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The next issue of EARTHMOVERS magazine is available on5 September
Being judgemental
This month I performed my favourite two gigs: being one of the judges of the Stars of the Future apprentice awards scheme, and then judging the innovation awards for the forthcoming PlantWorx show.
Both gigs were not as easy as they sound. The sheer quality of the nominations for the plant industry’s leading trainees genuinely caused the judging panel a lot of heartache, as it was difficult to separate all the outstanding individuals. It was a similar situation looking at innovative products being showcased at PlantWorx, where visitors to the show are certainly in for a treat.
The results from the Stars of the Future event are reported elsewhere in this issue, the PlantWorx innovation awards remain a closely guarded secret, until the ceremony on 23 September, the first evening of the show.
SHOW PREVIEW
This month we provide a taster of what is likely to be one of the main attractions of PlantWorx, the new site sustainability area. In the next issue there will be a full preview of the new machinery on show at the event. As usual, Earthmovers will have a stand in the Pavilion. Please pop along and say hello – there will be an opportunity to win a fantastic high-end scale model.
Yours till next month
Graham Black, Editor
CONTENTS
Hands on with the latest Hyundai 36-tonne excavator and electric mini.
A round-up of the latest news from the earthmoving and associated machinery industry.
In conversation with the
One of the first JD motor
Swedish contractor puts a heavyweight electric excavator to
Porteous Groundworks’ Hidropony, star of the recent Royal Cornwall Show.
Custom-designed high-tip bucket fitted to a new Develon wheel loader.
Machines with capacities up to 20 tonnes, provide high mobility alternatives.
One of two machines recycler Ashvin Metals recently added to its fleet.
The piling aspect of a huge solar farm project in County Tipperary.
Gary Brown and Daughters have just bought their first JCB excavator.
Groundworks firm decided to invest in high-spec Liebherr excavators.
A growing sector of the market, with some models less than 2m tall and 2m wide.
MJL Group team make best use of technology on a
74 PROCESSING
SBM JAWMAX 450
Latest additions to the Skillings fleet is a pair of Austrian jaw crushers.
77
OPERATOR INTERVIEW OSCAR MIRANDA
In conversation with a 21-year-old American operator of a motor scraper.
79 TRANSPORT D-MAX ROAD-RAILER
An Isuzu 4x4 crew cab vehicle converted for road-rail plant operation.
82
CLASSIC PLANT ADT HISTORY
The origins of the articulated dump truck from a British perspective.
87 SHOW PREVIEW PLANTWORX 2025
We report on a new initiative at the forthcoming PlantWorx show.
90 NEXT MONTH
Here’s a taster of just some of the exciting features planned for the next issue.
94 PLANTMOBILIA HYUNDAI
Reviews of new models of Hyundai machines that have been produced in a variety of scales.
97 TRAINING YOUNG OPERATORS
Career plans of two young operators at the Coram Training Centre.
A LONG WAY TOGETHER
EARTHMAX SR 41
No matter how challenging your needs, EARTHMAX SR 41 is your best ally when it comes to operations that require extraordinary traction. Thanks to its All Steel radial structure and the special block pattern, EARTHMAX SR 41 provides excellent resistance against punctures and an extended service life. In addition to long working hours without downtime, the tyre ensures extraordinary comfort.
EARTHMAX SR 41 is BKT’s response to withstand the toughest operating conditions in haulage, loading and dozing applications.
FIRST DRIVES //
HANDS ON WITH NEXT GENERATION MACHINES
Nick Drew reports from the cab of Hyundai’s impressive 36-tonne excavator and their first battery-powered mini-excavator
Two examples from the next generation of Hyundai excavators were shown to the public for the first time at the Bauma show in April. The HX360 was the focal point of the daily demonstrations on the stand, while the HX400, complete with a straight demolition boom, took centre stage as a static display. I recently had the opportunity to spend some time operating the new HX360 model at a construction industry training school not far from Hyundai’s European HQ at Tessenderlo in Belgium. Walking around the machine, I could not fail to be impressed with the dynamic and bold styling. However, this new generation of excavators is not just a cosmetic makeover, but features a new driveline, a superb cab and a host of new technologies.
HX360 DRIVELINE
Opening the engine bonnet at the top of the upper-structure reveals a big change. It is no longer home to a Cummins power pack, but rather a new six-cylinder, 7.5-litre DX08 Hyundai engine. Not to be confused with the old Doosan-developed engine, this is a clean sheet design that, together with the new four-cylinder DX05 power pack, have been voted the 2025 diesel engines of the year by the respected publication Powertrain International.
These engines will be used across future products from Hyundai and its sister brand Develon. In the HX360 excavator, the DX08 engine is rated at 227kW (304hp) at 1800rpm, while providing an impressive 1230Nm of torque at just 1200rpm.
A two-stage turbocharger helps to boost the power rating, while a huge dollop of torque
at a low engine speed contributes to a claimed 8% gain in fuel efficiency. This engine does not have the complexity of an exhaust gas recirculation (EGR) sub-system, the cleaning intervals of its diesel particulate filter (DPF) have been extended to 8000 hours, while engine oil and filter change intervals have been increased from 500 to 1000 hours.
Below and inset: The new HX360 is packed with a host of integrated technologies, while the HX19e mini is available with a huge capacity battery pack.
Back down at ground level, the offside rear compartment is home to the latest design of Rexroth main hydraulic pump. The HX360 and HX400 are the first Hyundai excavators to feature full electrohydraulic control of main pump flow and the individual control valves. The precise control of hydraulic output, through the use of an electronic pump optimising system (EPOS), together with a virtual bleed-off valve, is said to improve responsiveness to operator inputs and contribute to improved fuel consumption. The offside compartment also hosts easy-to-access engine oil and fuel filters and the standard fit electric refuelling pump and hose.
There are two separate panel doors on the nearside of the upper-structure: the cooling pack, complete with a reversible fan, is in the rearmost compartment. The other compartment hosts the air filter housing, 24v batteries and an isolation switch, the windscreen washer bottle and other electrical components. There are plastic covers on the batteries, so you could potentially store some lifting strops in there
Above and below: The HX360 is powered by Hyundai’s new six-cylinder, 7.5-litre DX08 engine. Service access around the machine is exceptional.
if needed. Sometimes it’s the little things that make a big difference – the panel door-opening handles and retaining latches have a quality feel about them.
The machines come as standard with Hyundai’s HiMATE telematic system and their equipment health management (EHM) technology, providing real-time monitoring of the condition of the machine, ensuring the service department can predict any future problems ahead of a costly breakdown.
The undercarriage is the well-proven X-frame design. This HX360L sat on standard 600mm-wide track pads, providing an overall track width of 3280mm. A narrower NL undercarriage version is also available, which allows for a transport width below 3m. Track frame length is 4958mm and features nine lower track rollers, two top rollers and three track guards. At the business end, this HX360 was configured with a standard 6500mm boom and a 3200mm dipper arm, with sensible routing of the hydraulic pipework to protect against accidental damage.
IN THE CAB
The current generation of Hyundai excavator cabs is well regarded, but the extremely spacious cab on this new generation machine is simply spectacular. This example was fitted with the optional
FIRST DRIVES // HYUNDAI HX360 & HX19E
‘comfort pack’ premium leather-like seat, a heated and cooled, air suspension version that would not look amiss in a luxury car. It certainly is luxurious to sit in, providing the support and comfort just where you need it. There is a decent-sized shelf behind the seat with cargo netting to retain a lunch bag, together with a cavernous cool box located to the left and a storage cubby hole to the right.
There is the usual arrangement of push-button controls and dials on the right-hand console, all of which have a quality look and feel to them. There is a start-stop button to the right of the right-hand joystick, with the added option of a digital key, which allows the cab to be opened and the engine started via a smart phone app. A light strip incorporated into front console illuminates the floor area, improving safe access into the seat during dark mornings. Talking of the floor area, a newly designed mat is fitted that makes it easy to sweep out the cab at the end of a shift.
A single 12.8in high-definition monitor was fitted on this pre-production machine, but production models will have the option of twin monitors. They are required, as this new generation has a host of standard and optional integrated technologies, including 2D machine control.
Included in the standard build is a new
multi-camera set-up, which replaces the innovative four-camera advanced around view monitoring (AAVM) system. The new smart around view monitoring (SAVM) system boasts six high-resolution cameras, three of which are embedded in the counterweight. The feed from all the cameras is monitored by an artificial intelligence (AI) system to detect a person encroaching into the machine’s operating radius, which is displayed on the monitor, accompanied by an audible warning.
An optional radar object warning system features three wide-angle radars. They are capable of detecting people, objects or even other items of plant approaching the machine’s working area, again creating an audible and visual alarm.
If the operator does not respond to these warnings, when activated, an E-stop feature will initially slow down machine movements, before bringing it to a halt. The optional E-boundary height and slew limiting system is used to set a ceiling height, floor or wall boundaries. For example, preventing the machine from slewing into a live traffic lane, or to prevent collisions with an overhead obstruction.
There are also optional on-board weighing system and lift assist features, the latter providing the operator with a visual guide on the monitor that displays safe lifting zones.
Left: The standard build includes the AI-powered, six-camera smart around view monitoring (SAVM) system, with the option of a radar object warning system.
“THEEXTREMELYSPACIOUSCABONTHISNEW
IN THE DIG
The machine sprang to life on pressing the start button. I was initially greeted by a loud beeping noise, informing me that the detection system had recognised that people were nearby, although outside of the danger zone. Sometimes it is necessary to operate around ground workers, or in this case fellow trade journalists taking photographs, so I decided to isolate the function via the monitor. I was greeted by the gentle purr of the new six-pot Hyundai engine, which marginally changed tone as I selected P for power mode on the throttle dial.
With a tug on the right-hand joystick the boom powered up and we were away. I liked the joystick-controlled tracking on this example. With just a click of an index finger on a lever on the left-hand joystick, I could travel and steer the tracks, a feature that would be very useful on site.
Climbing up on a heap of previously excavated material I proceeded to dig out more from the hole. The soil on this training ground was extremely sandy and had probably have been dug over thousands of times before, so it presented very little challenge to this 36-tonner, even
with its biggest bucket on board. However, the sandy soil was damp and therefore pretty heavy. With a full big bucket load slewed over the side I certainly felt it, but trying hard to unsettle the machine it largely remained planted to the ground.
In P mode the HX360 was lively enough, but I would best describe its overall pace as being steady. Feeling I needed a bit more, pressing the HP button, the change in both speed and power was quite dramatic, and I quickly warmed to the new performance level.
The machine features Hyundai’s new fully electro-hydraulic (FEH) joysticks. They digitally link to the aforementioned EPOS system, which in turn electronically controls the state-of-the-art hydraulic pump and valves. There is no back pressure or energy loss within this type of hydraulic control system, as the exact oil flow and pressure is delivered when required, resulting in better fuel efficiency over traditional hydraulic servo joysticks. It also results in more accurate and immediate operation of hydraulic functions.
As an old-school operator, this new generation of electro-hydraulic joysticks
Right, below and below left: The spacious new cab has generous storage behind the luxurious heated and cooled, air-suspended seat.
feels numb to me. My muscle memory of a quick flick of the dipper arm to fire some material towards the machine didn’t work as well as I expected. I also found fine grading a little bit tricky, as there seemed to be a dip at the transition point of bringing in the dipper. However, this is the future and I’m sure that I would get used to it after a day or so on site.
In all other aspects, the machine was super smooth, delivering impressive levels of power and performance from one of the best cabs on the market.
FIRST ELECTRIC MINI
FIRST DRIVES // HYUNDAI HX360 & HX19E
With my time up in the impressive 36-tonner, it was time to try something at the other end of the scale: Hyundai’s new battery-powered HX19e mini-excavator. Officially launched at the Bauma show, Hyundai’s first electric mini is now in full production.
It is available with a choice of two lithium-ion battery packs: the standard offering is 32kWh, but for those
Left and below: With the option of a 40kWh battery pack, the new HX19e should easily get through a full shift of hard work on a single charge.
Hyundai’s new HD130A dozer and HL955A wheel loader were also on show at the event.
FIRST DRIVES // HYUNDAI
requiring a longer range there is the option of specifying a 40kWh battery. The smaller battery pack represents a decent capacity, but the market leading 40kWh option should result in a full day of hard work on a single charge.
The HX19e features the widely adopted Type 2 connector, which enables the machine to be recharged via a 110v or 230v supply via an on-board charger. This provides a recharge time of 4.8 hours for the 32kWh battery and six hours for the 40kWh pack. Using the REMA DIN 320 connector, rapid recharging from a 380v or 440v supply can take as little as two hours, and 30 minutes longer for the large capacity battery.
The diesel-powered HX19A mini has a 12.1kW engine, which is replaced by a 13kW electric motor in the HX19e. It drives an open centre hydraulic system that provides the same 16kN of bucket breakout force, but with a slightly higher 9.4kN dipper arm breakout force. Its working envelope is comparable to the diesel powered HX19A, with a slightly less maximum digging depth of 2340mm, while the maximum digging reach at ground level is 3940mm. The standard build includes check valves on the main boom, the dipper arm and the dozer blade hydraulic cylinders, as is two-way auxiliary hydraulic piping.
this test example was fitted with a full cab and the larger 40kWh battery pack, which pushed its total operating weight up to 2296kg.
IN THE CAB
The light grey plastic trim in the cab was aesthetically pleasing, and I loved the simplicity of the monitor with its easy-to-read battery status and current power mode display.
A heater box was fitted in the rear of the cab that can also be set to blow cool air, but as with all these electric vehicles, you need to consider the impact that running a heater will have on the battery life. The cab felt like a nice place to be in, but I would have liked to see a cloth-covered seat, not the PVC style that is more suited to a canopy version.
In the dig, this machine performed just as well as the conventional diesel version, with just the usual whistles and squeals that seem to be the norm with electric minis. It feels rather strange at fi you stop thinking about the lack of engine noise and concentrate on the job in hand.
The HX19e is an extremely capable machine, but without exhaust fumes and with a distinct lack of noise.
Above, right and below right: Apart from a PVC seat, the heated cab of the HX19e is well appointed, with a simple-to-understand monitor.
NEW CAT 980GC LOADER
aterpillar has announced the availability of the new 980GC wheel loader, designed to carry buckets with capacities from 4.3 to 5.8 cubic metres on its Z-bar loader linkage. Its driveline consists of a Cat C13 engine with an auto-idle/shutdown function, driving an automatic planetary powershift 39.8kph transmission with four forward and reverse speeds.
The options include Cat Payload for Trade, which is type approved by the International Organization of Legal Metrology, while retaining all the features of the standard version of Cat Advanced Payload system.
BRETT’S NEW SAND WASHING PLANT
ith history dating back over 115 years, Brett is a building materials group providing aggregates, concrete and paving products to commercial and domestic markets. They have over 60 locations across the south-east of England and sell around six million tonnes of aggregate a year. The firm has recently opened a new 400tph sand washing plant in Portsmouth, provided by CDE.
A round-up of news stories in the plant and machinery construction industry ant
LIUGONG’S ELECTRIC FUTURE
Chinese manufacturer LiuGong has provided brief details of its plan to market more of its electricpowered construction equipment in Europe. Some 10 new models will be launched next year, including a 95-tonne excavator, a 35-tonne wheel loader, together with its first battery-powered skid-steer loaders.
In other news, LiuGong has appointed Dragon Plant Sales as its dealer for Wales. This follows the recent appointment of Lloyd as its dealer for northern England and Scotland.
ENGCON SIGNS DEAL WITH HITACHI
Tilt-rotator manufacturer Engcon has signed a supply agreement with Hitachi to distribute its products through the Japanese manufacturer’s European dealer network. This is a mutually non-exclusive agreement, allowing Engcon to further develop its own network, while allowing Hitachi dealers to choose to supply other brands of tilt-rotators.
IRELAND INFRASTRUCTURE SPEND WELCOMED
o. Tipperary-based Komatsu and Metso dealer McHale has welcomed the announcement by the Irish Government that it is finalising a major investment plan to inject up to €30bn of additional funding into Ireland’s infrastructure between 2026 and 2030.
Noting the separate action being taken to revise Ireland’s National Development Plan, by increasing overall investment in the State’s infrastructure to nearly €100bn over the next five to six years, McHale’s business development director Darragh O’Driscoll said, “With this new commitment and the plans that will accompany it, Ireland is investing in projects that have been long overdue. Properly planned spending on infrastructure can bring an economic return, spin-off tourist spending and in an enhanced level of convenience to residents, visitors and retailers.”
NEW THWAITES DEALERS FOR WALES
Site dumper manufacturer Thwaites has appointed two new dealers: Carmarthenshire-based Kubota dealer Tegfan Plant & Machinery will cover south-west and mid-Wales, while Cwmbran-based Sany dealer Fitzgerald Plant Services will cover south-east and north Wales.
MASSIVE JCB FLEET FOR FLANNERY
Pictured is Pat Flannery Snr with JCB chairman Anthony Bamford, standing next to Flannery Plant Hire’s original 1972 JCB 3C backhoe loader, which helped Pat establish the business. Now run by Pat’s sons Martin, Patrick Jnr and Paul, the fleet now consists of over 6500 machines.
The photo was taken to mark the latest chapter in the two firms’ long history, as Flannery Plant Hire has invested in a massive fleet of 220 new JCB machines in
a deal worth more than £22m. Supplied by dealer Greenshields JCB, the order includes Loadall telescopic handlers, X Series tracked excavators, site dumpers, mini-excavators and 3CX backhoe loaders. Current MD Patrick Flannery said: “Our customers continue to be delighted with the JCB range and we will continue to invest in the finest quality, innovative equipment available. We are particularly interested in JCB’s development of hydrogen powered machines and we plan to take the first hydrogen 3CX from JCB.”
GPS ACCURACY FOR NEW SUBSTATION
Hunter Environmental, a division of Hunter Plant Hire, extensively used Trimble dozer guidance systems, drone surveying and training from dealer Sitech to deliver the complex infrastructure works for a new 132kV substation at the JBM Doverdale Solar Farm in Worcestershire.
Company director Liam O’malley said, “With support from Sitech, the Doverdale project highlighted our capability in delivering technically demanding energy infrastructure. Trimble machine control technology helped our operators improve labour efficiency when laying reinforced concrete foundations, and during the integration of ducting and drainage systems. The centimetre-level accuracy of the technology was also a vital asset during the installation of a rainwater harvesting system.”
HS2 BRIDGE BOX SLIDE
Temporary works specialist, Altrad RMD Kwikform, played a key role in the construction and repositioning of the A46 Kenilworth bypass box structure, a critical element of the HS2 high-speed rail project. To accommodate the new HS2 rail line, a 14,500-tonne box structure was built adjacent to the carriageway before being manoeuvred into place beneath the A46. This approach significantly reduced disruption to road users by eliminating the need for up to two years of extensive roadworks.
Spanning 42m wide, this was the heaviest bridge move in the UK. To achieve this, specialist civil and structural engineering company Freyssinet designed a guiding raft and jacking mechanism to push the box at an average speed of 6.5 metres per hour, ensuring accuracy in positioning while safeguarding the structure’s integrity.
Adding to the complexity, the project required a continuous supply of temporary works solutions and on-site equipment to facilitate the move. At its peak, over 800 tonnes of equipment were in use, with additional resources mobilised for night shifts to maintain progress and keep the operation on schedule. To support the structure’s signifi cant weight, Altrad RMD Kwikform developed an innovative temporary works solution, adapting a combination of formwork and falsework supports.
Throughout the project, a series of concrete pours were meticulously executed to reinforce the structure. These included ten inclined wall pours, six tulip pier pours, four base pours and one deck pour. A summary total of over 4300cu.m of concrete was used during construction of the overbridge.
METSO ACQUIRES TL SOLUTION
The Metso Corporation has acquired the recycling operations and induction heating technology of the Finnish-based company TL Solution. TL has previously worked with Metso to develop its Poly-Met mill liner recycling services, which was launched in 2022. Now with complete control of the technologies and processes, Metso plans to expand this service, particularly to customers in North America.
HYUNDAI OPENS SMART FACTORY
Hyundai Construction Equipment is now producing excavators and wheel loaders from its redeveloped 4710sq.m factory at Ulsan in South Korea, which has seen a €131m investment over the past two years.
Robotic welders have been installed in the fabrication facility, those in the body welding production line have vision sensors to further enhance productivity and quality consistency. Unmanned transport vehicles and AI-based quality inspection systems have been installed in the extended assembly lines. Production and logistics have been streamlined under a single integrated factory system, plus a real-time product tracking system.
All this has resulted in over a 55% increase in production capacity to 15,000 machines a year. In addition, there will be an estimated labour productivity improvement of more than 20%, while the time required to complete a machine has decreased by up to 35%.
IMPROVED PILE-CROPPING CHISELS
Hydraulic pile croppers from National Pile Cropper (NPC) will now be fitted with the next generation of redesigned chisels that are manufactured in house from stronger and longer lasting steel. The new chisels not only penetrate the concrete pile, but leave a perfect finish with little or no tidying up required, with the cropped piece being easily lifted off the pile.
NPC director Lee Aston said, “We’ve literally addressed the cutting edge with the new chisels. Using a new design and face-hardened steel has resulted in all our croppers now being fitted with chisels that cut more effectively, efficiently, productively and safely.”
The NEW COMPACT TAKEUCHI TB370W, a versatile multi-tool carrier with 2-piece boom as standard. Delivering fast powerful productivity on busy construction sites.
TRAINING // STARS OF THE FUTURE
FUTURE BOSSES
Graham Black reports on the top construction equipment apprentices
This year there were a recordbreaking 103 nominations for the Construction Plant-hire Association’s (CPA) Stars of the Future Awards, in which I was part of the judging panel for the overall national awards. Such was the quality of the nominated apprentices and trainees that the judging process involved much head scratching and some indecision. Everybody that made the cut clearly has a bright future in the industry. However, the judging panel was not simply looking for the best apprentice – that would have been difficult enough – but looking for that something special. Something that marks the individual as a true star of the future. The nominees are judged against a complex set of formal criteria, all except for the judges’ special award, which is largely based on gut feel. Many congratulations to Kate MacLeod, who was
a worthy winner of the judges’ hearts and minds. Only 16 years old, Kate is already a talented plant operator with maturity and capabilities way beyond her age. She works for CalMax Construction on the Isle of Lewis, but travels to the National Construction College East in Bircham Newton, Norfolk, for training.
Closing the event, CPA chief executive officer Steve Mulholland said, “It’s really pleasing to see that the future of our industry is in safe hands. This has been a tremendous celebration of the talent in the construction plant sector and we would like to congratulate all the nominees and winners. Testimony to the success of the awards is that many previous Stars of the Future award winners have gone on to secure senior positions in the construction plant industry. We wish all of this year’s nominees every success in their careers moving forward.”
2025 STARS OF THE FUTURE
National Plant Mechanic of the Year
Winner: Jack Lovesey, Liebherr, Stafford College
Highly commended: Kristan Moody, Flannery, Reaseheath College
National Plant Technician of the Year
Winner: Richard Nnadiri, Flannery, Reaseheath College
Hire Controller of the Year
Winner: Kiera Beaumont, Sunbelt Rentals
Highly commended: Caithlin Ellis, Speedy Hire
Young Plant Operative of the Year
Winner: Molly Gill, Flannery Plant Hire
Plant Operative of the Year
Winner: James Grant, Flannery Plant Hire
Highly commended: Jensen Scoggins, TRU7
Plant Installer of the Year
Winner: Joel Munt, L Lynch Plant Hire & Haulage
Highly commended: Jack Fitzgerald, Falcon Tower Crane Services
Highly commended: Jak Brooks, Wolffkran
Technical Support Person of the Year
Winner: Charlie Jackson, Flannery Plant Hire
Highly commended: Roman Turner, Flannery Plant Hire
Individual Apprentice Mentor of the Year
Winner: Oliver Vickery, GAP Group
Group Apprentice Mentor of the Year
Winner: Paul Rawsterne, Watling JCB
Winner: Steve Mooney, Lowton Infrastructure Group
Highly commended: Paul Beard, Flannery Plant Hire
Best Personal Statement Award
Winner: Scott Kelly, Finning UK and Ireland
THE SKILLS OPPORTUNITY
Peter Haddock spoke with Aaron Davis, the safety & skills director of Flannery Plant Hire
Tt the recent CPA Stars of the Future awards event, national plant hirer Flannery had one of its most successful years ever, when their apprentices gained national recognition. This included wins for plant technician Richard Nnadiri, young plant operative Molly Gill, plant operative James Grant and technical support person, Charlie Jackson.
Flannery’s Aaron Davis said, “Stars of the Future is a fantastic event as we get to celebrate young people, their mentors and the colleges that support them. It also reflects the changes in our industry as the new technical support person award
highlights the new skills opportunities that now exist.
“Over the last five years in particular, we have witnessed a major change in plant machinery from onboard technologies, the addition of third party systems to new electric models.
Not forgetting the overall digitalisation of our sector with data analysis and connectivity. Equipment is becoming smarter, and we’re seeing more skills opportunities as the sector looks to adapt, not just its fleet. We’re now seeing more demand for people with technical and digital skills.
“Whether they’re coming from autoelectrical backgrounds or digital engineering, we need operators and technicians who can interface with this evolving kit. For example, we’ve had to look at what we’re doing with data from telematics and how we can turn it into useful digital-led insights for customerfacing platforms, which has led us to using gap analysis techniques. So we have to ask questions like, ‘What do our clients want?’ and ‘Have we got the people who can deliver that data clearly and meaningfully?’ and “How do we develop them or bring new people in?”
INDUSTRY COLLABORATION
Aaron continued, “This is why both industry and wider educational partnerships are so important to the future of our sector. We are working with clients, educators, training boards and the government to create opportunities from our expanding skills centres, like boot camps.
“As a sector, we also need to turn up the volume when it comes to shouting louder about the brilliant careers on offer so we can bring new people into the industry. And it’s not just about school leavers; we need to embrace career changers, veterans and those coming from rehabilitation programmes.
“It’s been over three years since we
launched our first operator skills hub near Birmingham with Balfour Beatty. In this time, we have collected a lot of data, which has helped us to work more closely with the Department for Education and devolved authorities to expand beyond our traditional sites in the West Midlands and south east.
If we know there’s a pocket of demand in a region, we are now able to respond. For example, our work on the TransPennine route upgrade has seen us partner with Kirklees College in Huddersfield.”
FUTURE FUELS
Standing next to a Faresin electric telehandler at the event, Aaron continued, “We’ve tested hydrogen and hydrogen/diesel blends and already have numerous all-electric equipment on our fleet.
One of the biggest skills opportunities is how we can work together to build a workforce that is ready to service, maintain and operate that plant safely and efficiently. This means preparing a road map that includes the equipment and future skills to match the roll out of future fuels.
“This is already changing our sector. Historically, parts of this industry have worked in silos. Now it’s about collaboration between manufacturers, hirers, contractors and clients. This is about piloting new products and solutions, measuring their impact, adjusting them as needed and sharing the learning. We also have to understand what works on one project may not work on another, so it’s about application and conversation with continual collaboration to make progress together.
“Ultimately, when it comes to skills, it’s all about leaving a legacy not just of projects completed but of people trained, careers started and communities supported. If we do that, the whole sector benefits.”
GRADING SCOTTISH FOREST ROADS
David Wylie reports on one of the first John Deere 622GP motor graders to be sold in the UK
Aframework contractor for Forestry and Land Scotland, Campbeltown-based McFadyens regularly undertakes construction and maintenance of forestry access roads for timber extraction and leisure activities.
Some 14 years ago, we first visited McFadyens to report on their new Volvo G940 motor grader. It has now clocked up over 11,000 hours and, largely thanks to its long-standing operator Bertie Wootton, still looks like new. However, the G940 has now been relegated to a standby machine on the McFadyens fleet. Bertie is now enjoying a well-earned retirement, but not after helping to train his replacement, Daniel MacBrayne, who now operates a new John Deere 622GP grader.
John Deere bought the German-based Wirtgen Group back in 2017, which also included the Vogele, Hamm, Kleemann and Benninghoven brands of machinery, all related to the road construction sector.
Through the Wirtgen Group, John Deere has been making available a limited number of models from its construction machinery ranges to European customers, to provide a total road construction package.
As part of its European expansion plans, John Deere invested £2.5m in a new customer service centre at Perth in Scotland in 2021, which supports both their forestry business and Wirtgen’s road construction machinery operations.
David McFadyen said, “The Volvo grader has always been extremely reliable. Our in-house workshop does a tremendous job of maintaining our ever-expanding fleet. The Volvo is still being used when we have a requirement for two graders.”
“THEGPMODELHASTHE
Right and below: This six-wheel drive grader features a direct drive powershift transmission for the rear four wheels, while the front wheels are independently driven by a hydrostatic system.
“When we were looking at upgrading our motor grader, we went to the market for the best possible machine available today. After completing thorough research, an order was placed for the John Deere.
“The GP model has the modern, easy-to-use joystick controls, automatic camber control and we also asked for the premium circle, as it’s more robust and easier to maintain. Since the 622GP machine has been put to work, it’s been highly utilised in this type of forestry work and has never missed a beat.”
DRIVELINE
The 622GP is powered by a six-cylinder, 6.8litre John Deere engine rated at up to 225hp in top gear. The main direct-drive to the rear wheels is via John Deere’s PowerShift Plus transmission, which features modulated shift-on-the-go, event-based shifting and an inching pedal. The eight-speed gearbox provides speeds from 4.0kph (2.5mph) in first gear to a 45.5kph (28.3mph) roading speed in top gear.
The front wheels are powered by a dual-path hydrostatic drive with separate left and right systems, comprising variabledisplacement pumps and axial-piston wheel
motors. This system provides automatic free-wheel at transport speeds, an operatorselectable 15-position rotary aggressiveness control and a precision inching mode when the grader is propelled by the front wheels only.
Compared with the four-wheel drive Volvo, David and his operators are impressed with the traction and rim pull performance available from the six-wheel drive John Deere. There is also a high level of control of the front axle, as each wheel station receives the exact level of power and flow to maintain traction and virtually eliminate the possibility of wheel spin. This results in automatic traction control, as the power bias of the six-wheel drive is adjustable on the fly by the operator to suit the steepness of the grade and ground conditions.
hydraulic, transmission and differential filter bank are within easy reach. The cooling pack features a swing-out, variablespeed, hydraulically driven fan to simplify core clean-out.
All the daily service points, including fuel and AdBlue fill points, are grouped on the left side of the machine for convenient ground-level access. On the right, periodicservice points including the engine oil, fuel,
The mouldboard is attached to a heavy-duty excavator-style slew ring known as a circle. McFadyens’ unit was specified with the premium circle option, which features a fully sealed bearing and pinion that runs smoother and quieter than the standard item. Deere says this design reduces operating costs, while delivering 40% more torque and 15% more speed than a traditional circle. With greasing intervals at every 500 hours, the premium circle is essentially maintenance free. In addition, there is no longer the need to compensate for wear in the circle, improving accuracy when using a grade-control system.
All Grade Pro (GP) variants of John Deere graders are equipped as standard with automated cross-slope, which makes it
Below and right: Configured with a front dozer blade and a rear ripper, this 22-tonne class motor grader is powered by a 225hp John Deere engine.
NEW PRODUCT // JOHN DEERE 622GP
simpler to hold a consistent slope by allowing operators to use a single control, while the machine automatically adjusts the opposite side of the blade. The machine has an open-architecture, allowing users to run any brand of gradecontrol system. Claimed to be an industryfirst, John Deere’s own SmartGrade system is fully integrated and calibrated from the factory. In-cylinder position sensing allows the machine to stay on grade no matter what blade pitch, articulation angle or circle offset is selected, without the
The previous generation Volvo grader had the traditional 10-lever control system in the cab. This new GP model is equipped with dual joystick controls, with both a steering wheel and joystick steering. It also features automatic return-to-straight, a highresolution reverse camera, a rear-mounted ripper and a front dozer blade. Deere’s automation suite reduces the number of controls needed to perform common tasks such as auto-articulation, blade flip and operator-selectable machine pre-sets.
OPERATOR FEEDBACK
We encountered the new grader and its operator working on the east side of the Kintyre peninsula, maintaining a forestry road using a rip ‘n’ roll working method,
JOHN DEERE 622GP SPECIFICATIONS
Engine six-cyl, 6.8-litre John Deere PowerTech PSS
Max power 225hp
Net peak torque 1035Nm (763lb.ft)
Main transmission Direct-drive John Deere PowerShift Plus
Brakes Multiple wet-disc brakes sealed in pressurized, cooled, filtered oil
Circle diameter 1524mm (60in)
Mouldboard
Base length 3.66m (12ft), 22mm thick
Operating weight 22,680 kg (50,000lb)
utilising the existing stone on the road to improve the surface finish while also resetting the cambers. Operator Daniel MacBrayne undertook several quick and accurate passes over a section of the road, using the mouldboard at different angles of attack to move the stone around, cambered to 4% for good water run-off performance. This was followed by passes from a Bomag DW213DH roller to compact the stone to make a hard wearing and durable surface.
limitations imposed by masted systems.
Top and above: Routine service items, including fuel and AdBlue refill points, are easily accessible from ground level on the nearside, while filters are grouped together on the right.
Below and right: This example of the 622GP is configured with the fully sealed bearing and pinion premium circle option, carrying a 12ft-wide blade.
NEW PRODUCT // JOHN DEERE 622GP
Daniel is clearly well pleased with his new mount, saying, “The air-conditioning system is a massive improvement. Compared to the old 10-lever set-up, the electronic joystick controls are a gamechanger for operator comfort, as you are not stretching forward to reach the manual levers. Visibility from the cab is also a marked improvement. The new LED light package on this grader is like night and day, particularly during the winter months to help extend productivity. Overall, the cab, controls, the seat and everything else help to make it a really nice place to spend a shift.
“The six-wheel drive is noticeably better and comes into its own when you need to push material uphill. The extra traction is amazing, you can split the power front and rear and to individual wheel stations for extra grip and wheel speeds.”
The Volvo has a 14ft-wide blade, but the new 622GP has a 12ft blade, on which Daniel commented, “We have not lost any productivity with a slightly smaller blade, as it’s a much better fit for this type of road line building/maintenance work.”
Daniel also praises the smooth ride control system, as this grader is fitted with hydraulic accumulators on the mouldboard blade and frame, which significantly reduces vibration coming through the machine with this damping system.
Automatically maintaining a 4% cross slope grade control system makes it an easier machine to drive and a highly consistent finish. The fuel burn is also good as, after five days of work, there were 80 litres left in its 400-litre tank.
SUMMARY
As one of the largest contractors in the west of Scotland, McFadyens have built up a fantastic reputation, stretching back over 100 years, to improve the on- and off-highway road network and general infrastructure in the region. This new John Deere 622GP motor grader is proving to be a highly productive, comfortable and fuel-efficient machine for this type of work.
Above, below and right: With dual joystick controls, as opposed to traditional multi levers in the luxurious cab, operator Daniel MacBrayne is clearly pleased with his new mount.
BATTERY-POWERED 35-TONNER
As Eoghan Daly reports, Swedish contractor Vabeko AB is about to put a heavyweight battery-electric excavator to work
ndertaking civils and groundworks projects mainly around the Stockholm area, contractor Vabeko AB is pioneering the use of battery-powered excavators in Sweden. The firm is just about to put a 35-tonne class tracked excavator into service that is designed to work a full shift on a single charge, dispelling the notion that battery technology is limited to machines with operating weights below 25 tonnes.
UBACKGROUND
Vabeko already operates a pair of battery-powered 17-tonne class wheeled excavators, Develon DX165W-7 models converted by the Netherlands-based firm the Staad Group, with a third example on order.
The initial investment was made to enable the firm to win a substantial contract for groundworks, service installation and pavement works on the Persikan project, a large-scale redevelopment of a brownfield site at Sodermalm, to the south of Stockholm. The project includes the construction of over 1200 apartments, in addition to commercial premises, two pre-schools, parks and other community spaces, for which Peab is the main contractor. However, the local authority wanted a new approach
to the construction of the Persikan project, demanding a significant reduction in carbon emissions.
Vabeko’s operations manager Lorentzo Jakborg said, “At the time, there was no solution in Sweden except using HVO fuel, but that wasn’t enough. Thus, we started doing research in what possibilities he could find through our machine supplier
Right and above right: At the time of our visit, the new Staad Electric DX355 excavator was being run through its final PDI checks in the premises of Develon dealer Maskinia.
TECHNOLOGY // ELECTRIC EXCAVATORS
Maskinia, Sweden’s Develon dealer.
electric wheeled excavator.”
“This began by visiting a work site in Oslo, Norway, with Maskinia, where they had an early version of a wheeled excavator converted by Staad Group. Then and there we could see that these machines actually exist and work, and we could also see that this is an inevitable future of groundworks. During that trip, we signed an order for Sweden’s first
The first converted DX165W-7 model, nicknamed Elsa, arrived at the end of 2023. The second machine, called Elvis, was put to work on the same project in April 2024. They are equipped with Engcon EC319 tilt-rotators and Moba 3D GPS machine guidance systems, and both are configured to use trailers. In addition to these zero-emissions wheeled excavators, main contractor Peab also deployed two battery electric HGV tipper trucks to serve the project.
CHARGING INFRASTRUCTURE
With four large battery-powered machines on site, a critical element in the success of this innovative working approach was to ensure that an appropriate charging system was put in place. There is a 63amp electric grid supply to the site, but there were concerns that simultaneously recharging these four machines would result in an unacceptable spike in demand.
The solution was to deploy a Plugit Pro Mobile recharging system that featured high capacity Northvolt battery packs, which would be charged from the site’s 63amp supply. This would allow the
machines to be recharged overnight using the Plugit’s standard AC mode, but would also allow mid-day top-ups using fast DC charging, which is rarely used on this project. Occupying a modest footprint, the Plugit Pro Mobile system is located in a segregated area of a car park within a residential area.
Mikael Andersson is the operator of the latest DX165W-7 to be deployed to the project. He said, “This is the fi rst battery electric wheeled excavator I have operated and, once early set-up issues were resolved, it has been very positive with no problems. The machines have enough battery power to last over a complete working day and we haven’t noticed any major difference in performance during the much lower temperatures in the winter months.”
LARGE EXCAVATOR
Sweden has a target of achieving a 50% reduction in emissions by 2030, based on a starting point of their estimated emissions in 2015. This will increase to a reduction of 75% by 2040, with the goal of achieving net zero by 2045.
Based on the success of their battery electric wheeled excavators and with aggressive emissions standards to meet in
Above and left: A pair of Staad converted Develon DX165W-7 wheeled excavators are currently in the Vabeko fleet, with a third example on order.
Below: On the Persikan project, two battery-powered wheeled excavators and a pair of electric HGV tipper trucks are refuelled from a Plugit Pro Mobile recharging system.
the near future, Vabeko took the bold decision to order a 35-tonne tracked excavator from the Staad Group through local Develon dealer Maskinia. It is based on a Develon DX300-7, which Staad designates as the Electric DX355 model. At the heart of the conversion is a pair of easily removed Powerbox 400kWh battery packs, located in what was the engine bay.
These battery packs power a 200kW Danfoss liquid cooled synchronous reluctance assisted permanent magnet electric motor. An e-Epos power management system is the digital brain of the system, matching the performance of the electric motor to the demands of the hydraulic system. There are two variable displacement axial piston pumps each delivering a hydraulic flow rating of 248 litres per minute.
Lorentzo said, “The dual Powerboxes deliver a total of 800kWh, which is more than enough to power through a full working day, even with overtime. It also has a battery swap function, where one battery replacement takes about three minutes.
“The batteries have a full service life of 10 years/3000 recharges, meaning after a decade of use they will have 80% capacity left. That would still be enough to keep working with the machine, or using the Powerboxes as energy storage in other applications.
“Our ambition for the DX355 is to work on larger projects and to excavate and build larger roads or larger-scale urban areas. The machine is a great size to be inside the heart of Stockholm with its limited and narrow spaces, but at the same time achieving great productivity due to its capacity. Any larger would not fit inside the city and any smaller would not reach maximum productivity.”
Above and right: The Staad Electric DX355 uses two Powerbox 400 battery packs to provide a total storage capacity of 800kWh.
TECHNOLOGY // ELECTRIC EXCAVATORS
WALK ROUND
Starting with the two nearside compartments, the standard cooling pack has been removed to provide space for the battery packs. The forward compartment hosts a small cooling pack serving the batteries and the hydraulic system. The Powerbox 400 battery packs feature an integrated temperature management system.
The offside rear compartment panel door opens to reveal the face of both battery packs. If a quick changeover is required, a pin is removed, allowing the central locking mechanism handle to be released. The power transfer lead is then removed and temporarily placed in a holster socket, allowing a battery pack to be lifted out of the machine.
“THESESTAADSARETHE ONLYMACHINESTHATARE
Forward of this a compartment hosts the machine’s hydraulic pump, together with the electrical connections to the electric motor. The AC and DC charge points are inside the compartment that would normally accommodate the AdBlue pump, together with the auxiliary battery isolator switch and a key-operated switch to completely isolate the machine’s electrics.
Making the ascent to the upper deck, the initial step that normally serves as a toolbox or storage chest opens to reveal the auxiliary service batteries. The next step, formerly housing the AdBlue refill cap and tank below, opens to reveal the end of the electric motor.
Moving further up the railed route, on reaching the former engine bay area, the two Powerbox 400 battery units come into view with a handrail running along the nearside of these power cassettes and thereby providing full boxing ring protection. The coolant expansion tanks are located to the rear of the boom base on the service platform area, which are covered by a protective steel shield.
The two Powerbox 400 battery packs weigh a total of 6280kg, which provides a high level of counterbalance, enabling the operator to make full use of the working range of this 35-tonne excavator, which is equipped with an Engcon EC233 tilt-rotator.
Below right and inset: A 200kW Danfoss electric motor drives two variable displacement axial piston pumps, each delivering a hydraulic flow rating of 248 litres per minute.
TECHNOLOGY
FULL SHIFT WORKING
With a whopping 800kWh of on-board storage, it is estimated the 35-tonne Electric DX355 excavator will have no difficulty operating a full shift without recharging. Although special recharging arrangements had to be put in place for the long term, multi-machine Persikan project, it is envisaged that recharging this machine on other sites will be a simpler affair.
Lorentzo said, “Here in Sweden, a 63amp connection is standard at every work site, unless you’re very far into the woods, which is extremely rare around Stockholm where
we mainly work. These Staad machines are still the only ones that are able to work constantly for a full working day of eight hours without charging. No other manufacturer has solved that puzzle yet. We can charge one battery to 100% with a 22kW charger overnight and the DX335 is capable of using two 22kW cables. Today, we only use one 22kW cable to charge our wheeled machines and they start every morning at 100% charge.”
The Staad Group has converted over 200 machines from diesel to battery electric drivelines, the vast majority being wheeled excavators, all of which have been from the Doosan and now Develon stable. Which is good news for Vabeko, as such excavators dominate its excavator fleet.
Lorentzo concluded, “This is not due to a contract with Maskinia or Develon, but because we’ve had and keep having a great experience with them.
“We are constantly searching for ways to renew a very unmodern industry and electric machines are just one step forward. We are also looking at new GPS machine control systems and AI solutions to integrate into our daily work on site to increase productivity and improve the work environment further.”
IN THE CAB
Little has changed inside the cab of the Electric DX355 compared with the factoryproduced DX300LC-7. One of the few in-cab changes is an additional display module for all data relevant to the electric driveline.
The main screen shows the power level and temperature of each of the two Powerbox 400 battery packs. On the opposite side of the display, the operating speed and torque level of the electric motor are shown, together with the operating temperatures of the electric motor and the hydraulics.
Striking the right balance of scale and clarity, the monitor does not become obtrusive thanks to its sensible proportions and still succeeds in keeping the operator informed of all key information.
In addition to this dedicated screen, the machine employs the standard Develon control system monitor as well as a separate screen for presenting footage from rear and side view cameras. In this example a large display module also serves the Moba 3D guidance system, as well as the control module for the Engcon tilt-rotator.
Below: The only significant change inside the cab is the addition of a monitor for the electric driveline.
STAR OF THE SHOW
“IREALLYHOPETHAT HIDROPONYWILL INSPIREMOREWOMEN TOCOMEINTOTHE CONSTRUCTION INDUSTRY”
Nick Drew reports on the Porteous Groundworks’ Hidropony, the star of the recent Royal Cornwall Show
More often than not, the construction machinery trade stands at the annual Royal Cornwall Show become a platform for West Country civil engineering companies to try and claim bragging rights for how many pieces of their new kit they can showcase. However, this year one machine totally stole the show, in the form of a stunning Hidromek HMK230-5 excavator from Porteous Groundworks on the MPS stand.
The firm was established in January 2022 by Ben Porteous, along with his brother Scott, his brother-in-law, a nephew and his sisters Sophie and Sam in the office, while mother Kathy takes care of the book keeping. A real family success story that saw them turn over £2.3m in their first year of trading and which continues to go from strength to strength.
Porteous has had a presence at the last few Royal Cornwall Shows, with new excavators especially prepared to be on the stand of MPS South West, the Hidromek dealer for the region. In 2023 this was an HMK230-5, featuring the first of a series of
wraps undertaken for them by Tavy Signs, based in Tavistock, Devon. The following year it was a smaller HMK140 model, which featured an all-black wrap, together with orange lettering, chevrons and trim. The big question was how they could top that for this year’s show, a task that was handed over by Ben to his sister Sophie.
BACKGROUND
Sophie Porteous is a fully qualified veterinary nurse by trade, something she is still involved in on a part-time basis. In her office role within the family business, she is involved in procurement and logistics, including managing their fleet of vans and machine servicing schedules. If they are short of staff due to illness or holidays, she is also known to go out on site and get hands on in any capacity. However, in conversation, overwhelmingly it’s her love of horses that really shines through. She does a bit of everything, including show jumping, cross-country and dressage. With a blank canvas in the form of a new Hidromek HMK230-5, it was her passion for horses, together with a desire to attract more women to the industry that influenced her creation.
Above and below: Sophie Porteous designed the Hidropony, a star attraction on Hirdomek dealer MPS South West’s stand at the recent Royal Cornwall Show.
Sophie said, “As I’m a proud horse owner, I wanted to create something revolving around an equestrian theme. I had several chats with Jason McCollough, the owner of MPS South West, and we bounced a few ideas off each other as to where we were going with it. I told him I wanted it to become known as the Hidropony, so we went off and did some research on horserelated images.
“We came across an image with a shield and a horse’s head and that sparked the imagination to create our own artwork based around that theme. We put all these ideas over to Joe Mouzouros, the graphic design guru at Tavy Signs. We must have changed it hundreds of times until I got it how I wanted. Having chosen the wrap, I couldn’t find the paint to match,
which was another hurdle to cross, but we got there in the end and I’m so happy with how it turned out.”
The wrap itself is in a stunning satin majestic pink, with digitally printed graphics, HD gloss pink chevrons and matching graphics. The boxing ring fall-from-height protection, handrails and track steps have all been painted in colour coded bright pink, and this is all topped off with the installation of tinted cab windows.
All the work was done in secret at MPS
South West’s premises at St Austell. The initial preparation of the machine for its transformation was also a family affair, as MPS owner Jason involved his wife Paige and their children, who all helped to peel off the original stickers and stripped off the handrails,
Jason said, “We all worked hard to get it ready in time. I’d say in total we put in at least 40 hours as a family, even before the Tavy Signs guys did their bit. We also got in a professional painter to spray the bucket and handrails, as we had never painted using pearlescent paint before, so we wanted it to be right.”
Sophie commented, “I’m very proud of it, and the fact that I stuck to my guns throughout the whole procedure. There
Top, above and right: The new Kubota was supplied with a variety of attachments and is being operated by Mitchell Speakman, who describes it as a ‘Full Monty’ piece of kit.
were a lot of opinions flying around in the office. For example how I should have this font, or that colour or this wrap etc. But I had a vision right from the start and stuck to it, and eventually got everything I wanted. I can honestly say there is not one thing I would change on it. I mean just look at it, it’s a thing of beauty.”
MARKET IMPACT
The pink and black Hidropony certainly made an impact at this year’s Royal Cornwall Show, it seemed as if everyone in the local groundworks sector was talking about it.
Sophie said, “It’s so common on sites to see standard machines; JCBs are yellow, Hitachi’s are orange, so they are just another digger. Whereas I have presented the boys with this amazing machine and they absolutely love it. It’s become their pride and joy and they send me photos of it all the time. They are
obviously looking after her, as I get messages requesting air fresheners and polish, which is great.
“Was it worth spending a lot of money on? Well, in my eyes, absolutely yes. I really do hope that the Hidropony will help to inspire more women to come into the construction industry, our office is heavily dominated by women, but on the ground it’s still largely men.”
Outside of the Porteous and McCollough families, one member of the Porteous team who was let into the secret prior to its unveiling at the show was Brad Burchell, the site supervisor/operator at a project near Falmouth, which was to be Hidropony’s first job.
On the time of our visit to Falmouth, the excavator was busy loading muck-away wagons, it was being operated by ‘Spud’ Davey, as Brad was busy organising other aspects on the job. For the purpose of our photoshoot, it was fitted with a pink Scandinavian-style bucket from the German manufacturer Holp, the plan is
to fit a Holp Rototop rotating hitch at a later date.
Aside from the amazing artwork, which has already attracted much positive comment on site, both Brad and Spud had nothing but good words to say about the performance of the Hidromek, with Brad stating, “Its fast, powerful and the cab is a great place to be spending your days, I really can’t fault it.”
CONCLUSION
Hidropony is an amazing looking machine, one that I’m sure Porteous will be proud of for many years to come. However, there was another strong contender for the best-looking excavator at the show, nicknamed the Swede Army Knife. It is a Volvo EC260F, resplendent in a black, grey and green wrap and fitted with a Steelwrist tilt-rotator. On display on the One Point Survey stand at the Royal Cornwall Show, it was designed by Sophie’s brother Scott and is another stunning example of what can be done to make machines, their owners and the operators stand out from the crowd. We are planning to visit this on site in the not-too-distant future.
Right: Sophie’s brother Scott Porteous designed this wonderful-looking Volvo EC260F, which was also on display at the Royal Cornwall show.
Inset: The ancillary metalwork and bucket were finished in colour-matched pink pearlescent paint.
Left: The first job for the new Hidromek HMK230-5 excavator was on a site near Falmouth, under the supervision of Brad Burchell (left) and operated by Spud Davey (right).
FARMING COMPOST
Paul Argent reports on a composting facility that has received its first custom-designed Ulrich high-tip bucket for one of its new Develon wheel loaders
Much of today’s countryside around Warrington, Wigan and St Helens in the north-west of England has been influenced by past mining activities. Unfortunately, it has left the ground in a poor state to grow crops, requiring the application of increasingly expensive potash and phosphates to add nutrients to the soil.
This was the situation faced by the Broster family, who have been farming at Diggle Green Farm near Warrington since 1977. Dave Broster said, “We were spending more each year to get less back. In the early 2000s we were approached by our agronomist with a view to improving our land quality, resulting in us dipping our toe in the water to produce small quantities of our own compost. Initially our operations were shred and spread, but this has gradually expanded to the production process we have today.”
The added nutrients from the compost not only increased yield, but also made the soil more workable, reducing costs to prepare it for the next growing season. As the use of compost started to make a huge
difference to the farming operation, the Brosters began to increase the volume produced while meeting PAS 100 standards. They then gained planning permission to turn a former railway cutting on their land into a large-scale compost production facility.
In turn, this led them into a venture with a larger company that operated an in-vessel composting (IVC) facility at Todmorden, to the north of Manchester. This allowed them to gain a greater foothold in the industry, but it ended suddenly when the partner got into difficulties, resulting in the Brosters taking over the entire operation at Todmorden.
Dave has massively invested into developing both the Todmorden and Warrington sites, which now process organic materials from Manchester and its suburbs. With an exacting paperwork trail, the operation can follow the waste from its initial collection through to compost production and eventually into which specific field and crop it is used on.
Dave said, “We are one of the only companies delivering such a detailed and local package. We collect the waste from source, deliver to either of our operational sites for processing and turn the waste into a valuable product.”
FLEET FOCUS
As compost production increased and work methods improved, so has the fleet of machinery required to undertake the work. This includes running eight-wheel loaders over the two locations. The site at Warrington is home to four Doosan and Develon wheel loaders together with a Hitachi excavator. The most recent additions to the fleet are a pair of Develon DL380-7 loaders, sourced from Blue Central.
Dave said, “We have run Doosan wheel loaders for several years and find them to be on top of the job. The latest Develon machines are a step above the older models, offering increased cab comfort, more power and a nicer drive. We take the loaders with a high-lift arm option, as it makes it easier and safer to load our walking-floor trailers and have specified them all with Ulrich high-tip buckets.
“Due to lot of wear and tear that the buckets go through, we wanted to see if there was a way of making them more resilient. We discussed the issue with Ulrich and their team came back to us with a bespoke solution for our requirements, the Broster bucket.
It’s a significantly beefed-up version of their high-tip design, with an increased toe-plate, increased side profiles, additional welding, larger pins and the option to attach it to the central greasing system, so we recently ordered three. The first of these units is performing exceptionally well, with little to no wear on any part of the bucket, which is exactly what we want.”
OPERATOR FEEDBACK
One of the new Develon/Ulrich loaders has been given to long serving operator Keith Dickenson, who originally came to Brosters for a week to help out, but has now been with the firm for 17 years.
Above, below and below right: Green waste collected from the Manchester area is initially fed into a Terex Ecotec TSS390 high-speed shredder.
ATTACHMENTS // ULRICH
He said, “I run my own small farm and was spreading slurry on Dave’s land when he asked if I could help out on the compost for a short spell, now he can’t get rid of me. Saying that, he’s a good bloke to work for and lets us get on with whatever we need to do to get the job done.”
The new DL380-7 is a 20-tonne class machine and is powered by a six-cylinder engine rated at 271hp. Keith added, “It has bags of power available; you have to be careful to keep the wheels from spinning. It’s a huge step up from the older machines in terms of comfort and performance.”
Mated to a five-speed auto-powershift transmission with lock-up torque converter allows Keith to push the machine into the piles of material waiting to be processed. He said, “It’s not an easy material to handle, but the added power of the new loader and the redesigned bucket seems to have made it smoother for me.”
While the loader is a relatively standard machine, Dave’s experience has seen
a couple of additions put on the new models to stop dirt and debris build-up. He said, “We have put extensions on to the front wheel arches to stop material being thrown up on to the cab and loader arms when the machines reverse. We have also filled in the gap between the rear wheel arch and the engine canopy to stop material build=up in this area. It’s not a huge change, but it will help keep the machines cleaner for the operators.”
A neat change to the Dash-7 machines is the relocation of the latch for the swing-out rear wings. On previous designs it was located underneath the arch and was always caked in muck according to Keith. Moving the mechanism out of the rear of the arch allows it to stay clean and clear of damage.
SITE VISIT
a short distance to a Terex Ecotec TSS390 high-speed shedder, which reduces the material down in size. Once this initial process is undertaken the material is then passed to the top of the site where the compost process continues. The final part of the process is screening the material to produce a fine, high-quality compost to enrich the farmland.
The additional 525mm given by the high-lift arm arrangement increases the pin height to 4.6m, which is again increased by the addition of the 5.5cu.m Ulrich high-tip bucket. The majority of Keith’s daily operations entail handling the incoming material. Tipped green waste is ferried
Dave continued, “It is a constant cycle to produce the significant quantities we need to keep feeding the fields. Once ready, our JCB Fastrac and trailer are constantly moving it to stockpiles. Once the crop is cut, we then use our own team of Fendt tractors and Bunning spreaders to spread it quickly.
While our fleet is mixed, we like to stick with what we know and like: we have Fendt tractors, Volvo trucks and Develon loaders. We find that back-up and servicing is far more important to us than anything. Both Ulrich and Blue Machinery, with Norwest Plant before that, have been great to deal with. They listen to us and work with us to iron out any issues we have, which gives the peace of mind any customer needs from a supplier.”
Above: Once matured and screened, the compost is transferred to a stockpiling area, ready for use on farmland.
Left and inset below: Operator Keith Dickenson praises the Dash 7 Develon wheel loader for its power and comfort.
Moss Road, Kearsley, Bolton, Lancashire BL4 8NE,
MARKET GUIDE // TRACKED CARRIERS
WHERE SITE DUMPERS FEAR TO TREAD
Numerous relatively small capacity tracked dumpers are available and are popular with those that have to transport materials over ground conditions that are unsuitable for wheeled site dumpers. However, a growing sector of the market is at the other end of the scale, where machines that offer capacities from 10 to 20 tonnes, provide high mobility alternatives to two-axle articulated dump trucks
YANMAR RANGE
Yanmar tracked dumpers extend from the 1150kg capacity C12R model up to the C50R that offers a payload of 3800kg.
The mid-range C30R model offers a payload capacity of 2500kg and is available as either a three-way tipping variant, or with a 180-degree swivelling skip. Both are powered by 34,3kW Yanmar engines, providing a maximum travel speed of 11kph.
The C50R is powered by an 83.2kW Yanmar engine and is again offered in two versions, with either a three-way or swivelling skip. Yanmar says that the hydraulic tensioning system in the undercarriage design reduces downtime, as it eliminates the need for manual track tensioning.
MARKET-LEADING DEALER
For many years, Colchester-based dealer Cautrac had held a dominant position in the UK and Irish markets for tracked dumpers, particularly the Morooka range. The larger capacity models in this range include the 11-tonne capacity MST110CR, previously known as the MST-2200VD, the 13-tonne MST130CR, the 16-tonne MST160CR and the mighty 20-tonne capacity MST200VDR.
Also in the range is the four-tonne capacity MST40CR, together with the eight-tonne MST80C and MST80CR. The CR suffix in the model’s name denotes that they are full 360-degree rotation machines. It is understood that Morooka will launch three-tonne capacity tracked dumpers next year.
In the meantime, Cautrac supplies the Canycom S300 model. Best known in the UK for its range of tracked brush cutters, Japanese-built Canycom is available with either a straight- or swivel-tip skip. It is powered by a 34.9kW Kubota engine driving through a two-speed transmission providing a maximum travel speed of 11kph.
Cautrac also supplies the 1200kg payload Yamaguchi WB12B. This ride-on tracked dumper is powered by a two-cylinder Kubota diesel engine mated to a hydrostatic transmission and configured with a three-way tipping skip.
BERGMANN 10-TONNER
ffering a payload of 10 tonnes, the German-made Bergmann C912S crawler dumper features a 360-dergree rotating dump bed, while the operator station within the cab can rotate by 180 degrees. It is powered by an 180kW Cummins engine, which drives through a ZF converter transmission providing a maximum speed of 15kph.
OTwo hydrostatic powertrains offer constant full power. The hydraulic parking brake holds the fully laden vehicle even on extreme inclines, making practically any terrain accessible.
T TOUGH TAKEUCHI
he 3.7-tonne capacity Takeuchi TCR50-2 features a 180-degree swivelling skip, with a 65-degree tip angle for flexible and efficient load discharge. It is powered by an 88.4kW Yanmar engine and has a top speed of 9.5kph.
The dumper is 4660mm long, 2200mm wide and 2725mm high and offers 435mm of ground clearance.
Inside the surprisingly large, climate- controlled ROPS/FOPS cab is an adjustable suspension seat, together with full pilot controls. Other features include a 180-degree rear view camera and a 14.5cm multi-function colour monitor.
PRINOTH TRACKED CARRIERS
With maximum payloads ranging from 5.7 to 21 tonnes, the seven-model Prinoth crawler carrier range can be equipped with a variety of working equipment, including a concrete mixer, drill equipment, a vacuum excavator or with standard dump bodies.
We recently featured an 11.3-tonne capacity Panther T12 model
that had been configured by an Irish contractor as a go-anywhere crane. In addition, UK plant hirer Tru Plant took several 12.2-tonne capacity T14R models on to its fleet, configured with a rotating dump body/upper-structure.
The Prinoth range of tracked dumpers is supplied and supported in the UK by Bradleys Machinery and in Ireland by McHale Plant Sales.
POWER BULLY TRACKED CARRIERS
Better known for their Pisten Bully range of robust, go-anywhere snow grooming machines, the Germanbased manufacturer Kassbohrer also manufactures the Power Bully range of tracked dumpers, offering payloads
MESSERSI RANGE
Italian-based manufacturer Messersi produces four compact tracked dumpers, the largest being the cabbed, five-tonne capacity TC550 model. The 2200mm-wide machine features a 180-degree swivelling skip with a volume of 2.9cu.m and is powered by an 85.9kW Perkins engine.
from 7.5 to 13.5 tonnes. The larger undercarriage and cab 18T model can carry up to 16.6 tonnes of specialist equipment and is powered by a 310hp Cummins engine mated to a 14.5kph hydrostatic transmission.
NEW ENTRANT
Although not thought to be currently available for sale in Europe, South Africa-based Bell – best known for its wide range or articulated dump trucks – produces the TC7A and the TC11A tracked dumpers. They are powered by Cummins engines rated at 168kW and 186kW, respectively, driving a Rexroth hydraulic system.
As Paul Argent reports, nonferrous scrap metal recycler Ashvin Metals recently added a pair of machines to its fleet, supplied by the Molson Group
Left and below: In addition to forklifts, Ashvin Metals’ yard at Poulton-Le-Fylde operates with just two front line machines, a Sennebogen handler and a Kobelco excavator.
Lancashire-based Ashvin Metals was founded in 2011 by John Howarth. Having grown up with a family-owned metal trading business, Howarth Metals in Manchester, John had all the necessary experience to get Ashvin to the force it is today. The company’s operations focus mainly on non-ferrous metal recycling. The metal is processed and baled before being dispatched around the world for further processing.
Investing back into the business and growing organically over the decades, the company moved its headquarters to Poulton-Le-Fylde on the Lancashire coast in 2014. The following year, Andrew Dixon became a partner in the business and has continued building on the reputation of the company, expanding its portfolio and increasing the productivity of its operations.
Andrew commented, “Our Poulton yard doesn’t deal in huge volumes of material compared to other recycling yards. What we do is clean and process the material correctly, ensuring it is in a fit and proper state to be recycled easily and can generate a good return for us.”
Along with a fleet of small forklifts distributing material around the yard and loading palletised goods out, the compact yard is home to just a pair of frontline machines, both of which have been sourced from the Molson Group.
NEW HANDLER
The latest addition to the fleet comes in the shape of a UK first, a Sennebogen 835G, one of the latest generation of materials handlers manufactured in Straubing, Bavaria. Its operating weight of around 50 tonnes, depending on the exact specification, makes this 835G appear a little heavy for this site.
Andrew continued, “We’ve gone for a larger machine than we had before. Our previous machine was around 40 tonnes and, while it was okay, the larger Sennebogen means we can almost keep it static in one corner of the yard and still reach the shear and scrap bays it needs to with ease.”
Like all Sennebogen handlers, there is vast array of configurations available. This 835G sits on a wheeled undercarriage that measures a little over 6m in length. Riding on 12.00-20 solid rubber tyres on heavy-duty axles, the undercarriage uses four-point
Below and left below:
The 20m industrial boom and stick hosts an 800-litre Kinshofer orange peel grab, allowing most operations around the yard to be conducted from a single spot.
stabilisers to create a wide, stable base from which to operate.
Access on to the undercarriage and onwards to the upper-structure is helped by well-placed, sturdy and galvanised handrails and steps. Each side of the undercarriage holds a convenient tool box with a removable ladder that can be secured to a rail on each chassis rail, allowing safe and easy access to the engine, hydraulic system and cooling packs.
The 835G is powered by a six-cylinder Cummins B6.7 engine developing 260hp, from which peak torque levels come in at just 1600rpm. Over and above the fuelefficient engine, further efficiency gains are made by the inclusion of a third, nitrogenfilled boom cylinder. Unlike the two standard hydraulic cylinders, as the boom is lowered this cylinder compresses the nitrogen, which is stored under pressure in a tank inside the upper-structure. This is used to assist with raising the boom, resulting in a reduced requirement for hydraulic power.
Ashvin has opted for the longer 20m industrial boom and stick configuration, fitted with an 800-litre Kinshofer orange peel grab. They also specified a hydraulically elevated cab, which provides the operator with a working height of almost 6m, allowing a great view into the skip of tipper trucks.
MATERIALS HANDLING // SENNEBOGEN
The extra reach also allows me to load over the back end of the body and still reach the headboard on most trailers. With the old machine, I always had to move a little to do this, as the boom fouled on the tailgate of the tipper. I can sit in the middle of the yard and handle material all around the bays, the shear and the other machine from one spot. The only time I have to move is if we have a tipper come in for a specific material to be loaded straight out.”
NEW EXCAVATOR
Ashvin Metals has also upgraded its yard excavator from a Kobelco SK85 midi up to a short swing radius Kobelco SK140SR. Andrew said, “We have had good service
Operator Luke Winter said, “It’s a really comfortable and reliable machine and it’s a great help being able to see into the body.
from the SK85, which was a great little machine, but with volumes increasing, we decided to look at replacing it with a larger excavator. The SK140SR was the ideal replacement and while it is almost double the weight of the SK85, the footprint isn’t massively different, which is important for us as the machine will spend much of its time in a single corner of the yard.”
The SK140SR sits on a long undercarriage fitted with rubber tracks. As the longer and wider undercarriage offers enhanced stability, the rubber tracks allow the machine to move round the yard without causing any damage to the concreted surface. Configured with a standard mono boom and 2.84m
Below: The middle boom cylinder is part of the nitrogen-based hybrid sub-system, compressing the gas as the boom is lowered, using this stored energy to assist with lifting the boom.
Below left: The 50-tonne class 835G is powered by a six-cylinder Cummins engine rated at 260hp. On-board ladders are provided to reach both compartments on the upper-structure.
Inset left: Operator Luke Winter says the new handler is comfortable and its huge working envelope allows a productive working method.
dipper stick, the reach on the SK140SR means operator Danny Moss can sit the machine right at the mouth of the baler and reach almost every bit of material around him without moving. The excavator has been supplied with a Zato shear and an NPK selector grab, and regularly swaps the attachments to process material when it comes into the yard.
Danny said, “We quite often have to cut some of the incoming material into smaller pieces to allow it to be handled by the LeFort baler. Having the shear is a far safer option than hot cutting the material and is a lot quicker to undertake.”
However, most of the work is done by the NPK selector grab, in particular to feed the baler with used tin cans. Already flattened, the cans are brought into the site packed in one-tonne dumpy bags. Danny’s job is pick up each bag and shake the slabs of tin free, load the cans into the baler and then bundle up the used bags for recycling.
The LeFort baler compresses around half a bag of tin cans into a 300mm square cube. Not only does this reduce the volume of the material, but it also makes it easier to handle and allows for easier and more cost effective transport for onward processing. The conveyor coming from the baler
pushes each block to a holding area, where the Kobelco is used to remove it to a stack ready for loading.
While the SK140SR has only been on site for a couple of months, it has already impressed its operator and the management team with its performance. Danny said, “We’ve had no issues whatsoever with it. The fuel consumption seems to be a little higher than the older machine, but this is something we knew we would have with the size difference. We are however getting a massive increase in the output with this excavator, and we are only slowed down by the speed of the baler. It’s very impressive!”
CONCLUSION
Ashvin’s depot manager Andrew Whitmore said, “You are buying quality when you buy from Molson, not just in terms of the product, but also in the way they look after you. We know there will always be issues with equipment, but the technical back-up from the Sennebogen specialists and the 24-7 service we get from Lisa and the team at the Warrington depot mean that if we have any issue, whatever the size, they will always be there to get us up and running as soon as possible. You simply don’t get that from other dealers.”
Right and below: Operator
Danny Moss’s new mount is a short swing Kobelco SK140 equipped with a Zato shear and an NPK selector grab.
SOLAR PILING
Eoghan Daly reports on the piling aspect of a huge solar farm project
County Tipperary, where the civils works were undertaken
ver recent years, large-scale solar farm projects have become an integral part of the portfolio of County Mayobased contractor Wills Bros, particularly those constructed on challenging ground conditions. Past projects include the Timahoe North solar farm, which included driving 62,500 piles across the immense 156-hectare site.
OWills Bros is currently working on an even larger project for client ILOS, which includes driving 76,000 piles on the Erkina Solar Farm, located near the County Tipperary town of Roscrea. The project comprises three interlinked areas: Erkina, The Sheehys (Derrymore) and Monaincha. In total, the site covers an area of 235 hectares and on completion will have a capacity of 222MWp and a maximum power export capacity of 156.66MW.
This will be fed into the national grid through a new on-site substation, which is being constructed under a separate contract. More than 70% of the project is within the footprint of an existing wind farm, demonstrating how the highest level of
utilisation is being derived from the sites.
The Erkina segment of the project is located on predominantly free-draining farmland and will ultimately see sheep grazing around the completed solar arrays. However, the other two areas of the development are located on peat bogs, which present a much different set of working challenges.
Having secured the civils contract for the ILOS project, Wills Bros established a site presence in late 2024 and soon got up to full working capacity. In addition to the installation of piles to support the tables on which the PV solar panels will be fitted, they are constructing the site access road network, the transformer pads, the associated crane pads for transformer installation, together and a considerable amount of ducting to link each area of the solar farm to the new substation.
ENABLING WORKS
Before the pile-driving effort could begin, much ground preparation had to be completed. This included reprofiling many areas of the huge site, particularly the peat land, which had been left in an undulating condition following peat extraction. A fleet of low ground pressure excavators, mostly 21-tonners, were used to undertake this work.
OTHER CIVILS WORKS
In addition to the installation of 76,000 piles, the Wills Bros civils package included the construction of 30 transformer pads, which alone required the excavation of some 16,000 cubic metres of material.
In addition, the installation of ducting throughout this immense site is a major undertaking.
In total, the ducting infrastructure requires the excavation of over 26km of trenches, into which a comprehensive degree of multiple ducts up to 200mm diameter are being installed. This work was subbed out to several firms, including County Mayo-based D&R Demolition and Plant Hire. Since the duct installation needs to be carried out across the same challenging ground conditions as the piling operation, low ground pressure excavators are also a mandatory requirement on this aspect of the project.
Unlike most of Wills Bros’ similar undertakings, the Erkina Solar Farm project was extremely complex when it came to pile distribution and driving. Based on ground surveys across the three sections, 13 different pile types were used, each identifiable by a colour coding system. The 76,000 individual piles ranged from 3.1m to 9.4m in length.
A critical factor in this aspect of the project was distributing the piles. The dedicated team used two Hitachi tracked dumpers, working with several low ground pressure excavators equipped with pallet forks. The pile distribution crews maintained a comfortable operating cushion ahead of the pile-driving crews, delivering up to 1000 piles per day.
Wills Bros adopted 3D GPS technology earlier than most in Ireland. An increased percentage of operations are co-ordinated using a variety of Leica equipment to accelerate project progress.
Engineer Martin Mulroy said, “We are setting out the string line and ground line for between 700 and 900 piles per day. Using the Leica rover makes this process so much easier and ensures complete accuracy. It is also a vital tool in checking the work following piling by the machines, while the whole package of having 3D GPS guidance on the machines means there is an up-to-date record of progress available.”
On the relatively straightforward Erkina section of the project, dedicated tracked piledriving rigs were used. However, such machines were
Machines serving the operation are from various manufacturers and are dominated by low ground pressure Hitachi units. There were also three XCMG excavators working on this aspect of the project, a pair of XE135E on stockpiling and loading pipe bedding material to feed the duct laying crews, while a reduced swing radius XE155E CR serves reinstatement works.
In addition, four horizontal directional drilling crossings are to be completed to install ducting beneath watercourses, areas of ecological sensitivity, local roads and the M7 motorway, which is required to link the Erkina section with the new substation.
Inset left, above and below: John Kennedy is the operator of Wills Bros’ Hitachi Zaxis 160LCN-7 low ground pressure excavator, equipped with an SG40 Movax piling attachment.
deemed unsuitable for the other two sections, as they would be unable to work over peat-based soils and their mast heights were unable to cope with the longer piles required for such ground. In their place, a fleet of GPS-equipped low ground pressure excavators were used, ranging from 13 to 21 tonnes, all configured with Movax vibratory pile-driving attachments.
FLEET FOCUS
Wills Bros deployed four of their own machines, two Hitachis and a pair of Komatsus, all of which were factory-built low ground pressure machines. The smallest excavator deployed on this piling application was a Hitachi Zaxis 130LCN-7 equipped with a Movax SG30 piling hammer. It sits on 1.2m-wide triple grouser tracks shoes on an extended and raised undercarriage. It also features a raised slewing turret for added clearance between the undercarriage and the upper-structure.
The larger Hitachi Zaxis 160LCN-7 model has a similar dedicated low ground pressure undercarriage, but runs on 1.4m-wide pads and was equipped with a larger Movax SG40 vibratory piling attachment. With 2328 hours of service recorded, this Hitachi 160 has been an exemplary performer with no issues experienced to inhibit progress on demanding projects such as this.
While the Hitachis feature a raised slewing turret design, the two Komatsu PC170LGP-11 swamp spec excavators do
not. Rated as 21.5-tonne units, they employ the upper-structure of a PC170 and the undercarriage frame of a PC210, allowing wider track shoes to be fitted. Both were equipped with Movax SG40 piling hammers and have a good track record of operating on solar farm and landfill applications.
Complementing the four factory-built Wills Bros low ground pressure excavators on this project were five converted Case excavators from the fleet of Pat Murphy from Lakeside Plant Hire, comprising CX210C and CX210D models.
The first conversion of a C series machine was carried out in house, which saw the
undercarriage lengthened and widened and the slew turret raised to provide extra clearance. In addition, the machine was fitted with more powerful track motors to match the demands of the larger undercarriage.
The more recent conversions of D series machines followed a similar theme, but without the need to upgrade the track motors, which were undertaken by Mooney Engineering. To facilitate fitment of the widest possible track shoes, the conversion process involved modification of the machine’s slewing turret. The tracks were also lengthened, taking 63 shoes instead
Below: Wills Bros deployed their pair of Komatsu PC170LGP-11 swamp spec excavators, again equipped with Movax SG40 piling hammers.
Below: A total of 76,000 piles will be driven across this 235-hectare project, mostly in peat land and ranging in length from 3.1m to 9.4m.
of the standard 49. The first CX210D originally ran on 1.6m-wide track shoes, which have been replaced by massive 1.8m-wide triple grouser pads with a 35-degree bevelled outer edge, sourced from M&S Plant Spares. Lakeside Plant Hire runs a fleet of machinery dedicated to undertaking the most extreme working challenges, which are constantly in demand. For this project they were equipped with Movax SG40 pile hammers, all except the most recent CX210D, which hosts a high-capacity SG45 model.
SITE VISIT
At the time of our visit, the piling team was working on The Sheehys (Derrymore) section of the project. All nine low ground pressure excavators operating in unison on adjoining lines of pile sets made for an impressive working spectacle. This level of progress is only possible due to the sterling efforts of the preceding set-out and pile delivery teams.
Under normal circumstances, the Movax piling hammers can drive in the Sigma piles to the required depth without problems. However, there are occasional exceptions when subterranean obstructions are
encountered. In these few cases the ground must be either drilled or excavated.
This mass piling approach allows for greater ease of co-ordination of the overall project, ensuring that large areas can be made ready for the specialist contractor to form the solar PV array tables on the driven piles. Unlike previous solar farm developments undertaken by Wills Bros, these piles protrude beyond the ground to a far greater level and incorporate the leg that will support the table assembly. This means there is no need to add extensions to the piles, thereby reducing the time that will be required to undertake this task. On this section of the project, each of the nine excavators was driving at least 80 piles per day, but this level of productivity is likely to increase as they move on to the Monaincha section. Project manager Damien Ryan said, “Since there are working spans running to over 800m in length on the Monaincha site, we expect they will exceed the current pile driving abilities. As each machine settles into much longer lines of piles, time
losses for relocation will be reduced, which will cut into production.
“We are very satisfied with the level of progress we have achieved on the project, which is a tribute to the extended site team. They work extremely well together and apply their experience, which results in the smooth running of the whole operation. It shows how much progress can be achieved, while still maintaining the highest safety and environmental standards, which is especially important on a sensitive site such as this.”
Below: Lakeside Plant Hire deployed five converted Case 21-tonne class low ground pressure excavators on this project.
Below: Three XCMG excavators were used by one of the sub-contractors installing some 26km of ducting on this project.
WELL PLANTED
Paul Argent reports on forestry contractor Gary Brown and Daughters, who have just bought their first JCB excavator
Left and above: Operator Carwyn Williams was surprised that his boss chose a JCB, but after a few weeks working with it he is delighted about its comfort and power.
As the demand for timber and biomass products is constantly growing, contractors are being asked to turn forestry sites round at a faster pace. While cutting and stacking timber make up a large portion of the effort, there is still a significant volume of work left to do to allow replanting to commence.
Based in Felinfach near Lampeter, Gary Brown and Daughters operates across Wales for private landowners and Government departments, undertaking a range of forestry operations. While they still take on small clearance projects, the bulk of their work is the preparation of land for replanting after the timber has been cleared.
Much of the brash clearance and mounding operations are carried out using a fleet of compact tailswing excavators. Recently in the market for a replacement machine, Gary stepped away from his traditional source and looked at a range of alternatives. He said, “We have been loyal to one brand for many years. The machines have been great for us, but we felt they were being left behind a little. This prompted us to take a look at a variety of 14-plus-tonne machines and liked the build quality of the new JCB 145XR.”
LONG-TERM OPERATOR
Supplied by Gunn JCB, the new arrival on the fleet has been handed to one of Gary’s more experienced operators, Carwyn Williams. He has been with the team for almost a decade, during which time he has undertaken many miles of mounding across the forests of Wales.
Initially taken aback when he was told that his new mount would be a JCB, Carwyn said, “We haven’t seen a yellow machine on the fleet in the time I’ve been here, and I was shocked that Gary would change brands. To be honest, I’m really pleased that he has. The new JCB is a far superior machine to my old mount, far more comfortable with more space in the cab and a lot more powerful too.”
The 145XR’s sculpted counterweight sticks out just under 200mm over the machine’s 700mm-wide tracks, Carwyn commented, “A standard machine would end up being caught on stumps from day one. We can be working at some steep angles and all it takes is for us to find a stump that hasn’t been cut at the right height and hitting it could cause thousands of pounds of damage.”
The LC undercarriage on the 145XR is the same that is offered on the standard tailswing 140X model and puts over 2.8m of track on the ground. It is currently fitted
Left: The sculpted counterweight of the 145XR sticks out just under 200mm over the machine’s 700mm wide tracks.
OPERATOR FEEDBACK // JCB
horns on the rear, which are ideal for grubbing up material.”
with JCB’s standard bottom roller guards, which will be replaced with full-length skids to offer more protection. The existing fleet of reduced tailswing excavators weigh in at around 15 tonnes, the 145XR model is about a tonne heavier.
Carwyn continued, “The only issue we may have with this is if we are on very wet ground. We can put a set of 800mm-wider pads on if we need, but I don’t think it will come to this, as the JCB seems to manage the terrain far better than my last machine. For the day-to-day work we do, we don’t want anything too wide, as we must fit in between the stumps. Wider tracks will ride up on the stumps if we’re not careful and can easily be damaged or taken off. So far, I’m really liking the way the digger sits and while it’s not the steepest of sites, it is very stable and the traction is excellent.”
The undercarriage is also fitted with an optional dozer blade, which Carwyn says is far heavier and a more robust design than he is used to, “It seems to be built exceptionally well and handles the weight of the machine with ease.”
At the business end of the machine sits the standard mono boom, a 3m stick and a JCB hydraulic coupler, which carries a customised Geith 600mm-wide bucket. Carwyn said, “This has been my bucket for a few years now and has been fitted with the
The compact tailswing upper-structure is dominated by the full-size, JCB Command Plus cab, the same as is used on other JCB X series machines, Carwyn said, “I am very impressed with the space in the cab. My last machine had very little space behind the seat, which meant coats and bags were either on the floor or right behind my head, which wasn’t great. I can put everything I need behind the seat and still have room left even with the seat right back.”
JCB 145 XR WALK ROUND
Since its launch, JCB’s X series Command Plus cab has been lauded by operators, including its excellent seat and well laid out controls. This recently-launched 145XR version features a new 10in monitor, which helps to make operating the excavator a calm and effortless task. The use of a high-spec 360-degree camera system on the 145XR may seem overkill in this application, but operator Carwyn says it is a great help when it comes to picking out stumps and piles of brash on the rear and offside of the machine.
The compact upper-structure houses JCB’s 4.8-litre DieselMax engine, in this application rated at 109hp. Access to the engine is on the offside of the upper-structure via a set of well-placed, non-slip steps and hi-viz handrails. Both the diesel and AdBlue filler points are built into the steps enabling them both to be easily accessible from ground level. Operator Carwyn pointed out the routing of the hoses along the rear of the boom, saying that they were a much neater design than his previous machine and allow him easy access to the engine bay, rather than shimmying around them as he did before.
Left: Sat on 700mm wide pads with over 2.8m of track on the ground and a heavy-duty blade, the JCB 145XR seemed well balanced.
Left, inset above, above and below left: With a customised 600mm wide bucket on a hydraulic coupler on the end of a 3m dipper stick, on mounding work the excavator tends to work art full stretch.
We met Carwyn as he and a colleague were part way through a relatively small project. At just 12 hectares, the slightly sloping site wasn’t a real test for the new excavator, but in just a couple of weeks of operating, Carwyn thinks that his boss Gary has made the right decision.
Moving up and down the hillside, Carwyn was digging between the stumps to provide a small mound of soil, on to which a new sapling will be planted in the forthcoming weeks. Picking a route between the stumps to keep the tracks from damage, he worked at full stretch around the machine to reduce tracking about the site.
In conclusion, he said, “I’m really happy with the machine. It’s comfortable and powerful and seems to be on par for fuel with my old machine. The detail on the machine is excellent even down to the LED lighting in the engine and side compartments, which is a nice touch when you work in remote locations as we do.”
Gary has also had a short stint on the new JCB and was also complimentary about its smooth operating style, “I can’t fault it. We got a good deal on it; it arrived on time and my operator likes it. As long as it’s reliable and can stand up to the job we do, which I’m sure it will, I think we’ve got a great machine.”
Top and above: The operator praises the full-sized cab on this reduced swing radius excavator; the multi-camera system is proving to be a worthwhile aid to avoid stumps.
GEARING UP FOR
THE FUTURE
Nick Drew reports on a groundworks firm based in the south-west of England that has recently made the decision to invest in high-spec Liebherr excavators
It has been five years since we visited Ionic Groundworks when it had just been established as a spin-off division of the Devon-based housing developer Harrington Homes. The business was formed essentially to provide Harrington Homes with an in-house groundworks firm, but a lot has changed since then, as it is now a completely separate entity.
While Harrington Homes is still being managed by Gareth Hughes, a new MD for Ionic Groundworks has been appointed in the shape of the highly experienced Steve Presland. Steve has amassed over 25 years in the civil engineering sector, both in the UK and Australia. He has been joined by Dave Collins as the head of technical and commercial
aspects of the business, together with Darren Stawski as the senior contracts manager.
Since the arrival of this forward-thinking trio of industry professionals, they have expanded the reach of Ionic, offering a complete groundworks package to
Below and inset: The firm plans to continue to invest in Wacker Neuson compact excavators and site dumpers from M&M Plant.
other developers. At the time of our visit they were working on ten sites for external clients, together with two sites for Harrington Homes. They typically have 35 to 40 employees on the books at any one time. In addition, Ionic now has its own reinforced concrete division for constructing structures such as retaining walls.
LARGER FLEET
As the workload increased, so did the need for more machines. Five years ago, the fledgling enterprise invested in Case excavators and Wacker Neuson site dumpers and compact excavators. The first two Case CX130D excavators that were purchased are still in operation, but have gone through a significant refurbishment by the dealer M&M Plant after reaching 4500 and 5000 hours.
This included a total respray and new company branding, together with green and white counterweight chevron decals supplied by Brandfix. Two Wacker Neuson ET90 site dumpers and three DW90 cabbed versions have recently joined the fleet, once again supplied by M&M Plant.
Darren Stawski said, “We have a long history of working with M&M and they are really good. We deal with Bruce Bellamy the manger a lot and even those in the offices, hire and servicing departments, they are all really good and helpful people.”
However, for the latest machines the company has, somewhat surprisingly, turned to Liebherr, which are not often seen
working in the groundworks sector in the south-west of England. Darren said, “There’s no doubt about it, Liebherr is a premium brand. We had good discussions with our local Liebherr sales manager Paul Beasley. With high resale values and predicted low fuel consumption, we feel they are a very good investment for our business.
“We are taking six machines, comprising two 22-tonne class R922s, which have both been delivered and we have four 15-tonne class R914 Compacts coming, with delivery commencing in July of this year.”
Darren confirmed that Ionic’s plan going forward is to stick with M&M Plant for the
smaller machinery, including compact excavators up to nine tonnes, site dumpers and compaction equipment, while the heavier excavators will be supplied by Liebherr.
SITE BACKGROUND
We caught up with one of their teams working for Harrington Homes on a groundworks contract at St Austell, Cornwall. Specifically the second phase of the West Carclaze Garden Village that, when completed, will become a new lakeside-based community, built around the unique and historical china clay landscape. This is a major development with in
Right and below: Ionic has placed an order with Liebherr for a pair of R922 excavators together with four R914 Compact models.
excess of 1000 dwellings being constructed, along with supporting schools, doctors and dentist surgeries, shops and pubs. Some 350 acres of surrounding land will become home to a new country park, enabling walks through parklands, while in the distance standing proud is famous Sky Tip, a protected structure that was first created from China Clay material in 1936.
The main developer is Eco-Bos who are working in partnership with Orascom Development Holding, specialists in the creation of sustainable and eco-friendly communities, together with Imerys who run the china clay extraction process in the area. All the properties will feature environmentally friendly designs including roof-mounted solar panels and air source heat pumps.
Ionic are undertaking a full groundworks programme with roads, sewers, foundations and build-up to DPC level.
Both the refurbished Case CX130Ds were working on this site, with fleet number 001 breaking out hard rock with a Soosan hammer, ahead of one of the new Liebherr R922 excavators.
OPERATOR FEEDBACK
getting used to it, I’m really embracing the concept.
“It’s not all a bed of roses though, as there are some annoying little issues.
I don’t like the fact that you can’t adjust the joystick pods independently, so I find it difficult to get a comfortable operating position. And, on the hydraulics front, it doesn’t seem to like doing two or three functions together. For instance, when tracking with a load on and you try to slew, one function saps the other and the movement can become a bit jerky.
“We have had some minor teething problems, but in all fairness they have been rectified pretty quickly. Overall, I’d have to say it’s an impressive and powerful excavator for sure.”
With regard to slewing performance, Chris reports that it’s pretty lively in the swing with a decent 12.9rpm listed on the spec sheet and a swing torque of 74.3kNm.
One thing I observed while watching this machine in action was just how quiet it is for a 22-tonne class excavator, it just purrs away as it effortlessly goes about its business. Its official external noise rating is 102dB(A), while inside the cab it’s only rated at a mere 70dB(A).
SUMMARY
It’s always a bold step changing from a brand of machinery that you have become accustomed to over the years. This is just the
LIEBHERR R922 DRIVELINE
Built in Liebherr’s factory at Colmar in France, the R922 Litronic Generation 8 model tips the scales between 22,250kg and 24,550kg depending on spec. It is powered by a four-cylinder FTP engine rated at 120kw (163hp) at 1800rpm.
At the heart of the hydraulic system is a Liebherr variable displacement, swashplate double pump offering a maximum oil flow of 2 x 210lit/min and a maximum pressure of 380bar. The controls are electro-hydraulic via proportional joystick levers, which are becoming the standard in the industry these days.
The undercarriage is a strong looking X-frame design, which you could say is like many aspects of Liebherr machines, essentially over-engineered, with integrated tie-down eyelets for transportation and lifetime lubricated track rollers. Overall track length is 4435mm on the LC version and features eight bottom rollers and two carrier rollers. This example also featured forward mounted track guards to help prevent de-tracking at the idler end.
start of Ionic’s association with Liebherr and it will be interesting to see how the relationship progresses going forward. There was definitely a lot of enthusiasm for the new Liebherr machines from the Ionic staff we spoke to on the day, and the addition of the compact radius R914 excavators will be another big step forward. Reduced tailswing machines are ideally suited to the house-building sector where space between plots is at a premium, allowing Ionic to further up their game.
At the controls of the Liebherr R922 was the well-known Cornish operator Chris Centini, who is no stranger to the pages of this magazine. He said, “It’s a solid, well-engineered piece of kit, some of the tech on it is mind blowing. It’s fully kitted out with Leica machine control and this is my first time using the GPS technology. I was a bit daunted at first, but now I’m
Left and far left: The Liebherr is fitted with Leica machine control and operated by Chris Centini, his first experience of working with a 3D GPS system.
Left and below: Ionic’s original pair of Case CX130D excavators have been refurbished by M&M Plant, including a new paint job.
TINY TELEHANDLERS
A growing sector of the market is compact telehandlers, the smallest of which are less than 2m tall and 2m wide, allowing access to restricted sites, but delivering surprisingly good lifting performance
MERLO RANGE
The Merlo range includes a pair of eWorker battery-powered compact telehandlers, available in two-wheel drive/60hp and four-wheel drive/90hp variants. They provide a maximum capacity of 2500kg and a maximum lift height of 5m. Offering a turning radius of just 2.85m and 3.25m respectively, the battery pack is said to give eight hours of continuous use. For added versatility, the eWorker can be specified with an access platform, from which the machine can be controlled.
The conventional P27.6 model offers a lift capacity of 2700kg and a lift height of 5.9m. It is powered by a 75hp Kohler engine mated to a single-speed hydrostatic transmission with an impressive top speed of 40kph. Under 2m high and less than 2m wide, it can access the most restricted sites.
Merlo’s TF33.7 and TF30.9 models offer lift heights of 6.6m and 8.6m, and maximum capacities of 3300kg and 3000kg respectively. They are also powered by a 75hp Kohler engine driving a hydrostatic transmission.
The compact P30.10 model features front axle-mounted stabilisers and offers a maximum lift height of 9.8m and maximum capacity of 3000kg.
NEW MAGNI MODEL
The new TH35.9 compact model from Magni offers a maximum lift capacity of 3500kg and a maximum reach height of 9m. It is equipped with Magni’s Load Moment Indicator (LMI) system as standard, which helps to ensure constant control in all lifting phases, avoiding the overloads experienced with the usual load cell-based systems. There is a 7in touch-screen in the cab that shows a real-time display of the load charts for the attachment being used.
Power comes from a 75hp Deutz engine and a hydrostatic transmission, which, combined with the drop-box with two forward and reverse speeds, enables it to cope with gradients of up to 89% and provides a top speed of 32kph. It is just 2m high and a fraction of 2m wide, allowing good access to restricted spaces. The cab is based on the new design introduced in 2024 on the TH3.6 model, but is more spacious inside.
TOWABLE MANITOUS
French-based Manitou offers an extensive range of telehandlers, of which the smallest two models are the ULM 412H and ULM 415H that can be towed on a suitable lightweight 3.5-tonne capacity trailer.
They are powered by a 26.2kW Yanmar engine and have maximum lift capacities of 1250kg and 1500kg, respectively, and both feature a maximum lift height of 4.3m. Less than 1.50m wide and 1.92m high, they can access extremely restricted job sites.
These two extremely compact telehandlers are also available from sister company Gehl, known as the GCT3-14 and GCT3-14+ models.
NEW WACKER NEUSON
he latest compact telehandler in Wacker Neuson’s range is the TH625, providing a maximum lift height of 6m and a maximum payload of 2.5 tonnes, it is available with a choice of either a 45kW or 55kW engine. It joins two other models in the range, the battery-powered TH412e and its diesel-powered sibling, the TH412. Both are under 2m tall and 2m wide and provide a maximum lift capacity of 1250kg and a maximum lift height of 4.3m.
TThe electric version is available with a choice of 96v lithium-ion battery packs, rated at either 18kWh or 28kWh.
The standard build includes a single 3kW on-board charger, with the option of a second 3kW unit to provide faster recharging times. The diesel version can be ordered with a choice of either an 18.4kW or 33.3kW engine.
SMALLEST SANY
any continues to expand its telehandler range. Latest model is the STH742, which offers a maximum lift height of 7m and a maximum load of 4200kg. It is powered by a 55kW Deutz engine.
ST COMPACT BOBCAT
he Super Compact TL25.60 telehandler is the smallest model in the Bobcat R series range. Powered by a 75hp Bobcat engine, it has a rated operating capacity of 2500kg and offers a maximum lift height of 5.9m and a maximum reach of 3.3m.
Like other models in the Bobcat R series, the offside engine hood has been designed to maximise visibility to the right-hand side of the machine, which is further assisted by slim cab pillars and a modern unobtrusive dashboard.
Bobcat claims that thanks to the flow sharing hydraulic system, including a hydrostatic transmission, movements are smooth and quick. Helped by a tight turning radius, this leads to fast cycle times. It can be configured with either a manual or hydraulic Bob-Tach carriage, which allows the TL25.60 to use attachments designed for Bobcat compact wheel loaders.
SMALL LIEBHERRS
The Liebherr range includes two compact models, the T32-7 and the T33-10, offering maximum lift capacities of 3200kg and 3300kg with maximum lift heights of 6.9m and 9.7m, respectively. They feature the EcoMotion system, which enables the telescopic arm to be lowered load-free, without having to increase the speed of the engine. At the same time, this function allows more efficient working movements, as the telescopic arm can be lowered faster and more evenly.
The cab is said to offer an excellent all-around view, while a spacious interior and ergonomic controls provide for relaxed and productive working. The hydrostatic drive with stepless acceleration and manoeuvrability ensure fast workflow, even in confined spaces.
DIECI DELIGHTS
talian manufacturer Dieci offers a wide selection of compact telehandlers, including two models from its Apollo range, the 20.4 Smart and the 26.6. The smaller model offers a capacity of 2000kg and a lift height of 4.35m, while its larger sibling is rated at 2600kg and 5.73m.
IThe four models from the Dedalus range start with the 30.7GD, which offers a capacity of 3000kg and a lift height 6.35m, up to the 34.7GD which has a capacity of 3400kg and the same maximum lift height. The GD suffix to the model names feature a Giugiaro Design cab, which Dieci claims offers unmatched comfort, together with intuitive controls.
BRITISH-BUILT MODELS
our Loadall telescopic handlers with operating weights of under 6t namely the 514-40, 520-40, 525-60 and the 525-60E battery electric model are offered by JCB.
The smallest model, the 514-40, is just 1.8m high, measures 1.56m wide and has been designed to access the most confined sites. The machine is powered by an 18.4kW engine and features permanent four-wheel drive and four-wheel steering.
Designed to deliver the same performance as the conventional diesel-powered machine, the 525-60E offers a maximum lift capacity of 2500kg and is capable of lifting 2000kg to its maximum lift height of 6m. It also offers the same 3.7m outside turning radius as the conventional 525-60 model.
The 520-40 model, which has an operating weight of 4400kg, provides a maximum lift height of 4m and a maximum lifting capacity of 2000kg.
HIGH-VISIBILITY AUSA
ive models make up the AUSA range of compact telehandlers, which offer load capacities from 1.35t to 2.30t and maximum lifting heights of 4.0m, 4.2m and 5.0m.
They include the battery-powered T164E model, which offers a maximum load capacity of 1600kg and a maximum lift height of 4.0m. Ausa claims it has been designed with sufficient capacity for a complete day of work without needing to be recharged. It can be recharged from a 110v or 230v supply or, if connected to a fast charger, from a 415v supply.
The key feature across the entire Ausa compact telehandler range is that the engine is located at the rear of the machine. This configuration results in narrow machines with a decent-sized cab, which is positioned forward over the front axle, offering excellent visibility.
F ELECTRIC FARESIN
Based in Breganze in Italy, Faresin Industries produces both dieselpowered and electric telehandlers. Their smallest diesel machine is the 6.26, which has a maximum capacity of 2600kg and a maximum lift height of 6m. The 7.32C and 9.32C models offer a maximum capacity of 3200kg, with maximum lift heights of 7m and 9m respectively. The option of a low cab enables an access and transport height of just 2.06m.
Faresin also offers a four-model range of battery-powered telehandlers, the smallest of which is the 6.26 model that offers a lifting capacity of 2600kg and a lift height of 6m. It works on an 80v system and is available with battery packs offering 24kWh, 32kWh or 43kWh of storage.
In addition to the on-board charger, options include an integrated rapid charger, an external rapid charger and an external charger suitable for a three-phase supply.
A CONNECTED SITE WORKING
Peter Haddock visits an MJL Group team that is delivering a large 3D-enabled groundworks project
year ago, groundworks contractor MJL Group was awarded its largest ever house-building project, the Foundry Lea development, located a few miles from Dorset’s Jurassic coastline and near the market town of Bridport. Over six years a consortium of house builders, including Barratt, David Wilson and Vistry Homes, will deliver 760 homes and a new primary school, together with business, retail and community facilities.
Due to the variety of earthworks requirements on the sloping site, including managing several watercourses, MJL has taken on multiple groundworks roles. They range from installing all the core underground utilities and the necessary infrastructure, including roads, bridges and attenuation
ponds, together with delivering individual housing plots for the different house builders.
MJL’s project manager Richard Patch said, “We are connecting into existing road infrastructure, so it has been important to manage this part of the project and keep vehicle movements to a minimum.
“As part of this material movement planning, we have worked with Coles Plant, who are managing the muck-shift element. This includes the creation of a large stockpile of excavated material that will be reused on site.
“This reduces the need to take material off the project, but also comes with additional management requirements because we have different clients on different parts of the site. Before we move excavated material, we survey the area and
work out volumes with the Coles Plant team, who then manage the movement and stockpile.
“To support opening up the different parts of the site and material management, we are currently installing several bridges over the existing watercourses. This has been quite a challenge because of the depth that we’ve had to go to put the embankments in. For example, on our largest bridge we are excavating down 4.5 metres lower than the river level. We must be very accurate with this part of the project.”
Above: The Foundry Lea development near Bridport will see 760 new homes built over six years, together with a primary school and various other community facilities.
DIGITAL MANAGEMENT
All the work is being undertaken using Leica 3D GPS machine control systems, while the complex project is managed through a digital model. Richard continued, “On a site like this, things change daily, so it’s really important that we keep our digital models on the machines up to date. To achieve this, we work closely with the team at JRC Consulting Engineers, who in turn share updates with Kemp, our land survey and 3D model partners.
“This allows Kemp to quickly make the relevant changes to our 3D earthworks models and remotely upload them to our machines. Kemp also handles key surveying tasks and helps us to provide as-built information to the wider client
teams for the core works and the individual house plots.
“Managing the earthworks modelling is critical to the project’s delivery. And it’s here that our set-up on site is so important. As soon as our site cabins were delivered, we ensured we had the right level of connectivity on site. We installed a Leica Geosystems base station to help us get really high levels of accuracy from this stationary GNSS (global navigation satellite system) receiver. It acts as a reference point by continuously monitoring satellite signals and calculating corrections to improve the accuracy, not just of the machines but also any survey rovers we have on site.
“Kemp also uses Leica surveying equipment, and we have enabled 14 of our machines on site with Leica machine control, all of which are supported by our local dealer, One Point Survey Equipment.
NEW TILTROTATOR OPERATOR
In addition to Leica machine control systems, tilt-rotators are also used on MJL’s mixed fleet of excavators. For Shane, an extremely experienced operator, this project was the first time he had worked with a tilt-rotator, an Engcon fitted to a new Volvo EC230. At the time of our visit, he was backfilling a bridge section He said, “As a business, we have been using tilt-rotators for this type of work for some time, so our MD Matt asked me to try one out. To be honest, I was a little nervous, but Matt said, ‘just have a go with it’. Once I had put some time into learning how the joysticks work with their extra buttons and control options, it wasn’t as difficult as I thought.
“One of the key areas that does take a little getting used to was learning to use the thumb controls and adjusting to the extra weight on the end of the boom. When I started using it around the bridge structure, it really came into its own. I could just sit the machine at one angle and work the batters without having to track around all the time.
“Backfilling and drainage work is also much easier. You can simply line up the machine and tilt-rotator on the tablet, whether it’s a drain line, a cambered road or a kerb, and there’s much less guesswork. You can see all your levels and even use the bucket to record points from the work you have completed.”
Talking about the new EC230 excavator, Shane continued, “I have been used to operating Volvo equipment for some time, my previous machine being an EC220, but this new model is quite a lot better. I particularly like the upgraded controls, electric servos and dash layout. The cab is also very large and the upgraded seat is really comfortable, which is especially beneficial as I operate the machine in my socks.”
Below: A new Volvo EC230 excavator is configured with an Engcon tilt-rotator in addition to a Leica 3D GPS system.
Above: MJL’s project manager Richard Patch is co-ordinating the works using Leica machine control systems and 3D digital models.
KOMATSU FAN NIGEL AVERY
Working on another area of the site, putting in a new road with a PC240 excavator, Komatsu super fan Nigel Avery said, “I have been operating Komatsu machines for over 20 years now, and when I joined MJL 18 months ago it was the first time I had used machine control on a machine.
“Having been an operator for decades, first getting in the seat with my dad when I was eight, I was very reluctant to take on machine control. I didn’t think I’d get used to it, but it’s very good, and it makes life easier. Now that I am used to it, it saves me a lot of time. I am also now helping the engineers with recording levels using my bucket and tablet. I wouldn’t want to be without it now, and it makes it easier for everyone on site.
“My morning routine has also changed as I now get in the machine and turn on the tablet. It will prompt me if a new model is available for download. If this is the case, I just hit a button and it uploads straight into the tablet, and I am ready to go.
“Currently, I am using the system constantly, as we place and remove layers of stone and material to allow for the correct installation of drainage and utilities. This is to prevent damage to the critical geotechnical membranes that we need to install.
“To complete this job, we lay down a running layer to reach the formation level and then all the services are installed. After that, we remove everything again to lay the geogrid and capping layer. It’s all got to be done properly, or the drainage work could cut through the membrane. It’s a quite intensive and detailed process that requires high levels of accuracy, as the materials used are expensive. This is why we rely on machine control to get the right layers.”
They look at everything from machine control to our rotating and pipe lasers. It makes a big difference knowing they’re on hand and understand our requirements. They even fit the machines with the systems and their engineer, Rob, works very closely with us to support our operators.
“This set-up allows real-time updates to be pushed directly to the machines. Once an operator receives a model update, they simply tap their screen, download the latest model and get to work. For the whole team and me this flexibility is a game changer. For example, if there’s a delay in one part of the site, we can shift an operator to another section with a few taps. They can even scroll through and select new tasks themselves.
“We’re GPS tracking everything that goes in the ground and co-ordinating it live. That means our operators can see exactly where services are, and they get real-time warnings for overhead cables or
underground pipes. By knowing exactly where the core services are, like the high-pressure water main and electricity feeds, when it comes to branching off these for the houses in particular, the process is much simpler as each utility and connection point is mapped.
“This minimises any risk of damage while building the site, but also helps to mitigate risk with any maintenance or repair works needed in the future, as we all know the impact of things like cable strikes. Equally, as we have a very fluid site with designs changing, this level of integration reduces downtime, increases safety and allows for more accurate as-built models. This is one area that is increasingly important to clients and developers managing long-term assets.”
With years of work still to be done on site and an expanding fleet of machines in operation across the south-west of England, there is certainly a lot of opportunity ahead for the MJL team.
Left and above: At the time of our visit a Leica-equipped Case CX210E was excavating trenches and installing concrete pipes.
Elsewhere on site, Eddie Capel was operating a Case CX210E, racing through the task of digging and then lifting concrete pipes into the ground. He said, “Until I joined MJL, I had never used a Case machine or Leica machine control, so it was all new to me, but I have been mightily impressed. Everything’s smoother and quicker with the Case compared to other machines I have used. Even just pulling the bucket through the ground feels massively different.
“With the digital model in the Leica tablet, even if I finish a task early, I flick through the system in the cab for the next job. All the files are right there, including the existing mains, drainage and other services. I just ask the site manager where they need me to move the machine, load the new model and off I go. It’s just easier. Everything is right at your fingertips, and the system is really intuitive.”
In his early 30s, Eddie has already seen how newer operators have to bridge the gap between traditional hands-on experience to using modern digital tools and systems. However, he’s concerned about how difficult it’s become for young people to break into the sector, adding, “Back in the day, you could just hop in a machine and learn on the job. Now, it’s all tickets, safety rules, and restricted access. That makes it hard for the next generation to even get a chance behind the levers. Machine control is great for new entries, it’s your guide, your mate in the cab so I’d recommend the job to anyone who’s serious and gets the right training.”
Left and below: Fitted with a Leica machine control system, a Komatsu PC240 excavator was working on one of the site’s new roads.
FUEL-EFFICIENT CRUSHING
Paul Argent reports on a pair of Austrian-made SBM jaw crushers, the latest additions to the Skillings Crushing fleet
We have featured the extensive Liebherr excavator fleet belonging to Skillings Crushing on several occasions. The firm is well known for its ability to tackle heavy demolition projects such as power stations, manufacturing facilities and anything where heavily reinforced concrete is found. Skillings’ reputation for dealing with this material makes them the first choice on many a regeneration project across the UK.
Liebherr excavators play a major role in the company’s fortunes. The thousands of tonnes of reinforced concrete that they generate each year requires processing to remove the last of the reinforcement and to turn the concrete into a high-quality, reusable material.
SBM CRUSHERS
Skillings recently changed its front line processing machines for a pair of SBM Jawmax 450 tracked crushers, supplied by Barry O’Regan from the Orba Group. SBM was founded by Franz Wageneder, the owner of a sand and gravel quarry who required an efficient and productive method of processing materials. Some 70 years ago after a fruitless, search for the right machine, he decided to build his own impact grinding mill.
Based at Oberweis in Austria, today SBM Mineral Processing manufactures a full range of stationary and mobile crushing,
screening and conveying systems, in addition to machinery for producing ready mixed concrete. The company currently offers four models in its Jawmax range of mobile jaw crushers. The top of the range 450 model offers a theoretical maximum production rate of 500 tonnes per hour, but is rated at 230t/hr when crushing concrete and brick.
JAWMAX 450
The Jawmax 450 features a highperformance pre-screening unit that helps reduce crusher wear, while improving the material production in terms of quality and output. This new circular-motion, doubledeck vibratory pre-screen is directly connected to the vibrating chute in the feed hopper. A triple flap on the screen
PROCESSING // SBM JAWMAX 450 //
allows two fractions to be discharged in full or in part as fines or added to the end product as crusher bypass.
The 450 model features an in-house manufactured STE 110-70 jaw crusher unit, which was specially developed by SBM for mobile applications. As one of the largest crushers in the 40-tonne size class, the machine’s 14-tonne jaw crusher unit features an inlet opening of 1100mm x 700mm and accepts a nominal feed size of up to 700mm, making it ideal for some of the irregularly shaped lumps of concrete often found on a demolition site.
Like all SBM mobile crushers, the Jawmax 450 can be specified with either a dieselelectric or fully electric drive system. Skillings has opted for the diesel-electric version, allowing them greater flexibility while working on fast moving sites. The dieselelectric drive unit consists of a 6.7-litre Cummins engine rated at 170kW at just 1500rpm. It is linked to a 200kVa on-board generator that feeds all electrical drive motors for the feeders, screens and conveyor belts, as well as the electrically operated hydraulics for the lifting cylinders and tracks.
The jaw crusher unit is driven, via a V-belt, by an 110kW electric motor. With its 34mm stroke and automatically monitored gap adjustment of 40mm to 160mm, which can be adjusted under load, the Jawmax 450 is designed to ensure continuously high production output of high-quality final aggregates.
The Jawmax 450 has been designed to allow ease of transportation between projects. With a transport weight of just under 40 tonnes and just 2.88m in width, the crusher folds down to just 14.71m in length and 3.6m in height. After unloading from a low-bed truck or uncoupling the optional three-axle dolly, the hopper walls, over-band magnet and discharge conveyors are positioned hydraulically without tools, making the plant fully operational in just over five minutes.
The crusher comes as standard with a multi-functional remote control, which includes the ability to enter set-up routines of the SBM Crush Control system, which also monitors and controls the fully automatic crushing operation in line with pre-set parameters. In addition, a webbased app allows remote access to all important operating and production data.
SITE VISIT
We encountered one of the new Jawmax 450 crushers on a site at Ironbridge, where Skillings are working alongside John F. Hunt.
Unlike many traditional diesel drive machines, the use of the diesel-electric drive system not only reduces fuel consumption but also offers a massive reduction in engine noise. A conversation can be had while standing just a few metres away from the unit, as it chews through reinforced concrete. On this site the
Left and above: The diesel-electric 40-tonne SBM Jawmax 450 crusher with a pre-screen consumes just 13 litres of diesel an hour, including powering the Screencore 480 tele-stacker.
Below: The jaw crusher unit is driven via a V-belt by an 110kW electric motor. The Jawmax 450 also features a powerful overband magnet to remove the last of the rebar.
TAIL END // PROCESSING //
crusher is consuming just 13 litres of diesel an hour.
Skillings site manager Liam McCarthy said, “We are very conscious about the volume of fuel we burn on any of our projects. Everyone knows the Liebherr machines are the best on fuel, and we believe we now have the most fuel-efficient crushers available too.”
Another feature of the Jawmax dieselelectric driveline is its ability to generate sufficient power supply to operate another new addition to the Skillings fleet, a Screencore 480 tele-stacker. Skillings has been using a variety of tele-stackers for several years, as they save money on running a wheel loader to handle the crushed material.
Liam continued, “Having a tele-stacker is the more cost-effective choice these days. The Screencore, which was also supplied by Orba Group, can use its own Cat C2.2 diesel engine to drive the two electric motors that power the 24m belt, but it can also run from a lead plugged directly into the SBM crusher.”
With a 1.2m-wide heavy-duty belt and 11.5m discharge height, the Screencore 480 uses a large hopper offering easy spotting for the discharge conveyor on the SBM. Like many crusher and screener manufacturers, Screencore is located in the heart of Northern Ireland’s crusher production region of Dungannon.
Manufacturing a range of crushers, scalpers, screeners and stock-pilers, the company focuses on compact, highly productive machines that can be transported between sites with minimal fuss.
WORKING METHOD
On this site, material is broken out of the ground by a pair of 70-tonne class Liebherr R966 excavators, together with a 55-tonne R956 and a 40t R938 model. All are fitted with OilQuick couplers and use a variety of Rammer hammers and Epiroc crackers to break the concrete into manageable pieces. While much of the rebar is removed at the point of demolition, some inevitably gets through to the crusher, which uses a powerful overband magnet to remove them to leave a clean, consistently sized product.
second Liebherr sits atop a pile of material loading the SBM tracked crusher. The Screencore 480 allows the team to stockpile a huge cone of processed material without the need for any intervention from any of the other busy machines on site.
The material is loaded on to Skillings’ new Liebherr TA230 ADT, which ferries the material to the processing area. One of the Liebherr 30-tonne class R930 excavators, fitted with an Epiroc processor, reduces larger lumps to a more manageable size and further removes any reinforcing bars. The material is pre-crushed before the
Not only have the new additions increased the company’s production figures, but they have also reduced the cost per tonne of material processed and in the same step lowered their carbon footprint of recycling demolition arisings.
Liam concluded, “We may not be seen as a green company in what we do, but with every little change we can make, we are doing our bit for a greener construction industry.”
Above and below: The Screencore 480 tele-stacker, which can be powered from an external electrical supply or by its own diesel engine, is a perfect partner to the Jawmax 450 crusher.
TEXAS ELEVATING CHAIN MUCKSHIFTING
On a recent road trip in America, Lucas Haddock had the chance to speak with a 21-year-old operator of a motor scraper
n a major housing development at Rockwall in Texas, Stephenson Dirt Contracting has deployed a large fleet of machinery, including three motor scrapers that are performing most of the bulk material movements. One of them is a 1998 Cat 623F single-engine elevating scraper, which has been retrofitted with a Leica 3D GPS system. At the time of our visit, this huge machine was undertaking relatively precise work, helping to get the route of the site roads down to grade.
Putting aside the sheer scale of the projects I visited in America, their machine choices are far different to European sites, as is their attitude to giving young adults a chance to operate on site. The Cat 623F was being operated by Oscar Miranda who is just 21 years old, but already has a few years of experience under his belt.
MACHINE PROGRESSION
Oscar said, “I was looking for a job after high school and wanted to get into construction, as I knew there were lots of opportunities in the sector. I started to look around at the companies in my area and came across Stephenson Dirt. After dropping off my details, they asked me in to talk about a role and started me on as a labourer. At first it was all about proving myself and getting stuck into working with the team.
“I then saw what the machine operators were doing and asked if I could try out being an operator. They then gave me an
Below and inset: Oscar Miranda (21) started out as a labourer with Stephenson Dirt and then quickly progressed to becoming an operator, gaining experience on a variety of machinery.
TAIL END // OPERATOR INTERVIEW // OSCAR MIRANDA
opportunity to get on a machine and I got stuck into operating.”
A common utility machine on most American sites is a skid-steer loader, which is what Oscar started out operating. He added, “The skid-steer was a lot of fun to drive and I learnt a lot about how to handle it in different tasks, from shifting dirt to moving materials around and generally keeping the yard clear. It was definitely the best machine to start on, as I had to quickly learn how to operate the joysticks and change attachments.”
Once he had mastered the skid-steer, Oscar went on to operate a backhoe loader, again a common machine on many American sites. He said, “With the backhoe again being a utility machine I found myself doing even more tasks like learning how to dig trenches.
“This helped me to progress into working on excavators, but I always had my eye on the bigger machines so pushed myself hard to get an opportunity to work on a dozer. The great thing about Stephenson Dirt is that, if you are keen, they will at least let you prove you have the passion to learn, as everyone has to start somewhere.”
SITE VISIT
Out of all the machines Oscar has operated, his current mount is by far his favourite, as the old school 623F is the only scraper on site to be fitted with 3D machine control. Known on this side of the pond as a paddle wheel scraper, the elevator system allows the bowl of the scraper to be quickly filled with the local dirt, without the
assistance of a push dozer.
Oscar continued, “Fitting Leica machine control to the scraper is a great idea. We are in the early stages of moving material on site, so it gives me a great guide to know where I need to lift and place the material. I am working alongside the dozer team and we can all see the same digital model, so can appreciate how we can operate as a team and hit the productivity targets we are given. I couldn’t tell you how much dirt I move in a day, but it’s certainly a lot, and with a scraper you can pick it up and drop it off quite quickly.”
As Eoghan Daly reports, McCormack Bros has added an Isuzu 4x4 crew cab vehicle to its range of road-rail plant operating on the Irish rail network
Above and inset: The road-rail conversion of this 4x4 Isuzu D-Max crew cab was undertaken to a high standard by Hanlon Rail.
Even though many operations on the rail network are mechanised, a significant volume of work is still undertaken by people on the ground, often to sections of the line far from the nearest access point. Since periods of rail possession to undertake such work are typically relatively short and there’s an overreaching need to conduct such operations to the highest of safety standards, there is a need for a road-rail transport solution for these workers, their tools and other equipment.
In recognition of the potential for a dedicated road rail pick-up truck on its plant hire fleet, County Longfordbased McCormack Bros recently put an Isuzu D-Max crew cab into service. It has been converted to road-rail configuration by specialist engineering company Hanlon Rail. McCormack operates several Atlas road-rail excavators and Davino rail dumpers that have been through Hanlon’s workshop in County Kildare, where they also have experience in converting Isuzu D-Max pick-up trucks.
DESIGN CONSIDERATIONS
In addition to ensuring that the finished vehicle meets all relevant rail safety and operating standards, the design of such a conversion must maintain the vehicle’s practical working ability, both on and off the road. Starting off with a standard five-seat D-Max, 1.9-litre twin-turbo automatic 4x4 vehicle, the level of cooperation received from Isuzu Ireland on this conversion was commendable.
“WHENITCOMESTO TRAVELLINGONTHE ROAD,YOUWOULDNOT
One of the first challenges was to design the attachment points for the pair of non-driven rail bogies, without modifying the vehicle’s chassis in any way. The rear bogie frame attaches to the vehicle’s existing towbar mounting point; the front bogie is attached by bolts on reinforcement bars.
Despite their durability, the rail bogie units represent only a marginal increase in the weight of the vehicle. The rear unit is 145kg, while the front bogie is slightly lighter at 135kg. Mounted low down, this lightweight solution allows the vehicle to maintain high levels of balance and handling, without an impact on its roading
abilities. This is aided by the rail wheels not protruding beyond the original overall width of the vehicle, so retaining its ability to negotiate traffic.
It was also important to maintain decent levels of off-road mobility, as it must be able to get on and off the rail network via access points where the angle up to and down from the track bed can be relatively sharp. The design of the bogies and their mounting arrangements maintains an acceptable level of ground clearance, together with surprisingly good approach and departure angles.
Below, inset and below right: McCormack Bros’ Sean Greaney reports that the vehicle is easy to get on and off the rail tracks, yet it retains its on-road driving capabilities.
ADDITIONAL SERVICES
The rail bogies are deployed and retracted hydraulically and together with a requirement to provide an air braking system for rail trailers, both these services had to be provided on the vehicle, but retaining as much of the rear load space as possible.
The major components for the hydraulic and air systems are mounted in a steel locker, located high up at the front of the load bed. This ensures that the floor length of this space is not compromised, allowing long-handled shovels and other tools to be accommodated without difficulty.
The load bed is covered by a hard top with side access panels as well as a rear door, together with a custom-made roof rack. The original spare wheel well now hosts an air tank, with the spare wheel either carried in the load bed or on this custom-made roof rack. The latter also carries a comprehensive lighting kit that meets the mandatory rail network standards for travel on a rail line. It also includes LED lights to assist with the safe access and egress of passengers and the retrieval or loading of tools to and from the load bed during night-time working.
The vehicle is also fitted with several cameras, principally to provide the driver with a view of the bogies to help positioning the vehicle, but also to provide a rear view when reversing. Incidentally, despite the presence of the rail bogies, the original front and rear parking system is still functional, albeit with some of the sensors disabled.
Hydraulics are controlled by a system provided by Dublin-based IFM, which includes a control monitor mounted on the vehicle’s dashboard. When the bogies are aligned with the rails, with the help of the cameras, they are lowered on to the line, and the hydraulic pressure applied to each bogie displayed in real time on the monitor.
The driver then locks the wheels into a straight-ahead position via a latch positioned on the top of the steering column housing.
VERSATILE WORKHORSE
Road-rail excavator operator Sean Greaney has been the principal driver of the new Isuzu D-Max. He said, “It is very user friendly to put it on and off the rail tracks and the cameras are a big help in aligning the rail wheels. There is also great space inside for four passengers and good storage space in the back for their equipment and tools. When it comes to travelling on the road, you would not know it was a rail conversion, as it
handles like any other four-wheel drive.
“The rail jeep has proved a great asset; we were transporting chainsaw operators to many parts of the network in the aftermath of winter storms, the Sligo area being one of the worst affected regions. We have also been providing transport for crews doing inspection of bridges and culverts, so its working roles have been varied.”
We met Sean and the D-Max on a job on the Limerick to Ballybrophy rail line, removing vegetation from an old stone bridge. Rail possession started late in the morning, lasting into mid-afternoon, and a road rail access platform was used to work at height. Sean transported the supervisor from Irish Rail and the operatives to and from the site, together with their fall arrest harnesses and hand tools.
After this job the D-Max has been used on a range of other operations on the Irish Rail network, including transporting personnel and their ultrasonic equipment to conduct rail-surveying projects.
Above, above right and below: Four passengers and their kit can be carried safely and in comfort to inaccessible stretches of the rail network.
Above: The durable but lightweight bogies are mounted to the vehicle without compromising its structural integrity.
BRITISH DESIGN HERITAGE
Keith Haddock explores the early history and origins of the articulated dump truck from a British perspective
Some 65 years ago, a new category of earthmoving machine went on sale. The articulated dump truck (ADT) was introduced to the global market by the Yorkshire-based manufacturer Northfield. It was followed in the early 1960s by several other British-built ADTs, all of which fell by the wayside as the muck-shifting industry of the time showed little interest in these pioneering designs.
However, with the notable exception of Volvo, the following generation of Britishdesigned ADTs went on to dominate the global market. Modern Caterpillar and Rokbak machines are still manufactured in their original factories in England and Scotland. In addition, Bell, Case and Develon/Hyundai articulated haulers have British DNA in their family tree.
BACKGROUND
Strictly speaking, the concept of off-road articulated haulers dates back to the 1940s, when prime movers designed for pulling scrapers were coupled to rear-dump or bottom-dump trailers. Following Letourneau’s Tournarocker, leading
manufacturers such as Allis-Chalmers, Caterpillar, International Harvester, Wooldridge and Euclid offered earthhauling trailer options for their scraper prime movers. However, they were a far cry from modern articulated dump trucks, which are both lighter, faster and designed for the sole purpose of hauling excavated material.
In the 1950s, several manufacturers began to offer earth wagons coupled to reinforced agricultural tractors, Fordson Major being the most popular prime mover for this purpose in the UK. Pulling a load
on a trailer was found to require less horsepower and was more efficient than carrying a load on the prime mover itself. Early British examples of this type of off-road hauler were built by ShawneePoole, Horley Dumpers (Morewear Goose) and Hudsons of Leeds (Leedsall).
ADT PIONEERS
A prototype of the first two-axle articulated hauler designed as an integral unit was built in 1957 by Northfield Industrial Fabrications of Ossett in Yorkshire. After an extensive testing period it was introduced
Below: Early articulated dump trucks used a scraper-type prime mover such as this Allis-Chalmers TR-200.
Below: The Northfield F7 is recognised as the forerunner of the modern-day articulated dump truck.
CLASSIC PLANT // ADT HISTORY
in 1960 as the Northfield F7 model, powered by a Ford 6D 96hp diesel engine. This forerunner of the modern-day ADT could carry 12 tons and boasted many features found in today’s designs, including 180-degree articulation actuated by two pairs of hydraulic rams.
The Northfield F7 was way ahead of its time. Apart from its surprising modernlooking appearance, it also featured a torque converter, epicyclic gearbox, two-pedal control and a top speed of 28mph. Its powerful double-acting hydraulic hoist rams could dump a load in seven seconds. George Cohen Sons was the UK dealer and sold the machine in 1961 for £3850.
Northfield replaced the F7 with the beefed-up 14-ton F9 in 1964, followed by the F12 model in 1965. This 20-ton machine was powered by a 120hp Perkins 6/354 diesel engine, with steering by two pairs of hydraulic cylinders.
CAMILL/MUIR-HILL
Another early ADT was the Camill dumper of 1963. The name is derived from an abbreviation of contractor Campbell & McGill of Devon, who initiated its design based on a six-cylinder Fordson 105hp engine. The power unit was mounted in a special frame featuring a robust hitch allowing 180 degrees of articulation and 15 degrees of lateral movement. The 10-ton capacity Model 6/10 was adopted by E. Boydell & Company of Manchester, makers of the Muir-Hill range of dumpers
Below: In 1963 Whitlock made a brave attempt to launch a hydrostatically-driven ADT. The 12-ton capacity DD105 was fitted with a transversemounted 105hp engine.
MARKET LEADER VOLVO
Although pioneering British ADT manufacturers during the mid-1960s were not successful, it was a different story in Sweden. In 1965, after previously building several tractor-trailer combinations using a farm tractor with power to the trailer wheels, Lihnell Vagn launched the DR630. It was a true articulated dump truck with a 4x4 configuration and a single-axle tractor.
Following much promotion by Lihnell, its ADT gained interest from Volvo, and in 1965 a marketing agreement between Volvo and Lihnell was established. The following year, Volvo launched the updated, 11-ton capacity DR631, the first ADT to carry the Volvo name. Its power unit was based on a BolinderMunktell BM350 tractor. This machine spawned the very successful Volvo range of ADTs and Volvo subsequently became the global market leader.
With the successful DR631 under its wing, Volvo introduced the much larger DR860 in 1968. With a capacity of 20 tons and a 150hp Volvo turbocharged engine, the machine had virtually no competition for its ability to travel on rough terrain with a full load. The front axle, as well as the front tandem axle, were powered in this 6x4 design. The Volvo ADT was the first to use long hydraulic rams mounted outside the chassis, a design later copied by others.
Volvo released the updated DR860A in 1970, and nine years later replaced it with the DR861. The DR861 was Volvo’s first truck offered with an all-wheel drive 6x6 option, a configuration that would eventually become standard in Volvo’s entire range.
and wheel loaders. The Camill ADT did not gain much popularity, but was used for many years by its design contractors on their own projects.
WHITLOCK
Whitlock Brothers of Great Yeldham in Essex, famous for its early loader-backhoe the Dinkum Digger, was also an early developer of a single-axle tractor as the prime mover for articulated dump trucks. The model DD95
Camill dumper of 1963. The 10-ton capacity machine was marketed by Muir-Hill.
Above: Whitlock was one of the pioneers of the single-axle tractor concept for ADTs, this 11-ton DD95 model was based on a 95hp Fordson tractor.
was based on a 95hp Fordson tractor with a standard mechanical transmission providing six forward and two reverse speeds. The unit had a rated capacity of 11 tons. Whitlock also offered the DD75 model with the same capacity, but equipped with a smaller 67hp engine. These dump trucks were only marketed for a few years in the early 1960s. In 1963, Whitlock made a brave attempt to market a hydrostatically-driven ADT. The 12-ton capacity DD105 model was fitted with a transverse-mounted 105hp engine. In two-wheel drive mode the front axle was powered and the vehicle could achieve a top speed of 20mph. In soft unfavourable conditions, the operator could select all-wheel drive with a top speed of 7mph. However, the market was not ready for this advanced design and the project was soon discontinued. In the early 1970s, British excavator manufacturer Hy-Mac took over Whitlock, but by then the haul trucks had long since been discontinued.
MODERN ADT ORIGINS
A milestone date in ADT history was 1973. That’s the year David John Brown formed DJB Engineering in Peterlee. DJB launched its first ADT, the D250 model, at the London Public Works Exhibition in 1974. It created immediate interest both in the UK and overseas, and production initially commenced at a rate of one per month. DJB machines featured Cat engines and drivetrains and benefited from sales through the global Caterpillar dealer network.
An extended range from 20 tons to a mighty 50-ton capacity machines were designed and built, with both 6x4 and 6x6 drive options.
DJB articulated haulers proved so successful that in 1986, Caterpillar acquired the rights to DJB and added ADTs to its vast product line. With access to the DJB designs, Caterpillar continually revised and upgraded them to meet changing industry expectations. The world-leading 55-ton capacity D550B model was dropped in 1987, but the range was broadened with new models up to 40 tons capacity. Revised C and D series began to appear in the late 1980s, including the 6x4 D40D introduced in 1989, having the same 40-ton capacity and 385hp engine as
Below: An original DJB 25-ton D25B two-axle ADT, one of a line produced at Peterlee, Durham, before Caterpillar took over the company in 1986.
Above: The 27-ton capacity Moxy 6225B from the 1980s with large-volume coal body.
Below: With a capacity of 40 tons, the Terex 4066C was top of the company’s ADT range in the 1980s.
CLASSIC PLANT // ADT HISTORY
the D400D with 6x6 drive configuration. Current Caterpillar ADTs are still built in the former DJB factory at Peterlee, County Durham.
MOXY
For decades, the UK muck-shifting community referred to any form of articulated hauler as a Moxy. Norwegianbased Moxy introduced its first ADT – the 18-ton capacity D16 – back in 1972. It was soon followed by the heavy-duty D16B model, powered by a 210hp Scania engine driving a Clark transmission.
Moxy came to prominence in 1982, when Yorkshire-based Brown Engineering took over the firm. The same year they introduced a new series of machines, including the 6200S model that boasted an advanced independent suspension system and the range increased over the following five years. Worthy of note was the 27-ton capacity 6225B, which featured a large coal body and was powered by a 254hp Scania engine. The smallest model in the Moxy range, the 13-ton capacity 3212 was introduced in 1984, manufactured on behalf of Brown Engineering by MT Agricultural Engineers of Essex.
In 1986, Moxy entered into an agreement to build ADTs for Komatsu. Unfortunately, in 1990 the company became insolvent when the Brown Group went into receivership. However, Komatsu wanted to keep the factory open and enlisted the help of the Norwegian mining group Olivin. From 1991 Moxy was owned jointly by Moxy and Olivin, and the MT series of ADTs was launched that year.
In 2000, after a series of complicated legal arrangements, Komatsu withdrew from the supply arrangement with Moxy
and decided to design and build its own range of ADTs. The same year Moxy introduced the MT series II, with capacities ranging from 26 to 40 tons. In 2008, Moxy was acquired by Doosan, and the ADTs branded Doosan Moxy until 2011. Doosan was bought by Hyundai in 2021, and Doosan became the Develon brand in 2023.
TEREX
Terex designed and developed its own ADT range at its Motherwell factory, releasing the first model in 1983. Known as the 32-04, the 25-ton capacity, three-axle 6x4-drive ADT was the forerunner of probably the most successful of all Terex product lines manufactured at its Scottish factory.
In 1998, Terex continued to take advantage of the latest technology in electronic engine management, emission
control and operator comfort. It replaced its former ADT line with the new TA-series consisting of the TA25, TA30, TA35 and TA40 models, with capacities from 25 to 40 tons. They featured automatic-slip differentials with three axles in permanent six-wheel drive, and a top speed of 34mph. Large numbers of these trucks were produced for use around the world, in 1999 alone over 1000 examples left the factory.
The Motherwell factory has been operating since 1950, first under the auspices of Euclid, then as Terex from 1968. In 2014, Volvo took over the company and continued to produce ADTs and other former Terex products at Motherwell as the Terex Truck division of Volvo Construction Equipment. Another name change took place in September 2021, when Volvo announced that its Scottish-built ADTs would be rebranded as RokBak.
HEATHFIELD HAULAMATIC
Heathfield Haulamatic was formed in 1994 by the merger of Heathfield Engineering and Haulamatic. Since the mid-1960s, both these British companies were known for their range of standard off-road dump trucks. A range of four ADTs was launched by Heathfield Haulamatic at the 1995 Hillhead Show, with capacities ranging from 17 to 36 metric tonnes and powered by Mercedes Benz engines. The same year, Heathfield Haulamatic was acquired by South African-based Bell Equipment, which introduced its own-designed ADTs to the UK market.
Bell had launched its first articulated dump truck back in 1985, the 25-ton B25, which made an immediate impact resulting in a broadened line of sizes extending to 40 tons capacity. Bell stated that most of the
Below: The British DDT design became part of the CNH Global empire in 1999, best known under Case branding.
Left: The takeover of Heathfield Haulamatic in 1995 resulted in the Bell Haulamatic range of ADTs.
TAIL END // CLASSIC PLANT // ADT
Below: Thwaites, best known for site dumpers, introduced the TD-18 articulated dump truck in 1996. Below right and bottom: JCB introduced its 17-ton capacity 716 model in 1990; the 22-ton 722 appeared in 2001.
main components in its trucks were mass-produced by other manufacturers, eliminating obscure parts difficult to find. In the early 1990s, Bell phased in upgraded B-series versions of its trucks, four machines with capacities from 17 to 40 tons, powered by Mercedes Benz engines. In 1998, Bell further revised its trucks to the C-series with improvements focusing on the operator’s cab and machine access.
DDT
Another company to gain worldwide recognition was DDT Engineering, established in Yorkshire in 1994 by Gordon Brown, the previous owner of Moxy. Their first ADT, the 30-tonne capacity 6x6 D630 model built by MT Agricultural Engineering of Essex, was shown at the
Bauma 95 show. It featured an ejector-based rear-discharge system. The following year the DDT range consisted of four models, with capacities from 14 to 40 tons.
The range was sold to the Italian company Astra, part of the Iveco/Fiat Group. As a result of the formation of CNH Global in 1999, Italian-built DDT designs were branded in different parts of the world as Astra, Case, Fiat-Hitachi, Link-Belt, O&K and New Holland machines.
OTHER BRITISH ADTS
JCB had designed a prototype ADT as far back as 1959, but it never went into production. Almost three decades later, the company entered the ADT market when it launched the two-axle 13-ton capacity 712 in 1988. It was followed by the 17-ton 716
model two years later. Equipped with a 139-flywheel horsepower engine, the 716 drove through a six-speed transmission with power to all four wheels.
In the mid-1990s, JCB temporarily withdrew from the dump truck market. Then in 2000 the company launched a new ADT, the model 714 with a capacity of 14 tons. It boasted a modern curvy appearance and state-of-the-art operator’s cab featuring a high suspended seat giving improved visibility.
JCB followed it with the similarly designed model 718 in 2001. This larger capacity machine carried a payload of 18 tons. Its 167hp engine drove through a six-speed transmission, an electricallyoperated automatic type incorporating a torque converter. It was followed by the 22-ton JCB 722, which made its first appearance at Bauma 2004. JCB later withdrew from the ADT market.
In 1991, Ernest Doe & Sons of Essex promoted its model 12000 MDT, a reardumping, four-wheel drive ADT with 13 tons capacity powered by a 103hp Ford engine.
In 1996, Thwaites Engineering, famous for its site dumpers, including some articulated models, extended its range upwards to include an ADT. The model TD18 was powered by a 160hp Iveco diesel engine and boasted 18 tons capacity.
SITE SUSTAINABILITY SHOWCASE
Peter Haddock reports on a new initiative at the forthcoming PlantWorx show
This year, the PlantWorx show will take place in its new home, the Newark Showground in Nottinghamshire, on 23 to 25 September. In addition to stands featuring over 300 exhibitors, the highlights of which will be previewed in the next issue, there is a site sustainability showcase area. In collaboration with industry leaders, the hire sector and government, the showcase will highlight cutting-edge, low-carbon technologies in a live, off-grid worksite environment.
Joanna Oliver, one of the show organisers, said, “The reason why we are putting together the showcase is that PlantWorx gives us a platform to highlight what our industry can already do with equipment that is currently on the market. This, in turn, will give visitors a great opportunity to see a sustainably designed, fully integrated construction site.
“By creating a hands-on experience, visitors will be able to see how different technologies can combine. For example, we will have battery energy storage systems with solar hybrid generators providing the power to charge compact machines and electric hand tools. Also, solar battery lighting towers will demonstrate how sites can transition from traditional diesel equivalents. We will even have sustainably powered welfare cabins to show how off-grid working can support those on site as well.”
During a recent PlantWorx webinar on alternative fuels there was much discussion about how the industry can embrace change and adopt more sustainable solutions and equipment.
SOLAR POWER
One of the other businesses supporting the sustainability showcase is UK-based Prolectric, which is using the event to launch its new ProCharge solar battery electric storage solution.
Prolectric’s Owen Pearson spoke about a recent project with Tier 1 contractor
Right and below: A comprehensive range of solar and battery storage solutions will be on display at the forthcoming PlantWorx show.
TAIL END // SHOW PREVIEW // PLANTWORX 2025
Kier, stating, “We were brought in at the planning stage to see if we could support a comprehensive off-grid lighting solution in a road building project, which is in an area of outstanding natural beauty and a designated dark sky area. By surveying the site, we were able to map out the lighting needs.
“As a result, nearly every aspect of the compound’s temporary and semipermanent infrastructure has been powered by solar or hybrid solutions. This includes solar-powered lighting towers, permanent solar street lighting for car parks, hybrid generators and our new battery system, which is used to power one of the larger office compounds.
“In addition, we were able to link the site up using our telemetry system so that each item could be remotely monitored. This included data insights on energy generation, storage levels and usage patterns. Using this information, we were able to validate the effectiveness of the technology and perform proactive maintenance where needed. This approach addressed the common concerns often raised about solar, such as whether it can perform in cloudy conditions or during shorter daylight hours with hard data.
HYDROGEN POWER
As part of the government funded trial called Element 1, various 20-tonne excavators were partly fuelled by hydrogen on projects with BAM and Skanska. UKbased Ulemco worked with Flannery Plant Hire and Plantforce Rentals to convert machines to run on a mix of green hydrogen produced by GeoPura.
Ulemco’s MD Amanda Lyne said, “With Element 1, we were able to look at the entire end-to-end process of using hydrogen as a fuel. From converting the equipment to testing different hydrogen blends, ranging from 30% to 50%, and how to optimise refuelling.
“The project also showed us the importance of introducing hydrogen to the jobsite from supply to setting up the on-site refuelling. In addition, through the way we conducted the conversion process, we were able to keep the equipment running on diesel if it ran out of hydrogen, so there was no loss in overall work carried out on site.
“The data we have now collected shows just how well the hydrogen blend has performed with added advantages of cleaner burns and less soot. We now also know that the conversion of both the Flannery Caterpillar and the Plantforce Kobelco excavators has proved to be both efficient and reliable.”
INCREASING DEMAND
Speedy Hire’s MD of power and energy, Dan Thompson, said, “In the last few years, we have seen a marked change in client demands, which have led to us investing in new alternative fuel solutions. For example, we already have over twenty 30kW hydrogen fuel cells on our hire fleet now, and we are seeing a much bigger demand for electricpowered equipment. As a fuel supplier, we are also delivering more HVO to sites across the country.
“What’s really important with introducing new alternative fuel options is getting your
early adopters on board and making sure you can then prove the value in real world applications. This helps to build a market demand that you can then scale, increasing the supply of hydrogen, for example. There is also a big education piece to undertake, sharing knowledge and experience across the industry so we can bring people on the journey.
“It’s then about using the data you create from sites and demonstration opportunities to demystify some of the challenges people perceive they will face.”
CONCLUSION
Joanna Oliver summed up, “When we can bring our sector together at an event like PlantWorx, we can really showcase how innovative it can be. The tailored briefings on the site sustainability showcase we will deliver to government regulators, public bodies, environmental NGOs, and visitors will also be important. Through these activities we hope to play our part in managing expectations around the realistic pace of decarbonisation across construction sites and the technical challenges still to be overcome.”
Right and below: The UK industry is on the verge of using hydrogen as a fuel, both for power generation and in machines’ internal combustion engines.
NEXT MONTH
EARTHMOVERS IN
SPECIAL ADAPTATION
LIEBHERR SHAFT DIGGER
The Bethell Group has invested in a pair of 40-tonne Liebherr R930 shaft diggers, offering a potential maximum digging depth of over 22 metres.
NEW PRODUCT MECALAC REVOTRUCK
We visit the first innovative Revotruck site dumper to be put to work in the south-west of England, on a tight job at St Ives in Cornwall.
SHOW PREVIEW PLANTWORX 2025
Some of the likely highlights of this key construction equipment event, taking place at Newark on 23 to 25 September.
FIRST IMPRESSIONS
VOLVO L120 ELECTRIC
Eoghan Daly reports from the cab of a factory-built battery electric Volvo wheel loader, which has now entered serial production.
TECHNOLOGY AUTONOMOUS HAULAGE
An exclusive report on autonomous Komatsu 930E haul trucks being operated at Boliden’s Aitik copper mine, situated above the Arctic circle.
FLEET FOCUS HART’S HAULAGE
We report from Redruth on several new Develon machines to enter the fleet of Hart’s Haulage, including a DL380-7 wheel loader.
SITE SERVICES
ARTIFACTS WANTED
WANTED OLD BOTTLES
Stone Ginger Beers, Stouts, Jugs, Pot Lids. All Early Glass & Stoneware, Enamel Signs, Chemist Bottles, Cream Pots. Old Pub & Tobacco, Memorabilia. Poison bottles and location of tips to dig. Top Prices Paid.
AG30E-30
AG60E-6
AG80E-80KVA
BREAKING FOR SPARES
PARTS FOR CONSTRUCTION MACHINERY
New And Used Spare Parts Available Final Drives, Hydraulic Pumps, Swing Drives Engine overhaul Kits, Bucket pins & Bushings. MACHINES
BREAKING FOR SPARE PARTS Samsung, Volvo, Komatsu, Case/Poclain Caterpillar, Daewoo, Hitachi, Liebherr, JCB
UNITED PARTS LTD Station Farm, Station Road, Kirton Lindsey, Gainsborough, Lincs, DN21 4BD, UK Tel UK 01652 648931 : Fax 01652 640769 : Mobile 07966 484425 Email sales@unitedparts.co.uk : Web www.unitedparts.co.uk Suppliers of Quality Used
SCALED TO PERFECTION
Steven Downes reviews new models of Hyundai machines that have been produced in a variety of scales
In the conventional 1:50 construction scale, one of the most detailed and visually stunning models to be released is the HX35Az miniexcavator. Despite its diminutive stature, it has been perfectly modelled, with a working dozer blade on the undercarriage, good movement of the front-end equipment and accurate replication of the cab interior. The small details, like the protective covers for the hydraulic rams and the rear-view mirrors, lights and aerial all stand out.
From a scale model perspective, one of the biggest surprises at the recent Bauma show was found on the Hyundai stand, in the form of a 1:32-scale resin and photo-etch model of the R1250-9 tracked excavator. The model, mounted on a plastic base, really captures the looks of the original, and no matter where you look, the level of detail and realism is outstanding. It is a limited-edition production run, and with a price tag of €1250, it is certainly not for everyone.
PLANTMOBILIA // HYUNDAI // TAIL END
eleased in 1:35 scale is a model of the new HX400 tracked excavator, which has some interesting features, starting with the opening cab door to get a better look at the interior. A body panel on the side opens to reveal the interior cooling system while up top, there is a panel can be lifted to uncover the internals of the engine bay. One of the most striking features of the model is the toothed bucket, adorned with a full complement of wear plating that really catches the eye.
ans of HO scale will be happy to hear that there are several models available in 1:87 scale, including an HL930A wheel loader and this HX520A tracked excavator. The excavator features a rubber band style tracked undercarriage and 360-degree rotation of the upper-structure. The surface engraving of the body panels is good, and with authentic scaled safety railings and cabin interior, this is a worthy release.
roduced in the smaller 1:60 scale is the HW210A wheeled excavator, which is a stunning model. The upperstructure rotates 360 degrees and the front-end equipment has a good range of movement, although the large pin heads do stand out and would have been better touched over. The pair of outriggers can be lifted, and while the blade is fixed, there is plenty of structural detail. With metal safety railings and surface engraving of the various body panels, not forgetting the cab with its interior, this is a very impressive release and comes mounted on a plastic base.
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Owned since 1993, and has worked on the farm since then, still capable of digging a hole or loading a trailer, comes with 3 spare rear wheels, 2 spare front wheels, also 9” drain bucket, 5’ ditching bucket, and bale spike for front bucket. New radiator about 4 years ago. Two owners from new, was road registered on a R plate, but have no documents for it.
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Good used and new parts inc. axles, transmissions, engines, hydraulic and electrical components, hubs, gears, shafts, rams, etc
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STARS IN THE MAKING
Nick Drew visits the Coram Construction Training Centre to speak with two teenage plant operators
Based at Windmill Farm, Montacute, near Yeovil in Somerset, Coram Construction Training, run by Neil Coram, provides a wide range of courses in the civil engineering sphere. The courses lead to qualifications from various awarding bodies such as CPCS, City and Guilds, NPORS and NOCN.
In addition to training rooms within a converted barn, the facilities include a dedicated plant training area that has level ground for excavating, inclines for manoeuvring, a designated lifting area and a scaffold tower for those learning to operate telescopic handlers.
Also, their confined spaces training area consists of a network of concrete tunnels with four metre drops and real manholes, ladders, step irons and the like. There is also a mock cul-de-sac road to conduct street works training.
YOUNG OPERATOR
Molly Spearing (17), who hails from Yeovil, wasn’t sure about what she wanted to do after leaving school, but she didn’t really fancy the idea of going down the college/university route. A family friend, Callum Aldridge, the owner of Bedrock Plant, talked to her about a potential career as a machine operator. Feeling she had nothing to lose, she decided to see how she liked it and hasn’t looked back since. Molly undertook her initial plant education at the training facility of the long-established Bristol-based firm Kelston Sparkes. She currently holds a CPCS trained operator red card for a ride-on
Above and below: Molly Spearing (17) currently operates a 30-tonne articulated dump truck for Bedrock Plant. She is keen to obtain additional tickets, particularly for excavators.
TAIL END // TRAINING // YOUNG OPERATORS
roller and articulated dump trucks. Her regular mount is a Bedrock Volvo A30G ADT, something she clearly enjoys driving.
Molly said, “My biggest influence has been Callum at Bedrock Plant. Having seen him operate all the different machines, even though I had never even set foot in a machine before, he encouraged me to start and give it a go. It’s pretty amazing really, I can’t thank Callum enough for giving me such a great opportunity and for having faith in me.
“I have worked on a few different sites, most recently on a large housing development in Dorset, where we were engaged in topsoil stripping and cut-and-fill work. The next one we are going to do is in Poole, at a large nature reserve, so I’m quite excited to be involved in that one.”
Bedrock also runs several Volvo excavators, including 30-tonners fitted with 3D GPS Trimble Earthworks systems, which have grabbed Molly’s interest. We met her at the Coram training centre as she was getting some stick time on one of the latest additions to their fleet, a Takeuchi TB325R compact radius mini. She also spent some time practising her skills on a Wacker Neuson DV60 dual-view site dumper.
Molly continued, “I’d really like to go on to take my digger ticket, so that’s the next exciting thing, as I really enjoy driving them whenever I get the chance. Then hopefully just keep on progressing up through the machines. I’m excited to see where I end up. I think the plan is for me to do my digger test next year, which will probably be back with Kelston Sparkes, so it will be nice to get that one under my belt.”
Asked how she has found it being a young female in a male dominated industry, she said, “I can honestly say I really do enjoy it. All the blokes at Bedrock have been really welcoming and we have a good laugh. But, at the same time, if I need a hand, they jump straight in. My confidence has grown massively since I first started on the firm, which is great.”
FUTURE OPERATOR
Neil Coram is currently looking to replace the training centre’s Case CX130D excavator with the latest CX130E model, which will potentially be fitted with an Engcon tilt-rotator. At the time of our visit, the CX130D was being operated by what looked at from a distance a seasoned professional. Digging, loading and grading were being undertaken at a speedy pace, as operator and machine worked in perfect harmony – an absolute joy to watch.
Much to my surprise, the operator in question turned out to be Louie Coram, Neil’s 15-year-old son. He has grown up around farms and farm machinery, which is where his main interest lies. However, by his
own admission, he does love his diggers. He said, “I am very lucky really, as the way things are these days, young people can’t go out on site and learn in the traditional old ways. But here, I have a safe and controlled space, where I can get on anything.”
Louie’s favourite machines come from the Case and Wacker Neuson stables, which is hardly surprising as there are many examples from each brand on the training centre’s fleet. He said, “You can’t go wrong with a Case, as you can see here, we really like them, they are nice and smooth to operate, with plenty of power and extremely reliable too. With both brands we get great support and back-up from M&M Plant Sales.”
Right and below: Louie Coram (15) has grown up around agricultural and construction equipment and is already an extremely proficient excavator operator.
“IAMVERY LUCKY,AS YOUNG PEOPLECAN’T GOOUTON SITEAND LEARNINTHE TRADITIONAL OLDWAYS”
Most weekends Louie can be found working on a local farm, which sees him running tractors, as well as undertaking some digger work as and when needed, enabling him to continue to hone his skills in a real working environment. Obviously, he would have a future within the training centre. However, he is keen to go off and get work experience, perhaps in agricultural contracting, before returning to the fold later in his career.
The UK South-West dealer, service and parts supplier. philip@reedsltd.co.uk / 07834 343696 - enquiries@reedsltd.co.uk / 01380 816516
