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Between a rock & a hard place

In one of the toughest working environments possible quarry equipment has to deliver day after day, around the clock. This is our selection of the top ten new products in the demanding market.

Although quarries are often among the toughest of working environments imaginable, when it comes to the plant used to extract and process products they are often at the cutting edge of new technology.
This is UK Plant Operators’ guide to the top ten new products for this challenging sector.

  1. ADTs – Bell
    Continuing a relationship that’s been in place since 2003, established plant operator Earthline has secured the purchase of two additional L2106 wheeled loaders, and a further B30E ADT, expanding the Bell Equipment element of its fleet to 16 machines. As one of the largest independent earthmoving, recycling and quarrying companies in the south of England, Earthline has steadily built its extensive fleet of 120 plant vehicles over 30 years, and with it developed a reputation for supplying clients with machines that perform consistently within extremely challenging environments.
    With B30Es and L2106 wheeled loaders already operating as part of the Earthline taskforce, Philip Coplestone, the company’s director, knows exactly what to expect from his recent order:
    “Our experience of both Bell Equipment models has been extremely positive, which is why we’ve no hesitation in returning to Bell for these latest machines,” he explains. “For years, we’ve put Bell loaders and ADTs to task in a series of demanding conditions and have, time and again, been extremely impressed with the performance, reliability, reduced downtime and productivity of these well-designed machines.
    “We’re delighted with the models’ fuel efficiencies, whilst the aftercare and support provided by the Bell team has never let us down. Together we’ve formed a relationship that meets our needs and helps us to progress our business, so we can get on with doing what we do best.”
  2. Wheel loaders – Doosan
    Doosan offers a comprehensive range of high performance wheel loaders, which comprises 13 models covering operating weights from 12 to 36 tonne and bucket capacities from 1.9 to 6.4 m³ to meet a wide range of material-handling and loading applications.
    Doosan wheel loaders offer as standard a number of advanced features which are available only as options on other machines on the market. All the models in the range meet Stage IV emission regulations without the need of a diesel particulate filter (DPF), through the use of cooled exhaust gas recirculation (EGR) and selective catalyst reduction (SCR) after-treatment technologies.
    The Doosan range of seven large wheel loaders – the DL300-5, DL350-5, DL420-5, DL420CVT-5, DL450-5, DL550-5 and DL580-5 – has bucket capacities from 3.0 to 6.4 m³ and is intended to meet a wide range of material-handling needs from loading and transporting aggregate material (such as sand and gravel) to industrial, mining and quarrying applications.
    The new DL420CVT-5 wheel loader is the first model in the Doosan wheel loader range to be equipped with a Continuously Variable Transmission (CVT). A CVT transmission is composed of a hydraulic motor combined with a hydraulic pump which provides a smooth and continuous speed variation. With the CVT, a fuel saving of up to 25% can be achieved.
    The latest introduction from Doosan is the new DL580-5 top-of-the-range wheel loader. With a bucket capacity of 6.4 m3, the DL580-5 has a similar look to the existing DL550-5 model, but features robust structural components and an advanced sophisticated double circuit axle cooling system to provide an ideal solution for applications such as block lifting and other heavier material-handling needs in industrial, construction, recycling, mining and quarrying applications.
  3. Crushing – Tesab
    A busy quarry in County Tyrone put a new Tesab jaw crusher to good use at the quarry face. The quarry at Sixmilecross outside Omagh has been operating a brand new Tesab 700i jaw crusher breaking down blasted material to 120 mm before it enters a screener to be separated into other saleable products.
    Struggling with their previous crusher set up, Tesab came in to review the application and used this information to tailor a spec for the 700i jaw crusher to help get the best solution that would enable the quarry to get the most out of their application.
    The 700i uses its pre-screen to clean up dirty sticky material from the blast, allowing a clean crushed end product. The 0-40 mm product taken out from the pre-screen is then used for further upstream processing giving an added value product to the customer.
    The new 700i was sold by Tesab’s Leon Connolly, who explained, “The 700i is the most popular Tesab crusher model, designed for quarry operators looking for maximum output with minimal downtime. The 700i is a high output, simple and highly reliable primary jaw crusher with no fancy electrics and no Carbus or FLD computer systems on board. With the 700i we have listened to the market to create a machine that provides a better quality material at less cost per ton.”
    The Tesab 700i is powered by a Cat C9 engine and the direct drive system and large flywheel makes it much more fuel efficient, coupled with the high throughput and material separation helps create an overall low cost per ton by increasing production and reducing wear costs.
    “As well as improving overall capacity, the 700i creates a much cleaner product at a lower cost, in this particular application the 700i is crushing primary rock which is then being fed into our two-deck screener – the result being extremely high quality aggregates,” said the quarry manager. “We have always been more concerned with a steady, continuous production rather than short, high peaks. With the 700i we are averaging over 250 tons per hour which shows visible results – we have even had to add a tracked stockpile to take the volume of pre-screened product away!”
  4. Screeners – Sandvik
    Sandvik Mining and Rock Technology, Mobile Crushers and Screens, has introduced a number of highly productive developments to its world leading product range this year. One of these recent developments has been the new ‘modular’ hanging screen for its latest mobile crushers.
    Sandvik’s new double deck modular hanging screen enables customers to produce two screened products and recirculate any oversize back into the crusher. Some of the benefits of this new modular hanging screen include; its ability to be adapted quickly for operation in open or closed circuit configurations.
    It features a patent pending adjustment system that allows the screen to be quickly reconfigured to produce one single sized finished product, or two sized finished products, depending upon the customer’s demands at that time. Whereby the screen is hydraulically repositioned to create a single deck hanging screen using the top deck as a breaker deck without the need for a screen mesh removal.
    The double deck hanging screen enables the plant to produce two screened products and recirculate the oversize back into the feed conveyor for reprocessing. The oversize conveyor may be hydraulically rotated for material stockpiling (90°) of up to three products on the ground, or removal (180°). The tail section can be raised hydraulically to give improved ground clearance for transport when loading or unloading.
    The complete modular hanging screen can be installed or removed from the plant in less than 30 minutes without any need for any lifting equipment on site.
    The patent pending hanging screen option delivers multi-functionality as a 1, 2 or 3-way split screener offering unrivalled flexibility to users.
  5. Conveyors – Telestack
    More and more quarry owner/operators and contractors are considering the use of mobile track-mounted conveyors/stackers and hopper feeders to move material/build stockpiles as opposed to more traditional methods of using wheel loaders and a number of factors are driving this trend.
    Firstly using a track conveyor reduces the potential for human error, reduces the volume of traffic movements on site and eliminates the need to drive up/reverse down stockpiles all of which means a safer site for all stakeholders.
    The track conveyor also reduces dust generation, noise levels, and emissions. They can also offer dual power and all electric power sources, all of which helps reduce the site’s impact on the environment
    Operating costs of the track conveyor tend to be 80% less than a wheel loader when labour, fuel and maintenance costs and ease of service are factored in.
    The track conveyor can safely build higher stockpiles, run continuously without a break (and so has less potential for downtime), eliminate the need for double handling of material, free up wheel loaders for other value added activities therefore increasing the productivity of the operation
    The flexibility of track conveyors allows the same machine to be used in stacking, reclaiming, load out, unloading and transfer/recirculation of materials. It can easily be moved around the site or from site to site.
    In recent years, Telestack has sold over 100 units in the UK alone (and thousands globally) and in many cases the quarry machines are helping our customers operate a safer, cleaner site delivering a reduced cost per ton. In the UK we have machines processing anything from 100-1500 tph of various lump sizes working in partnership with large primary crushers as well as screeners, grinders, shredders and wash plants. In most cases we have customised the machine to meet the customer’s exact requirements.
    Built in the UK, the smart design of the Telestack offers excellent resale values as the equipment can be packed into a container and shipped globally
  6. Rigid Mining Trucks – Caterpillar
    The Cat 794 AC mining truck is now available equipped to meet US EPA Tier 4 Final exhaust emissions standards. In field testing, the Tier 4 pilot trucks matched the superior performance and productivity of the Tier 2 equivalent versions of the 794 AC. The Tier 4 trucks also delivered lower operating costs by reducing diesel fuel consumption.
    The 290-tonne-class 794 AC features the Cat C175-16 diesel engine. The Tier 4 truck is equipped with an exhaust after treatment system using a selective catalytic reduction system (SCR), which uses diesel exhaust fluid to reduce emissions of nitrogen oxides. Caterpillar selected the SCR solution, because it provides the most robust and reliable Tier 4 Final emissions compliance without sacrificing engine performance.
    The modular SCR design, adopted from other Cat production machines, minimizes new content and design changes to the field-proven 794 AC. Designed for easy serviceability with readily accessible components, the after treatment system is aligned with truck preventive maintenance intervals to maintain high availability. This Cat emissions platform is proven through more than 20 million operating hours in the field.
    Caterpillar is using the same exhaust after treatment platform in the process to gain EU Stage V certification of the 794 AC. The Stage V certification process is currently in progress.
  7. Crusher buckets – Allu
    Allu says it held the ‘best ever’ meeting of its global dealer network back in February. Many representatives from over 50 Allu dealers came to Finland for what proved to be a fantastic occasion. During the event, Murray Plant was named ‘best performing new dealer’.
    In order to provide customers with the very latest developments in Allu’s increasing solutions portfolio, over 50 Allu distributors came to Finland. During the meeting, the dealers enjoyed a series of events aimed at providing them with the latest developments and application thinking concerning the Allu products. “The dealer conference and meeting was the perfect occasion for me to meet the Allu people in the field,” said Allu vice president of sales Jeroen Hinnen.
    At a gala dinner held on the last night of the meeting, an awards ceremony was held to recognise the outstanding performance of Allu’s dealers. Tianjin Deal Electronic and Mechanical Equipment Trading Company Ltd from China was presented with ‘dealer of the year’, with R D Williams from Australia being awarded the ‘Allu award for excellence’. Finally, newly appointed dealer, Murray Plant from the UK, was given the ‘best performing new dealer’ award.
    “Our dealers are vital link between us and the customers. And the dealer’s performance has been outstanding in 2018,” said Allu president Ola Ulmala. “Murray Plant’s performance has been amazing. Their professionalism, and expertise, has directly led to the company providing many UK customers with a first class product, and vitally, first class service.”
  8. Wheel wash systems – Glanaco
    Glanaco prides itself on building some of the best wheel cleaning systems in the world. The SiteWash range has evolved to be a market leader, by the company listening to the customer’s needs, evaluating site resources and providing the right model and solution to their cleaning problems. “The old saying; prevention is better than cure, is very applicable to many construction sites,” the company says. “If a wheel washing system is designed for purpose, and installed correctly, it dramatically reduces debris being brought onto the public road, and is much more cost effective than truck sweeper hire. It also satisfies planning requirements, environmental legislation, council rules, and provides an all-round good image and effort, to your neighbours and local community.”
  9. Hydraulic breakers – Epiroc
    Epiroc celebrates the 25th anniversary of its groundbreaking SB or ‘solid body’ concept for hydraulic breakers this year. The slim, lightweight solid body design offers a number of advantages compared to conventional hydraulic breakers which, at the time, had already been around for some years. Outstanding durability and reliability, easier handling, lower fuel consumption and other benefits continue to make SB Hydraulic Breakers leaders in a competitive market.
    First introduced by Atlas Copco 25 years ago, the solid body concept uses a patented internal component design that integrates the percussion mechanism and the guide system into a single piece. This eliminates the weakest components of conventional breakers and gives SB breakers their outstanding durability.
    The fact that solid body breakers have fewer parts than conventional hydraulic breakers reduces maintenance requirements and enhances reliability. The attachments are designed for large diameter tools which also contributes to their reliability.
    SB breakers are manufactured in Epiroc’s factory in Kalmar, Sweden. Designed for carriers in weight classes up to 24 t, they are available in nine models with service weights ranging from 55 kg to 1,060 kg. The range includes models to match any micro or mini excavator, backhoe, skid steer loader or demolition robot. Their outstanding durability makes them a popular choice for rental companies who can, with confidence, rent them to less experienced end-users.
  10. Excavators – Volvo CE
    Calder Masonry Ltd has opted for a seventy-five tonne Volvo EC750E as production increases at its sandstone quarry in Morley, West Yorkshire.
    Established in 1994, Calder Masonry Ltd acquired the Britannia Quarry and production facility in Morley, Leeds eighteen months ago from its previous owners. Since then, and having uncovered fresh reserves of the local ‘Woodkirk Yorkshire buff sandstone, it has invested heavily as part of a strategy to significantly increase production and sales.
    “When we moved here, the quarry, offices and workshops were somewhat run down. We’ve spent the last 18 months turning the situation around,” explains managing director, Ian Howgate. “We inherited some pretty tired plant and equipment when we took over the business. With at least 25 years of available reserves in the quarry and increasing demand for the product, we knew that we needed a serious machine for the critical block extraction process. Following a competitive tender process which included third-party references and site visits, we decided that the Volvo EC750E was the right machine for us.”

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