by Kerry Clines, Senior Editor

Specialty buckets for excavators allow operators to crush or screen material on site, on the go.

Rotobec

Rotobec says its FB crushing buckets provide the ideal crush-in-place solution with high-manganese-content wear plates that can be rotated. The plates are flat and feature an oscillating movement. A magnet base is optional. Buckets are available in four sizes and are set up to take a wide variety of lugging types.

Flip Screen Australia Pty Ltd.

Flip Screen says its new EX180 screening bucket attachment, suitable for 40- to 50-ton excavators, works by rotating 360 degrees, continuously, on a single axis. An easily interchangeable screen allows smaller particles to pass through, depending on mesh size, while a baffle retains larger material to be dumped separately. The bucket opening is 96 inches wide by 24 inches high with a screening capacity of approximately 2.3 cubic yards. The interchangeable screens are built from high-tensile steel mesh and range from 1/2 to 4 inches, with additional custom sizes available. Screen change out is said to take one operator less than five minutes to perform, with no tools required.

MB America, Inc.

MB says its crushing and screening buckets are simple to use, handle all types of materials directly on site, reduce the use of additional mechanical equipment, and cut down on transportation and management costs. The crusher bucket (shown) features a load capacity ranging from 0.65 to 1.30 inches; bucket openings range from 24 by 18 inches to 47 by 20 inches; and weight ranges from 3,330 to 10,800 pounds. The screening buckets fit excavators ranging in size from the smaller 10- to 20-ton machine up to 35 tons and larger.

Rotobec

The SR screening bucket from Rotobec uses a number of different screens to sort material down to 1 inch in size. The durable Hardox screen and bucket are said to provide years of use in a wide range of applications. The company says the rotating screen allows for a high throughput of material and is not prone to clogging when material is damp.

Excavator buckets must be able to dig through thick overburden, as well as handle various types of aggregate.

AIM Attachments

AIM HD60 excavator buckets feature AR400 steel cutting edges and side cutters. The buckets’ open design allows for easy clean-out. Standard features include thick horizontal wear straps, full-curve side wear straps, and lifting D-rings. Optional bolt-on side cutters and extra pins are available. The buckets are currently available in heavy-duty and severe-duty configuration for 40,000- to 60,000-pound excavators.

CP, a division of Paladin Construction Group

CP heavy-duty and severe-duty buckets are available in widths from 10 inches up to 84 inches to fit mini-excavators and excavators up to 200,000 pounds. A circular torque tube design enhances each bucket’s overall strength. One-piece, T-1 curved side cutters and side wear pads protect against premature wear of the bucket sides, while an abrasion-resistant double bottom up to 3/4 inches thick provides a hard, yet lightweight, barrier between the bucket and the material. The T-1 cutting edge with triple-pass welding sits at a downward angle for aggressive digging, faster scooping, and less stress on the excavator. Heavy-duty buckets are available in sizes ranging from 0.037 to 5.7 cubic yards; severe-duty buckets range in size from 0.106 to 3.9 cubic yards.

Wheel loaders are the workhorses of the quarry, but they can’t do their jobs without the right buckets.

Doosan Infracore Construction Equipment America

Doosan says its new rock buckets are built to tackle the toughest, most severe digging and loading applications. The buckets are available in three models with 4-, 4.5-, and 6-cubic-yard capacities. The two smaller buckets are 128.9 inches wide and 54 inches high; the large bucket is 136.2 inches wide and 68.5 inches high. All three models are available with pin-on mounting only and feature a spade nose design and standard weld-on teeth.

Volvo Construction Equipment

Volvo says its new rehandling buckets are easy to operate and provide better visibility for operators. The buckets are said to increase productivity with faster fill times, quicker overall machine cycle times, and increased material per load. According to the company, overall operating costs are low as a result of 10-percent fuel reduction, longer machine service life per ton of material moved, and low maintenance costs per ton of material moved.

Caterpillar, Inc.

Cat Performance Series Buckets come standard on Cat midsize wheel loaders. Designed with a systems approach, the buckets are shaped to work efficiently with each machine’s linkage, weight, lift, and tilt capacities. According to the company, the buckets deliver faster fill times and better material retention, reducing cycle time and improving productivity and fuel efficiency.

Even the smallest of machines, the skid-steer loader, works best when it has the proper bucket attachment.

CEAttachments, Inc.

CEAttachments says its Edge buckets feature excellent cutting-edge visibility and high breakout force. Sizes range from 48 to 96 inches with heaped capacities from 11.4 to 23 cubic feet. Toothbars, bolt-on cutting edges, and serrated bolt-on cutting edges are optional.

Teeth are the backbone of the bucket. The proper edge and shape can make a big impact on production.

ESCO Corp.

ESCO says its Ultralok construction tooth system offers a hammerless lock that is integrated into the point. The hammerless design is said to not only provide increased safety, but also eliminate the need to inventory separate pins or locks. The slim profile maximizes penetration and reduces fuel costs, according to the company.

Komatsu America Corp.

Komatsu says its KMAX System Teeth feature the patented G.E.T. system designed for maximum consumption ratios and strength, without unnecessary bulk. The shape of the teeth is said to promote smooth flow of material over the tooth-adapter for even, consistent wear. The teeth are reversible for extended life and feature a simple, functional, reusable fastener that can be unlocked with just a 90-degree turn of a socket for quick change-out.

Leading Edge Attachments, Inc.

Leading Edge Attachments says its patented Multi-Ripper Tooth — designed for excavators and backhoes — allows the operator to easily rip rock, coral shale, caliche, decomposed granite, limestone, sandstone, asphalt, or frozen ground with maximum breakout force. The operator is said to be able to focus the excavator’s full breakout force individually to each point of the special twin tiger tooth, thus greatly improving the ripping effect.

The mass may be smaller and the velocity may be slower than desired, but the rock is rolling in the right direction.

Momentum is sometimes hard to define. In sports, it may be a crucial play that changes the outcome of the game. In business, however, it might be something as simple as a sale that leads to an unexpected customer base. Often, it may seem like a small pebble, but once it starts rolling downhill— gaining mass and velocity along the way — its impact can be significant.

Movement alone, however, is not enough. Just look at the results of our forecast studies during the last eight years, and it’s clear that not all momentum is good momentum. For example, consider the industry’s historical response to business conditions. When answering our first forecast in 2004, 84.5 percent of respondents indicated positive business results (excellent, very good, or good). For a three-year window between 2008 and 2010, however, those numbers plummeted with an all-time low in 2009 when just one in three respondents (34 percent) reported favorable business ratings. Those numbers increased slightly in 2010, but 2011 respondents gave the most favorable business ratings (43.4 percent positive) since 2007.

Another favorable indication is the accuracy demonstrated in yearly predictions and the subsequent results. With the exception of those predicting a fair year, responses from last year’s forecast results versus this year’s actual results are all within 5 percent, and most forecast discrepancies erred toward being overly pessimistic.

• Excellent: 1.6 percent forecast; 5.7 percent actual (+4.1 percent difference);

• Very Good: 12 percent forecast; 13.2 percent actual (+1.2 percent difference);

• Good: 24.8 percent forecast; 24.5 percent actual (-0.3 percent difference);

• Fair: 44.0 percent forecast; 34.9 percent actual (-9.1 percent difference); and

• Poor: 17.6 percent forecast; 21.7 percent actual (+4.1 percent difference).

From a regional perspective, producers in the Northeast were the most likely to report positive results with nearly six in 10 (58.3 percent) indicating positive business results in 2011, while approximately two-thirds (67.5 percent) of those in the South reported fair or poor results.

Small producers (under 500,000 tons per year) were the most likely to indicate positive business results, with the level of optimism diminishing in a direct correlation to increasing tonnage until hitting the large end of the spectrum with producers of more than 5 million tons per year. This group was slightly more inclined to report favorably, with one in three reporting favorable results, compared to three in four reporting fair or poor business results in the next largest production category (3 to 5 million tons per year).

In terms of operators experiencing changes in production quantities throughout 2011, an equal number said they’d increased and decreased production. It’s worth noting that, of those reporting an increase, the average increase was 25 percent higher production. Among those indicating a decrease, the average decrease was 19 percent. The largest gains were had among producers of crushed stone and sand and gravel (30.8 percent reported an increase) and among those in the North Central region (43.5 percent indicated higher production levels).

So what’s next?

While gains appear evident within pockets of the industry, several years of inertia are challenging to reverse. Looking forward in 2012, small improvements are being predicted in most categories. Comparing forecast projections from 2012 to those from 2011, 6.6 percent expect an excellent year (+5 percent), 12.3 percent expect a very good year (+0.3 percent), and 26.4 percent expect a good year (+1.6 percent). In terms of negative expectations, 35.8 percent expect a fair year (-8.2 percent), while 18.9 percent expect a poor year (+1.3 percent) in 2012.

Sand and gravel producers are the most concerned looking forward. Nearly nine in 10 (88.9 percent) expect a fair or poor year in 2012. Those working in the Northeast and North Central regions are the most optimistic with 66.6 and 52.2 percent, respectively, calling for positive business results. In terms of size, small operators are the most hopeful, with 68.4 percent of those producing up to 500,000 tons per year and 53.3 percent of those producing 500,001 to 1 million tons per year calling for positive results.

In terms of production quantities, sand and gravel producers are the most upbeat. Twice as many anticipate an increase in production compared to those who expect tonnage to decline.

Consistency is key from a regional perspective. The majority of operators in all four regions expect production quantities to remain about the same. That said, operators in the North Central region were the most optimistic with 34.8 percent anticipating an increase compared to 13.0 percent calling for a decrease. Producers in the South are still skittish on demand; they were the only region with more respondents anticipating a decline (20.9 percent) than an increase (16.3 percent).

Personnel matters

In 2011, employment levels were slightly more stable throughout much of the aggregate industry. Overall, 27.4 percent (9.6 percent fewer than in 2010) of respondents said the work force decreased throughout the year, while 20.8 percent said their work force grew.

Crushed stone and sand & gravel operators were the most likely to report having a smaller work force (41.0 percent), while sand and gravel operators were most inclined to boost their numbers (33.3 percent). Crushed stone only operators had the most stable work force segment with 58.3 percent indicating the size of their work force was about the same as during the previous year.

From a regional perspective, the South’s declining production levels were reflected in its staffing; 46.5 percent of operators there reported work force declines. The most growth was seen in the North Central region where 26.1 percent of respondents’ operations grew their numbers.

By worker category, other hourly labor was the category to experience both the highest increase (13.2 percent) and the highest decrease (27.4 percent). The number of women in the workplace grew, as it was the only category to report more work force expansion (10.4 percent) than contraction (6.6 percent).

Industry challenges

Competition for sales has dominated operator concerns during the last four years. While the number who ranked it as a major concern diminished this year (25.5 percent), nearly 60 percent more called it a minor problem. Taken as a combined total, almost 85 percent noted it as a challenge — 25 percent more than the next most widespread problem.

When asked how they were dealing with this issue, many respondents indicated that they have lowered prices to seal the deal, including break-even pricing. Some vertically integrated operators noted using package deals to streamline costs. Others say they are analyzing markets, implementing long-term strategic planning, and exploring new and growing markets. Customer service, customer contact, and a focus on quality are among the business strategies being employed to maintain customer loyalty.

Other concerns, such as regulatory compliance and aggregates availability, are increasingly important to this year’s respondents, but the dominance of competitive sales indicates that the aggregate industry — while in a better place than recent years — remains intensely focused on each job and each customer.

Improvements may be modest and regional, but they do, indeed, appear to be real. If these results and those forecast for 2012 bear out, then the aggregate industry needs to ensure that objects in motion stay in motion. From there, it’s a matter of increasing mass and velocity. AM

Methodology, Objectives, and Sources

The objective of the 2012 Aggregates Manager Forecast Survey was to determine business, production volume, spending, and workforce trends. In November 2011, Aggregates Manager e-mailed questionnaires to a random selection of readers in the crushed stone and sand and gravel, crushed stone-only, and sand and gravel-only industries. A total of 106 useable surveys were completed.

To help get that work completed, Lafarge North America is counting on the performance of its fleet of trucks including PacLease’s 1,000th truck equipped with a PACCAR MX engine, leased through PACCAR Leasing (PacLease). This particular PacLease unit is a 2012 Kenworth T800 tractor operated in the New Orleans, La. area.

“PacLease is pleased to help Lafarge accomplish important projects that will protect New Orleans and its residents from future storms,” Olen Hunter, director of sales for PacLease said in a press release. “And it’s particularly gratifying that Lafarge will be doing some of that work using a Kenworth T800 tractor equipped with a PACCAR MX engine leased from our local PacLease franchise, Kenworth of South Louisiana-PacLease.

“Just 14 months after presenting the keys to a Kenworth T660 with the first PACCAR MX engine to Costco Wholesale, PacLease has leased its 1,000th PACCAR MX powered truck to Lafarge North America,” Hunter said. “The fact that it took a little over a year to lease 1,000 Kenworth and Peterbilt trucks with PACCAR MX engines is a clear demonstration of the popularity of the engine. The fact that so many customers have chosen this engine speaks highly to its reputation for performance and reliability.”

David Marchand, mobile equipment manager for Lafarge North America’s Louisiana operation, agrees. Lafarge leases 12 trucks at this location, including five Kenworth T800 mixers, delivered in November 2011, and three Kenworth T800 tractors, delivered earlier in 2011. The T800 Extended Day Cab mixers are equipped with 10-yard mixers for increased load capacities and enhanced efficiency. The three T800 tractors are spec’d with the Kenworth Extended Day Cab and the 485-horsepower PACCAR MX engine providing 1,650 foot-pounds of torque powered through an Eaton Ultrashift automatic transmission.

“Our drivers really like the quality of Kenworth trucks,” he said. “The cross members are heavier duty, and Kenworth uses huck bolts, not rivets, in the assembling of the cabs. That means our trucks don’t rattle after years of bouncing around in construction zones.”

Drivers also value the comfort that a Kenworth truck offers, particularly with the new trucks that are equipped with the Kenworth Extended Day Cab, Marchand said.

“The Extended Day Cab has become a standard specification for all of our new Kenworth trucks, and it has really made a huge difference,” he said. “The additional length and height allow our drivers to stretch their legs. Plus, the additional storage space for weather gear and other supplies helps provide a more productive work environment.

“The PACCAR MX engine is performing very well,” Marchand said. “It’s quiet, works in tandem with the automatic transmission, and provides our drivers the power and torque they need. We really like the fact that the PACCAR MX engine is 400 pounds lighter than other available engines, which allows us to carry more payload.”

“It’s really the whole equipment package,” he added.

Since 2006, Lafarge North America’s Louisiana operation has been turning to Kenworth trucks and Kenworth of South Louisiana to help complete construction projects in and around New Orleans. Reston, Va.-based Lafarge North America is the largest diversified supplier of construction materials in the United States and Canada with six gypsum production sites, 24 cement production sites, 302 aggregates quarries and 234 ready-mix plants.  It produces and sells cement, ready-mixed concrete, gypsum wallboard, aggregates, asphalt, paving and construction, precast solutions, and pipe products used in residential, commercial, and public works construction projects across North America. Its Louisiana operation includes 22 plants in the New Orleans area and extends north of New Orleans to the north shore of Lake Pontchartrain in Covington and west to Gramercy.

Marchand said the performance, durability, reliability, and comfort that Kenworth trucks have provided his operation has been critical to the success of many of the company’s projects, particularly the most challenging ones.

In addition to the T800 attributes Marchand also appreciates how full-service leasing through PacLease makes it easier for his operation to acquire quality Kenworth equipment.

“The full-service leasing option makes good operational sense. I deal with Kenworth of South Louisiana’s local PacLease operation, so I have a local contact that can help me get any maintenance issues resolved. Dave Russo and the folks at Kenworth of South Louisiana-PacLease take care of us.”

The move to full-service leasing was made easy by Marchand’s experience with Kenworth of South Louisiana-PacLease, which provides contract maintenance for many of the trucks in Lafarge’s Louisiana operation. The operation’s fleet of 120 trucks includes heavy-duty trucks with dump bodies, concrete ready-mix trucks with 10-yard drums, and tractors to pull a variety of support trailers.

Marchand particularly likes the ability and willingness of Kenworth of South Louisiana-PacLease to provide mobile maintenance service when the company is running trucks around the clock.

In 2010, as part of the work on the Inner Harbor Navigation Canal Lock Replacement Project, Lafarge took part in a 58-hour monolithic placement of 10,242 cubic yards of Agilia concrete. This placement of Agilia concrete still holds the world’s record for the largest monolithic (or continuously placed) underwater concrete pour.

Agilia, which is Lafarge’s proprietary high-performance, self-consolidating, self-leveling concrete mix, gave Lafarge North America an edge when bidding this special product, according to Lafarge product specialist Gerard Vitrano. The Agilia product, which requires superior mixing efficiencies, benefited from the power delivered by the Kenworth trucks, he added.

“With the complexity of our Agilia mix, we must have trucks that can handle the strict mixing demands,” Vitrano said.

Brad Trueting, area manager for Lafarge North America who served as project manager for the underwater pour, believes that the project’s success was enhanced by the reliability of the Kenworth Trucks and the support of full-service leasing from PacLease.

“When faced with the reality of having to place concrete for 58 hours straight, you must have your truck fleet as dependable as your hard-working labor force,” Treuting said. “And by leasing the Kenworth trucks from PacLease, we’re getting maximum return on the asset. Kenworth of South Louisiana-PacLease provides us remote servicing when the trucks need to be serviced. PacLease takes on the risk of residual value at the end of the lease. So, we’re not having to deal with any unforeseen costs through the life of the lease. And with even monthly payments, it’s easier to budget the use of the trucks on these different projects.”

Lafarge’s Louisiana operation recently delivered the remaining yardage of high-performance concrete to pour the final bridge pilings and the eastbound approach ramps for the new U.S. Interstate 10 Twin Span Bridge. This 5.4-mile long bridge over Lake Pontchartrain has 55,000 daily commuters. Hurricane Katrina severely damaged the original twin span in 2005. Temporary fixes immediately following the disaster restored traffic on the old twin span. Meanwhile construction of the new six-lane twin span bridge, which started in 2006, took five years to complete and cost more than $800 million. Lafarge poured all of the concrete used in its construction.

“When we’re involved in those kind of placements, we have a lot of equipment out there, plus dedicated concrete batch plants operating and mixers pouring concrete continuously,” Marchand said. “In order to complete them, we have to have trucks that we can depend on to perform. But just as importantly, we need a local dealer that we can rely on to help us choose the right specs for those trucks and keep them rolling. We get all that with Kenworth trucks, Kenworth of South Louisiana, and PacLease through their contract maintenance and full-service lease products.”

by Kerry Clines, Senior Editor

Kenworth Truck Co.

Set-back front axle

Kenworth says its T800 dump truck is rugged, reliable, and versatile. The truck features a set-back front axle to optimize payload potential and maneuverability; offers front and rear PTO options to handle challenging applications; and is said to be engineered to the application for added dependability, longevity, and lifecycle value. It can be specified with engines rated with a wide horsepower range, offers several radiator sizes up to 1,780 square inches for added cooling, and has a variety of rear axle ratings to meet specific customer requirements.

Volvo Trucks North America

Comfort and safety

The Volvo VHD dump truck features a spacious, comfortable cab with insulation and soundproofing. Doors are double sealed to keep out water, wind, and noise. The company says the truck is dependable, maneuverable, and offers the highest payload capacity. The truck’s high-strength steel cab is designed to protect drivers with three-point seat belts and a driver-side air bag. Heavy-duty safety systems come standard for added peace of mind.

Peterbilt Motors Co.

Maneuverable in tight spaces

Peterbilt says its Model 382 dump truck features a 50-degree wheel cut for maneuverability in tight spaces. Powered by a Cummins ILS9 engine, the truck provides 345 to 380 horsepower, up to 1,300 pound-feet of torque, and is available with rear engine power take-off (REPTO) and the Bendix ESP stability system. It can be configured to meet any need with front-axle offerings rated up to 20,000 pounds and rear axles rated up to 46,000 pounds.

Western Star Trucks

Tackles demanding jobs

Both powerful and versatile, the Western Star 4900 dump truck is said to be ideal for any application, featuring all the options necessary to tackle demanding jobs. Options include several different suspension configurations; rear engine, front engine, and transmission-driven PTO; frame rail clearance to mount wet kits and hydraulic tanks; various exhaust packaging configurations with horizontal outlets, or single or dual stacks; clean back of cab; suspended air and electrical harness; and up to 3.2 million RBM (resistance to bending moment) with a single channel frame.

Caterpillar Inc.

First model in vocational truck line

The Cat CT660 dump truck is the first model in a full line of Class 8 vocational trucks. Engine options include the Cat CT11, CT13, and CT15 with horsepower ratings from 330 to 550 and peak torque ratings from 1,450 to 1,850 pound-feet. The company says the combination of dual, sequential turbochargers and a precise fuel-injection system allows the engines to develop peak torque at lower speeds. The cab’s interior features an air-suspension driver’s seat with adjustable lumbar support that reclines and adjusts to fit any driver.

Mack Trucks, Inc.

Designed for extreme workloads

Mack says its Granite dump truck is designed to shoulder extreme workloads while delivering driver comfort. Available in axle-forward and axle-back configurations, the truck’s Cornerstone chassis uses lightweight advanced materials and application-specific crossmembers to carry heavy payloads. The spacious, ergonomic cab design gives drivers plenty of leg and head room, and air-suspended cab mounting protects drivers from harsh, rough roads. The 325- to 405-horsepower MP7 engine and 415- to 505-horsepower MP8 engine provide plenty of muscle and great low-end torque, according to the company.

Freightliner Trucks

Durable, lightweight cab

The Freightliner 108SD dump truck features a 42-inch, set-back axle configuration, and comes with a variety of standard features and options such as front frame extensions and radiator-mounted grilles. Its durable, yet lightweight, cab is constructed with corrosion-resistant aluminum reinforced with steel. The large windshield and sloping hood provide a clear view of the road and work sites.

Rugby Manufacturing Co.

Sleek, yet strong body

Rugby Manufacturing’s Titan Series dump body line features dirt-shedding top rails, 10-degree sloped tailgates, and radius front corner posts. The 10-gauge steel side construction, 8-gauge steel floor, 7-inch structural channel long sills, and 4-inch I-beam cross sills on 12-inch centers offer durability and reliability. The dump bodies are available in 4- to 5-yard, 5- to 7-yard, and 6- to 8-yard capacities.

Crysteel Manufacturing, Inc.

Custom dump bodies

Crysteel says its Select custom dump bodies allow customers to essentially design their own dump body without incurring the extra cost and time normally associated with custom-designed products. The bodies are available in traditional square body styles or elliptical bodies in sizes ranging from 5- to 20-cubic-yard capacities. Additional options are available for tailgate design, side height, floor material, and understructure design. A wide range of accessories is also available.

DuraClass

Dent resistant, durable

The Bedrock dump body from DuraClass features a contemporary design with high-strength Hardox 450 steel floor, sides, and rear for dent resistance and durability. The elliptical radius provides a smooth dumping action. The I-beam understructure provides maximum floor support. A heated understructure is available for cold-weather applications. Optional aluminum fenders keep body weight low to increase payload capacity. The body is available in lengths from 13 to 21 feet.

Poised between a Japan-like depression and inflation and stagnation, a careful course is necessary to correct the economy.

The good news is that the U.S. economy is growing — with the exception of the housing market — but the bad news is we’ve encountered the worst recession since the Great Depression, says Eugenio Aleman, director and senior economist at Wells Fargo.

“We went from -9 percent to almost 3 percent in almost three quarters,” Aleman explained during his “Construction Industry Economic Analysis & Outlook” presentation at the Construction Writers Association in San Antonio, which was attended by Aggregates Manager editors. “The only reason it [the economy] recovered is because the U.S. government intervened. During the Great Depression, the government didn’t intervene.”

Back then, the debt was 145 percent, and it’s rapidly approaching 100 percent now, Aleman says, noting it’s going to be very expensive coming out of this recession. “What we have done during the last three years, good or bad, left us very close to another depression.”

And though the recession is technically over, Aleman says the majority of Americans don’t consider the nation as on the way to recovery, particularly because jobs aren’t being created at a rapid pace. “We lost 9 million jobs in two years,” he says. “If you take 9 million jobs times the per capita income, you can see how bad this has been.”

It will take nearly five years to recover 9 million jobs — even though the economy is growing. Typically, the economy can grow at about $200,000 per month. Then the question of underemployment is raised. Is it really underemployment, Aleman asks, or is it just the new economy? “If you extract how many workers are being laid off by the public sector, you have to add 60,000 more jobs.”

The duration of unemployment shows a struggling labor market, and the biggest issue is that employment isn’t growing at as fast of a pace as necessary to get the country moving. However, consumer prices are beginning to increase, so there are higher prices but less work.

The Humpty-Dumpty Economy

The country has grown into what Aleman calls a “Humpty-Dumpty Economy.” Using a twist on the popular nursery rhyme, Aleman quips:

The U.S. economy sat on a wall,

The U.S economy had a great fall,

All the king’s treasury men,

And all the King’s Federal Reserve men,

Couldn’t put the U.S. economy together again.

“We have been on a brick wall for 11 years trying not to fall,” Aleman says. “On one side of the wall, there is a 1930s/Japan-like depression. On the other side of the wall, there is inflation and stagnation, which equals stagflation. It’s going to be tough to pull out of it, but the other side could go on for 20 years.”

It’s a shock because, for the last 11 years, the United States has been “throwing money out of a helicopter,” Aleman jokes as he shows a “Helicopter Ben” Ben Bernanke action figure in a helicopter with the slogan, “Now YOU can drop money out of a helicopter.”

“Cash is king” will remain the economic mantra, Aleman notes. “It’s very difficult to get a loan now,” he says. “You have to have a job, you have to have 20 percent down…banks are turning away customers. They don’t want their money…because lending is no longer a business.”

Aleman refers to the Federal Reserve balance sheet as a “monetary tsunami.” During economic times like this, the Federal Reserve lowers interest rates to reflate the economy. It did this during the last recession, Aleman says, and only one sector reflated: housing. “That bubble burst, and we went into a recession,” he says. “That’s where we are now.”

Although new home sales are very depressed, interest rates are at an all-time low, and credit-card lending “is non-existent,” there are some signs of stabilization, Aleman says. “The good news is that the economy is growing,” he points out. “Manufacturing has expanded for the past two years. The service sector is in expansion mode.”

Aleman is also confident that the housing market, which sets the tone for much of the construction market, will come back. “Home prices are going to come back,” he says. “Don’t ask me when, but they will. We can’t outsource home buying to China, so it has to come back.”

A tricky balance

At Aggregates Manager press time, U.S. Sen. John Cornyn (R-Texas) was calling on Congress to adopt “a strong balanced budget amendment (BBA) to the Constitution.” Cornyn, a member of the Senate Budget Committee, says a strong BBA “will treat the disease along with the symptoms. An amendment with too many exceptions and loopholes will not.”

In a speech before the Heritage Foundation, “Balanced Budget Amendment: Reclaiming Control Over America’s Future,” Cornyn asked the difference between the fiscal challenges the nation’s founders faced and the ones we currently face and then quipped that “the answer is pretty simple. Back then, federal government was the solution to the problem. Right now, the federal government is the cause of the problem. And the American people understand the difference.”

The U.S. government now borrows more than 40 cents of every dollar it spends, Cornyn noted, adding that “every child born in America today comes into the world as a debtor, to the tune of about $46,000. “Our gross debt is now larger than the entire U.S. economy, which means we are now on the same trajectory as Greece, Italy, and several other nations, and we do not like where that path leads,” he said. (To watch Sen. Cornyn’s speech, go to heritage.org/Events/2011/11/Balanced-Budget-Amendment.)

The question, however, is what form of BBA should be supported: A strong BBA that might not pass the House or a “clean BBA” that wouldn’t incorporate spending and taxing provisions, but might be enough to get the two-thirds supermajority vote?

Cornyn holds steadfastly to his support of a “strong bill” and cites two reasons. “First, a strong balanced budget amendment will actually solve the problem. Let’s all remember that the disease in Washington is out-of-control spending,” Cornyn said in his speech. “Big deficits are just a symptom of that disease. As any doctor will tell you, treating the symptoms without treating the underlying cause of those symptoms will likely do nothing to help the patient recover, and could make things worse.

“Second, a strong amendment will reassure financial markets and the American people that we get it. Think about the message that Standard and Poor’s sent us when they downgraded our credit rating (in 2011),” Cornyn added. “The financial markets are looking for a serious, long-term solution to our fiscal issues. They are not looking for more empty promises.” AM

Change out oil filters every 500 hours of operation, and when oil is changed seasonally; or when contamination is suspected.

Slackers beware. While some operations are right on target with the somewhat sophisticated hydraulics maintenance needs of major stationary crushing components or highly mobile portable plants, they may not allocate adequate maintenance time to material handling systems with simpler hydraulic setups, yet similar demands in day-to-day operating hours. Don’t fall prey to the common misconception that one can realize maximum performance from conveyor hydraulic systems with little to no maintenance attention — as the latter will surely lead to costly repairs, component failures, and safety risks regarding the operation of indispensible and hard-working material handling systems.

A proactive and preventive conveyor hydraulics maintenance program leads to greater cost- efficiency paybacks, plus the delivery of the reliable machine performance required for the high-volume feeding, transfer, and stockpiling of saleable products. Certainly a modest investment in time and effort is involved; however, conveyor hydraulic maintenance is not rocket science, but rather the adherence to simple common sense guidelines. According to material handling experts, here are the top factors to include in an effective hydraulics maintenance routine.

1.  Monitor fluid levels

Most importantly, always maintain the correct hydraulic oil level according to the gauge on the tank itself, and check the levels before starting the equipment. Inadequate oil levels may result in major component failures due to cavitation, or causing parts to starve for oil, or from aeration, which means that air is being sucked into the system, or from overheating. These issues result in a snowballing effect that ultimately deteriorates or even destroys the pump and contaminates the entire system. Note that, if a pump does not receive oil, severe damage can occur within as little as 10 seconds.

2.  Conduct routine maintenance inspections

Check for leaks and fix them. Letting them go is never acceptable, as leaks let oil escape and lead to system contamination and safety risks.

Weekly inspections should include checking fluid levels, filter indicators, temperature gauges, breather caps and filters, and checking all components, system hoses, and connections for leakage. Inspect for aeration which is identified in the reservoir by looking for foaming or little whirlpools that appear due to gulps of air being taken into the suction strainer. If detected, this may indicate low fluid levels, high viscosity, low fluid temperatures, faulty shaft seals, or air leaks in the suction line. Listen to pumps for any high-pitched whining sounds during operation, which may indicate signs of cavitation.

3.  Use the right hydraulic oils

Always use the manufacturer-recommended brand and do not mix oils. Use the proper viscosity grade. Viscosity is defined as a measurement of how resistant a fluid is to attempts to move through it. Low viscosity fluid is said to be thin, while high viscosity fluid is thick. The usage of the proper oil is integral to ensuring cold starts, offering high-temperature protection, and maintaining optimum system efficiency. Your manufacturer will work with you to select the right oils for the application and environment. Note that, depending upon climate and temperatures, oil heaters or cooling systems may be required. Additionally, highly dusty applications may require specialized breather systems, while extremely wet applications may require special attention to component seals.

4.  Eliminate leaks

Check all system hoses and connections for leaks.

Many say that hydraulic systems are invariably going to leak; therefore, leaks are commonly accepted in the industry. Think again — leaks should never be accepted — period. If you see a leak, fix it. Not only do leaks let oil escape, they are also an attraction for dirt that may build up on equipment, leading to contamination of the system, the product, and the environment; and safety hazards such as fire or injuries to workers from oil leakage contacting parts of the body.

5.  Maintain fluid cleanliness

On conveyor systems such as telescoping radial stackers, change the hydraulic oil every 1,000 hours or certainly whenever contamination is suspected. Don’t fall for the misconception that sealed hydraulic systems do not require oil changes, as they do have sources of pollution. Changes in temperature can induce moisture into the oil, and any leaks are a source for dirt contamination. Combine that with a lack of oil changes and one is running a dirty mix of oil with the potential of wearing out pumps and valves.

Properly store hydraulic oils in their original closed containers. Clean the top of the container before opening and pouring, and use a clean funnel with a built-in strainer when filling. Remember that particles as small as 10 microns can cause severe damage to a hydraulic system.

6.  Change oil filters and breathers

So often, it’s thought that just any filter will do. But balance the cost of the recommended filter against the prevention you receive — and don’t cut corners. Use only filters meeting performance specifications, as improper filters may lead to premature hydraulic failure. Change out the hydraulic oil filters every 500 hours of operation and also when the oil is changed seasonally. Change both the filters and the oil if contamination is suspected.

When the fluid level lowers in the reservoir, it is displaced with air. The breather is a fiber filter (located on the top of the tank) that allows free air flow in and out of the tank. The breather must be kept clean and maintained. It is not all that uncommon to see systems where breathers have been lost and not replaced, and that is unacceptable. The breather should be replaced once every season or more often if the unit is run in extremely dusty or abrasive conditions.

7.  Maintain an oil analysis program

An effective oil analysis program can detect some early warning signs of contamination or impending component failure. For example, rising metal levels in the oil can indicate serious pump wear and tear. Alternatively, analysis trends may indicate that oil change intervals can safely be increased. At minimum, check your hydraulic systems by analysis no less than annually. On a telescoping radial stacker, due to its continuous operation of belts, feeders, pump, and computerized hydraulic systems, oil sampling is recommended every 500 hours.

8.  Commit to a “complete” approach

Should a component failure occur, conduct a failure analysis. What caused the failure and how might it be avoided in the future? Consider that, if a hydraulic motor has failed, contamination has affected the entire system. If a pump has failed, metal is flaking into the system. Yes, replacing either of these components will get the system up and running, but it is a must to take the next step of cleaning out the entire system — including all the hoses and tanks — to ensure the removal of contamination. Make sure that systems are cleaned externally as well. It is advisable to pressure wash the outside and top of the hydraulic tank. Also, wash the oil filter assembly and the area around the oil filter.

The integrity of hydraulic systems is directly tied to the reliable performance of material handling systems. For example, in the case of telescoping radial stacking conveyors, hydraulics and valves hold the unit in position during operation. Valve contamination could allow inconsistent operating height levels and serious safety risks. So keep a heads up on hydraulic equipment, as its proper maintenance really does matter. AM

Material supplied by Superior Industries, a manufacturer of conveyor systems and components. Contributors include Superior Industries Customer Service Agent Lyle Hettver; and Brian Pichlar, service manager for Superior Industries dealer R.B. Scott.

Under the procedures in most MSHA districts, a mine operator and miners’ representative may request a conference regarding a contested citation or order — only after MSHA proposes a penalty assessment — and any settlements require approval by the commission. The new procedures are based on the results of a pilot program launched by MSHA Assistant Secretary Joseph A. Main in August 2010 that evaluated the effect of the pre-assessment conference on contested citations. The evaluation incorporated input from industry stakeholders, including mine operators and miners’ representatives, according to MSHA.

NSSGA says it believes that to be effective, “conferencing meetings need to be conducted in a manner independent of the district manager so that operators can have confidence that their arguments receive a full and fair hearing.”

The association does have concerns about the agency’s having predicated the program’s execution on available resources. In the last fiscal year, the agency was appropriated more than $357 million, NSSGA says. The association also notes that the aggregates industry was assessed $20.4 million for payment to U.S. government general revenue.

But being one of 11 Iowa highway “stimulus” projects worth, in total, $13.7 million, makes it a little less ordinary. So does its new surface.

The unbonded concrete pavement overlay of Oak Crest Hill Road from south of the city limits of Hills to the Washington County line was a nearly $1.845 million job completed by Iowa City, Iowa-based contractor Metro Pavers and funded through the American Reinvestment and Recovery Act (ARRA), more commonly known as “the stimulus.”

Iowa received nearly $358 million for state and local roadway, bridge, trail and freight rail projects through the stimulus, and Governor Chet Culver’s I-JOBS initiative kicked in $115 million for transportation projects.

The Oak Crest Hill Road concrete overlay covered two lanes and spanned approximately 5.5 miles from start to finish. The county required traffic to be maintained in one direction at all times, says Nick Kempf, co-owner of Metro Pavers.

“Because it is not a primary highway, it was not that heavily used, but they [the county] still wanted to improve the road system,” says Kempf.

“They tried to ‘re-profile’ it and take out some of the bumps.” And work went all the more easily, he says, because “most people along the roadway were happy to see the road improved.”

Straightforward doesn’t mean easy

The overall job was fairly straightforward, says Kempf, but that doesn’t mean it didn’t have some challenges. The University of Iowa is located in Johnson County and this means a fair amount of bicyclists. As part of the project, the county asked that bicycle lanes be developed “to make it safer,” Kempf says. However, this means the road has an extraordinary width for a secondary road. “The driving lanes are 24 feet plus the extra lane to bring it up to about 34 to 36 feet,” Kemps says. As a secondary road, there were no contraction baskets, Kempf pointed out, so his team cut every 15 feet for joining.

There has been a great deal of whitetopping in Johnson County. Concrete overlays have become commonplace in Iowa as an economical means to rehabilitate the secondary road system.

But for this project, rather than beginning with the removal of existing concrete, the concrete overlay was placed over an asphalt roadway. It was also poured on the shoulders that were compacted and then built up to accommodate the new bike lines. “We tried to maintain about 6 inches on the old roadbed and 8 inches on the shoulder,” Kempf says. “Our ditches had to be filled, compacted and then brought up to grade.”

The rock laid after the shoulders were compacted includes crushed recycled concrete and modified sub base. Although this wasn’t a difficult process, at times it was challenging. “We’d have weeks where the dirt contractor could not work because it was too wet,” Kempf points out. “We had to deal with the weather. We had the shoulders built up and were ready to pour on a Saturday, but then we had 2 inches of rain the night before.”

Keeping it cool
The timing of the job also presented challenges.

The Oak Crest Road job was the first time Metro Pavers undertook a concrete overlay in summer. Previous overlays had been done in the fall. The summer presented challenges,
but by waiting until fall Metro ran the risk of the maturity curve taking longer. And as the day warmed up, the asphalt had to be kept cool. “We had to bring in a water truck to cool off the asphalt before we could pour on it,” Kempf explains. “We didn’t need to bring it in until between 10:30 a.m. or 11 a.m., but then we would need it all afternoon.”

According to the specs, the asphalt couldn’t be more than 90 degrees Fahrenheit because it would set on the overlay but not on the rock, Kempf points out. “We had to keep a consistent ground temperature,” he says. “We had to cool it down and stay just ahead of the paving machine. We had to have it cooled off, but it couldn’t be wet.”

Concrete overlays can be a good choice for the widening of an old pavement with narrow traffic lanes, the addition of new travel lanes – as was done with the addition of shoulders for bicyclists on Oak Crest Hill Road – or the extension of ramps, according to the University of Iowa National Concrete Pavement Technology Center’s (NCPTC) “Guide to Concrete Overlay Solutions.”

(For a downloadable PDF of the Innovationsguide, go to http://www.cptechcenter.org/publications/guide_concrete_overlays.pdf.) “Adequately designed and constructed
widening can improve both faulting and cracking performance
of the pavement,” according to the guide. “Widened slabs should be used with care with concrete overlays on stiff foundations (such as on concrete pavements) because of the increased risk of longitudinal cracking.”

NCPTC gives these rules of thumb for widening:
• Keep joints out of wheel paths, especially for bonded resurfacing.
• Tie longitudinal joints with #4 bars to prevent separation.
• Keep panels as square as possible (1.5:1 maximum)
• The width of widening rather than depth has more of a positive effect in reducing loads to the top of the existing
pavement.

About the Job
Project: Concrete pavement overlay, unbonded, for Oak Crest Hill Road in Johnson County, Iowa, from south of the city limits of Hills to the Washington County line Award from Iowa DOT: $1,845,120.47

Contractors: Metro Pavers Inc., Iowa City, Iowa

Equipment used: CMI trimmer, Power Pavers/Power Curbers 2700 slipform paver and Power Pavers/Power Curbers TC-2700 texture curing machine. “The 2700 slipform paver worked very well for the job, Kempf says. “It’s very mobile for the kind of work we have, but it’s still heavy enough to do this kind of work. It’s a two-track machine – easy to load and easy to unload for transport.”

For a downloadable PDF of this article, click here or go to the January 2012 edition of Aggregates Manager. Go to http://www.betterroads.com and click on “Digital Edition.”

Before operation, check the unit visually. Look at the flange’s connection points and hardware to make sure they are tight. Become familiar with the equipment and the application.

by Thomas Aldridge

How many of us have gotten into our car for a quick run to the grocery store, and tried to start it only to hear a click, click, click? Anyone who has experienced this has learned that the car battery needs to be replaced every few years. We all know that we have to do other vehicle maintenance, such as oil changes, filters, lights, etc., on a regular basis as well. But what does it cost us if we don’t perform this maintenance — a delay and maybe some money while the repairs are made?

As an operator/owner of a quarry or a mine, we are faced with these same issues every day with all of our equipment — especially pumping equipment. Picture a pump on the site as the battery in the example above. What happens when that pump goes bad and stops the operation at the plant? How quickly do those lost minutes add up in time and cost? Just like proper maintenance on our personal vehicles, the pumps that we work with need regular maintenance and attention, too.

But where do we start?

Just like the start of the song “Do Re Mi,” let’s start at the very beginning. For any piece of equipment to be maintained properly, especially a pump, the first step is the selection of the “proper” pump. Part of this selection comes from the flow expectations and the head pressure necessary to overcome the system resistance. Is the pump going to be on a fixed system and maintain flow or pressure, or is it a utility pump that will be moved throughout the plant or site for flood control? When we choose a battery for our vehicle, we look at the cold-cranking amps and the size to make sure we are putting the right battery in.

The use of the pump is also a key factor. Knowledge of the application and the performance expectations help to make sure the pump meets the pumping needs of the engineering team, and knowledge of the maintenance meets the reliability needs of the operations team.

And what do we look for?

In a nutshell, pumps are mechanical equipment that are highly cyclical, so loading conditions have a significant impact on the maintenance requirements. And based on statistical reliability, for any piece of equipment, the question is not if it will fail, but when. We know that our battery will not last forever, so we have to prepare for when it needs attention. For pumps, preventive and regular maintenance is what helps to increase the life of the equipment.

A primary factor in appropriate maintenance is familiarity with the equipment and the application where it is used. You can tell a lot about equipment by looking and listening. Just like a doctor, scrutinize its performance over time and identify differences that occur from when the pump operated new versus how it acts over time. In most cases, the symptoms will show themselves in noise, vibration, or heat. When your car takes a little extra time to start or the lights seem dim, you know it may be time to check the battery.

The next basic maintenance check is to inspect for leaks and inspect the general wear parts. Maintain your fluid levels. These are items that can and should be done every day. A large number of maintenance failures are the result of easily fixed problems. Replacement wear parts should be kept on hand, and a regular program used to inspect and maintain them should be implemented. It can be as simple as brushing corrosion from your battery terminals.

Refer to manuals, operating instructions, and labels to become familiar with the equipment and service requirements.

Another maintenance factor in a mine or quarry application is the damage caused by abrasive materials. Are you pumping fine solids or slurries that erode the material and damage lip seals or mechanical seals? It is important to check the compatibility of the materials of construction and the materials being pumped to make sure they fit. Wear rings and wear plates should be adjusted periodically to keep the efficiency of the pump where it should be. Impellers should be inspected for damages. If abrasive material is a factor, be sure to use easily repaired or replaced materials. A fabricated component is sometimes easier to weld and repair than a casting that will require special welding materials or techniques.

The most frequently addressed area for maintenance is seals and bearings. They should be properly lubricated. Watch them for signs of heat and overloading. A bearing problem can amplify and result in additional problems with other parts of the system. Inspect drive-system components on a regular basis. Belts and sheaves are in constant contact with one another and wear over time. Keys can shear. Elastomeric drive components can be impacted by the environment, and then wear is accelerated with heavy and regular use.

Filters should be inspected and changed on a regular basis. In dusty situations, it may be necessary to use an air cleaner suitable for higher dust areas. Engine and drive manufacturers provide guidance on recommended service intervals that should be followed and adjusted based on actual operating conditions.

And lastly, one of the unspoken maintenance items is to watch for signs of abuse, misuse, or mishandling. As pumps are moved around a site, they can bounce and get bumped. Sometimes an unfamiliar operator or mechanic can create more problems than they fix.

So, what’s the next step?

It is important to know the equipment, the process, and the tools with which you are working. Identify the limits and the conditions around you. Have manuals and training materials available for reference. Establish procedures that are consistent and repeatable. Talk with co-workers, and share tips and tricks for maintenance. Use gauges and meters on the pumps and piping to compare to the specified or target values, as well as comparative information.

One of the hardest parts for most of us as engineers, mechanics, and all-around tinkerers is to keep up with maintenance, and then also think we can fix it if it does break. Be prepared to make the tough call and evaluate the repair versus replace situation on equipment. At a certain point, the equipment will start to increase in cost beyond what it becomes worth to use.

So, to make sure that we are not stuck without the battery, we need to look and know the equipment we use, make sure it is right for us, and then steadily maintain it. Kurt Vonnegut said, “Another flaw of the human character is that everybody wants to build, and nobody wants to do maintenance.” But in real life, if we don’t do the maintenance, we can’t build. After all, if our battery is dead, the car won’t go.

10 Keys to Pump Maintenance

1. Know the application.

2. Pick the right equipment.

3. Daily inspection and maintenance — look and listen to what is happening.

4. Watch abrasive and corrosive factors.

5. Check fluids and leaks.

6. Maintain wear parts.

7. Lubricate.

8. Perform proper weekly checks on engines and drives.

9. Watch for abuse or misuse.

0. Monitor performance.

Thomas Aldridge is a sales engineer with Griffin Pump & Equipment Inc.

A mobile laser scanning system can be mounted on the back of a standard SUV, allowing data points to be collected as the vehicle drives around the stockpile.

Performing physical inventories of material stockpiles is a task that most aggregate companies see as a necessary evil — it is something that has to be done for accounting purposes, but it takes up valuable resources and can slow down production. At the same time, the accuracy and traceability of the methods are important from the accounting side and need to be consistent from inventory to inventory so that the results can be relied upon. After all, these are valuable corporate assets that are being characterized.

Steve Brooks, plant manager for Tilcon in Poughkeepsie, N.Y., wanted to use the most accurate method available to inventory his company’s stockpiles. Tilcon, an Oldcastle Materials Group company, is an integrated materials company with multiple New York and New Jersey operations that include quarries, asphalt plants, recycling plants, water terminals, and a heavy highway construction division.

“About three years ago, we began to investigate the use of 3D laser scanning,” Brooks says. Instead of collecting 10 to 20 shots on a typical 20,000-cubic-yard stockpile using a total station measurement system, with laser scanning on the order of 100,000, 3D points are typically collected for that same pile. The spacing of the laser scanned points on the pile surface is typically on the order of 3 to 6 inches.

Manual surveys cannot begin to match this level of surface detail. In fact, the laser scanning field crew has to be careful not to collect too much data because this can bog down the post processing and data analysis without improving the end result.

“We were using a different laser scanning contractor when we became aware of the mobile laser scanning-based methodology that H2H offers,” Brooks says. “We made the decision to give it a try and have been very impressed with the results.” H2H Associates is a geo-consulting firm based in Troy, N.Y., with expertise in mining, engineering, geology, survey, regulatory, and environmental services.

Its mobile laser scanning system is mounted on the back of a standard SUV. The 3D point data is collected by driving around the stockpile, typically at a speed of 5 to 10 miles per hour, with the scanner rotating at 1,800 revolutions per minute. The mobile laser scanning system includes a global positioning system (GPS) receiver and inertial measurement unit (IMU) that allow the data to be geo-referenced to the exact location on the earth. This ensures that each inventory operation will be referenced to the same coordinate system and pile limits each time the inventory is performed.

Faster data collection and processing

Speed was the key factor in Vic Coleman’s decision to use a mobile laser scanning system. He is the CFO at Braen Stone, a New Jersey firm with more than 100 years of involvement with the aggregates industry. Braen uses the physical inventory surveys for both internal and external financial audits.

When Coleman first started doing quantity surveys, his crews were averaging two sites per week, but the mobile laser scanning system has allowed crews to assess three sites in two days. “The speed is remarkable, and we have a high degree of confidence in the results,” Coleman notes. He has seen three or four generations of technology, and says he is continually amazed at the pace of change. “I remember when the field crews had to keep the batteries warm with their hands,” he recalls.

Mobile laser scanning not only speeds up the data collection portion of the workflow, but, as compared to the use of aerial photogrammetry, it has led to much faster turnaround of the actual physical quantities. Using point cloud software supplied by the sensor manufacturer, the 3D data for a 20,000-cubic-yard stockpile can be reduced and computed into volumes within a matter of hours.

Gary Wall, operations manager for Tilcon Connecticut, a leading supplier of quality crushed stone, hot-mix asphalt, and ready-mix concrete throughout the state, notes that stockpile quantities are typically available within a couple of days of the survey.

Safety and standards

Site safety is another factor that leads companies to choose mobile laser scanning over other inventory methods. Wall notes, “The use of laser scanning, in general, is a safer and more accurate method for inventorying stockpiles.”

Once collected, stockpile data can be reduced and computed into volumes within a matter of hours.

Safety can be either prescribed, in the form of government regulations, or desired, in the form of company policies that reduce liability, property damage, and costly injuries. The U.S. Mine Safety and Health Administration has issued a number of regulations that apply to stockpiles and other related facilities such as drawholes, bins, hoppers, and surge piles. These regulations prohibit a worker from standing or walking on a pile when it may expose the person to a hazard. Other regulations require the construction of platforms, staging, or safety lines.

Laser scanning eliminates the need for anyone to walk on a storage pile and can, in the case of mobile scanning, keep the survey crew safely inside a vehicle. When the project requires the use of a tripod-mounted scanner, the survey crew generally has the flexibility to select locations that are not in harm’s way.

The use of mobile laser scanning as a standard method for inventorying aggregate stockpiles in the United States is being addressed by the American Society of Testing Materials International (ASTM). Originally formed in 1904, ASTM Committee D05 on Coal and Coke is responsible for a variety of standards for this industry that have application to aggregate and mineral mining and storage as well.

ASTM D6172 was originally developed to standardize photogrammetric measurement procedures for inventorying coal and coke stock piles. Recognizing the importance of laser scanning techniques, as well as GPS, this standard is now in the process of being updated to include these game-changing technologies.

Investing in the future

During a downturn in the economy, forward-looking companies may see the use of new technology as an opportunity to position themselves for future growth. Having up-to-date, accurate inventory information and confidence that it is being obtained in a cost-effective, safe, and defendable manner is critical to overall business operations and a potential source of competitive advantage for aggregate companies.

3D laser scanning is a powerful technology that, from a technical point of view, is well suited to the physical inventory of aggregates and minerals. Safety agencies, standards organizations, and owners are beginning to recognize the multiple benefits that this methodology offers. In this rapidly emerging world of 3D technology, it is not a question of if the use of laser scanning will become the preferred method of developing physical inventories of construction materials, it is just a question of when.

Richard A. Hisert Ph.D., principal, and Trevor R. Thomas, P.E. are with H2H Associates, LLC. Based in Troy, N.Y. H2H is a consulting firm that provides geologic, hydrogeologic, construction, regulatory, and environmental services.