Quarry December 2023

DECEMBER 2023

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

DECEMBER 2023

Steve Franklin explains the new methods being developed to gain a better geological understanding.

FLEXIBLE FULTON DELIVERS FOR AFLW Fulton Hogan has engaged some of Australia’s best female athletes to diversify its workforce.

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www.quarrymagazine.com

GEOLOGICAL TECHNOLOGY UPDATE

FAMILY TIES FOR MILESTONE BUSINESS WA Limestone has celebrated five decades since it was established as a small-scale Perth producer.

Komatsu iSite evolves into Smart Quarry Site: taking fleet and site management to the next level.

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IN THIS ISSUE

DECEMBER 2023

VOLUME 33, ISSUE 12

FEATURES 14 MANSAND WASHING WITH NO LOOSE ENDS 20 SUPERIOR GROWTH 22 SUPER SUSTAINABILITY 26 SMART QUARRY SITE’S INNOVATIVE THINKING

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GEOLOGICAL TECHNOLOGY UPDATE

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QUARRIES ARE CRITICAL TO NET-ZERO FUTURE

28 ‘TRANSFORMATIVE’ YEAR FOR BOA HYDRAULICS 30 PUMPED UP SERVICE 32 A SMARTER SOLUTION: VOLVO’S CARETRACK AND ACTIVECARE 34 A GREAT GRADER 36 SAFETY IN THE SPOTLIGHT 38 POWERING RELIABLE CRUSHING

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FLEXIBLE FULTON DELIVERS FOR AFLW

DECEMBER 2023

OFFICIAL JOURNAL OF THE INSTITUTE OF QUARRYING AUSTRALIA

DECEMBER 2023

FLEXIBLE FULTON DELIVERS FOR AFLW Fulton Hogan has engaged some of Australia’s best female athletes to diversify its workforc.

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44

QUARRY

16

www.quarrymagazine.com

GEOLOGICAL TECHNOLOGY UPDATE

Steve Franklin explains the new methods being developed to gain a better geological understanding

FAMILY TIES FOR MILESTONE BUSINESS WA Limestone has celebrated five decades since it was established as a small-scale Perth producer.

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FAMILY TIES FOR MILESTONE BUSINESS

TEREX JAQUES South East Sands’ partnership with Terex Washing Systems and Terex Jaques has been rewarded after nearly a decade in the making. Quarry spoke to South East Sands’ Peter Wilson and Terex Washing Systems sales manager for Australia and New Zealand Ben Willcox about the journey.

40 MAINTAINING GOOD VIBRATIONS 42 MOUNT COMPASS EXPLORES NEW MARKETS WITH MCLANAHAN

EVERY MONTH 06 FROM THE EDITOR

12 PRODUCT FOCUS

08 FROM THE PRESIDENT

48 IQA NEWS

10 INDUSTRY NEWS

50 GEOLOGY TALK

Quarry December 2023 3

EDITORIAL

VITAL LINKS IN THE CHAIN

T

he National Heavy Vehicle Regulator’s Chain of Responsibility regulations affect everyone who works with heavy vehicles, from the businesses the employ drivers, to the organisations that send and receive goods.

The regulations detail a primary duty to ensure everything is done to create a safe work environment. This means sites need to manage the risks and hazards that can arise from transport activities.

This means quarries need to identify and eliminate the risks involved with transport activities.

If they can’t be eliminated, they must instead be minimised as much as possible.

However, a chain is only as strong as its weakest link. That’s why the primary duty applies to all parties involved in the Chain of Responsibility.

Executives, managers, company directors or partners have a due diligence duty to ensure the business complies with the primary duty.

That means understanding the nature of the quarry’s transport activities, including the hazards and risks involved in these activities.

They will also need to ensure the business has the resources needed to eliminate or minimise these hazards and that information about incidents is received, considered, and responded to quickly.

Significant penalties can be imposed if someone part of the Chain of Responsibility does not comply.

Depending on the nature and seriousness of the action, the penalty could be a $300,000 fine and five years of imprisonment.

Executives who fail to exercise due diligence face similar penalties.

Safety is everyone’s responsibility, and to ensure quarries understand their responsibilities, the Institute of Quarrying Australia has several online courses available. It never hurts to stay up to date and informed.

Published by:

379 Docklands Drive

A CHAIN IS ONLY AS STRONG AS ITS WEAKEST LINK. THAT’S WHY THE PRIMARY DUTY APPLIES TO ALL PARTIES INVOLVED IN THE CHAIN OF RESPONSIBILITY.

Melbourne VIC 3008 T: 03 9690 8766

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Quarry December 2023

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30/10/2023 12:33 pm

PRESIDENT’S REPORT

THE NEXT GENERATION

O

ne of the key challenges our industry faces is recruitment.

The Australian skills shortage is affecting almost every industry.

There is a wealth of industrial expertise and wisdom available throughout the sector, which is why it is more important than ever to ensure young workers are supported throughout their careers.

Young workers can benefit greatly from guidance and support from industry veterans. It’s important to ensure they have all the opportunities possible to develop a successful career.

That’s the IQA’s Young Member Network’s (YMN) vision. Our national network has been established so like-minded young people can get to know their peers, share ideas and experiences, build key industry contacts, and perhaps develop new friendships.

Open to any IQA member 35 years or younger, the YMN provides support and assistance by having a network young people can turn to.

It also provides workers with forums and events that offer essential industry workshops and networking.

The network provides guidance and advice on career paths, with options for further career development, and offers assistance for those taking the first step towards professional recognition via a range of professional development opportunities.

The YMN is also planning to send a contingent of YMN members from the IQA to attend an international tour of quarry material related sites in the UK. This will be a two week period for attendees to experience the differences in operations of other product lines and businesses.

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Quarry December 2023

The Institute of Quarrying Australia

The study tour has the support of the IQ in the UK, and will take place in the middle of next year, at the same time as the Hillhead Exhibition.

Attendees will visit sites around Derbyshire and the south west (Somerset, Devon, and Cornwall).

I encourage anyone interested to register their interest.

Education and training is a life-long opportunity. It should be viewed in the broadest terms, involving initial qualifications gained at vocational and/or tertiary education programs, on the job training and ongoing professional development.

Continuing professional development is important in the extractive industry as it supports improvements in workplace safety, environmental management, community outcomes and business performance.

The IQA continues to develop and deliver educational platforms, through a consolidated single source, which are industry specific and designed to assist in meeting duty of care and competency requirements for statutory positions.

Whether you are young worker brand new to the industry, or an experienced quarry manager with years of experience, continuing professional development and quarry manager courses are important.

Ongoing education ensures you keep pace with current standards and regulation, have opportunities for career progression and can contribute to a safe work environment.

Duncan Harris President Institute of Quarrying Australia

Educating and connecting our extractive industry

www.quarry.com.au

YOUNG WORKERS CAN BENEFIT GREATLY FROM GUIDANCE AND SUPPORT FROM INDUSTRY VETERANS. IT’S IMPORTANT TO ENSURE THEY HAVE ALL THE OPPORTUNITIES POSSIBLE TO DEVELOP A SUCCESSFUL CAREER.

The IQA’s Strategic Plan 2023 to 2026 embodies the following vision, values and strategic priorities: Vision: Thriving communities supported by a sustainable industry Operational Priorities: • Deepen industry participation • Sustainable revenue streams • Highly capable team

• Technological innovation • Effective engagement • Great governance

Strategic Priorities: • Support industry participants with compliance and regulation

• Build a diverse and skilled industry workforce

• Foster strong industry connectivity

IQA Contacts:

Phone: 02 9484 0577 Email: admin@quarry.com.au Chief Executive Officer Clare Murray Deputy President Sarah Bellman

Company Secretary Rod Lester

For all education, member and branch enquires please email: admin@quarry.com.au.

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PRODUCT FOCUS

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COVER STORY

PRODUCER’S

PATIENCE REWARDED

South East Sands in Lang Lang is one of the biggest independent sand producers in Victoria.

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Quarry December 2023

South East Sands’ collaborative partnership with Terex Washing Systems and Terex Jaques has been rewarded after nearly a decade in the making.

L

ang Lang is an unassuming place.

Located 90 kilometres from Melbourne, it is partly known for being a halfway marker between the state’s capital and Phillip Island, the state’s penguin capital.

But within the town is South East Sands, one of the area’s newest opened businesses and, perhaps, one of its most successful.

By its own measure, South East Sands has become one of Victoria’s largest independent sand producers less than a year since it launched.

But behind that success was a nineyear period of planning and development to ensure the operation could be successful and compliant.

Quarry spoke to South East Sands’ Peter Wilson and Terex Washing Systems sales manager for Australia and New Zealand Ben Willcox about the journey and the plans for the Victorian producer.

The investors identified Lang Lang, with its unique sand, as a critical area that could serve a Victorian market in desperate need of sand.

“In the industry, there has been a consolidation of ownership between the major players, and a lot of independent quarries have been acquired by larger, vertically integrated, building materials companies,” Wilson said.

“We came in as the market was consolidating, demand for the product was increasing, and despite the delays, we had patient investors who believed in this opportunity.

“This sand is unique, very white, but it remains consistent with its gradings and retains the colour.

“It certainly wasn’t for the faint-hearted. Only a certain type of investor would have embarked on something like this, and they backed us in.”

There were obstacles to overcome before South East Sands could think about moving sand or commissioning its Terex Washing Systems plant.

The company spent time reshaping the entrance road, sealing it, realigning an intersection, upgrading the power supply, and satisfying numerous local government planning preconditions At the same time these works were being carried out, Lang Lang experienced its wettest

winter in more than 40 years, which held up the construction and commissioning of the processing plant.

“There were times I thought it would never happen because we’d get close to starting, and then the finish line would move again,” Wilson said.

“We knew the customers would support us, but now, looking back, it is very satisfying that we got to this point.”

PARTNERSHIP As South East Sands got ready to launch in the early stages, it secured Terex Washing Systems as a manufacturer and supplier behind the scenes.

The Terex brand is well-known across the Australian quarrying and aggregates industry.

Terex Washing Systems has been researching and developing its product portfolio across six decades to ensure its customers have up-todate equipment solutions.

By working with Terex Jaques and Terex Washing Systems, customers gain access to one of Australia’s largest and longestestablished engineering groups. The group can deliver specialist solutions for turn key plants, known for their reliability and durability.

Wilson recalled spending plenty of time speaking with Terex’s team of specialists and its engineering base to ensure its machines fit South East Sands’ purpose.

“We worked closely with Terex for about six months before we pulled the trigger on production because we were doing something that wasn’t straight out of the textbook.”

“There’s no one-size-fits-all plant that will do everything you want, but what Terex’s plant Terex Washing Systems and Terex Jaques have been key supporters of South East Sands.

does is it gives you the flexibility to tweak it or bolt on other equipment to be flexible.

“Terex’s equipment has allowed us the scope to fine-tune it to suit us to make the product that we want to make,” he said.

South East Sands started with concrete sand from its Terex Washing Systems plant. The modular plant includes an M2100 Tracked Rinser, FM200 Compact, deep cone thickener and flocculant dosing unit that allowed it to get underway with a small footprint.

The compact sand plant works on the principle that a raw dry feed is delivered to a rinsing screen where the material is sized and fluidised using the wash box equipped with a high-pressure spray. The sized sand is then pumped through a cyclone to remove the silts, where it is dewatered over a dewatering screen. The silts are then processed through a thickener, allowing 90 per cent of the plant’s water to be recovered for reuse.

Given the outlay for quarries in upfront costs, many often want to scale operations to make a return on investment. South East Sands was no different, and its partnership with Terex Washing Systems was vital.

After working collaboratively with Ben Willcox and the local Terex Jaques team, South East Sands bolted on an FM120 Compact plant to act as a fine sand recovery unit.

“We pride ourselves on working collaboratively with our customers to ensure that our equipment can help them achieve the business outcomes they’re looking for.”

“Most quarries will look to upscale their business, and by using the FM120 Compact, our solution for South East Sands allows them to achieve this and sets them up for the future.”

It provided two significant advantages to the Victorian producer: further quality control over its finished concrete sand production and the creation of fine sand.

The new machine’s fine sands opened new opportunities for South East Sands, ranging from garden centres in the retail sector to topdressing Melbourne’s golf courses.

“We always knew the original plant was the stepping stone to something bigger,” Wilson said.

“Part of the attraction to Terex’s products was that they were modular, and we could add pieces to flesh out the plant.

“The flexibility has allowed us to see where the market and our customers are going and meet their needs.

“We’ve been able to fill gaps in the market where supply has gone down, or the resources aren’t there anymore, and we’ve been able to pursue that largely thanks to Terex.”

FUTURE PLANS The partnership between Terex Washing Systems and South East Sands has fuelled a rapid rise in production. The Lang Lang producer has gone from zero customers in May of last year to selling half a million tonnes of sand and a complete range of products 15 months later.

Terex Washing Systems and South East Sands continue working behind the scenes to grow the Lang Lang site’s production.

Terex Washing Systems is working with South East Sands on a solution to help stockpile more sand on-site.

“We value our relationship with South East Sands, and our team is excited to collaborate with them to ensure our equipment can help them take the next steps on this journey,” Willcox said.

“We’ve effectively been there since the beginning of the South East Sands business and hope to be there for many more years.”

South East Sands expects the solution will help improve product grading and efficiency on-site and for truck operators.

After the nearly decade-long wait to start production, Wilson said the company felt bullish about its future.

“It’s very satisfying, and it feels like a vindication of our belief in this project from the start,” Wilson said.

“Good things come to those who wait, and we couldn’t have got there without Terex Washing Systems.” • For more information, visit terex.com

Quarry December 2023 13

SAND WASHING

EvoWash Sand Wash System with AquaCycle thickener in New South Wales.

MANSAND WASHING WITH NO LOOSE ENDS Australia has seen bursts of activity in the space of washing crusher fines as a replacement for natural sand.

A

lmost 20 years ago, the Cement Concrete and Aggregates Australia commissioned a report that highlighted the potential of beneficiated crusher fines, or more commonly known as manufactured sand (ManSand).

However, even as natural reserves of sand near exhaustion around the country’s capital cities, ManSand has not begun to replace it to a huge extent.

There are several potential reasons for this: 1. A quarry’s ability to put a fines beneficiation plant in retrospectively.

Constraints being development application amendments, access to space, water and power.

2. Crusher fines are bimodal with a lot of coarse grains and then a lot of bottom end (-75 micron) but do not contain enough medium/fine material to make a viable/ high percentage sand alternative, or it adversely affects concrete mix (strength/ slump/admix requirements).

3. Available solutions can tackle only part of the problem but can create more headaches for the operation and site downstream.

4. The quarry can already find a home for its fines and then buy in the sand it needs without a capital investment.

CDE has continued to develop systems to better tackle the beneficiation of manufactured sand, addressing all four of the above recognised pain points. It comes after the success of CDE’s compact systems across large parts of Asia and the Middle East, which was designed in response to a sand mining moratorium established by many countries.

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CDE washed ManSand almost eliminates organic and soluble impurities such as clay and silt that adversely affect the setting, slump, shrinkage and strength properties of a concrete mix.

In the Australian context, the industry typical AS:1141.33 sand test does not hold back the use of manufactured sand, as quality fine sand (even sub 75 micron) will settle out and not make a sample fail the typical <5 per cent silt by volume test.

An efficient washing system needs to: • Extract problems fines (actual silts and clays or excess ultra-fines causing mix issues) • Look to increase percentage of medium/ fine sand.

• Maximise productivity through water recovery, power and land availability.

CDE’s latest generation of EvoWash sand wash system, rinses and cyclone washes ultrafine sand, minimising overall water by reducing cyclone diameter. Water demand is a large contributor to the use of sand-screws in ManSand applications. Sand screws are not as efficient as they commonly lose sand up to and over 200micron which is precisely the sand crusher dust is usually missing.

Equally, with screws, waste becomes higher and tailings management can worsen.

Sand screws also often require additional equipment post-commissioning to retain the fines and increase dewatering.

After washing the rest of the downstream, a CDE system remains compact with an AquaCycle thickener, which can be as small as 4m. This would be placed alongside a containerised water and buffer tank that supports a decanter centrifuge or filter press.

ManSand plants are now capable of treating up to 100tph taking up less than a 200m2 (excluding sand stockpiles) and using less than 15m3/hr. Reject fines being presented as a spadable cake is ideal in most instances.

Regarding gradation control, CDE can utilise tight tolerance fine screens to cut down to 400 Microns for blending. At the same time, vertical shaft impactors (and more recently rolls crushers) have been integrated to turn fine aggregate/grit into medium/ fine sand in a more controlled manner. By only imparting a few breaks on stone, the company can create the sand missing from the particle size distribution (PSD) without creating ultrafines that go to waste.

CDE already has several installations in the Australasian region processing crusher fines to make quality manufactured sands. From landmark projects like Walker Quarries in NSW and the 300tph plant with TPI in Thailand, to early adopters such as Jungs Quarry in Coffs Harbour and more compact systems.

As natural resources continue to dwindle and with cartage costs continuing to rise, it is expected that quarries will once again look to crusher fines to make up a larger proportion of their concrete sand blend. While some quarries can move this material for bedding or in asphalt already, the industry is likely approaching a tipping point where the bottom line supports investment to offset more natural sand in construction/concrete sand.

CDE is developing systems that make this possible without requiring space and water that doesn’t exist, and without undesirable trade-offs around yield or dry dust tailings.

With an installation base across Australasia, CDE is also happy to arrange live site demonstration visits. • For more information, visit cdegroup.com

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GEOLOGY

GEOLOGICAL

TECHNOLOGY UPDATE Understanding the rock in a quarry and what can be made with it are fundamental pieces of knowledge that can make or break businesses. Steve Franklin, founder of Eltirus, explains the new methods being developed that can help gain a better understanding of both rock type and variability.

M

ost geological assessment comes from either the mapping of rocks that we can see (either on the surface or in a face) and from drilling (using methods such as chip and diamond core ) holes to obtain samples of rocks below the surface.

Samples (either from the surface or sub-surface) are then subjected to a range of tests to better understand their degree of weathering, composition, and physical characteristics.

One of the primary limitations of any physical sampling is that you are only

able to sample a part of the deposit and it can be difficult to ascertain how much sampling is required.

By this I mean, that while you may be able to determine with some accuracy the characteristics of a rock at each sample point, a geologist then has to determine what is between the sampling points by extrapolation.

In essence, if I know what is at point A and at point B (which is say 250m away), I can predict that what is in between will be of a similar set of qualities.

As you might imagine, this may or not be true and is primarily dependent on how consistent the deposit is – in other words, the more variability within the deposit, the more sampling that would be required to accurately describe it.

For example, you might completely miss say a dyke, simply because no drill hole intercepted it. Just because it is not in the model, doesn’t mean it doesn’t exist. As one geologist famously noted, “the best understanding you have of any deposit is when it is fully extracted.”

R D I P

R

Most geological assessment comes from either the mapping of rocks that we can and from drilling holes to obtain samples of rocks.

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Quarry December 2023

So, what other methods exist, particularly ones that can help us to better understand more variable deposits?

HYPERSPECTRAL SURVEY We recently had the opportunity to visit PlotLogic in Brisbane and find out about the ground-breaking work they are doing with hyperspectral survey.

The development of hyperspectral survey dates back to the early 1980s, when NASA started to build the first airborne hyperspectral imagers, such as the Airborne Imaging Spectrometer (AIS) and the Airborne Visible/Infrared Imaging Spectrometer (AVIRIS). These sensors demonstrated the potential of hyperspectral imaging for earth observation and space exploration as they could provide detailed spectral information that was not possible with other types of sensors.

A hyperspectral survey is a method of collecting and analysing information from

Borehole imaging can be used as a cost-effective alternative to drilling diamond holes.

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GEOLOGY

Understanding the rock in a quarry that can make or break a business.

across the electromagnetic spectrum with the purpose of identifying materials that are not visible to the human eye.

Hyperspectral surveys are performed by measuring the absorption of light as a function of wavelength, using imaging spectrometers or hyperspectral imagers. These devices can capture images in many narrow spectral bands, ranging from visible light to near and short-wave infrared light. The resulting images are combined to form a three-dimensional hyperspectral data cube, which can be processed and analysed to extract spectral signatures of different materials.

While hyperspectral survey methods have been known for a while, PlotLogic does something quite different with the technology to produce some amazing results. Their approach is to combine LiDAR and hyperspectral imaging technology with advanced machine learning algorithms to deliver highly accurate ore and material characterisation.

So successful has this technology been in the mining industry, that it enabled BHP Iron Ore to extend the life of one of their major operations by a further five years (approximately 85mt) – a remarkable result in anyone’s language.

By scanning a face and analysing the results with their AI based software, a picture of different material types can be created without drilling or sampling. For example, if you had lower quality or deleterious materials in a face, the PlotLogic system can identify them for you.

The system can also be used to scan drill core or be placed over a conveyor belt to determine material quality in real time.

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Quarry December 2023

At this stage, we are still exploring use cases in the aggregate industry, however we believe that the technology may have application in the determination of pyritic or other deleterious materials in hard rock quarries and identification of high silt/clay areas and organics in sand. It may also find an application in the cement industry identifying problem chemistry such as high sodium equivalent materials.

We look forward to continuing to work with PlotLogic to determine what kind of applications there may be in the aggregate, sand and cement industry. They are particularly interested in finding a quarry in the Brisbane area that is willing to participate in field trials – if you are interested, please contact me.

BOREHOLE IMAGING One of the other technologies we have had some success with is borehole imaging.

By this, I mean running a sensor down an RC (or blast hole) and taking a 360-degree photo of the borehole from top to bottom (or if filled with water, using sonic imaging). This approach can be used as a cost-effective alternative to drilling diamond holes.

Reverse Circulation (RC) or blastholes holes can be drilled, the chips logged, and downhole imaging used to gain a better idea of the structure of the material. In many cases the quality of the imagery is such that geotechnical logging can be conducted from the data.

To date, a primary issue is visualising the data. We have long been waiting for the ability to wrap the imagery around a borehole in our geological modelling software to see

the data in a more representative setting.

We have also trialled a combination of downhole logging with measure while drilling data (MWD) to determine what could be gained from it. The combination of imaging with drill rotation speed, feed pressure and other variables can help us gain a more comprehensive understanding of what is being drilled. This said, more work needs to be done to better understand the correlation between these two data sets. For example, just because penetration rate is low does not mean that the material is hard – it could just be that it is actually soft and the driller has slowed down to ensure the bit doesn’t become blocked.

While it is still early days, we expect to see an approach taken whereby blastholes are logged using hyperspectral downhole imaging and combined with measure while drilling performance data to provide near real-time analysis of likely rock type and deleterious materials before the shot is fired.

FURTHER ADVANCES For any that use Propeller (aka Trimble Stratus) you may be aware that there is functionality to add sub-surface designs.

Initially introduced for the construction industry to show underground services, we are having some good results with showing geological models and block models. Stay tuned for more information as we investigate this new functionality. • For more information, contact steve.franklin@eltirus.com

CRUSHER & SCREEN SALES PTY LTD

IMS DISTRIBUTOR for Australia, Papua New Guinea and South East Asia

Specialist Manufacturers of Quarry, Mining & Recycling Equipment Irish Manufacturing Services Ltd | www.ims-ltd.ie

IMS have added the new BP1200-48TB track electric twin power blender to its impressive collection of blenders and pugmills, the new BP1200-48TB has four separate feed hopper each five meters long holding 12m3 each. All feed hopper conveyors are fitted with belt scales and controlled by a PLC control and recording system that can be operated from an iPad or phone from its own Wi-Fi system from a loader or site office. A Cat C7 Generator powers the Nord electric motors all fitted with invertors offering variable speed to each feed hopper conveyor. The generator can be connected to mains power and could power an extra 24-meter radial stacker increasing the stockpile capacity.

A new IMS-PM1200-20TB Track Pugmill with twin 10m3 feed hoppers has just commissioned to Braeside Quarry on the New England Highway Warrick in Qld, the options the PM1200-20TB offered Braeside improved product management with the twin feed hoppers blending fines into roadbase to make spec or having two different products available ready for moisture control and CTB. The PLC control and recording system can be operated from an iPad in a loader managing all aspects of the operation including loading trucks and multiple trailers stopping when the required weight has been reached for each unit and recording the ID number of each load.

John Andersen +61(0)424 181 056 | Chris Wong +61(0)424 180 860 info@crusherscreen.com | www.crusherscreen.com | Unit 4, 181 Sandy Creek Road Yatala QLD 4207 Crusher and Screen Sales PTY Ltd | ABN: 55 150 600 418 Gold Coast QLD 4220 | PO Box 144 Southport QLD 4215

ACQUISITIONS

SUPERIOR GROWTH

Superior Industries has revealed the key reasons behind its latest acquisition, which will benefit the Australian market.

S

uperior Industries knew it wanted three key elements when it scoured the market for a vertical shaft impact (VSI) crusher.

It needed a brand with a strong reputation, good people and a quality product.

It found all three aspects in the heart of America’s southwest at CEMCO’s New Mexico headquarters.

The storied manufacturer is seen as one of the VSI crusher originators in North America, started by the Hise family more than six decades ago.

Superior Industries has finalised the acquisition of CEMCO in recent months. The deal will see CEMCO, its VSI crushers and a 147,500-square-foot (13703 square metres) manufacturing facility come under Superior Industries ownership.

“VSI crushers seem to generate a lot of brand loyalty in people; they know what they like, and they like to stick with those,” Poppe said.

“The CEMCO brand is extremely popular, it has a large following, and people trust it and know it will work.

“When you add all of those together, we’re excited to bring the CEMCO VSI crushers to our customers in Australia.”

FULL PORTFOLIO Superior Industries has its roots in bulk handling with its Telestacker conveyor that became popular for its design and durability.

But the Minnesota-based original equipment manufacturer has been equally as prominent in the aggregate industry after building up its crushing, screening, and washing equipment portfolio.

The CEMCO acquisition brings another VSI crusher to complement the company’s existing crushing and screening products.

Poppe said the VSI crusher is the perfect machine for cubicle-shaped crushing, especially road base.

Superior Industries CEMCO VSI crusher is well-regarded in the industry.

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“CEMCO is a pioneer and originator in the VSI crushing industry. It has a great name and a well-accepted VSI product, which was vital for us.

“It will allow our customers to access all their processing and handling equipment from one place.”

Superior’s Cemco VSI can process various materials from diverse industries. According to the company, its clients use the crusher for everything from fractured gravel to cubicle products to manufactured sand and precious metals recovery.

Its interchangeable chambers allow for several rotor and anvil configurations for application flexibility. The hydraulic lid lifter provides quick access for routine inspections and quick maintenance while the rotor assembly is replaceable or can be rebuilt in the shop.

OVERSEAS IMPACT Many quarries saw lead times and delays become a regular occurrence during the COVID-19 pandemic as supply chain issues permeated across the globe.

Superior Industries, which has been in the Australian market for about a decade, has tried to be proactive to ensure its products meet reasonable lead times.

A crucial part of Superior Industries’ proactive approach moving forward is the transition of CEMCO’s sprawling New Mexico manufacturing facility.

The site will become the home for all of Superior’s VSI crushers, as well as increasing stock of critical components and portable plant manufacturing by about 40 per cent, according to the company.

The facility will increase Superior Industries’ manufacturing capacity, which Poppe said will help decrease lead times for customers in America and overseas markets like Australia.

Superior Industries has established its presence through dealership agreements with 888 Crushing and Screening Equipment in Northern Territory, Southern Australia,

O

2019_Au_

“We’ve doubled down on our customer service over the last couple of years and have strong dealers in Australia.

“They’re focused on ensuring your product works right, runs as expected and lasts for a long time.”

Superior Industries have acquired the CEMCO brand and its major manufacturing facility in New Mexico.

Western Australia, and Tricon Mining Equipment in Australian Capital Territory, New South Wales, Queensland, Tasmania and Victoria.

“The industry is red hot with demand at the moment, and we want to help our customers take advantage of this opportunity,” Poppe said.

“With this acquisition now, we can offer international customers all the processing and handling products from one company, so they’re integrated products and a direct line if you need us.

LEGACY CEMCO has established a worldwide clientele since it ventured into crusher manufacturing in the 1960s.

At the time, workers were left frustrated by the shortcomings of crusher technology and set about building a durable crusher.

The design has withstood the full toll of the aggregates industry. One of its T-70 crushers only recently had its tub body replaced after 26 years of full-scale production, while the first-ever CEMCO crusher remains operational at a New Mexico site.

Poppe said it was essential for Superior Industries to maintain the CEMCO legacy.

The company has set about maintaining the

Hise family legacy under the new acquisition.

Superior will use CEMCO’s name as a trademark for its VSI crusher range, while members of the Hise family have agreed to stay on board as workers with Superior.

Superior Industries president Jason Adams has already announced plans to double the workforce at the New Mexico facility with local people.

“It’s crucial to maintain that family feel to our operation, and that’s what we found with CEMCO; you walk in, and their employees are so welcoming and hard-working with great customer service,” Poppe said.

“Those are the type of people who work well in our company, and that was something we were looking for in the acquisition.

“Our purpose is creating opportunity through innovation for our customers or communities. This move will help our customers deliver on the industry’s demand.”• For more information, visit superior-ind.com

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The high level of customer service, guaranteed by 18 trading subsidiaries worldwide, and long-lasting and performing products make us always ahead.

Our vibrators are designed for industrial applications in all sectors, from the most extreme environments such as quarries, mines and foundries to the food and pharmaceutical.

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2019_Au_BulkHandingMagazine_210x150.indd 1

09/12/2019 10:11:25

SUSTAINABILITY

SUPER SUSTAINABILITY Quarry investigates what measures Epiroc has undertaken to achieve its goal of providing a complete range of emissions-free equipment by 2030.

Epiroc is committed to providing sustainable solutions in its equipment range for quarries.

T

hrough its acquisitions, technology agreements and innovative product line, Epiroc is quickly pursuing a more sustainable portfolio of products to meet the needs of its customers.

The company’s clients, often with their own sustainability objectives, need suppliers who match the modern quarrying landscape.

With this in mind, the worldwide manufacturer has underlined its commitment to sustainability with a suite of initiatives to ensure its operations meet this standing.

Epiroc joined the Charging Interface Initiative (CharIN) last year. The agreement meant Epiroc would help work towards a standardised electric charging solution for vehicles and machines with other industry leaders across the globe.

In exchange, CharIN has provided field experience and technical knowledge to enhance the roll-out of Epiroc’s electric vehicle suite. This includes employing a combined charging system (CCS).

Epiroc’s operations manager, Lina Jorheden, said the work done with CharIN and other industry leaders would help connect Eprioc and other companies to an international charging standard.

CharIN is a global association with more than 280 members dedicated to promoting interoperability based on the CCS as the worldwide standard for charging vehicles.

“The decision to join CharIN connects us to an international standard of charging, which makes us unique in the industry,” Jorheden said.

ACQUISITIONS Epiroc has also acquired new ventures to fill out its sustainable equipment portfolio while maintaining its commitment to original manufacturing.

Epiroc acquired Australian manufacturer Schramm Australia, a Perth-based company which had been in voluntary administration.

The acquisition, one of many from 2023, followed on from nine purchases in 2022,

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including Remote Control Technologies (RCT), Mernok, Radlink, Geoscan, JTMEC, AARD Mining Equipment, RNP México, WainRoy and CR. The announcement secured employment for Schramm’s workers across its two WA production facilities and service centres in Queensland and South Australia.

The acquisition also boosted Epiroc’s portfolio of reverse circulation (RC) technology.

RC drilling is an economical way to retrieve the high-quality mineral-grade samples needed to plan quarrying operations efficiently.

The RC drilling method prevents crosscontamination and accrues a large number of sample bags in a short amount of time.

Sample bags are labelled with the exact location and depth information – and can be sent to a laboratory immediately after or during drilling.

Accurate information about deposits allows quarries to selectively pinpoint zones for drilling and blasting for maximum material recovery. It also creates a more sustainable operation by reducing environmental impact when carried out correctly.

Epiroc’s president and chief executive officer, Helena Hedblom, said the acquisition was essential for Epiroc.

“The Schramm products and brand are well known as a global leader in reverse circulation technology,” she said.

INNOVATION Hedbloom said Epiroc’s belief in thinking new was channelling its ever-expanding push into the sustainable mining and quarrying space.

In recent years, Epiroc has produced

many sustainable machines, including the SmartROC T35, the first-ever battery-electric surface drill rig. The company described this as a “milestone” for zero-emission drilling in quarrying.

Epiroc has invested heavily into developing electric and hybrid-powered equipment as part of its focus on electrification. The company is also working to increase the circularity of its operations to reduce waste and promote the reuse of materials.

This aligns with the company’s public statements, where it has committed to offering a complete range of emissions-free equipment by 2030. Due to this, Epiroc’s team of designers and engineers are working to develop new technologies and processes to increase the efficiency and sustainability of its operations.

Hedbloom said that Epiroc was committed to delivering sustainable solutions to its customers.

“Reduced emissions and improved environmental performance are features that are important to our customers. Batteryelectric equipment is increasingly popular among our customers,” she said.

“Delivering best-in-class machines is, of course, crucial, but equally important for customers is for the equipment to work efficiently with maximum uptime.

“Much of the investment in innovation is directed to our equipment divisions that provide, for example, the widest offering of battery-electric machines and world-leading automation solutions.” •

I H U

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For more information, visit epiroc.com

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INCREASE HYDRAULIC UPTIME The World's Fastest Hydraulic Hose Repair 1800 40 30 40 | boahydraulics.com

SAND PRODUCTION

QUARRIES

ARE CRITICAL TO NET-ZERO FUTURE

T

he United Nations warning of a global sand shortage was described

by United Nations Environment Programme’s Pascal Peduzzi as the “elephant in the room” for the 21st century.

The world’s second most consumed material is used to make roads, bridges and houses. Given the world’s reliance on natural sand in concrete creation, the “elephant in the room” left many searching for sustainable alternatives.

Manufactured sand is often used as a substitute for natural sand in concrete, especially in areas where accessible natural sand sources are scarce or of poor quality.

This is also true in countries where heavy government regulation limits companies mining natural sand for construction.

Kayasand-manufactured sand uses up to 20 per cent less cement than natural sand to create concrete of the same strength.

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Manufactured sand used to be solely about repurposing surplus quarry materials, like crusher dust. It was often labelled unequal to natural sand in concrete production, especially in developed construction industries. However, it has come a long way since it first entered the market.

Kayasand believes with the innovative technology available today, it’s more consistent in quality and performance and can be precisely engineered for specific construction applications.

When processed well, this ‘engineered’ sand has many advantages over traditional manufactured sands: precise shape, good particle size distribution, no contamination and regular consistency. In fact, it produces a stronger concrete than many natural sands with less cement.

Kayasand trials show that concrete made with Kayasand-manufactured sand uses up to 20 per cent less cement than natural sand to create concrete of the same strength.

While most countries support the future of manufactured sand, not all of them have embraced its potential. New Zealand Green Investment Finance delivered $3.5 million earlier this year to support Kayasand’s first V7 high-technology manufacturing demonstration plant in the Waikato region of New Zealand.

Global bodies, including the United Nations, have warned about the shortage of natural sand and the need to reduce carbon emissions, so manufactured sand is set to become an increasingly critical construction material.

A United Nations Environment Programme report suggests that 50 billion tons of sand and gravel are used yearly. This makes it the second most used resource after water.

In an interview with Quarry, Kayasand’s national sales manager, Frank Grech, said the opportunity for quarries selling manufactured sand is better than ever.

Image credit: SmartCrete CRC Ltd

Kayasand believes quarries are critical to the construction industry achieving net-zero carbon emissions by 2050.

THE PROCESS Innovative technology, like Kayasand’s Kemco quad-deck air screens and V7 sand plants, makes the process dust-free, low-noise and uses no water for washing. This means quarries no longer need sediment ponds or water tailings and there are no hidden costs for water management.

Kayasand’s unique design combines the accuracy of mesh screens with the high throughput of air classification system.

Their equipment specialises in screening materials that have high fines content. The fully enclosed nature of the V7 plant limits dust exposure, while its negative pressure from the built-in dust extractor keeps dust contained and away from operators.

Waste glass can be recycled into concrete sand. Cement substitutes can be created from limestone filler and waste slag using Kayasand’s V7 plant.

Grech says this versatility allows quarries to reduce their environmental impact while

Sand engineered for concrete is shaping as a critical resource.

increasing revenue opportunities and enabling a circular economy Researchers are exploring ways to enhance the properties of manufactured sand for use in sustainable concrete mixes.

By incorporating manufactured sand in innovative concrete formulations (such as carbon-sequestering concrete or highperformance, sustainable concrete), the construction industry can reduce its carbon footprint per unit of construction material.

Grech said engineering sand to have highly consistent properties, allows for more precise and optimised concrete mix designs.

This can lead to reduced material wastage during construction, which, in turn, facilitates a project’s overall carbon footprint.

ENVIRONMENTAL BENEFITS Using manufactured sand enables the construction industry to minimise waste generation and maximise resource utilisation to align with sustainable

development principles and carbon reduction reporting requirements.

It helps to conserve natural resources by reducing the riverbed and coastal sand demand. Preserving these ecosystems can help mitigate carbon emissions associated with habitat destruction.

Manufactured sand produced in quarries is often closer to construction sites, reducing the need for long-distance transportation.

Producing sand locally allows quarries to help reduce transportation emissions.

Grech said transporting natural sand over significant distances can result in higher emissions due to fuel consumption.

Given this and companies are trying to find ways to lower costs, it makes sense to embrace sustainable materials, like high quality, ‘engineered’ sand, and move towards a circular economy.

Peduzzi, who coordinated the United Nations Environment Programme’s report on the sand shortage, has supported the push

for such an economy.

“If we can get a grip on how to manage the most extracted solid material in the world, we can avert a crisis and move toward a circular economy,” he said.

“To achieve sustainable development, we need to drastically change the way we produce, build and consume products, infrastructures and service.”

The environmental benefits, lower carbon footprint, repeatable design quality, and circular economic potential make manufactured sand a viable and scalable solution.

By embracing manufactured sand, the construction industry across the value chain can build a more sustainable future.

As the construction industry sets its sights on achieving net-zero emissions by 2050, quarries that sell quality manufactured sand are essential to the vision. • For more information, visit kayasand.com

Quarry December 2023 25

INDUSTRY 4.0

Komatsu’s Smart Quarry Site is a complete fleet management solution.

SMART QUARRY

SITE’S PRODUCTIVITY IMPROVEMENTS Komatsu’s fleet management system is helping take the load-off quarry managers facing an ever-growing list of issues to tackle on-site.

D

emand for building materials across Australia has exceeded expectations, with large government infrastructure projects and housing development projects driving growth through the pandemic.

While meeting the demands from this growth, the quarrying industry is also working to lower emissions and achieve more productivity from its operators and machines.

As quarry managers and industry leaders juggle these competing tasks, Komatsu has rebranded its iSite product to Smart Quarry Site (SQS).

Komatsu’s SQS is a management tool that provides visibility to all aspects of quarry operation, enabling managers and operators to make data-backed solutions to match their objectives. SQS is designed to help quarries be more productive, efficient, and profitable.

“With this tool, quarry managers now have complete vision over the quarry’s operations to help them make decisions,” Komatsu Australia’s national business development manager Tony Clear said.

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Quarry December 2023

Quarry managers can use SQS to monitor the locations and status of their machines in real time. They can access critical information about volumes and tonnes being hauled and loaded to help inform their management decisions, both in real time and by replaying events “One of the key profitability drivers in SQS is the visibility of the tonnage being loaded that we give to the loader operator. With full vision, provided without any interaction from the loader or the haul truck, a loader can load a truck to maximum” Clear said.

“This increase in average tonnage per cycle can add up to hundreds of thousands of dollars in extra profit for a typical quarry.

Add to that the benefits from digital prestart recording, speed alerts, productivity reporting, and simple real time visibility, and the solution really adds a lot of value to any operation.”

The platform is brand-agnostic and compatible across mixed machinery fleets, regardless of the manufacturer.

As well as a productivity focus, SQS gives site managers utilisation and operator data that allows a site to better manage safety on site, as well as machine health and longevity.

By monitoring machine utilisation, site managers can optimise haul routes and load times, and by reviewing wait times and idle times, a machine’s tonnage per litre of fuel can be maximised.

“If you can bring idling time down, you can reduce your emissions count,” Smart Construction’s general manager James Muir said.

“An improvement to production is going to reduce emissions. With the latest ESG features added, the platform can produce heat maps showing emissions clouds. A site manager can see if there’s a concentration of machines operating in a particular area, as they will have more emissions in that spot.

This visualisation is particularly important when operating quarries close to urban areas.

Managers can then make decisions, based on this data, to reduce idle times, concentration of machinery, and therefore emissions as a whole.”

Komatsu spoke to a large cross-section of the industry in the design phase of the development of the SQS system. A key

industry driver was the need to enable machine operators to focus on machinery operation, and not to be burdened with data input or technology interaction. Designing this in conjunction with the needs for visibility of the operation at a management level was a critical component of the brief.

Muir said the resultant SQS solution can be tailored to each quarry site to ensure quarry managers and operators can access and view relevant data to improve their sites.

“Our first step,” Clear said,”is to to complete a site investigation.”

“We start by interviewing the site supervisors of the quarry and get an understanding of what they’re trying to achieve. Then, we start to build that into the system.

“Each site has its own set of KPIs, so we customise the platform’s parameters.

“It’s the same with safety in terms of the electronic pre-start checks. The checks are tailored to each machine because certain machines will have

The platform has been rebranded from Komatsu iSite to Smart Quarry Site.

different safety functions and startup requirements.”

This approach demonstrates Komatsu’s commitment to working with customers to achieve their specific defined goals while optimising productivity.

“We’re leaning into to support whereas some lean away from it.”

“We are aiming to provide a completely different experience to our customer base through support, Clear said. • For more information, visit komatsu.com.au

Help the move to a net-zero carbon future.

Sell sand that makes stronger, lower emissions concrete.

Sized to order

Washed without water

Made without natural sand

Using waste & recycled materials

Quality Sand for Sustainable Construction

Low emissions

FIND OUT HOW

Frank Grech | National Sales Manager Mob +61 409 123 364 | info@kayasand.com

KAYASAND.COM

THOUGHT LEADERSHIP

‘TRANSFORMATIVE’ YEAR FOR BOA HYDRAULICS BOA Hydraulics co-founder Simon Boakes breaks down the key challenges and solutions facing the quarry industry in 2024.

B

OA Hydraulics has become one of the fastest-growing hydraulic companies in Australia and New Zealand in the five years since it opened its doors.

The New Zealand-based company has helped more than 300 contractors save money and downtime with its unique 360 degree onsite hydraulic hose repair solution.

With a perspective spanning two countries across Australasia, Simon Boakes gave his perspective on the most significant issues facing the quarrying industry and potential solutions.

WHAT CHANGES AND CHALLENGES WERE MOST PERTINENT TO THE QUARRY INDUSTRY AND OPERATORS THIS YEAR? Like many industries, the quarry sector faced challenges related to supply chain disruptions, fluctuating material costs, and evolving environmental regulations.

These challenges put pressure on our customers to maintain productivity while being more cost-efficient and sustainable.

FROM YOUR PERSPECTIVE, HOW WAS 2023 FOR BOA AND ITS CUSTOMERS BROADLY? This year has been a transformative year for BOA Hydraulics.

The BOApod is an all-terrain, mobile hydraulic hose repair unit.

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The demand for efficient and userfriendly hydraulic hose repair solutions continued to grow. More and more quarry owners are looking at their internal processes and challenging where they can increase efficiencies.

With the BOApod being a mobile all-terrain repair and maintenance facility, we think our offering is well-placed to help customers facing these challenges save money and downtime.

HOW DID YOU CHANGE OR ADAPT YOUR APPROACH OR PRODUCT TO HELP CUSTOMERS TACKLE THESE CHALLENGES? We have collaborated closely with our customers to develop tailored hydraulic hose repair solutions that address their unique challenges.

We’ve also continued to invest in research and development to enhance our product offerings, making them more reliable and environmentally friendly.

We know that more quarry operators are considering their environmental footprint and how to lower it to fit their sustainability objectives.

Our solution answers many of the quarry industry’s challenges regarding productivity, profitability, and sustainability.

WITH THE BOAPOD, HOW DID YOU SEE ITS YEAR ON THE MARKET? The BOApod has had a remarkable year.

We’ve received some great feedback from the industry, both in Australia and New Zealand, about how it is helping operators either save downtime and increase profitability through better machine utilisation.

The BOApod’s success in the market can be attributed to its user-friendly design, ease of implementation, and the cost savings it offers to quarry operators. It gives the quarry industry more control over their downtime, optimising machine performance onsite.

We have contractors across a wide range of industries, from quarrying and mining to

BOA Hydraulics has over 300 contractors using the BOApod across Australia and New Zealand.

demolition and civil contracting, and they’ve given us good product feedback.

With productivity and efficiency becoming more important each year, we see our role in giving customers the critical components required to repair and maintain hydraulic hoses as essential to achieving their goals.

WHAT DO YOU SEE AS A CHALLENGE FOR THE YEAR AHEAD, AND HOW CAN QUARRIES TACKLE THIS CHALLENGE? As we look ahead, one of the significant challenges will be meeting increasingly stringent environmental regulations while maintaining operational efficiency.

BOA Hydraulics is committed to developing eco-friendly solutions that help our customers reduce emissions and minimise their environmental footprint while improving productivity and compliance.

WHAT INNOVATIONS OR PRODUCTS IS THE COMPANY WORKING ON FOR 2024?

In 2024, we are excited to introduce several innovative products. While I can’t reveal all the details yet, you can expect more focus on asset utilisation through technology regarding hydraulic hose repair.

Our BOAhub Hydraulic Hose Management system is growing rapidly, embracing innovation to reduce onsite downtime.

HOW HAS BOA HYDRAULICS USED TECHNOLOGY TO IMPROVE ITS OFFERING TO CUSTOMERS? We have integrated the BOAhub Hydraulic Hose Management system with our hose repair unit, the BOApod, allowing users to manage inventory, create job cards, tag hose assemblies, and assign hydraulic hoses to assets to give the quarry industry more control over their hose repairs, allowing them to track and report on hose repairs with ease.

Through tech, we are removing the fear of carrying out hydraulic hose repairs yourself, giving control back to the machinery users. • For more information, visit boahydraulics.com.

Join us on the journey towards a more sustainable quarry industry.

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Sustainability is central to Volvo’s commitment, spanning manufacturing to disposal

Volvo Caretrack CareTrack provides customers with onboard telematics and remote connectivity to manage their machines efficiently and provides customers with quality insight reporting and machine data analysis.

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PUMPS

The company’s product range has been tailored for the quarrying industry.

PUMPED UP SERVICE Quarry finds out why Toolkwip Pumps has expanded into south-eastern Queensland, and how it is helping customers across the east coast.

T

oolkwip Pumps has been serving the quarrying industry since it opened its doors in 1993.

The family-owned and operated company delivers turnkey pumping solutions, priding itself on quality service and support. It doesn’t just supply box products, instead the business carefully analyses a customer’s application to find the right pump for their needs.

To continue providing its high standards of service, the company has expanded north, opening a new branch in Queensland.

Tom Garrett, Toolkwip Pumps general manager said there was an overwhelming increase in demand in the southeast Queensland area over the past several years.

“This naturally led to the opening of our new office in Brisbane,” he said.

“Opening in Queensland is an exciting opportunity for us to better service our customers in the region.

“It will enable us to meet the growing needs of the Queensland sectors more efficiently while providing them with the highest level of quality products that are simply better.”

The new location is stocked with the leading brands of pumps, valves, hoses, fittings, and accessories to service Queensland’s civil, quarry and mining sectors.

Garrett said the company’s product range has been tailored for the quarrying industry over the past 20 years.

Toolkwip Pumps also runs a fleet of fully equipped onsite service vehicles.

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Quarry December 2023

The branch will also feature a fully equipped workshop for routine pump maintenance and repairs. Highly qualified service technicians and a fleet of service vehicles are available for onsite repairs directly on the worksite to get customers pumping again with little downtime.

Toolkwip’s workshops play a critical role for the company. With sites already established in Melbourne and Sydney, Toolkwip can perform routine maintenance and major repairs. Its team has the capacity to handle small chemical dosing pumps and diaphragm pumps through to large diesel powered pumpsets and everything in-between.

Minimising customer downtime is a key focus for the business. If a pump breaks on a busy day, this can cause missed deadlines, production downtime, unhappy customers, or even flooding.

This is why Toolkwip Pumps also runs a fleet of fully equipped onsite service vehicles with experienced and qualified mechanics and pump technicians for servicing and repairs.

These teams can provide design and fabrication assistance, troubleshoot pump systems and pipeworks, service pumps of all kinds, and treat internal parts for abrasion or corrosion resistance. They can also perform electric motor services, electrical services, motor alignments, coupling adjustments, pressure, and leak tests.

While it is still early days for the new branch, it has already had positive feedback from local customers, who are excited to benefit from the enhanced service offering.

“We made sure to find the right location that would be best suited for the region, providing ease of access and transport,” Garrett said.

The company plans to continue rigorously sourcing and evaluate new pump systems that feature innovative design and functionality. • For more information, visit toolkwippumps.com.au

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

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

MCLANAHAN ULTRAWASH McLanahan UltraWASH Modular Washing Systems offer the same world-class washing technology we’ve been supplying since 1835, but in containerized modules for shorter lead times, quick setup and ease of transport if producing at multiple locations or one very large site.

Whether processing natural or recycled aggregate, McLanahan offers a complete modular product line.

From crushing and screening to washing and water recycling, McLanahan provides a start-to-finish solution for your operation.

WASHING // SCREENING // SCRUBBING // CLASSIFYING // CRUSHING // FEEDING // TAILINGS & WATER MANAGEMENT ASIA | AUSTRALIA & ASIA PACIFIC | EUROPE | LATIN AMERICA | NORTH AMERICA

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INDUSTRY 4.0

A SMARTER SOLUTION:

VOLVO’S CARETRACK AND ACTIVECARE Volvo’s Caretrack and ActiveCare Solutions have entered the Australian market to help quarries make informed decisions and optimise their operations.

W

ith the rise of onboard telematics and remote connectivity, it is easy for operators and fleet managers to become overwhelmed by the mass of data being produced by modern construction machines.

CareTrack, a telematics and fleet management system developed by Volvo CE, provides customers with quality connected solutions in the most efficient way possible.

Customers can now benefit from real-time insight into how their machine is performing, presenting the opportunity for customers to get the most out of their machines.

Volvo Construction Equipment’s state-ofthe-art telematics system, CareTrack, is now standard on articulated haulers A25 to A60, wheel loaders L60 to L350, and excavators EC140 to EC950. CJD Equipment is now offering a complimentary ten-year free standard CareTrack connectivity package on new Volvo GPPE machines.

HOW CARETRACK WORKS Caretrack offers a variety of optional features that effectively enhance productivity and equipment availability. With time and geofencing functionalities, customers can pinpoint their machine’s exact locations and record the machine’s hours.

The geofencing capabilities allow fleet managers to oversee specific geographic areas, automatically identifying and tracking machine locations. This functionally proves invaluable for addressing transport restrictions in designated regions, compliance with weight and height limitations on routes or tunnels, or restricted access in urban areas.

To safeguard investments and mitigate theft risks, Caretrack provides an optional anti-theft tracking system. Various events trigger this system, including unauthorised machine use, tampering, movement detection, and geofencing functions. In the event of unauthorised use, the system allows for remote immobilisation of the machine, ensuring asset security.

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Caretrack offers a variety of optional features that effectively enhance productivity

Caretrack also offers customers unprecedented insights into the performance of their machines with the use of Volvo’s smarter solutions - Onboard Weighing (OBW) and Caretrack. The OBW system continuously monitors payload weight and transmits this data to the machine electronics, preventing overloading, unnecessary wear and tear, tire damage, and excessive fuel consumption.

The OBW system also allows operators to keep track of their load, keep track of all transported material to each dump zone, keep track of all types of material and monitor productivity data with the possibility of setting individual targets.

Caretrack information is conveniently accessible through the Caretrack portal.

Presented in a user-friendly format, customers can review details about their machine’s fuel consumption, utilisation percentage, and excessive idling to enhance operational efficiency.

UPGRADE TO ACTIVECARE ActiveCare is the enhanced version of Caretrack, allowing fleet managers to get extra insights into their machines. ActiveCare provides customers with weekly ActiveCare Reports, giving them insight into how their machines are being used and where uptime could be improved.

The advice provided in the ActiveCare reports can assist customers in making changes to their working methods that could

CareTrack, is now standard on articulated haulers A25 to A60, wheel loaders L60 to L350, and excavators EC140 to EC950.

have a positive impact on productivity and profitability. Alerts from the report can indicate the risk of premature component wear and future breakdowns if left unaddressed.

ActiveCare can also provide a summary of the machine’s technical status and identify alterations in operating behaviour that may be affecting the machine’s health.

Based on these ActiveCare Reports, CJD Equipment can initiate a case if there are technical issues that require priority attention.

This case may encompass a comprehensive

examination of the machine’s software, suggestions for improving operator behaviour where applicable, recommendations for reducing CO2 emissions, and any other pertinent information gleaned from the ActiveCare reports.

Finally, CareTrack and ActiveCare provide crucial insights into the machine’s operational uptime at various stages of its life cycle. These insights facilitate proactive service planning and advance spare parts ordering, ultimately minimising downtime—an invaluable resource.

VOLVO AND CJD EQUIPMENT Volvo Construction Equipment is well known as one of the world’s best manufacturers of safe, high-quality, and technologically advanced equipment – and CJD Equipment has been proudly offering its products to the Australian market for nearly half a century.

CareTrack is the next step forward in technological advancements, ensuring customers that their equipment is always performing at its very best. CareTrack allows CJD to provide advice and support as efficiently as possible, helping customers get their machines back to work quickly.

With a national supply network and 24/7 after-hours call-out service, you can rest assured that CJD Equipment has the support network to ensure you are well supported, no matter where or when. • For more information, visit cjd.com.au

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MACHINERY Komatsu GD955-7 grader is the company’s newest grader to hit the Australian market.

A GREAT GRADER Komatsu has built its newest grader, the GD955-7, from the blade up to ensure the best operator experience in its line-up.

M

ichael Hall had never operated a grader before he tried Komatsu’s GD955-7 grader, which was set to enter the Australian market in the upcoming year.

But after jumping in the cabin, within 20 minutes, Hall had created a level, flat service using the GD955-7 grader’s intuitive fingertip controls.

Hall, who is Komatsu’s national product manager, said the easy-to-use grader results from extensive implementation of customer feedback.

“When Komatsu decided to build a new mining grader, we had our customers at the front of mind,” he said.

“We spoke with our customers, listened to their needs and built a machine that will meet those needs now and into the future.”

The critical message that Komatsu’s design team heard was operators wanted more effective blade downforce.

The extra machine weight and hydraulic force are critical. Without the correct downforce, the blade can bounce along instead of cutting down and carrying through as required.

With this in mind, Komatsu’s designers and engineers built the GD955-7 grader from the blade up. The grader comes standard with

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an 18-foot blade, but it does have a 20-foot blade option if the conditions are suitable for a wider blade.

“The GD955-7 grader has significantly more power than other graders in its class. It

also has the highest operating weight in its class at nearly 47 tons,” Hall said.

“The GD955-7 grader is 33 per cent more productive than the previous Komatsu mining grader model because of the combination of its impressive 426-horsepower, higher effective blade downforce, and faster grading speed.”

The GD955-7 grader has been built from the blade up according to Komatsu.

Komatsu’s national product manager Michael Hall and Komatsu Australia national training manager for operator training Robert Missingham.

POWERFUL Komatsu’s newest grader features 426 horsepower and a middle-speed mode with intermediate gear speeds of F2.5 and F3.5, giving the operator greater control.

The GD955-7 grader comes with two transmission modes. The normal manual mode runs like a conventional power shift, while the automatic mode features a torque converter transmission.

“In auto mode, the torque converter will be engaged in the first two gears to assist the operator, preventing engine stalling and improving productivity,” Komatsu Australia national training manager for operator training Robert Missingham said.

“It also has automatic or manual differential locks. If I choose automatic, it’ll bring the diff locks in when it detects spin itself.

“Manual operation means that they’re engaged all the time.

“But on either one, whenever I start to turn the machine, it’ll detect after a certain couple of degrees and kick them out so you can do a fluent turn.”

Komatsu believes the tight turning circle makes the GD955-7 a good match for anything from 90-tonne haul trucks, including its HD785 Dump Truck, through to 240-tonne haul trucks like its 830E Dump Trucks.

COMFORTABLE SURROUNDS Operator comfort and safety was another key message delivered to Komatsu’s design team for the GD955-7 grader.

The new machine has a suite of features to help ensure workers can productively work in the quarry or mine even during a long shift.

It comes standard from the factory with KomVision, Komatsu’s 360° camera system.

The system features five cameras that provide a bird’s-eye view around the machine through an inbuilt monitor, an additional rearview monitor, and radar.

When the GD955-7 grader is operating, the KomVision radar will detect close objects, such as other vehicles, and notify the operator by an alarm.

The operator has complete control with a set-up that enables them to access multiple

controls with one hand. The grader has fingertip control and palm steer options to suit the operator.

Missingham said the time and practice it would take to upskill workers on the fingertip controls would improve productivity.

“It is extremely user-friendly and provides increased comfort for the operator.

“People may be operating these graders for up to 12 hours, so comfort was another vital factor in the machine’s design.

“For those coming off a conventional joystick control, it may take some getting used to, but with practice and time, the fingertip control is much more effective.”

Hall said that given his experience with the GD955-7 grader, it could be used by a new operator or an experienced industry veteran.

“I found the controls intuitive and easy-touse,” he said.

“We’ve channelled customer feedback into its design, this is a really operator-friendly grader we’re bringing to market.” • For more information, visit komatsu.com.au

Quarry December 2023 35

SUSTAINABILITY

SAFETY IN THE SPOTLIGHT John Deere has reaffirmed its position as one of the quarrying industry’s key original equipment manufacturers with a focus on sustainable products.

S

ustainability is not just a buzzword for John Deere; it is something that the company advocates for throughout the organisation.

From an executive level to the machines rolling out of the production room floor, John Deere has taken key steps to ensure its equipment and operations have sustainable features.

Quarry spoke to senior group product manager of precision construction, John Deere construction and forestry Andrew Kahler, about the year that was for John Deere.

“At John Deere, we continue to provide customers with groundbreaking, smart technologies aimed to improve user experience in the present and yield proven results in the future,” he said.

“Our portfolio of precision construction technologies is strategically curated to help our customers manage their fleets, improve job site performance, and enhance operator skillsets, helping to equip the next generations of construction professionals.”

ENVIRONMENTAL AIMS In 2023, at this year’s CONEXPO-CON/ AGG show, John Deere showcased its latest technology offerings. This included advanced vision and object detection solutions, SmartWeigh, standard EZ Grade on P-Tier small dozers and a variety of other grade management and automation solutions available to customers.

This year saw the rise of attention and education to important considerations for the industry, such as sustainability; with a committed approach to this John Deere set on reducing its carbon footprint and ensuring the sustainability of its engines.

Kahler said there were several key initiatives that the company is undertaking to reduce CO2 emissions.

These initiatives included improving the fuel efficiency of their machines. John Deere has achieved an average fuel efficiency improvement of 16 per cent across its

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John Deere presented at this year’s CONEXPO-CON/AGG show, one of the largest conventions of its kind.

construction equipment product line over the past decade.

“This is a significant achievement, and it has been accomplished through a combination of engine technology improvements and machine design enhancements,” Kahler said.

John Deere is also investing in alternative fuel technologies in addition to improving fuel efficiency.

For example, the company has developed a hybrid-electric powertrain for their wheel loader machines, which can reduce fuel consumption and emissions by up to 40 per cent. The company is also exploring the use of biofuels, such as biodiesel, to further reduce its carbon footprint in the coming year.

As a company, John Deere celebrated Reman Day this year. The event highlighted the environmental and economic benefits of remanufactured parts, and the effective role they can play in growing business and industry sustainability.

John Deere Reman is one of the world’s leading divisions in the production of remanufactured parts at an equal or better standard than the original, helping to reduce waste and conserve natural resources.

John Deere Australia and New Zealand aftermarket and customer support director, Emma Ford, said remanufacturing was an integral contributor to the company’s mission to connect with businesses and customers across the world to sustainably support communities as the global population grows.

Another important topic John Deere committed to improving this year was jobsite safety. The company set out to achieve this through precision construction and smart tech machines.

John Deere not only focuses on innovation in machines that make jobs easier and efficient but also machines that make the job safer.

“We all know that safety is the number one priority. Especially given that the jobsite is never the same two days in a row,” Kahler said.

John Deere’s Precision construction philosophy is about total control of what the operators is doing with the machine.

According to the company, the best way to do precision construction is with Deere Obstacle Intelligence. Obstacle Intelligence uses a combination of cameras, radar, and machine learning to protect anyone and anything in close proximity.

Kahler said John Deere was committed to making everyone’s livelihood better.

“The year that was 2023 proved to be an exciting and innovative year shaped by environmental and people-focused considerations,” he said.

“Looking to 2024 John Deere is excited and focused on improving and advancing the way machines can help people, and businesses and help make less impact on the environment.”• For more information, visit deere.com.au

CRUSHING

POWERING

RELIABLE CRUSHING

A

ndrew Hesketh was born and bred in Greenbushes, a timber and mining town in southwest Western Australia.

The Greenbushes mine has produced lithium concentrate since 1985 and is one of the largest lithium mines in the world.

As a young man, Hesketh was inspired to start his own business that could recycle the blasting waste at the mine, turning it into road base.

“The nearest quarries were 100km away,” he told Quarry. “I saw an opportunity there – it was a lot of material going to waste. Now, they’re re-using it on projects sites and the local community.”

Powering this operation is a fleet of powerful crushing and screening equipment.

As his company grew, Hesketh wanted to

grow its fleet. In particular, he wanted to add a direct drive system.

“The crushing industry is pretty small, we have friends in other businesses and heard good reviews about the Powerscreen 1300 Maxtrak,” he said.

The Powerscreen 1300 Maxtrak is a medium to large sized mobile cone crusher, ideal for secondary applications such as taking in feed from a primary crusher. It is based around the 1300 Automax cone crusher and excels in the production of sub-base or aggregates, providing excellent cubicity, throughput and reduction ratios.

Hesketh already had several Powerscreen machines in his fleet, and had worked with the company’s distributor, Lincom, for around 15 years.

The Powerscreen 1300 Maxtrak is a medium to large sized mobile cone crusher, ideal for secondary applications.

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“We’d heard from other people in the industry that once you use the 1300, you’d want a whole fleet of them because of how good a machine it is,” Hesketh said.

“Lincom are good business partners. Their backup and spare parts have been really good, and they’ve got a team of technicians on call as well.”

Lincom’s team can provide technical support and troubleshooting where necessary and are prepared to travel long distances to ensure the machines keep running.

Maximising availability is crucial in many crushing applications, as many are 24/7 operations. John van der Sluys, quarry manager at Mobile Concreting Solutions (MCS), said the 1300 Maxtrak’s reliability

Hesketh operates a fleet of powerful crushing and screening equipment.

was a crucial part of why the business selected the machine.

The cone crusher is being used as a secondary unit to process iron ore at a remote operation in the Goldfields of WA. It has been placed after a jaw and scalper, crushing the product to a 35mm size, with a recirc from the final product screen.

Van der Sluys told Quarry that MCS was looking to purchase a cone that was versatile in different applications.

“We were looking for a machine that will work in either iron ore or in hard rock quarries, as many of our machines move between these operations,” he said.

“Particularly in hard rock quarries, a machine that can be used as a secondary or as a tertiary crusher is of great benefit, and the 1300 Maxtrak is proven in both.”

When MCS purchased the machine in early October, it was floated almost 1000kms to a site near Wiluna. After being tracked off the float, it was walked straight into the circuit after a basic inspection and commissioned immediately by a technician from Lincom who had travelled up from Perth.

Since then, it has been crushing day and night in the circuit achieving more than 550 tph total throughput. Its first down time came when it was due for its first liner change, given its processing of an abrasive ore.

Van der Sluys said the machine is known for its ability to achieve good throughput, but also good particle shape, which is important for many aggregate products.

The roller bearing crusher is also capable of crushing very hard rock with good reduction ratios. An overpressure system helps protect the crusher from damage when and if steel or similar enters the chamber.

“Lincom have supported MCS in the past with timely parts back up. As with any operation, but more so when running 24/7 a long way from external help, having good quality parts being supplied when required is

crucial to achieving good crusher availability.”

“The Maxtrak 1300 has proven to be a reliable and cost-effective machine in a range of applications. With the back up of Lincom as the agent and the availability of quality parts and wear liners, the Maxtrak cone crushers are a very good choice for multiple applications,” he said. • For more information, visit lincom.com.au

The 1300 Automax cone crusher and excels in the production of sub-base or aggregates.

Quarry December 2023 39

MAINTENANCE

MAINTAINING

GOOD VIBRATIONS

Oli Vibrators Australia is helping quarries maintain and replace critical machinery components.

I

n the dynamic world of the quarry sector, the performance and longevity of equipment are pivotal to success.

Among the various components that play a vital role in this industry, vibrators are often unsung heroes.

They power the screens and conveyors that move raw materials, making them a linchpin in the quarrying process. Ensuring their seamless operation, maintenance, and immediate replacement when necessary are crucial.

Mark Thompson, general manager of Oli Vibrators Australia, said the company stands as an unwavering pillar in this pursuit.

“Quarry operators understand the essential nature of maintaining and replacing vibrators in their machinery,” he told Quarry.

“Without them, the entire production line can come to a standstill, causing downtime and financial losses. Oli Australia has recognised this need and made it their mission to not only provide top-tier vibrators but to also ensure clients are never left hanging when maintenance or replacements are required.”

Maintenance areas to consider: 1. Keep your vibrators clean, a build up of dust and material can cause overheating.

2. Periodically check the torques setting on your fixing bolts, it only takes one bolt to snap and or come loose and the others will follow, leading to a catastrophic failure of the vibrator.

3. Check the running temperature of your vibrators, it could be a sign of bearing ware if the temperature is up.

4. Be sure the weights on each vibrator set exactly the same on a single machine. If you reset one, you must reset them all.

5. Periodic greasing is carried out as per the manufacture’s recommendations, don’t over grease, this can lead to bearing failure, it will also drive up the amps and lead to overheating.

6. Be sure to only dose the recommended amount of the correct grease, do not mix the grease, seek out the recommended grease from your vibrator specialist.

7. Check the integrity of the cable gland.

Degradation of the cable gland can lead to the ingress of water or corrosive liquids into the terminal box, this can lead to failure of the internal winding.

8. Make sure the safety chain is intact and there are no strange noises coming from your motors.

Be sure the weights on each vibrator set exactly the same on a single machine.

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Thompson said one of the standout features of Oli Australia is its extensive stock.

“Our warehouses are strategically located in Melbourne, making them readily accessible to clients across the country,” he said.

“This means that when you’re in a bind and need a replacement vibrator fast, Oli can deliver. Their commitment to maintaining an ample supply of vibrators ensures that your operations can resume without unnecessary delays.”

“However, Oli Australia’s value extends beyond mere stock availability. Our reputation for reliability and quality is second to none.

When you invest in an Oli vibrator, you’re investing in a component that has been built to withstand the harsh conditions of the quarry sector. This durability translates to reduced downtime, less frequent replacements, and ultimately, substantial cost savings over time.”

It’s not just about the materials that Oli uses. The company’s quality comes from the engineering and innovation it incorporates into each vibrator. Its products are designed to maximise efficiency and minimise energy consumption, which reduces carbon footprint in the long term.

It only takes one bolt to snap and or come loose and the others will follow.

Over greasing can lead to bearing failure.

Oli Australia also has a network of distributors throughout the country. This means quarries are never far from a knowledgeable partner that can choose the right vibrator for the specific application.

Sizing and selecting the appropriate vibrator can significantly impact its performance and longevity, and Oli Australia’s team of experts is there to guide customers through this process.

Thompson said in the fast-paced world of quarrying, every minute counts.

“Oli Vibrators Australia understands the importance of maintenance and the availability of replacement vibrators, and

A build up of dust and material can cause overheating.

we’ve tailored our services to cater to this critical aspect of your operations,” he said.

“We’re not just a supplier; we’re a reliable partner that you can trust.

“Our extensive stock, unmatched reputation for reliability and quality, and a widespread network of distributors makes us the

ideal partner for maintenance, sizing, and replacement of vibrators. Trust in Oli Australia, and your quarry operations will run smoother, more efficiently, and with reduced downtime, ultimately boosting your bottom line.”• For more information, visit olivibra.com

SAND

MOUNT COMPASS

EXPLORES NEW MARKETS WITH MCLANAHAN Mount Compass purchased a McLanahan UltraSAND Plant through Lincom to produce specialty sands and to increase production.

A South Australian sand producer is creating clean, high-quality sand products with greater efficiency with the use of McLanahan’s UltraSAND Plant.

M

ount Compass Sand and Loam, located 60 km south of Adelaide, produces quality sands for use in the landscaping and construction industries.

It’s current owner and director, Rodney Miller purchased the business in 2007, and since then, he has endeavoured to expand the company’s product range.

Originally, the company used a dry screening method to separate out its sand products.

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However, the number of products the company could make this way was limited.

To make its products, Mount Compass had to purchase sand from other suppliers, which Miller said increased business costs.

Then in 2012, a McLanahan representative visited Mount Compass and pointed out new ways the company’s sand could be used that Miller hadn’t even considered.

Mount Compass has a unique sand that meets the American Petroleum Institute’s specifications for frac sand – the sand particles are round, spherical and very hard.

“It opened our eyes to the opportunity that down the track we would look at a wash plant that would enable us to exploit those markets,” Miller said.

As Mount Compass considered its options, McLanahan offered support by

recommending solutions that would help Mount Compass meet its production goals.

In the meantime, McLanahan formed a partnership with Lincom to represent its aggregate wet processing line in Australia.

Lincom already had a relationship with Mount Compass through the dry processing side of its business.

Ten years after the McLanahan representative’s first visit, Mount Compass upgraded its dry screening process with a McLanahan UltraSAND Plant through Lincom to produce specialty sands and to increase production.

“From the very beginning, McLanahan has supported us with looking at various options over the years,” Miller said.

“We’ve been very slow to make this large of an investment, but they have been with us all

The McLanahan UltraSAND Plant is a modular sand-washing system which can be delivered and set up easily.

the way over 10 years of looking at the best options that are available for the products we wanted to produce.”

The McLanahan UltraSAND Plant is a sandwashing solution that consists of a sump, pump, hydrocyclones and dewatering screen in a compact, modular system for ease of delivery and rapid setup.

“The McLanahan UltraSAND Plant came in a couple of containers, which were very easy to offload,” Miller said, “and I guess it’s really just like putting together a big Meccano set.

With the support of their installing team and our boys, it was a very simple operation to put together.”

He was pleased by the equipment training and service his team received from

McLanahan and Lincom as Mount Compass ventured into this new washing operation.

“The support that we received to have the plant up and running has been very exceptionally good.”

The UltraSAND Plant features the flexibility to wash and dewater up to two sand products on the same screen.

“The McLanahan UltraSAND Plant enables us to wash two products at the one time, which enables us with the landscape products to have a very high-quality product as well as an oval construction product,” Miller said.

“The wash plant has given us the opportunity to wash out the clay and silt, which then take all the impurities out of the sand.”

The plant’ operators find the UltraSAND Plant easy use.

RESULTS With the McLanahan UltraSAND Plant producing washed and dewatered sand products, Mount Compass no longer has to buy sand from other suppliers to create its products. It has also reduced the threestep dry screening process into a onestep process.

“It’s making a fine, clean sand, which will enable us to look at other options down the track,” Miller said.

He said the plant is simple to operate and his operators find it easy use.

“It’s better than what we expected,” Miller said. “The production that is coming off the McLanahan UltraSAND Plant is better than what our expectation was.”

Not only is the UltraSAND Plant enabling Mount Compass to create clean, high-quality sand products, but the efficiency of system is allowing the company to see additional benefits as well, such as pursuing the production of specialty sands.

“The McLanahan UltraSAND Plant has enabled us to increase our product range, as well as the production of our oval mixes, Miller said. “The production of the oval mixes is a more efficient operation using the McLanahan UltraSAND Plant.

“Having an efficient wash plant has enabled us to not only enter into new markets, but it has made some of our existing products more affordable to produce, giving us a better margin overall from a business point of view.” • For more information, visit mclanahan.com

Quarry December 2023 43

SPECIAL REPORT

Editorial credit: Emagnetic / Shutterstock.com

Fulton Hogan has designed a program to deliver AFLW players with jobs on the worksite.

FULTON HOGAN

DELIVERS FOR AFLW

Fulton Hogan has engaged some of Australia’s best female athletes to diversify its workforce and provide much-needed opportunities.

P

hoebe Monahan arrived in Melbourne to join the Richmond Tigers’ AFLW team, looking for more than on-field results.

Monahan wanted to set herself up for life after football. The defender arrived at Punt Road from the GWS Giants and noticed her teammates were employed at Fulton Hogan.

“I saw the opportunity come up and, as a qualified carpenter, thought it was a good opportunity to get back into construction and back on the tools,” she said.

“I jumped at it, and that started my journey.”

Tayla Stahl was one of Monahan’s teammates who embraced Fulton Hogan’s pathway program.

“I kind of fell into it, the opportunity came up to work at Fulton Hogan through Richmond and jumped at it,” she said.

“Three or four years later, I am still working with them and enjoying it.”

Grace Egan was in a similar situation after joining Richmond from Carlton’s AFLW side.

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Quarry December 2023

After 12 games for the Tigers last season, Egan has found an opportunity to be set up with the help of an employer who values flexibility..

“There are a lot of challenges that come with playing AFLW, and it’s a tough conversation we have to have with our employers to find that balance,” she said.

“It makes a huge difference to have a stable job outside of football because football isn’t forever.”

More than their feats on-field, the three athletes’ pathways into industry could be the blueprint for greater diversity.

FLEXIBILITY IS KEY Many industries, quarrying and construction included, are eager to diversify their workforces.

Data shows that these industries have remained mainly male-dominated.

A report from Ernest and Young, Women in

Mining 2022: You can’t be what you can’t see, showed mining and construction have the lowest proportion of female employees.

Fulton Hogan operations manager Marty Roszka said flexible working conditions would only help to diversify the industry.

He pointed to flexible hours, reduced working hours or job sharing as potential methods to increase flexibility.

“The stigma in construction is long hours and a shortage of resources at the moment, not only for general labourers but also skilled labourers.

“We need to find new ways to bring people into the business if we want to make the business and industry more diverse.”

Fulton Hogan has been a long-time partner for Richmond AFLW’s team with its flexible pathway programs. AFLW players have very particular circumstances for employers to meet. They need access to flexible schedules and certain days off and can be out of work with injury as they juggle professional sports and a day job.

This is why Fulton Hogan has provided flexible working opportunities in the season

BENEFITS Working conditions, including flexible hours, job stability and working arrangements, have been shown to help employees.

A recent report from Randstad showed that 83.2 per cent of Australian workers consider flexibility in terms of working hours to be necessary.

While specific industries, including quarrying and construction, can struggle to offer remote work, they can provide other benefits, including job stability.

Stahl retired from AFLW after being unable to get a medical clearance to return to the field. While it could have been a nervewracking moment for some, her employment outside of football provided peace of mind.

“I knew that when I got that news that I

Image credit: max blain / Shutterstock.com

Richmond Football Club’s AFLW team has a strong partnership with Fulton Hogan.

Image credit: Benjamin Crone / Shutterstock.com

and full-time work during the off-season.

Fulton Hogan has supported players after they’ve left Richmond to access opportunities in other states as they move clubs.

Monahan travelled across Australia for an AFLW opportunity again in 2021 after being delisted by Richmond.

The defender found a home at the Brisbane Lions’ AFLW side. Fortunately, Fulton Hogan provided her with the support and flexibility to continue pursuing construction in the Sunshine State.

“Moving to Brisbane was definitely a big deal,” she said.

“They’ve been flexible and supportive with us girls and the training load we have as semi-professional athletes trying to maintain a career.

“The support to have that flexibility is huge.

Unfortunately, some girls don’t get that, and you can see the toll it takes on them.

“Fulton Hogan’s support has been incredibly beneficial for me.”

Fulton Hogan Alliance Manager Dean Riha said having many pathways open to female workers was significant.

“Female athletes make wonderful employees; they come from a fast-paced background, and they’re very strong leaders, and they love dealing with change,” he said.

“The sporting industry is quite cutthroat, especially when you look at AFLW careers.

They can be pretty short in nature.

“Knowing that when that sporting career may come to an end, you’ve got that longterm career ahead of you is imperative and is a great outcome.

“If we can expand these opportunities, I think it will be a fantastic outcome.”

AFLW players need flexible employment opportunities as semi-professional players.

couldn’t play anymore, I still had a full time job with Fulton Hogan,” she said.

“The security of that was really important to me.”

Richmond’s head of women’s football, Kate Sheahan, said the stable employment had benefitted the players’ performance and was essential to the club in the future.

“We’ve been fortunate in this partnership, and through the years, we’ve had many

players and staff come through this pathway,” she said.

“The flexibility they’ve provided has been so significant to the success of our players.”

“I think they can see the benefit of having more females in your work environment, and they make the workplace a better workplace to be in.

“I think Fulton Hogan has set the tone for employment for females.” •

Quarry December 2023 45

IQA MEMBER WA Limestone provided 1.5m tons of stone in 18 months for the Ocean Reef Marina.

FAMILY TIES

FOR MILESTONE BUSINESS WA Limestone has celebrated five decades since it was established as a small-scale Perth producer, becoming one of the state’s best producers.

T

he year 1973 will be remembered for how it shaped two family legacies.

Two brothers, Malcolm and Angus Young, took the stage in Sydney’s Chequers nightclub as the first iteration of AC/DC on December 31, 1973.

Across the country in Western Australia, two brothers, Michael and Renzo Della Bona and their brother-in-law Peter Zamboni, started a small-scale limestone producer the same year.

Director Steven Della Bona said it felt special to reflect on five decades of the family-owned operation, passed down from generation to generation.

“To carry on in their father’s work is a great feeling and one that I treasure,” he said.

“It’s not easy, and it comes with some pressure, especially with running a business; it can be hard.

“Being family, we all pull in the same direction, and you have that connection, and that’s one of our strengths that we can rely on each other.

“Quarrying is in our blood, and we know we’ve got that security and trust of each other.”

The company has kept its family ties throughout the years. Steven (son of Michael) and David Della Bona (son of Renzo) are

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Quarry December 2023

David and Steven Della Bona are both directors at the company.

directors. Peter Della Bona manages the daily quarrying operations, while James Della Bona looks after the contracting and seawall projects.

For Steven, he has always had the dream to follow in his father’s footsteps. There’s an implicit trust and respect among the family members to protect their legacy and keep the family business strong for years.

WAY OUT IN WATTLEUP Wattleup is found in the south of Perth and around 15 minutes from Fremantle Port.

It is also where Michael and Renzo, alongside Zamboni, went all-in on a smallscale start-up from a single limestone source.

The brothers and Zamboni made up three of WA Limestone’s five employees. It was hard graft early on as they battled to establish themselves in the market against rival start-ups.

In 1978, WA Limestone received a breakthrough with the Fremantle Sailing Club. The family-owned operation was contracted to help build a seawall of around 400,000 tonnes of limestone.

Shortly after, the company found success at Port Denison in Dongara for half a million tonnes of limestone for its seawall.

The marine projects gave WA Limestone its sea legs and proved it could match competitors in constructing WA’s major infrastructure projects.

Michael Della Bona left a major mark on the WA quarrying industry.

“That set the tone and proved we could match the pace for these projects, even in remote areas outside of metropolitan Perth,” Steven said.

“These were significant projects, allowing us to go from project to project. We did the Challenger Harbour in Fremantle for the America’s Cup and up to the Dawesville Channel, which was four of five million tonnes of rock.

“These fairly important jobs across the state set the foundation for WA Limestone and what we do today.”

MODERN DAY WA Limestone has grown immensely from the five-person operation in Wattleup.

The company employs around 350 people across the state with 10 metropolitan quarries in Perth, five concrete plants and four hard-rock quarries in Karratha, Port Headland, Onslow and Byford.

The company has grown to incorporate WA Limestone, WA Bluemetal, WA Premix, WA Limestone Contracting, WA Limestone/ Jurali Joint Venture, Limestone Building Block Company, WA Limestone Heavy Haulage, Australian Sands International and Quarry Farm WA. WA Limestone has continued to be a significant force in shaping the state’s infrastructure. It partnered with Main Roads, Leighton Contractors and GHD as part of the Southern Gateway Alliance to deliver the Kwinana Freeway extension and the freewaystandard Forrest Highway completed in 2009. The latter was, at the time, Western Australia’s biggest infrastructure project.

It was a significant production with four to five million tonnes of roadbase and sand required for the project across five years.

“The reputation that we had where we always delivered on what we promised and those relationships and that reputation our

Renzo Della Bona started WA Limestone alongside brother Michael Della Bona and Peter Zamboni.

dads created early on, was critical to us,” Steven said.

“Everyone wants a supplier or contractor that can perform, and we’ve proven that we can, and we have the resources to do it; we’ve been able to continue that reputation.”

The company has recently completed the

Peter Della Bona is a director at WA Limestone.

James Della Bona is a director at WA Limestone.

“landmark project” Mandurah Bridge in Perth and the Perth’s Ocean Reef Marina breakwall.

The latter was a $60 million project for constructing two breakwaters alongside Italia

Stone Group. These breakwaters covered about 80 hectares and encompassed some 550 boat pens, stackers, and the city’s first ocean pool.

For its work on highways and across the state’s seawalls, WA Limestone has developed projects that have become award-winning.

The award recognition extends to its staff.

Earlier this year, Steven was awarded the Institute of Quarrying Australia’s Industry Hero Award for his contribution to quarrying.

“To be nominated and have that award as a recognition of my achievements but also the company was incredibly special,” Steven said.

“I love the IQA, and it has done a lot for me along the way, introduced me to some great people and opportunities, and allowed me to form exceptional relationships.”

“It was a proud moment for me.”

FUTURE GROWTH From small beginnings in Wattleup to becoming one of Western Australia’s preeminent aggregate suppliers and contractors has been no easy feat.

The family business is working to evolve new aspects of the company to complement its existing brands in the WA Limestone Group.

Steven said the company was looking at all options, including property development.

“That’s sort of the future, and we’re going down a slightly different path while maintaining the quarrying products and services,” Steven said.

“We want to think about the next generation and ensure the business is in a strong position when they come through.

“Hopefully, with the proper planning, this company will still be going in another generation. That’s the next challenge for us: to keep this dream alive.

“It’s a special feeling to look back and see what our family has achieved.”•

Quarry December 2023 47

IQA NEWS

The Institute of Quarrying Australia

OUT AND ABOUT WITH THE IQA BRANCHES

L-R: Luke Stephens, Wayne Barker, Peter Mannix, Clare Murray, Kevin Short, Tayla Vandam, James Rowe.

SA AGM BRANCH DINNER James Rowe, newly elected Branch Chairperson hosted the final Branch dinner for 2023 at the Pullman Hotel, Adelaide.

James took the opportunity to welcome Clare Murray (IQA CEO) to her first SA event. The dinner was once again fully supported with 100 guests in attendance.

It was very pleasing to welcome three new members, Luke Stephens (Porter Plant), Tayla Vandam (Hallett Group) and Kevin Short (Hallett Group) who were all presented with their member certificates by Clare Murray.

Upgrade membership certificates were also

L-R: James Rowe, Kane Salisbury, Clare Murray.

presented to Peter Mannix (Hallett Group) and Wayne Barker (Boral).

Guest presenter Kane Salisbury, Hallett Group CEO, provided an overview of Hallett Group’s Green Cement Transformation and alternate uses of Supplementary Cementitious Materials (SCM’s). Hallett Group is a South Australian company and are passionate about the use of alternate sustainable raw materials including Fly Ash and Slag, historically known waste sources in Port Pirie and Port Augusta, South Australia.

Kane is a Fellow and has been a long-term supporter of the IQA and the promotion of

the Young Members Network (YMN). On the evening, Kane committed to funding three (3) of his companies Young Members to attend the IQA YMN International Study Tour of the UK being planned for 2024. This demonstrates Hallett Group’s commitment to supporting our up and coming leaders in the industry.

As always, our appreciation goes to our Branch sponsors for their ongoing support.

This concludes the formalities for the 2023 year, 2024 is looking exciting with plans well underway for the IQA National Conference to be held in Adelaide in October 2024.

UPCOMING COURSES AND EVENTS Event

Date

Time

Location

Introduction to quarrying | Online workshop

Fri 1 Dec 2023

12.00pm - 4.00pm AEDT

Online Via Zoom

Chain of Responsibility | Online workshop

Tue 5 Dec 2023

12:00pm - 3:30pm AEDT

Online

VIC slope stability workshop

Tue 5 Dec 2023

8.00am - 4.00pm AEDT

Holcim Pakenham Quarry | 95 Mount Shamrock Rd, Pakenham

Introduction to safety and health management systems | Webinar

Wed 6 Dec2023

9:00am - 10:00am AEDT

Online

Emergency management webinar

Wed 6 Dec2023

1:00pm - 2:00pm AEDT

Online

Quarry roads and onsite vehicle safety webinar

Thu 7 Dec 2023

12:30pm - 2.00pm AEDT

Online

48

Quarry December 2023

IQA NEWS

The Institute of Quarrying Australia

IQA MEMBER SPOTLIGHT: KATHRYN CZAPNIK Quarry magazine spoke with Kathryn Czapnik, Boral Construction Materials project manager, and member of the IQA. What is your current role and what does it involve?

Project Manager for Quarries in Victoria. I am currently focusing on a large site that was a recent acquisition by Boral. My role is to assist the site in performance, help to quantify the future reserves and hopefully obtain permission for the quarry to expand.

How long have you been in the industry?

25 years of industry experience, with around half of that directly in extractives and mining.

What upcoming IQA events are you most excited about?

Probably the End of year Dinner in Bendigo.

There is usually a good turn out and opportunity to catch up with a lot of people from across Victoria.

Have you made any long-lasting connections through the IQA? The IQA has served as an avenue to stay connected to people that I have known over the years, which has led to important longlasting relationships. The industry is small, and people move around, so it has been a great way to maintain these connections.

The IQA has also assisted me in meeting new people, particularly suppliers, which has proven to be beneficial. I have learnt a lot from being a part of the network.

What role do you think the younger generations have to play when it comes to representing the quarrying industry?

The younger generation is facing a challenging environment as constraints on quarrying increase through regulatory requirements, community concerns and limited available resources. The role the younger generation in the quarrying industry will need to be sensitive to this, while being able to apply innovative methods to manage some of these limitations. Personally, I believe the younger generation have so much to offer the quarrying industry and are better at navigating the complicated world that we now live in. The younger generation can improve the perception of quarrying through being advocates for improvement and positively influence the way that quarries are perceived by regulators and the communities we work within.

What do you love the most about the quarry industry?

I am passionate about rocks, and as a geologist and environmental engineer, I love the interaction of rock, and how the environment forms around it. I love seeing exposed faces as it can tell a story of its geological history spanning across hundreds of millions of years – it never ceases to amaze me. Geology forms to building blocks for various bioregions and shapes the landscape which also can alter the local climate. I love witnessing how these aspects interplay.

There is so much variety in quarries, and each site has its own challenges, which keeps me engaged. What I also love most is travelling to different sites and working with multiple people, especially front-line workers.

What advice do you have for a young person looking for a career in quarrying?

I would always encourage a young person to enter into the quarry industry. The hours can be long, but it is rewarding, and there are many opportunities to learn, grow and even change roles within the same quarry. The advantage that quarries have over mining, is that most quarries are close to metropolitan or regional centres, meaning that you can be home most days and it is less dependent on variability in market prices. My advice is to approach the businesses or Quarry Managers and express their interest. We are always looking for keen people to train and upskill. I have found that most people who work in quarries also have a love of their work and sites, and usually happy to share knowledge and enjoy sharing information.

What’s one thing that you learned in the last month?

In the last month, one thing that I have found particularly interesting is learning about sand-washing plants and the subtle art between raw feed and the various products it produces. When there is variability in the resource extent and quality, it can take a fair bit of time trying to understand which materials can go into the plant. Going back to the plant and seeking advice from the plant operators has changed the way I look at what makes good raw feed and what can be considered a reserve. There is also a lot of innovation that is being applied on the

industry level on plant optimisation and upgrades, which has also been great to learn about.

Where do you see the future of the industry?

We are seeing great initiatives in the use of recycled products, but there will always be a need for raw materials. Quarrying has been around for thousands of years, and it will continue for many years to come.

Further work is required in extractives to look at alternative to our use of diesel and also nitrogen-based explosives, not only to ensure there is a reduction in greenhouse gas emissions, but these may become less available and more uneconomical in the future. Climate modelling suggests that we will need to cope with less rainfall, increased flooding (when it does rain) and more extreme weather events. This may not only impact our ability to quarry and produce, but can cut off supply chains and impact on logistics. Our ability to work in the future will require us to be adaptive and implement mechanisms to become resilient to our changing world.

Why did you join the IQA? There is so much I still need to learn about quarrying and IQA offers a lot of great training opportunities. In general, the people at IQA are great, and it is always good to hear what issues or concerns others share and if they are willing to offer some advice.•

Quarry December 2023 49

GEOLOGY TALK

Editorial credit: Natakorn Sapermsap / Shutterstock.com

SOUTH WALES STOUSH

Rex Parrington was a professor at Cambridge University in England.

A South Wales quarry was ground zero for a quirky heist that left two UK palaeontologists in dispute for years about a fossil robbery.

T

wo university professors enter a South Wales quarry in the 1960s and leave with a dispute that rumbled on and strained their friendship.

It sounds like the set-up to a terrible joke, but for Professor Rex Parrington from Cambridge University and Professor Kenneth Kermack from University College, London (UCL), this became a reality according to new reports.

The two professors had established strong reputations for their studies of the world’s oldest mammals from the Jurassic and Triassic periods.

South Wales was a hotbed for fossil finds in the 1960s. Professor Kermack, who according to a new report, favoured certain South Wales quarries to excavate and process clay at UCL for fossil deposits.

Until, as he believed, members of Professor Rex Parrington’s team stole close to four tonnes of clay from his site at the South Wales quarry.

From that moment, it is believed, Kermack and Parrington’s relationship soured.

The report, from the University of Bristol and published in the Zoological Journal

50

Quarry December 2023

of the Linnean Society, has unearthed accounts that confirm the fossil fracas in the South Wales quarry occurred.

“We spoke to Cambridge students of the time,” said Professor Mike Benton, lead author of the paper.

“They reported that this pile of sediment was their main work for a long time. The students processed the clay in different chemicals to break it down and picked out teeth and jaw bones under the microscope.

They got some excellent specimens, which Parrington was able to study.

“Kermack was furious and made his views clear that Parrington had stolen his rocks.”

The fossil heist is believed to have involved Parrington’s team using a truck to haul the clay deposits away from the South Wales quarry to Cambridge in 1966.

Whether Parrington commanded the heist is unknown, although, according to reports, he believed Kermack had left the clay deposits to rot.

Pam Gill was a Ph.D student with Professor Kermack in the 1970s and noticed the strained relations between the pair as a result of the clay conquering.

Kenneth Kermack was a professor at University College London.

“I knew that relations were strained between my supervisor and Professor Parrington, but, by working on the fossil mammals in both their collections, I rather naïvely got caught in the cross-fire,” she told the University of Bristol.

“This all matters because these locations in south Wales were nearly the only source of such ancient mammal fossils anywhere in the world, and palaeontologists around the world were waiting for the latest reports from Kermack or Parrington to understand these rather limited but rare clues about the earliest mammals.

“Now we have amazing fossils from China, Brazil, and other parts of the world, and it’s hard to realise just how important those British fossils were at that time.”

British fossils have become increasingly prominent as further research is conducted.

In the past, Quarry has reported on David Attenborough interest in unique fossils found in a Swindon quarry while James Jordan and Sarah Moore found a 400,000-year-old mammoth tusk in a Cambridgeshire quarry.

However, those discoveries may have come without the rumbling tension from the South Wales quarry. •

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