December 2006

Aggregates Manager’s
Top 25 RollOuts for 2006
From crushers and screens to mobile equipment,
2006 was a year of noteworthy product introductions.

by , Editorial Director
and , Executive Editor

How we made our choices

When we ask readers how we can best help them keep track of changes in the products and services they use to produce aggregates, almost everyone wants an annual short list of the really important stuff.

No wonder. The sheer volume of introductions is overwhelming. Aggregates Manager covers hundreds of products each year in its 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 December 2005 issue through the November 2006 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.

New off-highway truck series

Caterpillar has rolled out the F-series version of three off-highway truck models, including the 60-ton 773, the 70-ton 775, and the 100-ton 777. The trucks get new engines and radiators, improved transmissions and brakes, and new cabs and operator stations. The 703-horsepower 773F engine meets Tier 3 emission requirements, while the 740-horsepower 775F and the 938-horsepower 777F engines meet Tier 2 standards. All three models feature 500-hour engine service intervals, twice what their predecessors required. QuickEvac, Cat’s on-board engine oil evacuation and pre-lube system, is standard equipment and is said to reduce oil change time by up to 50 percent. The new seven-speed transmission uses an electronic clutch pressure control system to produce smoother shifts and a better ride, and to extend the life of drivetrain components. The new braking system is all hydraulic, rather than air over hydraulics, and delivers better reliability, response, control, serviceability, and modulation, according to Cat.

Click 236  on Reader Service card

New cone crusher debuts

Metso used Intermat 2006 to officially launch its new Nordberg HP4 cone crusher, though a few machines had already been delivered in Europe. According to Metso, the crushers feature a unique combination of crusher speed, throw, and cavity design that yields both high capacity and quality crushing. One Spanish quarry reportedly installed the HP4 along with new conveyors and screens to double production of 0-20mm sized basalt chips. Metso says the rock is a very hard “Ofite” and the new operation is achieving a production rate of 250 tons per hour.

Click 232  on Reader Service card

Upgraded jaw crusher

Terex Pegson has upgraded its 24- by 36-inch Metrotrak M Series single-toggle jaw crusher. The company says the aggressive crushing action of the newer, bigger machine enables high output in recycling and aggregates applications, even at tight settings. The tracked unit is said to also feature fast setup time and ease of transportation.

Click 227  on Reader Service card

Highest safe lift rate

Flexible Steel Lacing Co. (Flexco) has rolled out a new conveyor belt lifter with a 4,000-pound safe-lift rating, the highest available, according to the company. The Flex-Lifter can safely lift fully loaded troughed belts using adjustable wings, and flat belts using a return lift bar. It is available in two models: the Medium Flex-Lifter, for 36- to 60-inch belts, and the Large, for 48- to 72-inch belts.

Click 230  on Reader Service card

High-capacity rinser

Powerscreen says its new track-mounted, three-deck Chieftain 2100 Rinser can produce up to 500 tons per hour depending on mesh and material. The fully mobile washing screen can work independently or as part of a Powerscreen multi-machine, full-range wash plant. It can also be easily converted to a dry screen, according to the company.

Features include the ability to produce one, two, or three grades of sand. On-board conveyors can stockpile all product grades without traditional stand-alone conveyors. The unit features Powerscreen’s patented four-bearing, free-floating screen box for smooth operation and long service life.

Click 223  on Reader Service card

D-series of excavators debuts

John Deere has introduced six models in its D-series excavator line, ranging from the 54,244-pound 240D LC to the 185,520-pound 850D LC. Along with Tier 3 engines, the series makeover includes totally redesigned cabs with dramatic increases in sight lines, more leg room, shorter pilot controls, and fully adjustable suspension seats. Hydraulic flow has been increased for more digging power and precise control, and daily operating costs have been reduced with a series of designed in features, including a 5,000-hour service interval on the hydraulic system.

Click 229  on Reader Service card

Three-deck screen cloth

Major Wire’s Flex-Mat 3 High-Performance, Self-Cleaning Screen Cloth has been introduced to increase screening efficiency for all three decks of a screen box by eliminating blinding, pegging, and clogging, the company says. According to the manufacturer, the screen cloth moves material efficiently from one deck to the next and increases production by up to 40 percent compared to woven wire or polyurethane panels. The Flex-Mat screen cloth is said to offer better resistance to breakage (when properly sized and installed), thereby allowing producers to use it with smaller wire diameters in the same application while increasing both open area and wear life. Meanwhile, the independently vibrating wires help eliminate pegging and clogging on the top and middle decks with more material getting through to the bottom deck rather than building up as fines.

Click 238  on Reader Service card

Redesigned slotted opening screens

W.S. Tyler says it has redesigned its Ton-Cap and Ty-Rod slotted opening screens to meet a wider range of high capacity and high production applications. The slotted openings are said to offer 10 to 50 percent more open area than equivalent square mesh, and allow the manufacturer to use heavier, more durable wire.

Click 245  on Reader Service card

Automated underground loader

Caterpillar says Minegem is the first loader automation system that allows the operator to work from a safe, remote work station far from the loader, on the surface or underground. Minegem is said to give unprecedented control to the machine without the operator on board, so the operator is not exposed to the risks of the underground environment. It can also improve productivity by eliminating operator changeover time and rest breaks. The system automatically avoids contact with walls and is expected to produce less damage to the machine than teleremote operations.

Click 231  on Reader Service card

New series of wheel loaders

Case has added Tier 3 engines, a new cab design, and improved service and maintenance features on its new 721 and 821 E-series wheel loaders. Cab upgrades include lower noise levels, better vision, more space and adjustable steering column, seat, arm rests, and control placement. The Tier 3 engine can be managed with three power curves — max, standard, and economy power. The machines also have four work modes — max, standard, economy, and auto. Service checks require no tools and can be done from the ground, and remote drains are provided for coolant, engine oil, and hydraulic oil. The 183-horsepower 721E has a 3-cubic-yard standard bucket, while the 213-horsepower 821E has a 3.8-cubic-yard bucket.

Click 235  on Reader Service card

Mass excavator debuts

Hitachi has unveiled a Dash-3 version of its Zaxis 450LC mass excavator. The 106,000 machine now features a 348-horsepower, Tier-3-compliant engine, a new regenerative hydraulic system, a new cab, and increased structural strength. The new machine is said to be considerably more fuel efficient than its predecessor. Hitachi says the new hydraulics make arm, boom, and bucket actions faster, and increase digging forces. The new cab features a wider seat, more foot room, and 47 percent more glass on the right side.

Click 237  on Reader Service card

Down-the-hole drilling

Sandvik Mining and Construction has designed its “C” Series of Mission hammers with a new thread design on both ends of the piston case and corresponding top sub and driver sub to prevent premature failures of internal components, including piston failures.

The new design also reduces unintentional unscrewing of the driver sub, the manufacturer says. Intended to avoid problems resulting from loose drilling, the hammers are suitable for soft- to medium-rock formations. The hammers are available in 3- to 12-inch sizes, and all use the standard Mission shank.

Click 225  on Reader Service card

Production loader debuts

John Deere has introduced its first entry in the 7-cubic-yard wheel loader class. The new 844J features an electronically controlled 12.5-liter engine that develops 380 net horsepower at 1,600 rpm. It is linked to a Deere Powershift transmission that uses the company’s smart shift technology to continuously sense speeds and loads and adjust clutch pressures accordingly. The company says the result is best-in-class shift quality. The 844J weighs 69,300 pounds and comes with a 7.25-cubic-yard standard bucket.

Click 226  on Reader Service card

Crusher reduces fines production

McLanahan Corp. has introduced its DDC-Sizer series as an efficient means of primary and secondary crushing of low silica materials such as limestone. The DDC-Sizer is an evolution of the double roll crusher and is ideally suited to handle wet, sticky feeds contaminated with clay while producing a cubical product size due to the intermeshing teeth and slow rotational speeds of the rolls. According to the company, the primary advantage of this style of crusher is the significant reduction of undesirable fines in comparison to other primary and secondary crushers on the market, maximizing product yields. With a low-profile, low-headroom design, the DDC-Sizer is supplied with retractable wheels at each corner so that it can be rolled out from under hoppers or chutes for easier access during normal maintenance. Capacities range from 500 to 5,000 tons per hour with each unit designed for the application.

Click 222  on Reader Service card

New generation loaders

Liebherr is calling the new L 566 and L 580 its “Generation 6” wheel loaders. The 259-horsepower L 566 weighs 50,570 pounds; it has a 5.25-cubic-yard standard bucket capacity and a tipping load of 24,750 pounds. The 272-horsepower L 580 weighs 54,185 pounds; it has a 6.5-cubic-yard standard bucket and a tipping load rating of 39,850 pounds. Both feature Tier 3 engines with more power than the models they replace. Their cabs are 28 percent larger than the previous models and feature single-part laminated front windscreens.

Click 234  on Reader Service card

Advanced hard rock scaling

Breaker Technology, Inc. (BTI) president Frank Cargould says his company’s QS45 Vibratory Pick Scaler “represents the biggest advance in hard rock scaling in the last 40 years.” BTI says the scaler will double the production of a standard scaler with half the maintenance. Its vibratory pick can be used as a standard pick, or the integral hammer can be engaged to give extra impact energy when needed. The unit’s purpose-built carrier has a telescopic boom with a 45-foot reach, 330-degree boom rotation, and twin 6-inch lift cylinders. The tilt cylinder develops 40,000 pounds of peak force to the pick tip and the telescoping cylinder develops 35,000 pounds of thrust in each direction.

Click 239  on Reader Service card

Redefining the quarry truck

Caterpillar has introduced two completely new trucks in the 40- and 50-ton payload classes. The 476-horsepower 770 has a heaped capacity of 32.8 cubic yards with the standard body and takes a 40-ton payload. The 535-horsepower 772 has a 41-cubic-yard capacity and is designed for a 50-ton payload. They replace Cat’s 769 and 771; the venerable 769 first came to market in 1962, while the 771 debuted in 1992.

Among the proprietary features on the new trucks is a choice of five different body liner systems — three steel, two rubber — so that customers can configure their trucks for optimum capacity and durability in specific applications. The trucks also feature Cat’s new center-mounted cab and an optional rear-view camera system.

Also new is Cat Messenger, a machine management system that provides real-time and stored machine performance and diagnostic data through an LCD display in the cab. When combined with the optional Truck Payload Management System, Messenger also shows payload state, payload weight, loaded travel time, loaded travel distance, and accumulated weight. The payload system now has second-gear weighing capability and 2,400-cycle storage for data analysis.

Click 241  on Reader Service card

Mobile cone crushing

Sandvik Mining and Construction has rolled out its latest Crawlmaster mobile crushing unit — The Crawlmaster H4800i — that can be used either independently or in a multi-stage crushing circuit. Material flow through the unit, which features a Hydrocone 4800 cone crusher, can be controlled automatically or manually overridden. If manual operation is selected, the manufacturer says that each step is simplified with user-friendly messages explaining the process. In a multi-stage process, the system facilitates communication through the units, with the H4800i functioning as the secondary crushing unit. The portable crusher features a wide range of mantles for different crusher settings while the ASRi automatically controls the crusher to protect it from damaging overloads and helps increase production. The

ASRi’s color graphics, touch-screen interface, and automatic functions help increase the operator’s ability to consistently meet spec requirements, the company says.

Click 244  on Reader Service card

New construction trucks

Mack has introduced a new generation of its Granite and Granite Axle Back truck series. The new models feature the all-new MackPower MP7 engine, an 11-liter block available in six horsepower ratings between 325 and 405 horsepower. Hallmarks of the new engine are said to be a significant improvement in fuel economy and “tremendous low-end torque response.” The new trucks are built on the 116-inch BBC Mack Cornerstone chassis. Their cabs have an extra 4 inches of depth for more leg and belly room, and to allow a seat recline angle of more than 20 degrees. Also new: a wrap-around, cockpit style dash, one-piece windshield, and a broadly adjustable steering column with driver foot pedal controls suspended, rather than floor-mounted. The pedal arrangement means the driver’s heel never has to leave the floor when switching between fuel and brake pedals.

Click 224  on Reader Service card

Size reduction

Stedman has designed its V-Slam Impactor specifically for the size reduction of limestone, gravel, slag, and other minerals and ores. It is capable of as much as a 15:1 size-reduction ratio and can produce 5 to 100 tons per hour. The crusher also is equipped with an indexing feed tube and anvil ring and has a hydraulic-powered opening of the top housing for easy access and an automatic recirculating lubrication system.

Click 243  on Reader Service card

Automated bagging

Continuous, trouble-free automated bagging of crushed stone, concrete, sand, and other abrasive, difficult-to-control products is the goal of virtually all bagging operations. The Hamer model 3100 is built specifically to meet such challenging environments, the manufacturer says. Double-sealed, self-cleaning pulleys, self-cleaning bag conveyors, advanced dust control, and bag seal cleaning to ensure a proper seal are among the innovations featured in this system. Its rugged construction includes a powder-coated frame and 1/2-inch steel-plate internal components. A variety of bag features, including handles and corner seals, are also available.

Click 228  on Reader Service card

Automated log washer

A patented new automated log washer from GreyStone, Inc., increases efficiency and lowers labor costs, while producing consistent quality aggregate, the company says. Designed in cooperation with an aggregate producer, the automated log washer features a hydraulic support system tied to a PLC sensor that detects the tonnage going through the unit. When tonnage decreases, the system detects it and increases the angle of inclination until the sensor detects the proper tonnage. If tonnage increases, the hydraulic system automatically decreases the angle of inclination until the proper tonnage is detected. Upper and lower limit switches are employed to prevent excess inclination or damage to the unit. Automating the variable incline section of the log washer — which typically runs at inclinations of between 5 and 10.5 degrees — removes the need for human input beyond the an initial calibration by the operator. According to the manufacturer, the result is an increase in efficiency and the elimination of unnecessary labor costs while solving the problems of inconsistent feed rate and uneven product quality.

Click 221  on Reader Service card

Mass excavator

Case Construction Equipment has unveiled another high-production excavator, the 70-metric-ton CX700. The new machine fits between the 46-ton CX460 and the 80-ton CX800. The new machine shares the CX800 frame and has a 425 net horsepower engine. It has standard Case features, including four work modes, auto power boost, and a climate-controlled cab. New is a switch that lets the operator give priority to either the boom or swing functions.

Case has also announced Tier 3 engine upgrades for the CX330, which gets a 5-percent increase in horsepower and an 8- to 10-percent boost in fuel economy, along with a beefed up undercarriage.

Click 233  on Reader Service card

Virtual training system

Caterpillar rolled out a series of PC-based Virtual Training Systems for training entry-level equipment operators. The systems use personal simulators and training modules to orient and train operators in basic machine operation and application skills. Cat says the training can be used as a self-study tool or as part of a program led by an instructor.

Click 242  on Reader Service card

Severe-duty crusher debuts

Telsmith says its Model 3258 Jaw Crusher delivers higher production rates and lower costs per ton in severe-duty applications such as processing very hard rock or challenging demolition debris. Its features include a 32- by 58-inch feed opening and a uniquely long crushing chamber with shallow nip angles to deliver aggressive crushing action and consistent high-capacity throughput. The company says the unit is suitable for stationary operations and is compact enough to mount on portable plants. It also says the new crusher incorporates a revolutionary hydraulic adjustment and overload protection system that utilizes a moving toggle beam. The system positions the toggle beam and holds the crusher setting; hydraulic tensioning cylinders hold proper toggle tension through the entire adjustment range and overload protection is automatic.

Click 240  on Reader Service card

Reprinted from Aggregates Manager Magazine
December 2006