Cubical Crushing


September 1, 2012

Luxembourg family-based business takes the first look at Atlas Copco’s new crusher.


Schotterwerk Moersdorf is a Luxembourg company that has been a regional leader in the stone and aggregate market for years. It has a reputation for precisely and reliably producing the high-quality fractured stone its customers require in consistent cubic fractions for a variety of applications.

Cubic stone is in great demand among the operation’s customer base, says Uwe Bälder, Moersdorf’s managing director.

Schotterwerk Moersdorf, or the Moersdorf Gravel Works, sits on a stone quarry site in the northwest European Duchy of Luxembourg near its German border. The old stone quarry, which was first opened in 1908, has worked under Elenz-Goertz family ownership since 1961. Today, Moersdorf extracts and shapes natural stone for a variety of quality-controlled end products for a number of applications, from backfill to aggregate for concrete and asphalt to customizable gabion retaining systems.

Moersdorf’s products are used as road construction base and as aggregate for concrete and asphalt. The stone is also used in public works projects and for horticulture and landscape construction. Some is used as blast-furnace aggregate. In addition to providing raw materials, Schotterwerk Moersdorf has also been an industry leader in asphalt recycling and has become a model of land reclamation practices for mines and quarries.

About 350,000 metric tons of backfill are sold annually. And since 1993, the quarries have been receiving more than 250,000 metric tons per year of soil for quarry reclamation projects, filling in its stone excavations.

Schotterwerk Moersdorf began to expand its Luxembourg operations in 2008.

The entire Moersdorf operation was modernized in 2002, and, by 2008, it began expanding the quarry to meet customer needs.

The quarry expansion wasn’t just about producing more stone. Customers also rely on Moersdorf’s high quality and on-time delivery. The company is able to exceed customer expectations through careful quality control. For example, it has its own quality-control monitoring facility, which ensures the product surpasses government regulations and industry standards for building materials. Moersdorf also makes sure it uses the most dependable equipment for the job, including an Atlas Copco Powercrusher PC6.

The mobile crushing plant is used to produce six different fraction qualities from the rock. But it is also used for recycling of concrete and asphalt, resulting in a final product that is perfect for backfill in construction projects.

“This is the perfect stone for our customers,” Moersdorf’s Managing Director Uwe Bälder says. “It’s a cubic stone. This is what we want.”

While independent laboratory tests had demonstrated that the jaw crusher’s unique Quattro Movement would create high-quality, cubical products, Moersdorf’s operation offered the opportunity to field prove those results. The unique Quattro Movement is made possible by an up-thrust toggle plate position. This causes a figure-8 motion in the moving jaw, which increases the feeding capacity and produces a post-crush at the crusher outlet.

The company’s road construction clients, in particular, prefer the cube-shaped fragments. “Cubic stone compacts best,” Bälder says.

The decision to purchase the PC6 was based on several factors that made it a complete package for Moersdorf’s operations, he adds.

“We bought it because of how its grizzly screen separates the small fraction from the bigger stones so well,” Bälder says. The double-deck independent grizzly section operates separately from the hopper and efficiently screens out the fine material prior to it entering the crushing chamber. And by using the screen box, the crusher gives operations the ability to produce two sellable products.

“Then there’s the crusher, the ‘Quattro Movement,’ which gives good shape to the stones,” Bälder says, adding that ease of maintenance also played a significant role in the unit’s selection. “All three sides are totally 100-percent accessible. And that’s a nice thing for maintenance, for service. The competitors do not have this easy access.”

The crusher is remote controlled by the operator in the excavator. Moersdorf’s operators, Bälder says, can safely and easily adjust the position or move the machine to another task.

Dependability is key in the competitive rock crushing and concrete business, Bälder says: “It’s reliable. We cannot afford any breakdowns because our customers want to have the product in the time, in the quantity, and quality we have promised them.”

There have not been any major service or repair issues, but Bälder says he is confident of Atlas Copco’s ability to provide service and 24-hour turnaround on spare parts.

For Moersdorf, a company that specializes in shaping rocks for tight compaction, the crusher itself has been a perfect fit. AM


Article courtesy of Atlas Copco.

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