December 2005

Top 25 RollOuts for 2005
A big show year leads to strong equipment introductions and an
 opportunity to improve operational efficiencies.

by  Editorial Director
 and   Executive Editor

No wonder. The sheer volume of introductions is overwhelming. Aggregates Manager covers hundreds of products each year in our RollOuts columns and Supply Lines features.

So each year, our staff reviews all the product introductions we’ve covered for the past year (our Top RollOuts “year” actually runs from the November/December 2004 issue through the November 2005 issue) to pick out 25 that we believe are worth further review. Our priorities are new concept products, which are rare, new series/new generation products in categories that relate to the aggregates industry, and other rollouts which serve our readers’ interests by increasing competition in a product category.

Inevitably, we omit deserving products, either because we just didn’t understand the significance of the product or because the announcing company didn’t communicate what was special about the product, or both. In either case, we apologize in advance for these omissions.

That said, this has been an especially difficult year to make choices, in part because so many equipment manufacturers concentrated their rollouts in the time period surrounding ConExpo-Con/Agg 2005, the behemoth equipment exposition that takes place every three years.

Loads 110- to 165-ton trucks fast

Leibherr has introduced its R 994 B Litronic excavator to the North American market as a state-of-the-art loading machine for mining trucks in the 110- to 165-ton range. With a backhoe attachment, the machine weighs 661,500 pounds, and with a shovel arrangement, 675,000 pounds.

It uses a 12-cylinder, 1,500-horsepower engine and a 23.5-cubic-yard bucket. Liebherr says the unit loads 100-ton trucks in three passes and 165-ton trucks in six passes. The machine can travel at speeds up to 1.9 mph.

Giant haul truck debuts

Hitachi has introduced its largest rigid-frame haul truck, the EH5000. With a payload of 320 to 360 tons, depending on trim, the new machine has a maximum gross machine weight rating of 1.16 million pounds. It employs Hitachi’s proprietary AC drive technology and is available with a choice of 2,700-horsepower engines or an optional 3,000-horsepower engine. Hitachi claims its drive system has 51 percent more rimpull and 37 percent more retarding speed than competing AC systems. It is also said to be 2 to 3 percent more efficient than comparable DC drives.

Click 222 on Reader Service card

Severe-duty truck debuts

International’s new 7700 line of severe service trucks offer users a step beyond the 7600 series with new options that specifically target bridge-formula mixer, dump, super dump, and block hauler applications. The company says the three-model series combines the style and drivability of its 7600 line with the chassis strength and packaging of its 5000i.

The new truck’s style and drivability features include liberal use of chrome and a new front taper leaf-spring suspension system that delivers a smooth ride under load or empty, according to International.

To maximize payload, two 7700 models feature a new front-bumper-to-axle setting of 29.1 inches and a frame system that optimizes payload weights for states that follow bridge formula limits. The company says the frame system for all three models uses a single 12.25-inch frame that is 400 pounds lighter than many double 10-inch frames, enhancing payload potential.

The standard drive train for the 7700 series is a 305-horsepower engine with a 1,150-pound-foot torque rating, and a 10-speed overdrive transmission. Options include a 470-horsepower engine.

Click 229 on Reader Service card

New rock hammer

Atlas Copco Secoroc has replaced its long-serving Strike Force 6 hammer with a new model that incorporates major design upgrades. The new DHD60 incorporates the company’s QL design bit shank, so owners can use the same bit in any Secoroc hammer. Penetration rates have been improved so that the new model outdrills competing models, according to the company. Other new features include better fluid handling, fewer parts, interchangeable parts with other Secoroc models, and a fully reversible hammer case.

Click 245 on Reader Service card

Pre-cleaner for tough conditions

Flexco's EZP1 precleaner debuted as the first product in the company's new Rockline Conveyor Products, a family of high-performance, economically priced, do-it-yourself belt conveyor accessories designed for the aggregates market. The precleaner features material path blade sizing that helps correct belt contact and reduces the frequency of blade retensioning, a visual indicator for precise tension control, and a urethane blade that renews its edge as it wears.

Click 225 on Reader Service card

Big-time screening

Powerscreen engineered its new 20- by 5-foot triple-deck dry screen for large-scale operations. The highly mobile Chieftain 2100 can process up to 500 tons per hour, depending on mesh size and material type, and sets up to run in 15 minutes. It uses large bearings to produce 25 percent more force in the screen, providing optimum performance in wet, sticky applications. Other features include aggressive 10- mm throw (9-mm under load) and a radio-controlled, angle-adjustable tipping grid.

Click 241 on Reader Service card

Mobile equipment debuts

Metso Minerals unveiled its new Lokotrack LT200HP cone crusher. Metso designed the Lokotrack LT200HP for mobile secondary and fine crushing. Built around the Nordberg HP200 cone crusher, the unit has a 210-mm feed opening and can process up to 275 tons per hour.

A 425-horsepower diesel combined with hydraulic drive provides variable crusher speed, allowing operators to adjust to different liners and feed stock. Metso’s IC600 interactive, intelligent control system is a standard feature; the system monitors and controls the crushing process to ensure continuous and stable material flow to the cone.

Click 231 on Reader Service card

New open-tank design

Kolberg-Pioneer has introduced a completely new line of classifying tanks. The 7000 series provides an open tank design that eliminates all internal cross supports and provides for more uniform material settling, according to the company. The new bridge design offers verifiable and real-time valve function information to the operator. The new series is available in portable, semi-portable, and stationary configurations, and in sizes ranging from 8 by 20 feet to 12 by 48 feet.

Click 234 on Reader Service card

Coolant conversion kit

ChevronTexaco says its new FleetFix Conversion Pack lets fleet owners convert conventional coolant currently being used in heavy duty vehicles and equipment to an extended life coolant — without having to drain, flush, and refill the cooling system. In addition to saving time and labor, the company says its conversion pack helps owners avoid cross-contamination. FleetFix-modified coolant can have a service life of up to 600,000 miles, six years, or 12,000 hours using an extender addition at the halfway point, according to ChevronTexaco.

Click 233 on Reader Service card

Design your own truck

Caterpillar’s new 793D mining truck is available in five different configurations. The standard configuration is designed for speed on grade. An extended wheel life station design has more robust wheel stations, as well as larger spindles and bearings for long uphill applications. The extra speed configuration uses a new input transfer gear set and a different ratio to achieve up to 10 percent greater top speed on relatively long, flat haul profiles. The extra retarding package provides up to 35 percent more maximum retarding speed for downhill loading applications. And, the high altitude package mates a short-stroke engine with a special compound turbo-charging arrangement; it also includes the extra retarding package.

Click 228 on Reader Service card

Large-scale screening solution

Major Wire Industries Limited rolled out the third generation of its screen media — Flex-Mat 3. It is the result of developing a new manufacturing process that allows the company to offer what it calls the industry’s broadest range of screen opening sizes, from 40 mesh to 4 inches, in a wide range of wire diameters. Major Wire also says that it is the only company that can provide larger openings, including 2- to 4-inch openings, which allow aggregate producers to fine-tune their screening solutions to optimal output. The screening media is comprised of a unique combination of polyurethane strips bonded with individual wires that eliminates the need for traditional woven wires. With no cross wires, the company says its product lasts up to two to three times longer than woven wire.

Click 244 on Reader Service card

Handles dry bulk material

Sandvik Mining and Construction's rock processing group has unveiled the telescopic chute and the WearTuff line of modular wear protection products to the North American market. The telescopic chute is designed to prevent the emission of dust and the loss of material in the handling of dry bulk materials.

A vacuum is created in the chute by the material flow, reducing the need for filtration systems. The WearTuff products come in rubber, metal-backed, polyurethane, and ceramic/rubber configurations.

Click 223 on Reader Service card

Stand-alone automation package

Telsmith has rolled out Trac10, a new stand-alone automation package for its SBS cone crushers to enhance efficiency and productivity for aggregate operations. The company calls it an affordably priced package for those who want the advantages of crusher automation but don’t have PLC controls throughout the plant. The base package provides remote control of the SBS crusher, including adjustment, auto-calibration, and an auto-protect mode. It also interfaces with optional feeder controls for automatic choke feed.

Click 230 on Reader Service card

Rapid truck unloading

Superior Industries’ new low-profile truck unloader discharges material from trucks onto conveyors in minutes. Featuring a transport width less than 12 feet, the unit has a 72-inch wide conveyor belt and a discharge hood that directs material onto a smaller-width belt. Superior says the unit can deliver up to 1,500 tons per hour with no spillage and can transfer 25 tons of 100 PCF material from dump trucks in minutes.

Click 240 on Reader Service card

New generation wheel loaders

Caterpillar has ushered in a new generation of large wheel loaders with the introduction of the 980H and 988H models this year.

The 980H features a new Tier-3 compliant 318-horsepower engine, faster loading cycles, a quieter cab, and improved serviceability. Equipped with an 8-cubic-yard bucket, the 980H is said to be 10 percent faster in loading cycles than its predecessor, the 980G-Series II with a 7.5-cubic-yard bucket. Other performance enhancing changes include an electronic clutch pressure control system for smoother shifts, and a new cooling system designed to resist plugging.

Improved cab sealing and insulation reduce noise levels inside the cab by half compared to the G-series model – from 80 decibels to 76 decibels. Serviceability enhancements include a faster hood-opening system, easy-access pressure taps, and rear fenders that cover twice as much of the wheel area as the previous design to reduce mud splatter.

The 354-horsepower, 9-cubic-yard 988H wheel loader also features a Tier-3 compliant engine that Cat says will be more reliable and durable than the engine it replaces because it has fewer parts, fewer cooling challenges and is less sensitive to internal acid formation, fuel sulfur content, and internal wear. The 988H has virtually identical productivity potential as the 988G, but it is quieter, more fuel efficient and costs less to own and maintain. A new rimpull control system improves fuel efficiency and tire life by providing different traction settings for different applications to prevent tire slippage and improve cycle times in difficult conditions.

Click 221 on Reader Service card

70-ton excavator

Volvo Construction Equipment unveiled its new 70-ton hydraulic excavator, the EC700B. Designed to “redefine performance” in the 70-ton class, the new machine features the highest-capacity engine in the class as 464-horsepower and weighs between 149,000 and 155,000 pounds, depending on boom, arm, and track selections. Volvo says the main pump, swing motor and bearing, and the track rollers are of higher capacities than those normally found in the 70-ton class. Designed for mass excavation and quarry loading, production models of the EC700B are being field tested worldwide, with full-scale production planned for late 2005.

Click 243 on Reader Service card

Precision drilling control

Sandvik Mining and Construction's Tamrock Rock Pilot system guarantees smooth drilling, straight holes, and excellent performance even in the most demanding ground conditions. It is said to adjust drilling power automatically, reacting quickly to changing rock formations and sending the optimal amount of power to the rock, improving hole quality and extending steel life dramatically.

Click 239 on Reader Service card

High-frequency dewatering screen

GreyStone’s new 4- by 8-foot dewatering screen makes it simple for producers to adjust bed depth, table tilt, and vibrator variables in order to tackle most variation of sand specifications. The screen uses two high-frequency 4.3 horsepower vibrators with adjustable weights that initiate a linear motion, driving particle in an uphill direction, while water is strained down through the sand bed and screen deck. Other features include an adjustable discharge dam, a 1- by 2-foot, 0.25-mm aperture urethane screen with quick-release design, and a ridged-steel bed and frame assembly.

Click 236 on Reader Service card

Massive plant debuts

Eagle Crusher describes its new UltraMax 1600-69 as “massive.” The unit features what the company claims is the industry’s largest solid-steel rotor, a 3-bar design that can process a variety of materials at up to 800 tons per hour. Designed for primary or secondary crushing, the 1600-69 is capable of reduction ratios in excess of 24:1. The portable unit has a choice of power plants, including a 500- or 800-horsepower electric, or 521-horsepower diesel engine.

Click 237 on Reader Service card

Aggressive washing

McLanahan’s newest log washer, the X-Treme Log Washer, features heavy-duty paddle bases, motor horsepower, and clean out grades, allowing for processing rates of 500 tons per hour. The company says that an efficient, compact reducer, adjustable slope, and paddles designed to resist wear enable its log washers to offer aggressive washing capabilities. A twin-seal pak bearing assembly is standard on all of the company’s log washers.

Click 224 on Reader Service card

Long-lasting tires

Michelin Earthmover unveiled its X-Super Terrain AD tire, which was built for articulated dump trucks, scrapers, and loaders. The E4 radial tire’s deep tread and rubber compound help it last longer, and its sidewall and shoulder design help protect it, according to the manufacturer. Additionally, the tire features a self-cleaning tread and a low-rolling resistance to help maximize fuel economy. The tire is available in 23.5R25.

Click 235 on Reader Service card

Long-life inserts

Higher hardness properties and longer-lasting performance are the hallmarks of Rockmore’s new Marathon carbide insert for button bits. The advanced carbide grade uses a new manufacturing process to improve overall bit performance for a variety of down-the-hole hammers and a broad range of drill-rig models, according to Rockmore. The company says the carbides lasted up to 20 percent longer than previous designs in mining and water-well environments during trials. Wear flats appeared slower and later compared to inserts with traditional composition.

Click 232 on Reader Service card

Extreme duty aluminum trailers

Ontario, Canada-based Titan Trailers has introduced a V-Plow cleaning system for its live-bottom, aluminum wall trailers. The self-cleaning system expands the hauling and back-hauling options open to the owner, according to Titan. The company introduced its extreme duty, live-bottom trailers last year, combining its aluminum Thinwall trailer walls with a Keith Walking Floor solid steel V-Floor. The live floor gives haulers more backhaul choices, according to Titan, while the aluminum walls provide more payload. The trailer is recommended for hauling aggregates, ore, and demolition materials.

Click 242 on Reader Service card

Strongest idler roller ever

Continental Conveyor and Equipment Co. unveiled what it describes as the strongest idler in the history of conveying earlier this year. The SDX-F Plus — as well as the SDX-F — are rated at 4,000 pounds and 3,000 pounds, respectively. The company says an 84-inch-wide SDX-F Plus belt can move more than 8 tons per second.

Click 227 on Reader Service card

World’s largest hydraulic breaker

Atlas Copco Construction Tools Inc., has introduced its new HB 7000 hydraulic breaker attachment — said to be the world’s largest hydraulic breaker.

With a service weight of 13 tons, the breaker has an impact rate of 450 blows per minute and can accommodate a maximum hydraulic flow of 119 gallons per minute at 2,610 psi of pressure.

Click 226 on Reader Service card

Reprinted from Aggregates Manager Magazine
December 2005