Canada’s “Rock to Road” Magazine

May/June 2004 Issue

• Bauma 2004 - Bigger than ever
• Momentum builds for Perpetual Pavements in Ontario
• Smart crushing plant promises high capacity, product quality
• Quebec leads way in tracked plants
• Crusher change delivers multiple improvements
• What’s new in tracked crushers
  

For a copy of the issue that contains these articles with colour photos, click here.

Bauma Post-Show Report

Bauma 2004 - Bigger than ever

By Robert L. Consedine, Editor

    Billed as the world’s biggest construction industry trade fair, Bauma 2004 lived up to its reputation as a record-setting 410,000 visitors from 171 countries and 2,801 exhibitors from 47 nations packed the Trade Fair Centre in Munich, Germany from March 29th to April 4th during the show's Golden Jubilee.
     Originally called “Building Machinery and Equipment for Use”, the first exhibition was held in 1954 at an open-air site in central Munich and drew a reported 58 exhibitors and 8000 visitors. In 1956, the name of the exhibition was changed to Bauma and, that year, the number of exhibitors doubled. As Bauma benefited from the post-war construction boom in Germany in the 1960s, the show moved several times between locations in Munich to better accommodate the growing number of exhibitors and visitors. In the process, it also became the premier international venue for the introduction of new construction machinery and building technology. In 1998, Bauma was permanently moved from its central Munich site to the New Munich Trade Fair Centre where new records for both attendance and the exhibitors were established. Those benchmarks didn't last long. The next show in 2001 set a new record of 2,341 exhibitors and 406,000 visitors. Bauma 2004, however, surpassed all expectations as the number of exhibitors jumped by 20 per cent over the previous show while the display space used increased 10 per cent from 450 000 m2 to a whopping 500 000 m2. By way of comparison, organizers for next year's CONEXPO-CON/AGG show in Las Vegas predict that some 2300 exhibitors will use approximately 170 000 m2 of indoor and outdoor space.
     Contributing to the resounding success of Bauma 2004 was the warm, sunny weather that prevailed throughout most of the show. In the week leading up to the show's opening on March 29th, however, mother nature was considerably less kind to the exhibitors and their setup crews. A late spring snowstorm and sub-zero temperatures created miserable working conditions for exhibitor personnel. In the end, the extraordinary effort by all concerned ensured Bauma 2004 got off to a flawless start on the first day.
     The Canadian aggregate industry was officially represented at Bauma 2004 by a group of 15 members of the Aggregates Producers' Association of Ontario, including Richard Seibel, APAO chairman. The Bauma trip was organized by APAO's Conference and Special Event Planner, Julie Harrington, and comprised site visits to aggregate operations near Cologne, Germany where specialized machinery manufactured by Metso Minerals and W.S. Tyler is being used to increase production efficiency. One of these operations featured W.S. Tyler's new Hydro-Clean technology which washes materials before processing using high pressure with minimal water loads and low power consumption. In addition, the APAO itinerary featured a tour of a Liebherr's manufacturing facility near Munich. At Bauma, the group attended a reception hosted by the Canadian Consul to Germany, Stephan Charbonneau and Vice Consul, Brian Young. Liebherr Canada also organized a separate Bauma tour of approximately 80 of its Canadian customers and suppliers who visited Liebherr crane and excavating equipment manufacturing plants in several German locations.
     The following report looks at some of the exhibitors and what they were showcasing at Bauma 2004.
     One of the biggest draws during the show was Liebherr's giant T 282B. On public display for the first time, the massive new 229 000 kg diesel-electric hauler measures 7.4 m high, 8.8 m wide and 14.5 m long, reportedly making it the biggest two-axle mining truck in the world. According to the manufacturer, more than 200 improvements have been made to this newest version of the T 282 that was first introduced in 1999. The most significant change is the increase in payload capacity from 327 to 363 tonnes (204 m3 heaped). The T 282B also now has a 35 per cent more powerful engine that delivers up to 3650 hp. The Siemens/Liebherr AC drive can attain a maximum speed of 64 km/h. Interestingly, the T282B hauler was built in Newport News, Virginia where all Liebherr mining trucks are built, and shipped to the German port of Bremerhaven in late January. From there, the major components, including the 71-tonne truck frame, were transported by special low-loader trucks across central Germany to Munich for re-assembly at the Bauma exhibition site. The six 3.8 m diameter tires were sent by the Spanish manufacturer directly to the assembly area at Bauma on two extra-wide transport vehicles.
     Featured among the Liebherr products introduced at the show were five new 'Stereo' series wheel loaders. The new models have outputs ranging from 42 to 58 kW for moving maximum loads between 3234 and 4580 kg. The loaders derive the 'Stereo' designation from the unique combination of centre pivot and rear-wheel steering and the interaction of oscillating frame articulation and centre-pivot axle.
     Liebherr's 11 000 m2 outdoor stand contained over 70 exhibits from the company various product lines including hydraulic excavators, wheel loaders, mining trucks and tower cranes.
     Another major exhibitor of earthmoving machinery was Volvo Construction Equipment which presented a comprehensive selection of new and current Volvo CE branded products at its 2200 m2 indoor stand and 8200 m2 outdoor demonstration area. The indoor display showcased several new products including the L50E wheel loader which was launched at the Bauma exhibition. The new loader is powered by Volvo's latest inline four-cylinder D4DLAE2 diesel engine, capable of delivering 101 hp at 2200 rpm and certified according to Step 2 emission standards. The outdoor area was used to demonstrate earthmoving applications utilizing Volvo hydraulic excavators, articulated dumptrucks and compact construction machines.
     Ulrich Meyer, managing director, Volvo Construction Europe, says his company is extremely pleased with the results of the fair. “We had considerably more visitors than at the last Bauma, which was also reflected by the number of orders we received. We had increases in the double-digital percent range. Despite our concerns about the distance between our stand in the hall and at the open-air site, our concept worked very well.”
     Volvo also used Bauma 2004 to preview new technological developments such as its new V-ACT (Volvo Advanced Combustion Technology) engine to meet the new Tier 3 and Step 3 (EU) emission regulations and the manufacturer's 'SfnX Project', a futuristic look of how excavators may evolve over the next twenty years. According to Lorenzo Terreno, vice president, Product Portfolio and Advanced Engineering at Volvo CE, the design concept incorporates the latest research as well as inventing some of its own. Among its innovative ideas is the replacement of the main swing bearing by an electro-magnetic field allowing for zero friction and high speed turning and smooth braking of the superstructure. Another idea is the replacement of the diesel engine with a small, environmentally-friendly fuel cell to produce electric energy while emitting only heat and water vapour.
     One of the Bauma 2004 highlights for the Swedish manufacturer was a public event during which Tony Helsham, Volvo CE president and CEO, officially handed over a symbolic key to the German rental firm, Theisen KG, representing its purchase of 522 Volvo CE compact wheel loaders and excavators.
     One of the largest roadbuilding and paving exhibits at Bauma 2004 was produced by the Wirtgen Group who used 8000 m2 to display over 70 machines including Hamm compaction products, Vogele asphalt pavers and Wirtgen milling, recycling and stabilizing machines.
     Jürgen and Stefan Wirtgen, managing partners of Wirtgen Group were extremely pleased with Bauma 2004. “The number of visitors at our stand was enormous from the first day of the fair. And business transactions with customers from around the world created a positive atmosphere.”
     Sandvik Mining and Construction unveiled a raft of new innovations and products that included the Tamrock Ranger 800 crawler drill and Rammer's new m14 hydraulic hammer. The Ranger 800 from Tamrock Surface Division is a highly manoeuverable 15-tonne rig that carries a 21 kW HL800T hydraulic drifter for drilling 89-127 mm diameter blastholes. The Ranger 800 is equipped with a unique superstructure that can be turned 120 degrees (180 degrees, optional) to enable vertical and inclined drilling at right angles to the tracks. This, together with a folding boom that has extended reach, enables several holes to be drilled from the same set-up for increased productivity.
     Rammer, Sandvik's breaker division, introduced the m14 hammer to complement the m18 model which was launched last year. The m-series hammers for 25 to 30 tonne carriers have a modular design that allows them to be better matched to individual customer's power, performance and application requirements. In conjunction with the m14 introduction, Rammer has initiated its unique mQualification scheme that focuses on dealer assistance, training and accreditation. Rammer also introduced it new 'In' series of hydraulic hammers for mini-excavators and other small carriers.
     Among the numerous other products on display was Sandvik Rock Processing's Hydrocone H6800 cone crusher, the third largest unit in the Hydrocone lineup, and Sandvik's innovative new dust-encapsulation system called the Telescopic Chute.
     The huge 8000 m2 indoor exhibit mounted by Caterpillar and its German dealer Zeppelin at Bauma 2004 was more like a show within a show. Some 75 machines, all new or improved models, were on display with other stands dedicated to showcasing the latest Caterpillar technology and customer support services. Highlights of the main exhibit in Hall B6 were a product support tunnel that offered a virtual tour of the machine lifecycle and a Caterpillar Style Show featuring the latest in Caterpillar fashions and footwear that attracted large crowds for every show.
     Among the new technologies presented at Bauma 2004 by the world's largest construction equipment manufacturer included Eco-Mate, a revolutionary new attachment that is claimed to significantly reduce the operating costs of larger Cat excavators. According to Caterpillar, the Eco-Mate fuel saving attachment represents a major advance in the company's excavator development, producing fuel savings of up to 25 per cent in typical production loading applications. Initially being offered on the 50-tonne class Cat 345B Series II, the Eco-Mate system features high pressure accumulators that store the hydraulic energy created each time the excavator's boom is lowered. The accumulated energy is then released backed into the hydraulic system, resulting in less demand on the engine.
     Another technology showcased at Bauma 2004 was Caterpillar's new AccuGuide laser grade control system for track-type tractor users who need greater accuracy, higher productivity and lower costs.
     The factory-fitted AccuGrade option is designed specifically for use with Cat's new D3G, D4G and D5G tractors. The system features a series of laser receivers mounted on the blade that automatically control the machine's hydraulic system. A thin beam of light from an off-board laser transmitter provides precise elevation data that is picked up by the receivers. In turn, the blade's lift and tilt are automatically adjusted as the machine moves over the area. Because the transmitter emits a 360-degree beam, it creates a grade reference over the entire work area and allows multiple machines to use it. The system can provide flat, single or dual slope surfaces within 6 mm of grade.
     Metso Minerals launched a number of products including the new Barmac B7150SE vertical shaft impact (VSI) crusher and a new generation of Trellex modular screen panels. The Barmac VSI has a throughput capacity of 260-490 tonnes/h and is suitable for crushing abrasive or sticky materials. The new Trellex modular step system is designed to improve wear life, increase panel strength and facilitate panel replacement. The Trellex system is claimed to fit all types of screening machines. Decks are made of interchangeable modules, each measuring 300 mm x 600 mm, which create a rigid surface for edge-to-edge screening capability. As wearing occurs, only the module or modules in that section need replacing, rather than the entire screen.
     Aggregate and recycling equipment manufacturer, Erin Systems of Rivi³re-du-Loup, Que., was the largest Canadian exhibitor at Bauma 2004. The company's outdoor exhibit showcased its line of portable and track-mounted products was presented including the self-propelled Powercrusher jaw and impactor crushers as well as its Fingerscreener and Trident 125T screening plants.
     Developed by Erin Systems and its strategic partner Hartl Anagenbau GmbH, the heavy-duty Powercrusher range comprises three jaw crusher models and six five impactors including the new 350 tonnes/h 1375I. (More information on the 1375I can be found in this issue's special report on track-mounted crushing plants.)
     The Erin Fingerscreener series has been designed to deliver high production in difficult screening applications. Its direct feed screenbox combines self-cleaning top deck Grizzly» fingers and bottom deck Cascade» fingers to prevent clogging and improve separation. Three tracked models and one on wheels are currently available with production output ranging from 400 to 800 tonnes/h.
     The Erin Trident is a track-mounted mobile screening machine designed to size sand, gravel, crushed stone, topsoil and other materials. It features a 3.7 m long x 1.5 m wide double-deck screenbox for more throughput and improved screening efficiency. The machine is mounted on broader tracks for better mobility on difficult work sites.
     Vancouver-headquartered Ritchie Bros. Auctioneers used 90 m2 of space at Bauma to present its range of services including its global internet rbauctionBid-Live service at www.rbauction.com. Guylain Turgeon, managing director of Ritchie Bros.' European office and auction site in Moerdijk, The Netherlands, told Aggregates & Roadbuilding that the high-tech exhibit proved very successful in drawing visitors from all over the world. Since its founding in 1964, Ritchie Bros. has become the world's largest industrial auctioneer. The company conducts over 140 unreserved public auctions every year at its 90 international locations.

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Momentum builds for Perpetual Pavements in Ontario

By Andy Bateman, Engineering Editor

    Last year was a good year for perpetual pavements in Ontario. The province's Ministry of Transportation (MTO) identified perpetual pavement projects for each of 2004, 2005 and 2006, the Don Valley Parkway received a prestigious Perpetual Pavement Award and perpetual pavements led the list of promising technologies at an asphalt technology symposium.
     At last year's Ontario Hot Mix Producers Association (OHMPA) annual asphalt seminar, the MTO's Becca Lane described the ministry's plans for perpetual pavement projects. As background, Lane explained that an asphalt technology symposium, held in early 2003 and attended by a number of industry stakeholders, had identified perpetual pavements as the most promising asphalt technology. A MTO survey confirmed that a number of industry associations and U.S. agencies already had or were implementing a long-life flexible pavement concept, while a summary of perpetual pavements built across the U.S. indicated total asphalt thickness ranging from 390 mm to 440 mm.
     The MTO has identified three potential projects for perpetual pavement trials, with one each for 2004, 2005 and 2006. The 2004 perpetual pavement trial will be on a 5.2 km long project to twin a section of Highway 406 near Thorold on the Niagara Peninsula. The twinning project was originally designed as a conventional pavement and will now be constructed as 50 per cent conventional and 50 per cent perpetual pavement. The 2005 trial will take place on a 17 km section of Highway 7 east of Carleton Place, a two lane arterial highway, with a proposed four lane divided highway currently under design. The 2006 project is slated for a 9.3 km section of Highway 402 between Sarnia and London.

     Introducing the Perpetual Pavement Award, OHMPA's Vince Aurilio explained that the award is evaluated by the National Center for Asphalt Technology (NCAT) according to several criteria. These include a service life of 35 years or more, resurfacing intervals of no less than 12 years, no structural failures and minimum maintenance throughout a pavement's service life. Aurilio described a perpetual pavement as having three distinct hot mix asphalt layers; a flexible and fatigue resistant bottom layer, a high modulus rut resistant asphalt middle layer and a rut resistant renewable surface layer of Stone Mastic Asphalt (SMA), Open Graded Friction Course (OGFC) or Superpave asphalt. The overall thickness of these layers) means that the strain in the bottom asphalt remains low even under heavy loading, resulting in a pavement with unlimited fatigue life.
     Nazzarano Capano, from the City of Toronto's Infrastructure Asset Management & Programming Department, described the background behind the submission of the Don Valley Parkway (DVP) for the Perpetual Pavement Award. The DVP is not only its first Canadian recipient but also the first municipal road ever to be recognised under the award. (Aggregates & Roadbuilding March/April 2003).
     Capano noted that a perpetual pavement delivers a number of benefits, including reduced fatigue cracking and rutting, with pavement distresses confined to the upper wearing layer. Upkeep costs are minimised while extended pavement life provides lower life cycle costs. Any necessary repairs such as surface renewal can be done quickly during overnight closures, thereby reducing the impact on motorists. In addition, the RAP milled from the renewable wearing surface is recyclable with attendant benefits to the environment. In terms of the DVP's specific performance, its service life (to date) is an impressive 46 years, with the first resurfacing occurring at 21 years. There have been no structural failures and maintenance has been restricted to a crack sealing and programmed resurfacing. The DVP pavement design includes 50 mm or HL1 or SMA mix, 170 mm of HL8 base mix and 80 mm of HL6 sub-base on 175 mm of Granular B base material. Capano concluded that the DVP represents an alternative design in which Toronto has confidence and one that will be considered on the next expressway project. In addition, the DVP experience has allowed Toronto to keep the road in a state of good repair longer, has reduced inconvenience to motorists and the pavement design.
     Seminar presenters also included Marvin Traylor of the Illinois Asphalt Pavement Association, who described his experience on the Illinois Perpetual Pavement Mega Project. Traylor began by demonstrating how concrete, rather than asphalt, has historically been the roadbuilding material of choice in Illinois. With only 3 per cent of its pavements constructed with asphalt, Illinois ranks 49th out of 50 U.S. states. At the other extreme, 15 states, headed by Alaska at 100 per cent, all have 90 per cent or more of their pavements constructed with asphalt. Against this background, the completion of a major Interstate rehabilitation project in Illinois using hot mix asphalt was a major accomplishment. I-70 is one of the country's principal eastÆwest transportation routes, with 24,000 Average Daily Traffic (ADT) and, a more important from a design point of view, a very high ratio (49 per cent) of truck traffic.
     Traylor explained that pavement designs utilising hot mix asphalt have been handicapped under existing state design criteria which result in an excessively thick asphalt section, compared to concrete, for the same traffic loading. Fatigue theory for thick pavements indicates that an asphalt pavement can have unlimited fatigue life, provided it is thick enough to keep the microstrain below 70 in the bottom asphalt lift (i.e. near the asphalt/base material interface).
     On the project section of the I-70, the original 1969 pavement section consisted of 203 mm of concrete on 102 mm of granular base, with the concrete later receiving an 83 mm thick bituminous overlay. The rehabilitation process included milling the overlay and rubbilizing the concrete, which then received four asphalt lifts having a combined thickness of 445 mm. This thickness compares to the over 700 mm that would have been required by the Illinois DOT mechanistic design methodology and the 292 mm maximum required bituminous overlay thickness required to provide unlimited fatigue life for rubbilized pavements.
     On site, the US$44million roadbuilding contract was completed to an aggressive schedule which required 550 000 tonnes of hot mix to be placed an average rate of at least 5400 tonnes/day. To tackle the job, two local contractors formed a joint venture and made major investments in asphalt production and laydown equipment. The actual average placement rate achieved was 7300 tonnes/day, with daily peaks approaching 10 000 tonnes. Special contract features included a five-year warranty against rutting, cracking, flushing, ravelling or roughness. Additional contract provisions included incentives and disincentives for both smoothness and completion date. In the event, the job went well with no rubbilizing problems, no serious accidents, award of the smoothness bonus and contract completion 52 days ahead of schedule.

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Smart crushing plant promises high capacity, product quality

By Andy Bateman, Engineering Editor

      For St. Catharines-based Silverline Trucking, business activities to date have consisted of trucking, excavation, concrete forming and site grading for home builders and commercial clients. Project manager Bob Cornelius explains the background behind the company's first venture into aggregate production: “In our existing business we are dealing with waste concrete on a regular basis, both from site clearance and concrete forming projects. At the same time we are a hauler and user of aggregates, so acquiring our own equipment to crush concrete into aggregates was a natural development of the business.”
     Believed to be the first mobile plant to provide complete crushing and screening for both primary and secondary applications, the Metso Minerals Nordberg LT1213S consists of an impact crusher and screen on a common tracked mounted chassis. Aggregates & Roadbuilding saw the unit in a recycling application where Silverline was contracted to crush some 14 000 tonnes of returned concrete at the Burlington plant of Dufferin Concrete. Here, the unit was producing one graded product, 19 mm minus crusher run, with all the feed material crushed to finished product size. In operation, a Caterpillar 325BL excavator charged the unit's 9 m3 vibrating feeder, which in turn regulated material flow into the 900 mm x 1300 mm intake opening of a horizontal shaft impact crusher. Any remaining rebar in the crusher run was removed by a Master Magnets separator mounted above the plant's main conveyor and ahead of a 1300 mm x 3000 mm single deck inclined screen. Sized product from the screen's discharge conveyor was stockpiled by a Superior Industries 762 mm x 24.4 m stacking conveyor while a recirculating conveyor returned oversize material to the feeder. The average production rate of this set up to date has been about 150 tonnes/h.
    One of the most striking aspects of this plant's design is its level of automation. According to the manufacturer, the crushing operation can be started with a single button. After that, the plant's IC 500 intelligent controller takes over and adjusts all main operating functions and reportedly has the ability to learn. Mounted on the side of the plant's frame, the IC 500 display gives online information on the status of several different process stages. An optional radio control unit for use by the operator of the loading machine provides remote control of a number of operating functions, including machine forward and reverse, feeder speed control and emergency stop.
     The LT1213S can also be configured in open circuit mode to make two different end product sizes. In this configuration, the (optional) recirculating conveyor is swung away from the feeder and functions instead as a product stockpile conveyor. In either single or two product configuration, fines passing through two zigzag grizzly sections in the feeder can be directed onto a side conveyor for separate stockpiling. The modular construction of the LT 1213S means that the plant can be adapted to a number of different applications. At the feed end, a standard 6 m3 capacity feed hopper enables the LT to be fed with an excavator, while the optional 9 m3 hopper enables loading by either an excavator or wheel loader. At the product end of the unit, the screen module can be detached to allow the direct stockpiling of crusher run in quarry primary crushing applications. In this case, where the unit is crushing shot rock, the unit's nominal capacity is 400 tonnes/h based on feed material sized to 700 mm and a product size of up to 250 mm. In recycling applications where the unit is crushing demolition concrete containing rebar, its nominal capacity is up to 300 tonnes/h when equipped with recycling accessories. In those applications where the screen is utilised, the manufacturer quotes end product sizes ranging from 20 mm to 70 mm, although Cornelius expects to make smaller sizes as well. Increased screening flexibility is provided by changing the direction of screen rotation. To increase screen throughput, the screen is rotated in the direction of material flow, while rotation against the flow holds material longer on the screen, thereby improving the separation of difficult materials or smaller fractions.
     Power is provided by a 6-cylinder Caterpillar engine developing 317 kW and supplied from a 600-litre capacity on-board fuel tank. There are no electric drive motors on the LT 1213S. Instead, it is equipped with an extensive hydraulic system, with provides hydraulic drive to all major components including the feeder, crusher, screen and all conveyors, as well hydraulic cylinders to facilitate crusher access, screen lowering and the position of components such as feeder walls, product conveyors and support legs. Ready for transport, Silverline' unit is 17.2 m long, 3 m wide and 3.4 m high, weighing in at 47.5 tonnes. Arriving at a new location, Cornelius estimates that the typical set up time will be about two hours.
     The new plant has already scored high marks with Silverline operators Kevin Cramp and Rick Chassie. Popular features include a hydraulically operated gate ahead of the impactor to deal with pulses of oversize or irregular material. The crusher itself has four single impact bars for fast bar replacement compared to twin bar designs, with bar installation facilitated by the unit's on board service hoist.
     Also popular is the hydraulic screen lowering system that allows screen servicing and mesh changes to be completed at ground level. Screen changes are further aided by the use of wedges to retain the screen cloths rather than conventional bolt systems. Like all owners of new equipment, Silverline has gone through a learning curve with the new plant. When moving the plant around a site, it has been found that a reasonably level travelling surface is essential to maintain adequate ground clearance to the underside of the recirculating conveyor and the unit's hydraulic support legs.
     Still on the topic of site moves, plans are in hand to attach the stacking conveyor to the new plant and move them as a combined unit rather than having to move each piece separately. To improve plant feeding, Cramp notes that the 1422 mm wide bucket currently fitted to the excavator will shortly be replaced by a 1067 mm bucket to provide a better match with the feeder as well as improved material sorting. When crushing concrete in wet conditions, care must be taken to avoid the bridging of fine material in the chute under the grizzly.
     Overall, Cornelius is pleased with the plant's performance to date, “This plant was originally selected because it can produce a sized finished product with a single crusher and screen combination. We have already developed a good understanding of what the plant is capable of and are confident it will deliver what we are looking for. The flexibility of the design, combined with new technology, means that the plant can handle several different types crushing jobs including those with relatively small quantities of raw material. During our first construction season, we expect to be involved in the crushing of reclaimed asphalt and dolomitic limestone as well as additional concrete crushing.”

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Quebec leads way in tracked plants

By Robert L. Consedine, Editor

     The amount of recycled aggregates currently used in Canada is estimated to be less than 4 per cent of the country's total annual production or roughly 15 million tonnes. This figure, however, could easily double in the next few years as new high quality, near-market sources of aggregates become more difficult to license and extract. Also, the federal, provincial and municipal governments are now implementing stringent new regulations mandating the increased use of recycled construction materials. Vancouver, Calgary, Edmonton, Toronto and Montreal have concrete and asphalt recycling operations within their respective borders that each total in the range of 1.5-2.5 million tonnes/year. Most of the recycling plants currently operating in Canada are chassis-mounted jaw, cone and impact crushers. These conventional plants, however, have serious limitations both in terms of output as well as cost-efficiency as they are primarily designed for crushing rock.
     A trend has started in Quebec that could find its way to other metropolitan regions across the country. In the last 18 months, at least seven Montreal-area companies have commissioned track-mounted recycling machinery to take on the task of processing construction debris as well as limestone, basalt and other rock types. According to industry estimates, there are currently more than 25 track-mounted crushing and screening plants operating within a 100 km radius of Montreal. Four Montreal-area contractors recently visited by Aggregates & Roadbuilding are using near-identical Metso Minerals' track-mounted spreads comprised of the following units: a 28x42 Nordberg LT105 jaw plant equipped with grizzly feeder, hydraulic breaker, magnet and discharge conveyors; a Nordberg LT1213 impact crusher and, a Nordberg 5x16 ST356 double-deck screen plant. Each of these companies have produced more than 300,000 tonnes of recycled materials last year and all expect to significantly increase their outputs in 2004. Another Quebec-based company has teamed their LT105 with a LT300HP tracked cone crusher and Metso Minerals recently introduced ST620 triple-deck mobile screen for quarrying applications.
     One of the companies visited by Aggregates & Roadbuilding was Excel Excavation Ltee. which produced 375 000 tonnes of recycled concrete and 120 000 tonnes of RAP material in 2003. The firm also used their LT105 jaw, LT1213 impactor and ST356 screen to produce 100 000 tonnes of 19 mm minus quarried limestone last year. Excel's owner Pierre-Luc Bouchard reports that the tracked-mounted mobile crushing and screening spread produces 3000 tonnes/h of 19 mm minus materials per 9-hour day and 4500 tonnes/d of 38 mm minus products.
     According to Bouchard, the three-unit mobile spread can be set up and crushing 300 tonnes/h less than 90 minutes.

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Crusher change delivers multiple improvements

A recent crusher change to a portable aggregate spread has delivered improvements in particle shape, product yield, productivity and cost savings for an Ontario producer.

    At a time when many aggregate producers have installed vertical shaft impact crushers to meet Superpave (fracture) specifications, The Sarjeant Co. Ltd. has gone in the opposite direction, recently replacing a vertical shaft impactor (VSI) with a new cone crusher.
     Doug Kelly, Sarjeant's assistant operations manager, explains, “About 80 per cent of the product from our main pit is used in house by the company's ready mixed concrete plants at Barrie, Midland, Orillia and Brechin, so our main objective is to maximize the output of quality concrete aggregate. Our 10-year old VSI made good products and was still in reasonable shape, but climbing repair costs indicated it was time for a replacement.
     “We knew that our Timmins operation was obtaining good results with a cone and decided to follow suit. Since installing the new cone a few weeks ago, we have found that it produces well-shaped coarse concrete aggregate. In addition, the overall yield of concrete aggregates has increased, with a corresponding drop in unwanted fines. Further improvements include an increase in overall plant capacity and cost savings in wear parts and energy.”
     Specifically, production of 20 mm x 4.75 mm concrete stone has increased by about 25 per cent from 80 tonnes/h to 100 tonnes/h, while the capacity of the secondary crushing stage has been increased by 50 per cent from 200 tonnes/h to 300 tonnes/h.
     The cost savings will come from avoiding the replacement of shoes (wear parts) on the VSI every two weeks, together with reduced energy consumption; the new cone is driven by a 200 hp motor, just half the size of the 400 hp motor formerly driving the VSI.
     The new crusher is a Sandvik H3800 Hyrocone crusher in the secondary crushing position of an ElRus portable spread. In typical operating conditions, 152 mm minus bank run is hauled to the plant by two Caterpillar 980G wheel loaders on load and carry duty. The feed material is then reduced to 102 mm minus by an ElRus 20x36 jaw crusher and conveyed to a surge bin. From there, a variable speed feeder regulates material flow to twin ElRus 6x20 screens, where all 102 mm by 19 mm material is directed to the H3800. The cone is typically set at a 22 mm close side setting (CSS) and operates in closed circuit with the second screen. Most of the spread’s Granular A product is conveyed to the pit’s upper level where it is utilised as feedstock for a separate wash plant. Here, a 6x16 Dillon screen is teamed with an AEI Ortner 4000 plant to produce washed coarse and fine concrete aggregates.
     This H3800 cone features Sandvik’s ASRi crusher control system. There are reportedly only three such systems currently operating in Canada, of which Sarjeant has two. According to the manufacturer, the ASRi intelligent crusher control system allows up to twenty different crushing programs to be stored, with the user able to choose between three operating modes for each program. The first mode allows the operator to enter a specific close side setting (CSS) to keep the crusher running at the same setting. Should an overload occur, the crusher opens to relieve the overload and returns the mainshaft to the desired position when the load reverts to normal. In Sarjeant’s application, the effect of an overload would be a temporary increase in recirculating load until steady throughput was restored. The second mode regulates the crusher load setting (to optimize crusher productivity). If, for instance, the highest load level is selected, the CSS will always be the smallest possible, resulting in maximum reduction for a particular application.
     Finally, the system can be set to a multi-CSS function. In this mode, the crusher automatically switches between two different settings to give two product curves. This switching takes place on a time share basis, such that the end product contains the desired proportion of finer and coarser materials. One of the most innovative features of ASRi is said to be its Process Optimization Tool (POT). To utilise this feature, the results of three laboratory test results on crusher products are keyed into the ASRi. The POT then enables the user to predict the product curves and product qualities that will be produced by different crusher settings. In addition, the user can study the effect of a change in set point or anticipate the consequences of switching between different feed materials. ASRi also features an intelligent wear compensation feature that means less frequent calibration for the user, while a single press of a button now does metal-to-metal calibration.
     Additional functions include alarm, event log, operating data and historical data. In large operations with multiple crushers, the ASRi system on each crusher can communicate with a higher level system by way of an Ethernet connection. The basic requirement for using an automatic regulator like the ASRi system is a crusher with hydraulic adjustment setting that allows for repeated rapid setting adjustments during operation with the crusher under full load. It is therefore suitable for all Sandvik Hydrocone crushers.
     As part of ongoing plant improvements, Sarjeant has also recently changed the power supply for both the portable crushing spread and the wash plant. A Detroit Diesel Series 600 generator set, rated at 681 kVA will power the ElRus crushing spread while the wash plant will be powered by a smaller Detroit Diesel Series 300 generator set rated at 338 kVA.
     The Sarjeant Co. Ltd is based in Barrie, Ontario. Its construction materials business interests include the 7th of Oro (Township) and Phelpston sand and gravel operations, four ready mix concrete plants and shared ownership of a hot mix asphalt plant. Non-construction interests include fuel oil distribution, 24-hour fuel stations, heating and cooling (supply and installation) and commercial real estate.

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What’s new in tracked crushers

One of the fastest growing segments of the aggregate machinery manufacturing industry has been the development of track-mounted, fully mobile crushing plants for rock crushing and recycling applications. The following report looks at some of the latest tracked crusher models.

Cedarapids
Track crusher joins Cobra Series

    Cedarapids has introduced the new highly mobile CobraTrack 1100 open circuit jaw crusher to its CobraTrack line. Designed for aggregate production and recycling work requiring up to 270 tonnes/h of output, the new low-profile model is said to be fully operational in less than an hour after arrival on site. The standard remote control device allows machine tracking and feeder control from ground level. The 400 mm wide, 3734 mm long tracks deliver a low ground contact pressure of less than 17 psi and travel speeds of up to 1 km/h. A full length feed hopper allows for either excavator or loader feed without spillage.
     The self-contained plant is designed to be transported without component disassembly, including the standard recycle magnet, or re-assembly once on site. With a gross weight of 43 091 kg, a track width of 2840 mm and a height of 3660 mm, the heart of the CobraTrack 1100 is the Cedarapids/Jaques hydraulically adjustable 30x42 jaw crusher. According to the manufacturer, the jaw features a superior nip angle coupled with a sloped stationary jaw die, a long crushing chamber and an aggressive stroke throughout the length of the crusher. This design is said to deliver reliable performance when tackling slabby concrete material, milled or ripped asphalt and all types of abrasive materials. The jaw also incorporates a hydraulic wedge adjustment system for making quick and convenient setting changes. The wedge system for holding the stationary jaw die in place is accessible from the side of the jaw rather than from the back of the jaw for easier manganese replacement.
     Once the crusher’s fluid coupling drive is engaged, all plant functions are operated from ground level for operator convenience and safety. A remote control unit provides operator control over the CobraTracks’s movement and turns the vibrating grizzly feeder on and off, plus controls its speed. A second ground-level panel allows the operator control over the 300 hp Cummins diesel engine. Emergency stop buttons are mounted on both sides of the plant and can be accessed from ground level for added safety. Dust suppression spray nozzles come as standard equipment.
www.cedarapids.com

Metso Minerals
Two machines in one

    The LT110S and the LT300HPB are the latest additions to Metso Minerals’ Nordberg LT series of track-mounted crushing and screening plants which now totals 13 models.
     With a production capacity of 200-400 tonnes/h for large contract crushing operations or quarrying, the 70 000 kg LT110S combines the standard LT110 primary jaw crushing plant with a detachable, heavy-duty screen unit that can be removed for transport and installed for operation in a matter of minutes. The 1.37 m x 3 m single-deck screen works with two product conveyors for splitting the jaw output into two fractions, up to 200 mm as product 1 and 90 mm as product 2. The screen rotation direction can be changed to gain either higher capacity or improved screening efficiency in more difficult applications such as wet material or the need for smaller fractions. Servicing the screen or changing the mesh is safely done at ground level, eliminating the need for a crane. The longer than standard discharge conveyor offers considerably larger stockpile capacity, according to the manufacturer.
     The LT110S is equipped with the field-proven Nordberg C110 jaw crusher, which can handle feed up to 670 mm. It is also equipped with a 1.3 m x 4.4 m grizzly feeder, a 5 m3 capacity feed hopper with hydraulic folding walls and by-pass chute.
     The plant is mounted on a Cat D7A undercarriage and powered by a 430 hp Cat C-12 diesel engine. Maximum travel speed is 1 km/h and the maximum climbing gradient is 20 degrees.
     A number of options are available including a 1 m x 1.52 m scalping screen, a hydraulic boom and breaker system, a 660 mm side conveyor, a water spraying system, remote radio control and a transport bogie.
     Equipped with Nordberg’s high performance HP300 cone crusher and a three-deck horizontal screen, the LT300HPB is claimed to be the most efficient secondary crushing and screening unit on the market that can be transported from site to site as a single unit. The plant accepts feed up to 200 mm and can produce 75 mm minus fractions at a maximum throughput of 450 tonnes/h. A Cat D7A undercarriage facilitates on-site moves at 1 km/h and climbing grades of up to 20 degrees.
     The 65 000 kg plant can be transported from job to job on its own bogie and king pin tractor attachment instead on normal transport on a low-bed trailer.
     In addition to the HP300 cone crusher and B3100T screening unit, the basic plant consists of a feed conveyor, a vibrating feeder chute, a lifting conveyor, a discharge conveyor, a 412 hp Cat diesel engine, an 800-litre fuel tank, a 420-litre hydraulic oil tank and an AC generator and control panel.
     Option equipment includes side conveyors for the second and third deck products, a material level control system, dust encapsulation, a dust removal unit, a water spraying system, remote radio control, a metal detector and an engine pre-heater.
www.metsominerals.com

Erin Systems
New impactor added to Powercrusher line

    Now available from Erin Systems is the Powercrusher PC 1375 I, the fifth model in Erin’s range of tracked impact crushers. The Quebec-based company also offers four tracked jaw crushers along with a full line of Erin Fingerscreener, Fingertrommel, Powertrommel and Trident series track-mounted screening machines.
     Distinguished by a futuristic and innovative design, the 38 000 kg PC 1375I has an inlet opening of 1250 mm x 750 mm for crushing recycled concrete and asphalt as well as virgin aggregates at rates of up to 350 tonnes/h.
     A 390 hp Cat diesel engine powers the plant which is capable of crushing and tracking simultaneously. The engine and operating controls are fully enclosed. Transport dimensions are 14.43 m long, 2.57 m wide and 3.20 m high. The hydraulically controlled main and side conveyors, swingbeam adjustment as well as the fines conveyor allow easy direction changes without the need to dismantle any components.
     Features include automatic feed adjustment, hydraulic gap adjustment, a permanent magnetic separator, a load sensing hydraulic system for lower fuel and power consumption and a variable speed rotor that regulates the percentage of fines produced. The feeder and stepped grizzly pre-feeder facilitates plant feeding by either an excavator or wheel loader. A reversible conveyor enables the operator to direct the prescreened fines to the side conveyor or main belt. Easy access to all maintenance areas has been provided.
www.erinsystems.com

Komatsu
Mobile jaw crusher launched

    The BR380JG-1 jaw crusher is the latest model in Komatsu’s mobile crusher family bringing to four the number of jaw crushers now available. The line also includes the BR480RG-1 impact crusher.
     Designed for mobile crushing applications including highway construction, demolition, quarry and excavation work, the 31 570 kg BR380JG-1 self-propelled crusher helps reduce costs associated with trucking and waste disposal.
     The BR380JG-1 is described by the manufacturer as having a simple, easy-to-maintain design that has a high commonality of parts with other Komatsu equipment. The plant is built on the same track undercarriage as Komatsu excavators and offers the user high travel speeds.
     Komatsu has also incorporated its patented HydrauMind» hydraulic technology into the new crusher. Komatsu claims to be the only OEM to offer a fully hydraulic drive-system crusher. The system supplies the optimal amount of oil through load-sensing and pressure compensated valves, which sense overloads and automatically slows the feed.
     Equipped with a 42x22 jaw, the BR380JG-1 is powered by a 180 hp Komatsu SAA6D102E-2 diesel engine and has a rated production output of 50 to 240 tonnes/h. Crushing performance is said to be improved with the addition of a load-presetting semi-automatic feeder and increased crusher rotation speed for improved crushing efficiency in concrete recycle and fine aggregate crushing applications. The machine also incorporates a one-touch setting adjustment for added control over crushing capacity.
     The manufacturer also claims that the BR380JG-1 features the first hydraulic protection mechanism that allows the jaw crusher to protect itself when it is clogged or jammed with metal or uncrushable debris. In addition, the high speed feeder conveyor has a reverse mode to help remove jammed material.
     Other major features include a real-time monitoring system that displays and monitors all of the machine’s components in order to alert the operator to problems. Also, sprinkler nozzles are located at the top of the crusher and at the head of the main conveyor to limit the amount of dust entering the atmosphere.
www.komatsu.ca

The Screen Machine
Compact design for tracked impactor

    The 4043T impact crusher is the latest track-mounted machine to be released by The Screen Machine’s Crushing Division. The 4043T is described by the manufacturer as a heavy-duty machine designed for producing high quality aggregates. The 35 909 kg plant has an overall width of 3.01 m and a height of 3.5 m.
     Equipped with a Caterpillar-built undercarriage for high speed travel and a 300 hp Caterpillar diesel engine, the plant features a 40x43 horizontal impact crusher, a 43x32 feed inlet opening and full remote controlled operation. The four-bar, 1016 mm diameter rotor has a one-piece shaft design and variable speed operation. The three-stage crushing system utilizes two interchangeable anvils and one fixed anvil.
     One of the 4043T’s key features is a unique split housing design that allows for blockage clearance during operation and ease of maintenance. The housing is lined with replaceable and interchangeable hardened alloy sideliners. Other features are a 1016 mm x 3.96 m remote controlled variable speed grizzly feeder, a hydraulic clutch to prevent unscheduled downtime, a 610 mm wide side discharge conveyor with diversion gate and a fully adjustable cross belt magnet with stainless steel chute.
www.impactcrusher.com

Extec
New tracked jaw crushers have compact design

    Now offered by Extec Screens & Crushers are the new C-10 and C-12 tracked jaw crushers for rock crushing or recycling asphalt, concrete and other construction debris. The compact, self-propelled machines are designed for remote controlled high speed crushing in small quarries as well as on urban demolition sites where operating space is often at a premium.
     The two new plants both feature a vibratory feeder with automatic control to regulate the feed into the crusher and a fully adjustable hydraulically controlled jaw. A reverse crushing action assists in relieving blockages while a unique fast-track system allows tangled steel re-bar to clear the machine. A full dust suppression kit is fitted as standard equipment. The complete machine is raised hydraulically for cleaning and servicing.
     The C-10 has a transport length of 8.76 m, a width of 2.5 m and a height of 3.2 m. In working mode, the plant is 11.46 m long, 3.8 m wide and 3.54 m high.
     The C-12 transport measurements are 13.96 m long, 2.8 m wide and 3.3 m high. Its working configuration is 14.11 m long, 4.1 m wide and 4.06 m high.
     Both models can be transported from site to site without a trailer when the optional bogie is employed.
www.extecscreens.com

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May/June 2004 issue

Aggregates and Roadbuilding Magazine
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