacity to manage hundreds of projects at any one time - Australia wide.

With one of the largest and youngest heavy rental fleets in Australia, our fleet is meticulously maintained and regularly upgraded to ensure we capitalise on late model machinery and the efficiencies they bring to a client’s project or site specific requirements.

Delta Rent have equipment available for hire under flexible short, medium and long term rental plans, let Delta Rent provide your next solution to your quarry requirements.

CRUSHING & SCREENING The LT220D is producing an end product of DGB 20mm minus road base material.

CRUSHING OPERATION ACQUIRES MOBILE COMBO

Cooper Civil & Crushing is taking advantage of industry growth following the Australian Government’s large infrastructure investment post-COVID-19.

C

ooper Civil & Crushing’s operations are based out of company headquarters in Grenfell, Central New South Wales.

Having founded the company in 2017, Daniel Cooper serves clients in both the private and public sectors. Cooper Civil & Crushing has completed several projects, including subdivisions, treatment pond construction, grain bunker storages, supplying road base from its quarries to local Government, and campaign crushing for local Government authorities. Cooper did his industry-based training with Mitton Bros Earthmoving in

Grenfell and has been in the agribusiness/ farming sector for more than 20 years.

Celebrating the achievements of the company and its stakeholders, Cooper and his team are proud of everything they’ve achieved. Since the company started almost five years ago, Cooper has identified several opportunities for solid and proactive earthworks solutions. The company’s core values include operational safety, transparency, integrity, accountability, fairness, respect, quality of artistry, and relationships. In this industry, operators like

The Lokotrack LT220D in operation on a Cooper Civil & Crushing job.

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Quarry October 2021

Cooper and his team constantly face tough delivery challenges that can only be met through a commitment to problem-solving combined with reliable plant and equipment at its core.

After the Australian Government’s significant COVID-19 infrastructure investment lead to unprecedented industry growth, Cooper needed to add another mobile crushing train to the company’s fleet. In the past four years Cooper Civil & Crushing occasionally tapped into Tutt Bryant Equipment (TBE) resources but has recently sought more of a partnership and relationship that falls in line with its core company values. In Cooper’s own words, “TBE offers a great range of equipment and reliable back-up and spare parts range which is critical for our operation to be successful”.

Cooper’s objective is to provide the Civil Earthworks side of his business with quality aggregate products that meet specifications, produced consistently with reliable Metso Outotec Lokotrack crushing and screening equipment backed up by TBE’s after-sales service and support. A requirement for this additional mobile crushing train was for the primary and secondary units to be linked via supplied and standard Metso Outotec hardware. This linked/automated set-up increases plant efficiency by constantly measuring and adjusting various parameters communicated autonomously across connected crushing and screening units,

ultimately and consistently achieving the desired final product quality.

In this specific application, a 600mm medium granite had to be crushed/processed down to a 20mm minus Densely Graded Base (DGB) compliant with NSW Roads and Maritime Services (RMS) specification 3051, suitable for use as road base material under bitumen in developments, sub-divisions and council roadways. The solution included Metso Outotec’s LT220D Lokotrack cone crusher and screen combination to align with the Metso Outotec LT106 Lokotrack primary jaw crusher. The achieved results include an optimised and automated mobile crushing and screening plant set-up/ arrangement supplying a quality product within specification.

Standard practice for TBE is to have all customer-ordered units go through a pre-delivery inspection (PDI) at all of its nationwide facilities. These units are prepared for “mission readiness”,

conforming to the highest standards and specifications before delivery to a customer’s site is scheduled. After the arrival of the Metso Outotec LT220D Lokotrack cone crusher and screen combination on location, commissioning/handover training begins and is precisely executed by TBE’s Sydney-based service support team.

A major part of the delivery to Cooper Crushing & Civil was the commissioning/ handover training. It included linking the Metso Outotec LT106 Lokotrack primary jaw with the LT220D Lokotrack and running these units in process with rock feeding through this plant. During the initial consultation process with Cooper, this plant set-up was proposed and simulated using Metso Outotec’s advanced Bruno Simulation Software. When using this software, TBE’s service support team uses conservative yet realistic values in all the calculations. Bruno calculations estimated average production figures equating to about 200 tonnes per

hour (tph). The calculations were then confirmed in the commissioning/handover training, with the actual figures reaching precisely that.

The mission objective was achieved, and in Cooper’s own words, “Cooper Civil & Crushing would recommend TBE to other companies looking at buying crushing and screening equipment”.

He added, “So far, it has been a very successful relationship because of the product support, reliable spare parts, range and quality of Metso Outotec’s Lokotrack crushing and screening equipment on offer.”

Tutt Bryant Equipment continues to provide technical support to Cooper Civil & Crushing with its ongoing equipment, parts and service needs. For more information on Cooper Civil & Crushing, its experience with Metso Outotec’s Lokotracks, or to discuss Cooper’s range of services, visit coopercc.com.au • For more about Metso Outotec equipment, visit tuttbryant.com.au/metso

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CRUSHING & SCREENING

AUTOMATED CONE

BOOSTS EFFICIENCY, UPTIME A 145ha limestone operation has raised its output and reduced maintenance costs after installing an automated cone in its secondary crushing circuit.

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ulsa Rock Quarry has boosted plant uptime and crushing efficiency. The 145ha limestone operation is one of six locations owned by the Anchor Stone Company, which has long provided high quality construction aggregates to the Tulsa region in Oklahoma, USA. Tulsa Rock replaced its older impact crusher with an automated cone crusher in its secondary crushing circuit, leading to major gains in daily output at lower costs per tonne.

“We needed to get away from impact crushing and reduce our maintenance costs and power consumption,” Anchor Stone’s

The P500’s auto-feed function maintains optimum production levels.

processing engineer Mike Neal said. He added one of the problems with impact crushers is keeping an eye on the primary, constantly monitoring the feed that is sent to the secondary circuit.

“An impactor can easily plug, causing hours

The recently installed Patriot P500 cone crusher at the Anchor Stone Company’s Tulsa Rock Quarry.

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Quarry October 2021

of downtime and potential damage to crusher components. We had to open the impactor up every night and inspect it,” he said.

Neal added that with the new cone, that maintenance downtime is eliminated. “Quite simply – figuring out what operating costs were before and what they are now – it makes sense to upgrade to an automated cone. We’ve lowered our operating costs and improving our plant uptime,” he said.

Anchor Stone installed a P500 Patriot cone crusher, manufactured by Superior Industries, a single-source, global provider of bulk material processing and handling systems.

Neal said the cone was chosen for its innovative design, heavy-duty construction, ease of maintenance, and a versatile and simple automation system.

Superior’s product engineering and inhouse automation teams worked closely with Anchor Stone on-site to ensure the the crushing circuit would perform to exact specifications.

NEXT LEVEL CONE DESIGN “With the latest cone designs, it’s such a benefit to have a new cone crusher in our plant,” Neal said of the P500 Patriot. He added that the operation had always avoided cones as older-style units did not offer tramp relief. “A piece of metal stuck within the cone demanded the dangerous task of cutting it

out with a torch,” he said.

Superior Industries’ crushing product champion Mike Schultz said that the Patriot cone’s design and automation ensures daily reliability, and prevents costly damage.

He said the cone’s tramp relief system is designed with fewer accumulators for minimised maintenance. He pointed out that even if “an accumulator fails, the secondary relief valve will provide immediate pressure relief, allowing the crusher to open”.

The inverted design of the tramp release cylinders means the hydraulic cylinder rod seal is not exposed during operation, greatly reducing potential contamination and failure.

Schultz added the cone’s automation package acts as a warning system, alerting operators to conditions such as bowl float, excessive amperage or temperatures, and lubrication or low-flow oil issues.

He said the unit is more robust than the typical cone. “Superior’s engineers have beefed up the strength of the machine with

a heavier-duty adjustment ring, base frame, eccentric, and clamp ring.”

USER-FRIENDLY AUTOMATION The Patriot cone is equipped with Superior’s Vantage Automation system. Anchor Stone plant operator/electrician Joey Doolittle described the automation system as userfriendly. “The touchscreen is simple to operate, and we can train a new person on it quickly,” he said.

Doolittle said one of the Vantage Automation system’s best features is its sensor communication network that accesses a standard four-wire cable system from the cone crusher to all auxiliary systems.

“This streamlines set-up, diagnostics, and troubleshooting. All the sensors wire back to a junction box on the cone, and we had to run one cable from that junction box to the PLC, which cut our wiring time and allows ease of maintenance over time,” he explained.

Doolittle said other systems are more

complicated and run dozens of conductor wires from the PLC to each component.

Neal said the biggest benefit of the new crushing circuit was making setting adjustments on the fly. “This gives us flexibility when we have changes in material feed and allows us to easily tweak material processing within all circuits of the plant,” he said.

The auto-feed function, Neal said, is another advantage. “It takes the worries out of cone operation. Regardless of changes in the feed, the system will always maintain the desired levels within the cone – and it will maintain the desired amperage on the motor to ensure it’s operating at highest efficiency.”

As a veteran processing engineer, Neal said that by maintaining the level and amperage, you achieve the desired throughput. “This cone runs all day, every day, in and out – and that’s a big benefit right there.” • For more about Superior Industries equipment, visit superior-ind.com or the Tricon Equipment website: triconequipment.com.au

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CRUSHING & SCREENING

HOMEGROWN CONTRACTOR

SHINES IN SUNSHINE COAST PROJECT

An Indigenous-owned mining, quarrying and construction contractor has purchased eight new mobile crushers and screens in the past nine months after going to work on a quarry project in its own backyard.

B

lack Cat Civil is a Supply Nation company based in Nambour, Queensland. It offers mining, civil works, earthmoving, road works and land development services across Australia.

The company, which has been operating since 2006, is staffed with 230 employees.

Aside from its Nambour HQ, Black Cat Civil operates in hubs in Groote Eylandt, Darwin, Nhulunbuy and Alice Springs in the Northern Territory, and in Blackwater and Rockhampton in Central Queensland. The company has worked on numerous infrastructure projects, including the Brisbane Airport New Parallel Runways, the Cooroy to Curra Section D of the Bruce Highway, the North Stuart Highway duplication works in Alice Springs, the Woolgoolga to Ballina upgrade on the Pacific Highway, and the Blackwater Creek OLC Crossing remediation, near the Curragh coal mine. Black Cat Civil has also managed civil projects for the Australian Defence Force in the Northern Territory, including demolition works and bulk and earthmoving works at the Robertson Barracks in Darwin.

“We have support services but our three

main divisions are in projects, mining services, and plant hire, mainly earthmoving equipment on road infrastructure and mining services contracts,” Jai Tomlinson, director at Black Cat Civil, explained. “We’ve been playing around in the extractive industries market for the past five years. We’re currently contract crushing more than a million tonnes of aggregates per year.”

In December 2020, the Sunshine Coast Council awarded Black Cat Civil an $8.5 million contract to crush, scalp, blend and screen about 350,000 tonnes per annum of rhyolite and basalt shot rock at the councilowned Image Flat and Dulong Quarries in Nambour. While Black Cat Civil had been operating in the Nambour area for nearly 15 years, it was the first time the company had netted a major job on home soil.

“This is our first contract with Sunshine Coast Council – it’s a significant contract for us to win because we’d been trying to win contracts in this region for some time,” Tomlinson told Quarry. “We’re keen to service this contract correctly and show the Sunshine Coast and the community that we’re good at our work. We’ve

never had a job of this capacity before in our own backyard.”

Image Flat Quarry has been operating since 1959. A spokesman for the council’s Sunshine Coast Quarry Services has previously told Quarry that the site has a remaining life of 60 years, with up to 30 million tonnes of aggregates in reserve. Dulong Quarry has been operating since 1984, has a life span of 80 years and has about 16 million tonnes of reserves.

While both quarries feature rhyolite and basalt deposits, Tomlinson said some of the materials are being transported from Dulong Quarry and being crushed on-site at Image Flat Quarry. The source rocks are being used for road base, landscaping, rock products, drainage aggregates, maintenance gravels and asphalt applications. The end products include 300mm rubble, 100mm to 200mm stone, 40/70, 30/40 and 20mm and 10mm fines, 2.5 roadbase and crusher dust.

“Different local industries such as landscaping might use our by-products for topdressing because of the minerals in the crusher dust,” Tomlinson said. “Concreters

Black Cat Civil purchased six Sandvik mobile units for Image Flat Quarry. From left: the QA451 screen, the QH331 cone crusher feeds the QA441 scalper, the QH332 cone, the QE342 scalper, and the QJ341 jaw crusher.

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Quarry October 2021

will use it for base preparation and concrete slabs.”

RACE TO SITE When the Sunshine Coast Quarry Services contract was awarded, Black Cat Civil had less than a month to prepare for work at Image Flat Quarry, which commenced on 4 January, 2021.

Even as it was tendering for the contract, Black Cat Civil went to the quarrying market for a single source solution to the mobile crushing and screening component of the contract.

“The requirements were for a reliable, versatile processing equipment solution to primarily produce road base and aggregate yet have the flexibility to make up to 40 different products,” Jimmy Murphy, the Sandvik product specialist for Porter Equipment Australia, said.

“We provided plant designs from Sandvik’s PlantDesigner program which were produced along with scaled layouts of the overall footprint. Black Cat settled on the solution to

meet their production requirements.”

Black Cat Civil purchased six mobile units for Image Flat Quarry: a Sandvik QJ341 jaw crusher, QH331 and QH332 cone crushers, QA441 and QA451 screens and a QE342 scalper.

Tomlinson said that while Black Cat Civil owns other brands of mobile crushers and screens in its fleet, it had not previously ordered mobile units from Porter. Nonetheless, he was impressed with the scale and speed of the delivery of the Sandvik units. “We had a very tight window for delivery and we needed six machines quickly, depending on which OEM or dealer could provide and service this project. We worked with Sandvik and Porter during the tender period, and when the tender was awarded, we had a short delivery time frame. The work Porter put in to deliver these machines throughout the Christmas period was outstanding.

“The contract stated we had to be on site from 4 January, and we also shipped these

large machines around, with Sandvik and the Porter Group gathering them from different locations. Our business is pretty agile and it moves pretty quickly when we make a decision, and it was great to have a supplier that shared our focus and vision and knew it had to act quickly for us to succeed. It’s formed an early solid relationship, which is why we’ve bought two more new machines out of Porter in the past two months – that averages out to one machine per month this calendar year.”

Murphy agreed that the turnaround time for the delivery of the six mobile units was quick, particularly with the Christmas/New Year shutdown period. “All the machines were in stock, a couple of them at our interstate branches. Our national branch network allowed us to turn them around, with sitespecific requirements completed at our Brisbane branch. The workshop there put in a fantastic effort to meet the deadline, with the first crusher arriving to site two weeks early.”

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CRUSHING & SCREENING

MOBILE UNITS Murphy said that the Sandvik mobile units at Image Flat Quarry would work in a three-stage crushing circuit. The circuit starts with the QJ341 primary jaw crusher, which incorporates a 1200mm x 750mm single toggle jaw crusher with hydraulic adjustable closed side setting (CSS) that can accept up to 650mm into the chamber. Its hydrostatic drive enables reverse function for safe unblocking and the ability to restart with a full chamber, and a jaw level sensor regulates material flow to the chamber.

The QH331 and QH332 cone crushers are fitted with Sandvik’s CH430 cone chamber, which features six concave liners in one top shell and eight different bush settings. The top and bottom supported cone is tolerable to higher crushing forces and the longer, steeper chamber offers an improved product shape. Sandvik’s Hydroset system and automation offer a simplified calibration and CSS adjustment (six to 41mm) at the push of a button and while crushing. The constant liner performance maintains the feed opening, throughput and longer, usable liner life.

There is no need for a backing compound during liner changes. In fact, Murphy said the absence of cure time affords quarries more opportunities to start producing materials when the crusher is changed.

The QA441 and QA451 sizing screens are fitted with Sandvik’s Doublescreen system which utilises two 3m x 1.5m high velocity screenboxes (1200mm rotations per minute [rpm] shaft speed) in the one machine. The primary screenbox acts as a fines extractor and the secondary box as a grader. Murphy said Sandvik’s Doublescreen system can produce up to 30 per cent more volumes of inspec material than conventional incline screens working in the same footprint. The QA451 also has the benefit of a 6.15 g-force which effectively moves and separates the material.

The QE342 heavy-duty scalping screen is being used by Black Cat Civil at Image Flat Quarry to scalp after the QJ341. It can accept up to a 600mm feed and has an aggressive rpm, a 9mm throw and adjustable screenbox angles. The scalping screen is equipped with a simple control system with single button sequential start/stop functions, fault-finding and diagnostics, wireless remote controls, extensive use of steel piping throughout and simple access outlets for maintenance. In the hydraulic system, oil change-outs are recommended at 4000 hours, subject to sampling analysis; the usual industry standard is change-outs at 2000 hours.

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Quarry October 2021

The QH331 and QH332 cone crushers either side of the QA441 scalper (middle).

SMOOTH OPERATION After nine months of operation into a two-year contract, Tomlinson reported the six units at Image Flat Quarry have been performing well.

“We’ve had no major issues with them.

We’re starting to gain some traction with our throughput and achieving the goals and targets that we set for ourselves, and I can honestly say the targets we’re hitting are far better than expected,” Tomlinson explained.

“That says to me the gear is performing really well. There are synergies between our earthmoving gear – which is 100 per cent Caterpillar – and the Cat engines on the Sandvik gear, which means the product is easy to maintain and service.

“It takes a team to understand how the machines work and finetune them – and there has been great communication between ourselves and Porter’s technical team to achieve maximum productivity,” he continued.

“We work in directly with the Porter Group in Mackay, including Jimmy Murphy. They have been exceptional. It’s the service you’d expect but their performance and communication has been outstanding and fantastic.”

Murphy affirmed that Black Cat Civil has been pleased with Porter’s support in the previous nine months. “Black Cat Civil made a significant investment with the Porter Group in purchasing the Sandvik mobiles, and our commitment extends beyond commissioning of the plant through group emphasis on product support and life cycle,” he added.

“Having a Sunshine Coast-based resident fitter has provided quick response times to servicing requests and the right people have been in place to address troubleshooting issues. There are also facilities for application requests via phone and email, which have been of huge benefit and there have been site visits to meet and exceed customer requirements. Parts availability through our Brisbane warehouse has been advantageous in preparing for planned shutdowns.”

As mentioned, Black Cat Civil has bought two more Sandvik mobile units off Porter Equipment for other projects. A QE442 scalper, which is virtually identical in functionality to the QE342 scalper at Image Flat Quarry, is currently working at the Caval Ridge mine in Central Queensland. Another QH332 cone crusher was commissioned and, to quote Murphy, “bedded in” at Nambour before it was moved to another crushing and screening assignment in Nhulunbuy, more than 3000km away.

“Obviously in the midst of a pandemic both parties wanted to ensure diligence in having the QH332 commissioned prior to moving it,” Murphy added. “There was a real possibility of travel restrictions being in place when it reached site to produce roadbase.”

Tomlinson is optimistic about Black Cat Civil’s work at Image Flat Quarry and anticipates that work will continue beyond the original two-year Sunshine Coast Quarry Services contract. “There’s definitely an option period. The aim is to do a great job and provide a great product,” he said, “and then obviously, other project managers in the Sunshine Coast Council and across the region will recognise that and be more likely to use our products and services in the future.”

In his own dry humour, Tomlinson was reluctant to recommend Porter Equipment to other contractors and quarrying producers.

“As we’re growing our business in this mobile crushing and screening space, I’m going to have to say ‘No’ to that one because I want them all for myself!” he laughed. “Our business wants them available and ready so if we talk them up too much, other people will want to use the Porter and Sandvik Groups!

The real answer is ‘Yes’, I’d have no problem recommending them. The boys are great!” • To learn more about Black Cat Civil and how it can best assist quarries, visit blackcatcivil.com.au For more information about Porter Equipment, visit porterce.com.au

MAINTENANCE

THE RIVERGUM GURU HELPS METROMIX TO SHINE

The ‘open flow reducer’ designed by Hankins to improve the efficiencies of Metromix Teralba.

A

sand washing specialist is supporting an aggregates business in New South Wales. With the right equipment and a lifetime of know-how, Rivergum Industries has enabled the growth of businesses near and far.

Teralba Quarry has operated just outside Newcastle since 1964. It provides construction materials to the Hunter, Central Coast and Sydney regions.

Operated by Metromix since 1986, the site produces fine and coarse aggregates well suited to road making, concrete and construction, as infrastructure has continued to boom in New South Wales.

But supplying these resources to integral projects like a major miner’s site remediation project or the Kooragang wharf terminal project takes top notch management and reliable equipment.

Thanks to the expertise afforded by a relationship with Rivergum Industries, Metromix can supply the cleanest of aggregates for when clients demand the best.

Working out of Engadine, south of Sydney, Rivergum has supplied sand and aggregate washing equipment to the construction industry for more than 20 years. With that experience, of course, comes a lifetime of knowledge on how to get the best out of the equipment.

Jim Hankins is the managing director of Rivergum and the brains behind his company’s quality sand washing service.

Metromix Teralba Quarry supervisor Darryn

Bosch said Hankins was able to fine tune his machines until the outcome was just right for the job.

“They provide us with the equipment as well as wear parts to help maintain the equipment,” Bosch said.

“Jim’s always got a bit of ingenuity about himself. He likes to improve and look at ways to improve our current washing plant. He’s usually coming to me with different ideas for process improvement.”

While Rivergum’s equipment is supplied by three notable third parties – FL Smidth, Superior Industries, and Manufacturer’s Equipment Co – the value is truly added by Hankins’ bespoke solutions.

Bosch mentioned a time when this approach worked wonders for Metromix, as Hankins devised an open flow reducer to improve efficiencies.

“A good example of this was when he came up with a new rubber lining for a pipe which comes out of a screen and goes into a pump,” Bosch said.

“It’s in a high wear environment so Jim contacted one of his suppliers and they trialled this ceramic lining to improve its resistance and it has worked really well for us.”

Whether it’s an attachment like the new lining, or simply a fresh way to position the plant, Bosch was adamant the quarry performance has improved with the support of Hankins.

“Rivergum supplied our blade mill and part of the installation had a few minor issues where we needed some higher quality out of the end product,” Bosch said.

“So, Jim came along and suggested we try to get a bit more height out of the plant, helped us to reconfigure it, and we got just the result we were after.”

For Metromix, the relationship with Rivergum was sealed years ago. Not quite as far back as the formation of the business itself but certainly to 2013 when Teralba Quarry manager Muhammad Yunusa first met Hankins.

From student to supervisor, Yunusa thanks Hankins for the assistance he has provided himself and the people at Metromix.

“When I first worked for Metromix, I was an engineering intern and I worked closely with Jim as he helped me to finish my thesis on optimising the crushing plant,” Yunusa said.

“As he mentored me, he gave me some sound advice and references on what would be suitable for our needs, and that ended up helping with things like selecting the blade mill.

“Using Jim’s advice, we looked at the pros and cons around what kind of material we put through it.

“He talked me through things like rotary scrubbers, trommel screens, blade mills, log washers, aggregate screws, and gave me a wealth of knowledge being a young graduate.

“From there, we ended up getting a blade mill and it’s ended up largely being a success.”

The Metromix team said Hankins would even go as far as taking samples of the quarry away to work on fine-tuning the final product for them.

Bosch and Yunusa both said they were proud to contribute to the various projects in their region with their fingerprints on them.

But of course, none of it would be near as simple without the fingerprints of Rivergum Industries and Jim Hankins. •

Rivergum Industries helped to supply and optimise a blade mill to Metromix Teralba.

Quarry October 2021 43

DRILL & BLAST

WHY IS VIBRATION SO HARD TO PREDICT ACCURATELY?

Despite years of intensive research and practical applications, predictions in drill and blast scenarios remain as uncertain as ever. Kim Henley and Rob Domotor, of Orica, explain how stress waves work and how vibrations are determined in rock formations.

I

n blasting, stress waves are produced by the detonation of explosives in a blast hole. The rock may be shocked close to the blasthole wall but such shocks rapidly decay and disperse to produce the familiar P- and S-waves (compressional and shear waves), known as body waves. These waves travel throughout the rock mass, compressing and shearing the material.

The waves reflect from and refract around the rock structure (joints, foliations, etc) and interact with imperfections, dislocations and the like, causing damage to the rock fabric, resulting in small increases in the local temperature, changes in the grain and crystal structures of the different components and ultimately the growth and coalescence of cracks, leading to fracturing.

The body waves (P- and S-) interact with all surfaces and with all the different joints, bedding planes and the like. When each of these waves hit such surfaces, they undergo mode conversion: an incident P-wave will transmit a P-wave across a joint, for example, but will also produce a reflected P-wave as well as a reflected S-wave, polarised by the interaction with surface. So for every incident P- or S- wave,

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Figure 1. Rayleigh waves “raise the dust” radiating away from nearly every blast.

a combination of P- and S- transmitted and reflected waves are generated, each with their attendant co-efficients (or extents) of transmission and/or reflection and polarisation. There is a similar, even more complex process involving the equivalent refracted components.

These mode conversions determine the nature of the so-called surface waves. A Rayleigh wave (Figure 1) is produced at a rock-air interface (the bench surface or the bench face) and is a combination of

the mode-converted waves that manifest on the surface as an elliptically polarised wave that is one wavelength deep but decaying with depth and travelling along the surface for great distances with relatively high amplitude. The Rayleigh waves are responsible for “raising the dust” radiating away from nearly every blast.

Rayleigh waves are part of a class of waves known as “Lamb waves”. The Rayleigh wave is associated with a single surface whereas the Lamb waves are

Figure 2. The effect of layered geology, generated by finite element modelling.

associated with multiple surfaces in plates or distinct layers within the rock mass. They propagate parallel to the surface throughout the thickness of the material. A Rayleigh wave will transition to a Lamb wave if the

Figure 3. The finite element model contains seven horizontal layers with density increasing downwards.

plate thickness is less than the wavelength of the Rayleigh wave.

The Rayleigh wave (R-wave) is the most dominant surface wave. These waves can travel for long distances at relatively

high amplitudes. While it is true that a structure will be impacted by the R-wave, if the ground between the source and the building has a prominent density gradient, then the P- and S-waves can travel through

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DRILL & BLAST

Figure 4. Stress waves travelling up a blast hole.

Figure 6. An Indigenous heritage rock formation.

Figure 5. Stress waves from a blast.

and across the layers, initially travelling downwards (because the waves are threedimensional) but then curving upwards by refraction as the density decreases towards the surface. One would then say that damage at the building is caused by the body waves themselves which have effectively moved laterally and “exited” at the surface.

The effect of layered geology is shown in Figures 2 and 3 (on page 45), generated by finite element modelling. In Figure 2 there is one block of rock without layers. The wave leading the rock response at around 400 metres is the P-wave, and the small wave near at 250m is the S-wave. This is followed by the Rayleigh wave, which is the large section at about 150m to 200m. There is a more energy in the R-wave than the P- and S- waves, where white is high amplitude.

In Figure 3, the finite element model contains seven horizontal layers with density increasing downwards. The individual wavefronts cannot be seen but you can clearly see that the high amplitude is spread broadly across the surface, indicating a response that is sustained for a longer period than the case without layers. This complex response is created by the P- and S-waves moving laterally and refracting upward from the lower layers to superimpose to produce a dramatic and complex wave structure that will cause extended vibration at the surface.

NO EFFECT OF VOD ON VIBRATION Many people ask whether velocity of detonation (VOD) affects vibration. The quick answer is no. Many researchers have attempted to determine whether there is a relationship, but so far none has been found.

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Quarry October 2021

Figure 4 shows stress around a detonating blast hole and includes structural discontinuities in the model. You can see the major stress wave generated by the detonation as it travels up the blast hole.

It is reasonable to consider that a higher VOD would generate higher stress, and so therefore higher vibration.

This may well be true if we were to measure vibration quite close to the blast hole where we would measure vibration without much interaction with the rock mass, as proximity to the explosive charge is quite small. But we don’t measure vibration here.

We usually measure it a long distance from the blasthole.

Figure 5 shows the stress of an entire blast and the rock structure around the blast.

The stress wave effect on the more distant rock mass shows that the rock response is not driven by a particular stress or strain wave coming from a single blasthole. The stress wave reflects and refracts at every

joint as noted above, ensuring that the effect of stress at any point in the rock mass is a complex combination of direct and indirect reflections and refractions from every blast hole. Thus, the distant effects are driven by geological variability, and the combined effect of many holes, so we must consider blast vibration in the context of variable geology, rather than the micro-variations that may occur close to the blast hole.

WHY IS VIBRATION HARD TO PREDICT? Understanding how a structure responds to loading is a classic structural design problem, that every civil engineer deals with, either using direct calculation or by the application of design codes that approximate the problem. The codes and analysis methods assume elastic behaviour of the material, and the connections between structure components are either fixed or have some degree of freedom that may be rotating or sliding.

A naturally formed indigenous heritage rock formation (Figure 6) in northern Queensland is an isolated column of boulder-sized rocks stacked on top of each other up to 6m high.

Although the rocks comprising these heritage structures will behave elastically, the connections between them are not defined and it would be presumptuous to think that they could be reasonably defined using classical mechanics due to their random shape and contact surfaces.

A paper by Shah, Fallah and Louca presents a comprehensive study on counterintuitive or chaotic dynamic response using prototype discrete parameter models of single or multiple degrees of freedom subject to blast or impact loading.1 The nonlinear dynamic behaviour of single degree of freedom (SDOF) and multi-degree of freedom (MDOF) systems were studied.

The paper shows that a SDOF system exhibits a chaotic response below a

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DRILL & BLAST

Figure 7. A phase portrait of a highly periodic vibration response showing chaotic response at low vibration.

Figure 8. Below about 1.3 mm/s velocity and 0.03mm displacement, the response of the Radial component is chaotic.

threshold amplitude but over a particular threshold frequency and amplitude, motion changes to periodic (non-chaotic). In the context of the vibration effects on structures the change to a periodic response represents a resonant or pseudo-resonant response with low damping and therefore high potential for significant amplification.

The paper shows that transition of a two-degree of freedom (2DOF) system from chaotic to periodic is independent of frequency but dependent on amplitude.

In this context a chaotic response reflects the complexity of the source vibration and the complex propagation path, as defined by the input vibration signature and is non-resonant. A periodic response is a resonant or pseudo-resonant response that is likely to result in high amplitude structural amplification.

The significance of a transition from chaotic to periodic response as amplitude increases is a possible explanation for the phenomenon that we frequently find where vibration is predictable at low vibration amplitudes but the vibration becomes unpredictably high when it crosses a particular threshold amplitude. The paper shows that the nature of a complex system is such that a small change in the initial

48

Quarry October 2021

amplitude can result in an abrupt change in response and is thus counter-intuitive.

You might think that you’re blasting carefully but the odd higher vibration can result in unpredictable results that have no clear explanation.

The following phase portraits from the paper, generated by plotting model displacement on the X-axis and velocity on the Y-axis, show a range of responses.

Periodic response from a SDOF, and chaotic/periodic responses from a 2DOF system of first and second order.

The predictable, periodic shape of the SDOF example is clear and represents an approximate constant amplitude waveform over many cycles which is likely to induce amplified response in a structure. The difference between the 2DOF chaotic and periodic examples is subtle but there is increased consistency in the shape of the periodic examples. The main thing to take away from these examples is the greater “randomness” of the chaotic examples, remembering that increased random, or chaotic, behaviour is likely to reduce structural resonant amplification.

Figure 7 (top of this page) displays the phase portrait of a blast monitor that shows an unusually high response to a blast in

the Radial component. This component has an unusual response about three times the amplitude of the other two components and is highly periodic. All components show a highly periodic response, but there is also a lot more chaotic behaviour occurring in the Transverse and Vertical components.

If our understanding of the paper is correct, then at low amplitude, below the transition from chaotic to periodic response, we should see a more chaotic response (Figure 8).

The enlarged diagram shows this. Below about 1.3mm per second (mm/s) velocity and 0.03mm displacement, the response of the Radial component is chaotic. In fact, the transition to periodic response is quite sudden, indicated by the banding of the periodic response surrounding the low amplitude chaotic response. This is a case where the Radial component has exceeded the threshold of chaotic behaviour for the structure and its motion has changed to periodic, resulting in significant amplification.

MANAGING VIBRATION It helps us to recognise that sometimes the vibration we are trying to manage is difficult. Our only response therefore is to be more conservative with our input blast design to account for the apparently random response of a structure, recognising that a transition from chaotic to periodic should be avoided to limit structural amplification. Yet we don’t know the threshold amplitude of the likely transition to periodic response. All we may be able to do is to limit the amount of vibration energy going into the ground to ensure the response of the structure does not exceed the critical transition limit. Of course, it would be very helpful to know at least the magnitude of the critical limit of a geological structure such as this, but the last few million years of its history will remain silent. • Kim Henley and Rob Domotor are senior specialist technical services engineers at Orica.

REFERENCES & FURTHER READING 1. Shah SKA, Soleiman Fallah A and Louca LA. On the chaotic dynamic response of deterministic nonlinear single and multi-degree-of-freedom systems. Journal of Mechanical Science and Technology 26(6); 2012: 1697~1709.

DOI 10.1007/s12206-012-0418-3.

DRILL & BLAST

HOLE NAVIGATION ENSURES RELIABLE DRILLING PRACTICE, DELIVERS SMOOTH OPERATION

E

piroc has cemented itself as a leader in drill rig technology – so much so that about 95 per cent of orders for its SmartROC drill rigs include its Hole Navigation System (HNS).

As infrastructure demand has grown around Australia – with Victoria breaking decade-old extractive production records, Greater Sydney placing in the Western world’s top 10 fastestgrowing regions, and Western Australia and Queensland benefitting from the HomeBuilder program – technologies of efficiency, safety and productivity have become necessities.

Epiroc’s surface division product manager Kris Thomas said the days of manual drill mapping were well over.

“The traditional method prior to HNS was to have a surveyor walk along the bench to mark out the desired blasting area,” Thomas told Quarry. “The operator would then have a sheet he would have to follow – making sure he was moving correctly from one position to the next and hitting the right depths.

“It was pretty labour-intensive work and obviously having to mark the dots out, it wasn’t as safe as it could have been.”

HNS can be installed by adding some simple hardware and software to any of Epiroc’s SmartROC drill rig range.

Thomas explained the ins and outs of the underlying technology.

“It uses existing satellite constellations to get the machine’s position to an accuracy of 50mm,” he said.

“In this way, you can create your drill map off-site, load it into the machine via USB or 3G, and the operator can then view the dots on their screen rather than some paint on the ground.

“The machine can then allow you to digitally and physically navigate to the correct position, and the rig can also calculate the right depth it needs to go to.”

By removing the need for an operator or surveyor to venture out onto the bench, you remove the possibility of injury or wasted time, compared to viewing the rig’s efforts on-screen.

To further remove the operator from harm’s way, the HNS can be used to complement Epiroc’s benchREMOTE station which can

control a SmartROC drill rig from up to 100 metres horizontally and 30m vertically.

Thomas said as demand for quarried resources grows the need for final products to be delivered with efficiency and accuracy grows with it.

“There’s a much lower margin for error these days,” he said. “Especially as these technologies continue to be implemented by the wider market.

“If an operator misses the required depth and causes overdrills, potentially they’ll adversely affect the next bench down.

“If they blast too deep or too shallow, they will create an uneven bench when they get down to the next level.”

For this reason, Thomas said technology like the HNS is just another box to tick in growing a reputable quarry business.

“Over the last three years, we’ve seen it implemented more and more for the quarry market. Almost all the SmartROCs we send out, customers have chosen to include the

HNS,” he said.

“If you want to progress to become one of the bigger quarry owners, you need to get up to speed with the technology.”

One of the only requirements – besides a SmartROC drill rig – to take advantage of the HNS would be a GPS base station.

This device is used to ensure the HNS can live up to its lofty standards of just a fivecentimetre margin for error.

“The contractor will need to have a base station or very often the site will have a surveyor’s base station which the HNS can connect to. This is a very important requirement,” Thomas said.

“The base station gives a correction message from the satellites because, where the accuracy with the GPS on something like a mobile phone is something like 10m, the base station corrects the signal to within 50 millimetres for the HNS.”• For more information about the Epiroc HNS system, visit epiroc.com/en-au

HNS takes minimal set up and few pieces of hardware.

Quarry October 2021 49

DUST CONTROL

POLO CITRUS EXPAND

DUST SUPPRESSION OFFERING

D

ust Bind has a range of applications across quarrying and construction.

It is particularly useful for controlling stockpiles.

While it’s best known for its foaming dust suppression system in the crushing process, Polo Citrus has other products to assist with dust control in the extractive industry.

One such product is Dust Bind – a strong and pliable acrylic polymer-based product, easily diluted with water for ease of treatment in applications where wind-affected areas and dust lift-off is present.

Dust Bind applications include tailings dams, stockpiles, construction areas and any uncovered ground where a strong seal is required for the prevention of dust generation in wind-affected areas.

Dust Bind is a high quality acrylic polymer encrusting agent formulated to penetrate and bind soil, limestone and other particles to prevent dust liberation and drift.

Some of the key features of the Polo Citrus’ Dust Bind include: • A milky white colour coating on the stockpile that dries clear.

• A dye that can be added for some sites, so they know which stockpiles have been coated.

• A significant reduction in water requirements.

• Once dry, it will not re-emulsify.

• It is pH neutral.

• It offers one application for extended protection.

A Polo Citrus customer in road construction was working on a bridge and the reconstruction and alignment of roads in the area.

This customer decided to use Dust Bind with a green dye to keep a cut stable while also keeping dust in its stockpiled area.

All in all, Polo Citrus reported the customer was well satisfied by the product and continues to use it on other projects around the country.

The application of the Dust Bind product is simple and administered through a spray bar with a pump from a trailer, keeping costs to a minimum. • For more information about Dust Bind and other Polo Citrus products, visit polocitrus.com.au

Dust Bind leaves a milky white colour coating on the stockpile that dries clear.

MISTING SYSTEM

FOR DRILL APPLICATIONS

T

he TE30851R misting system, from US-based TEI Rock Drills, is available in Australia via distributor Quarry Mining & Construction Equipment, based on the east coast.

The TE30851R injects water into the drill flush air, reducing dust. This high quality portable system targets hard rock, quarries and civil markets to comply with workplace exposure standards for silica dust during percussive drilling operations.

Equipped with a 95-litre water tank, the misting system can provide dust suppression for four to eight hours, depending on the size of the hole.

The TE30851R is a simple system which employs a pneumatic water pump, which

50

Quarry October 2021

receives air power from the drill flush air. The water pump creates more pressure than the air and injects the water back into the airline creating a mist that can be easily adjusted for water to air ratio.

To learn more about Quarry Mining’s dust control products, visit quarrymining.com/products/dustsuppression

Quarry Mining also recommends using its DUST KING surfactants product as an alternative to water, as that will offer an even better performance from the misting system.

DUST KING is a water additive product that is used as a key control measure for reducing respirable and airborne dust. It can be simply added in very low concentration to the water supply via a dosing unit that reduces the surface tension of water and increases dust capture when using water sprays.

Equipped with a 95-litre water tank, the TE30851R misting system can provide dust suppression for four to eight hours.

t u o g n i s Mis y newsletters

on our weekl m? o c . e n i z a g a m y r r a and qu

You’re missing • Weekly news updates • New Product information • Exclusive access to 10 years of archived content • Your Number #1 industry reference source

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Do you want to access

quarrymagazine.com

to stay informed?

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DUST CONTROL

POLO CITRUS EXPAND

DUST SUPPRESSION OFFERING

D

ust Bind has a range of applications across quarrying and construction.

It is particularly useful for controlling stockpiles.

While it’s best known for its foaming dust suppression system in the crushing process, Polo Citrus has other products to assist with dust control in the extractive industry.

One such product is Dust Bind – a strong and pliable acrylic polymer-based product, easily diluted with water for ease of treatment in applications where wind-affected areas and dust lift-off is present.

Dust Bind applications include tailings dams, stockpiles, construction areas and any uncovered ground where a strong seal is required for the prevention of dust generation in wind-affected areas.

Dust Bind is a high quality acrylic polymer encrusting agent formulated to penetrate and bind soil, limestone and other particles to prevent dust liberation and drift.

Some of the key features of the Polo Citrus’ Dust Bind include: • A milky white colour coating on the stockpile that dries clear.

• A dye that can be added for some sites, so they know which stockpiles have been coated.

• A significant reduction in water requirements.

• Once dry, it will not re-emulsify.

• It is pH neutral.

• It offers one application for extended protection.

A Polo Citrus customer in road construction was working on a bridge and the reconstruction and alignment of roads in the area.

This customer decided to use Dust Bind with a green dye to keep a cut stable while also keeping dust in its stockpiled area.

All in all, Polo Citrus reported the customer was well satisfied by the product and continues to use it on other projects around the country.

The application of the Dust Bind product is simple and administered through a spray bar with a pump from a trailer, keeping costs to a minimum. • For more information about Dust Bind and other Polo Citrus products, visit polocitrus.com.au

Dust Bind leaves a milky white colour coating on the stockpile that dries clear.

MISTING SYSTEM

FOR DRILL APPLICATIONS

T

he TE30851R misting system, from US-based TEI Rock Drills, is available in Australia via distributor Quarry Mining & Construction Equipment, based on the east coast.

The TE30851R injects water into the drill flush air, reducing dust. This high quality portable system targets hard rock, quarries and civil markets to comply with workplace exposure standards for silica dust during percussive drilling operations.

Equipped with a 95-litre water tank, the misting system can provide dust suppression for four to eight hours, depending on the size of the hole.

The TE30851R is a simple system which employs a pneumatic water pump, which

50

Quarry October 2021

receives air power from the drill flush air. The water pump creates more pressure than the air and injects the water back into the airline creating a mist that can be easily adjusted for water to air ratio.

To learn more about Quarry Mining’s dust control products, visit quarrymining.com/products/dustsuppression

Quarry Mining also recommends using its DUST KING surfactants product as an alternative to water, as that will offer an even better performance from the misting system.

DUST KING is a water additive product that is used as a key control measure for reducing respirable and airborne dust. It can be simply added in very low concentration to the water supply via a dosing unit that reduces the surface tension of water and increases dust capture when using water sprays.

Equipped with a 95-litre water tank, the TE30851R misting system can provide dust suppression for four to eight hours.

t u o g n i s Mis y newsletters

on our weekl m? o c . e n i z a g a m y r r a and qu

You’re missing • Weekly news updates • New Product information • Exclusive access to 10 years of archived content • Your Number #1 industry reference source

Need help?

Do you want to access

quarrymagazine.com

to stay informed?

Log on to the website and subscribe to our newsletter!

EDUCATION

TRUST IN

YOUR LEADERSHIP In the seventh chapter of a series on the characteristics of effective leadership, IQA President Shane Braddy discusses the challenges of being a manager and developing trust, honesty and rapport with workers and staff.

E

arlier this year, the Institute of Quarrying Australia (IQA) invited me to present a monthly article based on each of the seven core characteristics of effective leadership (see Figure 1 on page 54).

Rather than write all seven of these scenarios myself, I invited a number of people to make a contribution, from a diverse demographic and a number of industries, which I hope you have found interesting.

This is the sixth piece from IQA President Shane Braddy, who selected Trust in your Leadership, his story on becoming an Effective Leader.

I suggest that you find a comfortable spot to sit and enjoy a coffee while you read this enlightening piece.

I offered the following brief explanation for Trust in your Leadership in my book The Emerging Leader: Appreciate yourself, exhibit your values, walk your talk and trust in your worth.

Trustworthy leaders work with their people to establish believability, dependability and reliability through open and transparent behaviour that lacks self-interest.

Mike Cameron

SHANE BRADDY’S STORY Stephen Covey’s The Seven Habits of Highly Effective People was one of the books that gave me some sort of insight because, from a leadership perspective, I have always felt different and I was looking for learning that resonated with my beliefs and values on what it takes to be an effective leader.

What do I mean? Leadership is all about what we are doing together - it cannot be about you – it is striving to do something with a sense of commitment together with your team. It is the strong connection you make with team members. It is about being inspired and being inspirational. It is about

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Quarry October 2021

having vision and values that are shared by your team.

You need to build strong relationships with your team because you are not only employing the person, you are also going to have an impact on their whole being. There is so much going on in people’s lives and you need to build trust – enough trust that they will share things with you.

Because of your vision and values, you have your direction, you know where you want to go, and there are bound to be times when you may tend to leave people behind.

Sometimes, with other stuff going on, your team may get lost and feel unable to keep up with your plans. Perhaps something is going on in their personal or work life, they may be dealing with another manager or team member with whom they have a problem.

When you sense that a person does not quite agree with you, or they are not there yet, be prepared to invest time to unpack their concerns, to recognise what is going on, look for those triggers by asking open-ended questions. Explore with them their reasons for not being fully involved or fully embracing it right now. Encourage them to open up and to have enough trust to be able to tell you what is affecting them and whether it is an issue at work or at home.

Some people have an unrealistic notion of leadership, where the leader inspires the people and they blindly follow. Well, it does not happen that way! Leadership is about constantly monitoring progress and, when necessary, returning to the back of the pack to encourage those who are struggling.

As the leader, your buttons will be pushed – and you can over-react – I definitely overreacted during my first two formative years as a quarry manager, thinking that it was the manager’s role to hold people accountable at all times and I let several people go on

Shane Braddy: When you see people in need, you look out for them.

the basis that they were not doing their job properly. I know it was misguided back in those days, although that was the industry norm when productivity was below expectations, due to what was perceived or otherwise, eg operators stopping equipment to talk with mates.

With experience, I realised my actions were not wise and not always right as they were based on perception rather than fact. I always felt uncomfortable making those harsh decisions but it was only when I worked out what was triggering my reactions, I realised if I kept on doing this, I would not get the best out my team or me– because it was not who I am.

BEING YOUR BEST I did not have a formal mentor at that time.

However, there was a chap that I looked up to who was a very experienced manager and a father of a large family - I believe of 11 children - so you can imagine I considered that he had a greater mastery of leadership than I did. He was a calming influence and suggested that I should not over-react.

To take time to find out the facts, to listen carefully and be considered when making decisions.

There is no doubt that I had started at the wrong end of the stick but I found my way, as I began to mature and learn different things, through a number of people who influenced me at various times and helped and guided me. Mostly, I just wanted to be the best I

63RD IQA NATIONAL CONFERENCE NEWCASTLE, NSW 29 – 31 MARCH 2022 To register or for further information visit the Conference Website https://iqa.eventsair.com/conference

The Institute of Quarrying Australia

EDUCATION

could be – but sometimes I was trying to prove myself too much because I had come from the frontline.

I was given a lucky break, for which I am forever grateful, because of my connection with the Melbourne Football Club at the time, when one of the company’s senior managers, who had previously played for Melbourne, asked me if I wanted to join the trainee quarry manager’s program which enabled me to go to Box Hill TAFE relatively early and start my formal management training.

I also have been lucky in terms of my family upbringing for which I feel fortunate. It is not just about you, it is about making sure you are doing your best to produce the best outcomes for your family, and whenever your family is in need, you go and help. My father’s mantra was always “I don’t care what happens in life, just make sure you are there for one another”. The same mantra is followed by our families.

I guess that key message carries on into work and many other things. When you see people in need, you look out for them. With this underlying principle, I can go into a workplace and pick up the vibe. I just chat with people and, before too long, I sense the culture, I can see what is going on and I learn by listening to their stories. Sometimes it is necessary to get around a little more frequently, to speak to various people, to ask questions and actively listen – because you may find that there is a systemic issue at this site that is driving poor culture.

LEADERSHIP EFFECTIVENESS I was introduced to a book by Tim Spiker – Who, not What – which said that three quarters of your effectiveness as a leader comes from who you are, not what you do. It talks about being inwardly sound and othersfocused. To elaborate: • The “who” of leadership means inwardly sound and others focused:

- Inwardly sound means being secure and settled, self-aware, principled, holistically healthy, and purposeful.

- Others-focused means being humble, attentive, curious, empathic and emotionally mature.

• The “what” of leadership means to communicate effectively, ensure execution, marshal resources, drive culture, pursue vision, think strategically, cultivate talent and unleash motivation.

Being an effective leader takes courage and being vulnerable from time to time.

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Quarry October 2021

Figure 1. The Effective Leadership model.

Vulnerability is both a strength and a weakness. It is a weakness when you do not know what to do with it. It is a strength when you know your weaknesses and you are always seeking improvement and trying to do your best. When you know that there are going to be gaps in terms of what you do, you seek to learn, you seek other ways to do it. It gets frustrating at times because always trying to do something better or different may be difficult to sustain, but you are seeking a better way, so that is the vulnerability of who you are.

So from my earliest days of being appointed quarry manager, I was extremely vulnerable in both technical and leadership knowledge.

My weakness was not responding well and reacting in a way that you think others expect you to react – even when that is not who you really are. My strength was that I understood that I was vulnerable and did not know a lot of things. I was largely aware of my lack of competency in a number of areas which allowed me a chance to do something about it, but there are some people who are “unconsciously incompetent” or in other

words lack self-awareness and they do not know where those gaps are and therefore the opportunities for improvement.

TRANSPARENCY Leadership is about being transparent and being yourself. I think that people appreciate you more when they see your vulnerability.

You are not putting on a show, not pretending, you don’t wear a mask, you are who you are and not what you do, so when you get things wrong, people are prepared to give you some slack because you are seen as being genuine, they understand your intent, your motivation and what you are trying to do. However, if it is all about you, then watch out!

Here is a final thought. As I completed this piece, I received a text from a friend I work with whom I greatly respect. It read: “When I talk to managers, I get the feeling that they are important. When I talk to leaders, I get the feeling that I am important.” • Shane Braddy is the IQA President and the national quarries general manager for resources and development at Boral Australia.

IQA NEWS

The Institute of Quarrying Australia

The opening night of IQA2021 at Newcastle Museum will introduce delegates to a city where old meets new.

NEWCASTLE 2022: WHERE OLD MEETS NEW In a different world, we would be together this month at the 63rd IQA National Conference in Newcastle, NSW. That is not to be with the conference being postponed due to the limitations on travel and uncertain circumstances presented by the current COVID-19 pandemic.

The IQA is now looking ahead to 29–31 March, 2022, when we are hopeful that restrictions will have eased and that the current lockdowns in Victoria, NSW and other states will be a thing of the past, buoyed by increased vaccination rates.

One thing is certain – that IQA2021 will provide a welcome opportunity for members of the extractive and associated industries to get together and re-connect after a challenging and unpredictable two years.

While there has been a change of date, the impact on the overall conference will be minimal.

The Conference Organising Committee has secured the same venues for the plenary and social program and the speaker line-up also remains relatively unchanged.

This means that our two keynote speakers in Michael McQueen and Rachael Robertson are both locked in to join us in March 2022.

Michael, a renowned futurist, will provide an insight into the future of work and skill requirements for our industry while Rachael will focus on demonstrating big leadership in small moments.

The Leadership Panel will follow the ReThink theme with the Outlook for the Extractive Industry session being explored and discussed by industry leaders from Adbri, Boral, Hanson

and Holcim. In the history of the IQA national conference, we have never had the opportunity to welcome all four industry leaders to the stage.

This is certainly a component of the program that is not to be missed.

March is a perfect time to visit the host city of Newcastle and the IQA2021 social program will provide delegates with the opportunity to experience all that the city has to offer. The opening night at Newcastle Museum, proudly sponsored by Hitachi Construction Machinery Australia, will be the perfect introduction to a city where old meets new, with the Museum housed in a railway workshop dating back to the 1800s. We have exclusive use of the Museum for the night, so delegates can catch up with industry colleagues, while exploring the history of Newcastle and enjoying some local produce, including beer and wines from the Hunter Region.

We will celebrate the 100th anniversary of Komatsu on the second evening with the Conference Dinner at Newcastle Racecourse.

The Racecourse is the social hub of Newcastle and has also been operating for about 100 years, providing the perfect synergy for this special occasion.

while they are at IQA2021. If you’re not keen on walking, the IQA2021 shuttle bus, sponsored by Ausrocks, will run on a loop between the hotels and conference venue each day.

Delegate partners haven’t been forgotten with the itinerary for the Orica Partner Day taking shape. The partner day has been a conference tradition for many years, and we encourage delegates to bring their partners and extend their stay to make the most of their time in Newcastle.

There is so much to look forward to about IQA2021. We can’t wait to deliver a comprehensive and informative program in an environment which enables delegates and stakeholders to network, build relationships and share knowledge.

Early bird registrations are now open until 28 January, 2022. However, availability for site visits and accommodation is limited so act quickly to secure your place. For further information or to register, visit www.iqa.eventsair.conference We look forward to you joining us in Newcastle in March 2022.

The Caterpillar Gala Dinner on the final evening will be a night of sophistication and elegance that will see The Arena at NEX transformed. It will be an event that is sure to cap off the social program perfectly.

Surrounded by golden sand beaches, a breathtaking coastline and a beautiful working harbour, Newcastle is a great place to explore.

The IQA has negotiated some great rates at hotels within walking distance of the conference venue to allow delegates to discover the city

Surrounded by golden sand beaches, a breathtaking coastline and a beautiful working harbour, Newcastle is a great place to explore.

Quarry October 2021 55

IQA NEWS GET INVOLVED IN THE IQA Quarry Magazine Content Advisor – contract role The Quarry Magazine Content Advisor is responsible for supporting the technical accuracy of articles in Quarry magazine (print and electronic). They are responsible for providing advice to help with factually correct technical information.

The contractor will collaborate with the editor of Quarry, the IQA CEO and the magazine’s editorial panel to identify relevant news stories and support editorial content.

For more information, download the EOI form from the IQA website: quarry.com.au (> Extractive Industry > Our Partners).

Membership Review Committee nomination The IQA is seeking an EOI for up to five additional representatives from industry, branches and sub-branches, and suppliers to join the Membership Review Committee (MRC). The MRC’s role will be to: i) Determine applications for member status, where applicants do not have a formal or exempting qualification. ii) Determine applications for membership that are referred to it by the National Office staff or Chair of the Committee. iii) Determine applications for membership that are referred to it by applicants that are not happy with the decision of the National Office staff or Chair of the Committee. iv) Review and provide recommendations to the Board via the Chief Executive Officer on all nominations for Fellowship. v) Review and provide recommendations to

The Institute of Quarrying Australia

vi) Review and provide advice to the CEO on all membership matters.

Brisbane on 27 July, 2021 to 27 attendees.

The workshop was facilitated by Peter Ambrose and held at the Colmslie Hotel and Conference Centre in Morningside, Brisbane.

vii) Review and provide advice to the CEO on strategies to sustain and grow membership.

The sold-out workshop was well received by all delegates, with both positive and constructive feedback supplied post-event.

viii) Refer matters of Committee composition, membership guideline amendments, membership grades and annual membership fees to the Board via the CEO.

The IQA acknowledges Pro Crush which supported the event by sending several delegates to benefit from this professional development opportunity.

the Board via the CEO on all nominations for Honorary Fellowship.

For more information, download the EOI form from the IQA website: quarry.com.au (>Membership Review Committee).

QUEENSLAND BRANCH NEWS Networking Dinner & AGM, 25 August 2021 The Queensland branch and Central Queensland sub-branch held a dinner meeting and AGM at the Treasury Brisbane.

The event was attended by 50 members and associates.

Former Chair David Smith welcomed attendees and started AGM proceedings with the Chair’s report and then election of the FY2021-22 Queensland & Central Queensland Committee.

Attendees at dinner heard a presentation from CDE Global’s Australasian manager Daniel Webber and Simon Crooks, the project director of the Destination Brisbane Consortium, delivered an engaging presentation on the Queen’s Wharf Project, followed by a Q&A session.

Supervising for Safety Workshop, Brisbane The IQA successfully delivered a face to face Supervising for Safety workshop in

2021-22 AGM ELECTIONS & APPOINTMENTS The IQA’s branches and sub-branches ran their Annual General Meetings in the months of August and September. The following branch and sub-branch committees have been announced for FY2021-22: Queensland Branch & Central Queensland Sub-branch Office bearers: Blake Ardrey FIQ (Chair), Anita Waihi MIQ (Deputy Chair), Carl Morandy AIQ (Treasurer/Secretary), Jenny Krasny AIQ (WIQ Coordinator). Committee members: Ajith Dissanayake FIQ, Jason Egan AIQ, Steve Franklin MIQ, Alec Harries AIQ, Robert Hemming MIQ, Clayton Hill FIQ, Chris Nussey AIQ, David Smith FIQ, Tamara Undy AIQ, Brett Evans MIQ (Central Queensland Sub-branch Co-ordinator).

North Queensland Branch & FNQ Sub-branch Office bearers: Lawrence Fahey MIQ (Chair), Tim Lowy AIQ (Deputy Chair), Brad Hamilton AIQ (Treasurer/Secretary), Paul Hooton MIQ (YMN Co-ordinator), Kelly Hurle FAQ (WIQ Co-ordinator). Committee members: Michael Bavdek MIQ, James Douglas-Henry MIQ, Niall Ivory (pending), Megan Kernan AIQ, Michelle Lergessner MIQ, Dennis Marchant MIQ, Luke Payne TMIQ, Greg Rains MIQ, Kate Pemberton AIQ, Keoni Kidner AIQ.

New South Wales Branch Office bearers: James Collings MIQ (Chair), Scott Whittaker AIQ (Deputy Chair), Christopher Hamilton FIQ (Treasurer), Angus Shedden FIQ (Secretary), Shane Anderson TMIQ (YMN Co-ordinator), Natalie Hansen MIQ (WIQ Co-ordinator). Committee members: Paul Eimbrodt FIQ, Paul

UPCOMING BRANCH EVENTS

Chenery AIQ, David Kelly MIQ, David Salim MIQ

NSW Hunter Sub-branch

• 8 Oct

North Queensland Golf Day, Mackay

Office bearers: Greg Dressler MIQ (Chair), Dayne Steggles AIQ (Deputy

• 13 Oct

Central Queensland Sub-branch Technical Dinner Meeting, Rockhampton

Chair), Greg Thomson FIQ (Secretary), Bradley Brown AIQ (Treasurer).

• 10 Nov

Tasmanian Branch Industry Update Workshop & Dinner Meeting, Launceston

• 26-28 Nov Tasmanian Technical & Social Weekend, Bruny Island To register for these events, email admin@quarry.com.au or visit the ‘Networking & Branches’ section of the IQA website: quarry.com.au

Committee members: Joel Fleming, Matthew Frost MIQ, Muhammad Ali Yunusa, Colin Loveday

WA Branch Office bearers: Tinus Nagel AIQ (Chair), Royce Sallur AIQ (Deputy Chair/ Secretary), Damon Case FIQ (Treasurer), Melissa Zadra MIQ (WIQ Co-

To discuss further online education opportunities on offer via the IQA, please contact us on 02 9484 0577 or email admin@quarry.com.au

Scott Langford MIQ, Neil O’Connor AIQ

Other training events in October include:

SA Branch

• 12 Oct

Roads and Transport Webinar

• 21 Oct

Quarry Products Technical Training Workshop

• 26 Oct

Learning from Disasters Workshop

56

Quarry October 2021

ordinator). Committee members: Phil Harris FIQ, Steve Della Bonna FIQ,

Office bearers: Andrew Wilson MIQ (Chair), James Rowe FIQ (Vice Chair), Kevan Barrie FIQ (Treasurer), Todd Threadgold MIQ (Secretary), Mikayla Schwarz AIQ (WIQ Chair), Tristan Throup AIQ (YMN Chair).Committee

members: Michael Close FIQ, Irene Harasymyszyn AIQ, Rodney Kazem

The Institute of Quarrying Australia

A YEAR OF PERSONAL AND

PROFESSIONAL RESILIENCE The cycle of Annual General Meetings (AGMs) showcase the amazing individuals who support the Institute. We have again seen a range of people from all parts of the industry nominate for the branch and sub-branch committees and take up office bearing roles.

These committees drive local innovation and ensure the Institute remains connected to the issues facing the industry and needs.

The IQA’s 2020-21 Annual Report is now available by visiting quarry.com.au In looking back on 2020-21, the report highlights it was a year that required both personal and professional resilience, as we all continued to adapt and navigate through the challenges of COVID-19. The IQA’s resilience in facing these challenges was due to the support and commitment of branch and subbranch committees, the Women in Quarrying and Young Member Network co-ordinators,

and our sponsors and partners.

The year ahead is an exciting one – that won’t be without its challenges and may again test our resilience. The strength of the committees will help guide the IQA and events/education we provide. As we welcome many experienced committee members back, as well as welcoming many new faces to our committees, I am looking forward to innovating, responding to local issues and working to keep the industry connected through events.

The AGM of the Institute of Quarrying Australia will be held on Tuesday 5 October,

2021 commencing at 4:00pm (AEDST). I encourage you to join us and look forward to seeing many of you online.

KYLIE FAHEY Chief Executive Officer Institute of Quarrying Australia

AIQ, Susan Lewis MIQ, David O’Farrell AIQ, Colin Stornmonth AIQ, Mark Taylor AIQ, Paul Thompson MIQ, Michael Williams FIQ

Victorian Branch Office bearers: Michael Oppedisano MIQ (Chair), Christopher Prowse FIQ (Deputy Chair/Secretary), Alastair Delooze MIQ (Treasurer), Samuel Powell AIQ (YMN Co-ordinator), Joanne Murray MIQ (WIQ Co-ordinator).

Committee members: Warren Colbert AIQ, Brad Dawson MIQ, Tylah Drochmann TMIQ, Michael Ewing AIQ, Tony Ferrazza MIQ, Graham Gordon AIQ, Tej Panesar AIQ, Jason Rudge FIQ, Ian Turnbull FIQ

Victorian Sub-branch Office bearers: Adrian Bourke MIQ (Chair), Brad Godden MIQ (Deputy Chair), Craig Staggard MIQ (Treasurer/Secretary).

Committee members: Adrian Bull MIQ, Damian Eastman FIQ, Jarrod Flint MIQ, Andrew Fowkes AIQ, Ian McCartney AIQ, John Miltos AIQ, Alister Shaw AIQ, Alan Tapping AIQ, Leigh Vaughan AIQ

ACT Branch Office bearers: Adam Bertram MIQ (Chair), Jason McCamish MIQ (Deputy Chair), Phillip Messenger AIQ (Treasurer/Secretary)

Tasmanian Branch Office bearers: Ben Palmer AIQ (Chair), Nicholas Palmer MIQ ( Deputy Chair), Nicholas Armstrong MIQ (Secretary), Doug Fulton AIQ (Treasurer), Sam Benson AIQ (YMN Co-ordinator). Committee member: Stephen

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Daniel Dix Andrew Dell Ben Milne Justin Roylance Breigh-Anna Kingsley Sam Abulughod James Richards Glenn Blair Amila Wickramasinghe Norman Shepherd Michael Greenwood Thomas Cilento Laura Richardson Fem Michel Mark Martin Kanella Dimos Drew Michelmore Craig Bewley Shari Rankin Gerard Hehir Marcus Zambelli Bernard O’Sullivan

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Quarry October 2021 57

GEOLOGY TALK

AUSTRALIA’S FIVE BEST ROCKS FOR BUDDING GEOLOGISTS

The crater of an erupted volcano near Mount Gambier, South Australia.

The Australian Age of Dinosaurs Museum - home to our largest collection of dinosaur fossils.

An academic and scientist has described the five most interesting rocks to be found on Australian soil.

They will display alternating layers of chert which is made of quartz and as is the norm in WA will show-off deep reds, silvers and blacks.

“The Hamersley Province in the northwestern part of Western Australia has the thickest and most extensive banded iron formations in the world. They are about 2.45 to 2.78 billion years old,” Finch writes.

“Banded iron formation is exciting because it no longer forms on Earth today, meaning it records an ancient process that we no longer see happening.”

The bands are thought to have formed in the oceans where continental shelfs expanded out from the land and fell away to the ocean floor.

Finally, on Finch’s list of Australia’s best rocks, are dinosaur fossils.

Central and western Queensland are good for these discoveries, according to Finch, if you want to get a glimpse into life up to 250 million years ago.

“If you’re really lucky, you might even have dinosaur bones on your property, like the huge, long-necked sauropod discovered just this year on a Queensland cattle farm,” Finch concluded. •

E

mily Finch, a beamline scientist at the Australian Nuclear Science and Technology Organisation and a research affiliate at Monash University penned the article for The Conversation, stating that each rock represents not just a period in the Earth’s history, but a significant time in our own.

The first of the “five rocks any great Australian rock collection should have” was a Mantle xenolith.

“The youngest rocks in Australia are those that erupted out of Australia’s youngest volcano in Mount Gambier, South Australia, 4000 to 8000 years ago,” Finch writes.

“That volcano is the culmination of an enormous field of volcanoes that span central and western Victoria.”

Victoria is scarcely known for its volcanic activity but a ring of the geological formations was the cause of mantle xenoliths. While magma rose from between the Earth’s core and crust – the mantle – it brought pieces of the mantle with it from almost 3km deep.

These black or brown rocks were consequently named mantle xenoliths and hold inside them a surprising piece of green

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Quarry October 2021

mineral, like a big geological seed.

Finch awarded second place to meteorites – often found in the Nullabor, South Australia and Western Australia.

“The dry environment is ideal for preserving meteorites that fall to Earth, and the light colour of the limestone country rock and lack of vegetation means the black and brown meteorites are easier to see,” Finch writes.

These space-spawned rocks can be found using magnets and have been known to hold up to 40,000-year-old secrets.

Broken Hill is home to Finch’s third favourite Australian rock – the metamorphic kind.

Metamorphic rocks begin as sand and mud and are slowly compressed by years of extreme heat and compression underground – reaching more than 700oC℃below the surface.

This process brings a stripey, “garnet-rich” sample to the rock for geologists to admire.

The fourth edition to this list comes as a rock formation – namely, a banded iron formation.

These are commonly found in Western Australia and may be harder to take home.

To read Finch’s article in full, visit theconversation.com/5-rocks-any-greataustralian-rock-collection-should-haveand-where-to-find-them-163578

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