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Published by the Aggregate and Mining Group of Astec Industries, Inc.

• Volume 2, Number 1

PAGES 18-19
MARCH 15-19
3 The word is “modular” 2704 W. LeFevre Road
Sterling IL 61081
6 Road trips Fax: 815-626-6430
8 The new math: 1 = 3 E-mail:
10 Non-stop screening
12 Powering up for peak performance 35 Elgin Street 800-567-8267
14 Booming construction in Boca Chica Thornbury, Ontario, Canada

14 The People’s Republic of China Fax: 519-599-6803

14 Mining seashells in Peru

16 The third-tallest dam in the world

18 ConExpo/Con-Agg Display 86470 Franklin Boulevard
Eugene OR 97405
20 Expanding a big crushing operation Fax: 541-988-9401

22 A unique rail-unloading system E-mail:
24 Portable crushing plant
26 Another first for South Africa 700 West 21st Street 800-542-9311
Yankton SD 57078
28 Right tools for growing a business 605-665-8771
Fax: 605-665-8858
30 How to get the performance you need E-mail:
31 Combo Screen for a combo product
32 Inventing a tool for the customer PO Box 8182 +27 11 820-7600
34 How to reduce primary downtime Johannesburg
Elandsfontein, 1406
Fax: +27 11 388-1136
South Africa
Aggregate & Mining Journal E-mail:
Volume 2, Number 1
Copyright © 2005
Aggregate & Mining Journal
is published 10910 N. Industrial Drive 800-765-6601
by the Aggregate and Mining Group Mequon WI 53092
of Astec Industries, Inc.
Fax: 262-242-5812
If you would like to receive a free
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Aggregate & Mining Journal,
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Pembroke Pines FL 33028 866-376-1331
company name, and mailing address to:
Jackie Keul Fax: 954-436-4724
Telsmith, Inc. E-mail:
PO Box 539
Mequon WI 53092-0539

Page 2 —Volume 2, Number 1

For most people, “sitting on a goldmine”

is nothing more than an expression. But
one aggregate-producing company in New
Jersey found itself in a situation that made
that saying almost true—except instead
of gold, the producer’s plant was sitting

on high-quality trap-rock.
Tilcon New York, Inc., is a division of
Oldcastle Materials. It is a full-service
company that provides aggregate, hot-mix
asphalt, recycling, soil remediation, high-
Tilcon partnered with Telsmith to provide way construction, and paving services to
city, county, state, and private customers
a turnkey solution for a new crushing plant in New York City, Long Island, the lower
Hudson Valley, central and northern New
at its Millington quarry in New Jersey Jersey, and eastern Pennsylvania.
In 1999, Tilcon acquired a 100-year-old
quarry near Millington, New Jersey. A
crushing-and-screening facility that had
been pieced together in the 1980s was
already in place and provided satisfactory
production rates for the quarry’s new
operators. But in 2003, Tilcon was draw-
ing close to exhausting all of the quarry’s
reserves—all of them, that is, except for
the substantial reserves that lay beneath
the existing aggregate-production facility.
And that’s where the expression “sitting
on a goldmine” came in: If Tilcon could
gain access to those reserves, they would
have enough rock to continue production
for another five to seven years. But the old
plant’s presence on top of those reserves
presented a substantial problem: Moving
a 25-year-old plant was not feasible; it
would have to be torn down.
According to John Brownell, the New
Jersey-area manager for Tilcon, there was
not a lot of choice. “We only had three
options. We could get a subcontractor in
there to take the rest of the rock out. Or
we could leave the old plant there and
just close the quarry down when we felt
we had gotten all the rock we could get.
Or we could purchase our own new plant.
“We looked at it and considered all of the
options,” he said. “And we found that with
a deal we could make with Telsmith, we
would be able to put in our own plant and
still be ahead of the game.”
In order for the purchase of a new plant
to be an affordable option, the facility
would need to be designed to meet a few
tight specifications:
❏ First, it had to be designed, delivered,
and erected very quickly.
❏ Second, it would need to be efficient
and economical to operate, requiring only
a small number of people to keep it run-
ning in a productive manner.

Volume 2, Number 1 — Page 3

❏ And third, it would need to be easy to “The modular construction was the best Troubleshooting is also streamlined by an
move since the plant would only be there part about this project,” said Brownell. intriguing innovation: the plant can be
for an additional five to seven years. “Telsmith set a deadline of when the operated from a remote location, includ-
installation was going to be done—and ing Telsmith headquarters in Milwaukee,
In order to meet these needs, Tilcon
they had the plant delivered and erected Wisconsin and the Astec headquarters in
worked closely with Telsmith to design an
by that date. The modular framework that Chattanooga, Tennessee where the control
aggregate-production facility that would
comes from the factory is beautiful. It system was designed.
have two major time- and cost-cutting
comes right out to the site and sits right “One of the nicest things about this oper-
features working to their advantage:
on the pad. They lay out where it’s going ation is that when something goes down,
(1) It would be designed to be to go and then everything just bolts we are connected to the Milwaukee office
modular to speed and simplify together, quickly and easily. It’s a lot faster and also the Chattanooga office,” said
installation; than if you had a couple flatbed loads of Brownell. “The technicians get on the
(2) And its day-to-day operation steel sitting out here and about 20 welders phone right then and there—and they can
would be completely automated. fabricating and working from blueprints. troubleshoot the plant over the phone.
Instead, it’s all been done at the factory. They can actually run our plant from
Modular construction It’s finished, painted, and ready to go!” Milwaukee or Chattanooga. They tell our
A conventional aggregate-production plant
is erected at the jobsite, one piece of Fully automated operation, ‘Just let go of the controls and
To ensure efficient operation, the engineers let us do it.’ They run it from a distance
structural steel at a time. In other words,
at Telsmith took automation to an entirely of almost 1,000 miles (1,600 km) .”
it is “stick-built.” This can be time-con-
suming when it comes to the installation new level. The new facility features PC- In addition to being completely operable
of the equipment in the field since modi- based controls that use PROFIsafe tech- over a network—thereby eliminating old-
fications to the equipment must be made nology. This technology, based on the fashioned push-button controls that can
on-site in order to get all those pieces to PROFIBUS fieldbus system, lets the plant cause glitches—the Telsmith plant is also
fit together properly. operator perform emergency stops across fully automated.
a network. This eliminates the need to
To avoid that time-consuming assembly “The automation starts right from the pri-
install additional emergency wiring.
effort, Telsmith gave Tilcon the option of mary feeder and runs all the way through
modular construction. With modular con- Inside the plant’s control room, two PCs the plant,” said Brownell. “You can set
struction, the plant’s various components control the entire plant. Using a Windows your feed rates. You can go up into the
are preassembled into modules and then interface and the click of a mouse, the control tower at any time and know the
shipped to the jobsite. In this way, when operator is able to start the plant and then tonnage that you’re doing at that current
the parts arrive at the quarry, each mod- monitor the status of every single feed bin, moment and what you have done over
ule fits to the next quickly and easily. crusher, and conveyor. the course of the day.”

The Tilcon facility in its Millington quarry has been described as “clean, simple, and safe.” Perhaps the
most interesting feature of the plant is its modular design: It was preassembled in modules at the Telsmith
factory and the modules were then fitted together at the jobsite. In these photos, you can see some of the
worker-friendly features of the plant: extra clearance under the plant for cleanup; large service platforms;
and extra-wide walkways in critical areas. There are even wrap-around catwalks at the head pulleys to
allow maintenance crews to service the bearings from both sides of the conveyor.

Page 4 — Volume 2, Number 1

Brownell explained that the feeders that “Now, the automation runs the plant at a pieces and painting them. They’re actually
supply material to the three crushers are secure level. The automation finds the building an aggregate-production plant—
able to adjust their feed rates according happy medium there and runs the plant at and they want to see the end result, too.
to the amount of material the crusher is a strong and steady pace.” “When I went out to the factory, I was
using at that time. Since the Telsmith plant went into opera- given a complete tour,” Brownell said.
“You just dial in what you want to make, tion in September of 2004, it has proved “This is definitely a first-class operation
and the plant will make it,” Brownell said. itself by producing about 10,000 tons there at Telsmith. I was very impressed.”
“It’s really something. You’ll be sitting (9,100 tonnes) per day at that strong and
Looking to the future
there, just watching it. And suddenly, the steady pace. It is expected that the plant
According to Brownell, the reserves that
feeder will slow down. Then, a couple will produce about 2 million tons (1.8
seconds later, you’ll see it speed back up. million tonnes) of aggregate per year. their old plant was sitting on will pay
What you’re seeing is the feeder giving dividends for another seven years or so.
Overall, Brownell said that the experience When all of the stone reserves have been
the crusher a chance to lower itself down
of acquiring this state-of-the-art plant has mined, crushed, and sold, the quarry will
and then it can speed back up again.”
been a positive one. When asked if there be reclaimed and housing developments
This streamlined automation means fewer was anything he would tell another pro- with lakefront access will appear.
crew members are needed to run the plant. ducer who was considering the purchase
It also reduces costs by preventing human of a new aggregate-production facility, Because of the modular concept that
error and maximizing the plant’s produc- Brownell said to take a close look at the Telsmith developed for the plant, Tilcon
tion potential. people who are making the equipment. will be able to disassemble the plant and
relocate it efficiently to another Tilcon
“A big benefit of the automation is the “One thing that I thought was interesting operational facility.
fact that it reduces operator error,” said about Telsmith was the fact that every
Brownell. “The fact is that the operators month they meet with the employees “This modular plant was certainly the
want to play it on the safe side sometimes who work in the factory and show them right decision for our company,” he said.
—they don’t really want to push the plant. the finished product,” said Brownell. “So “Telsmith listened to our ideas and needs
Which makes sense: Instead of cleaning there’s a vested interest in quality as far —and they were right there the whole
up a big mess, you’re going to back off a as the employees at the factory are con- time, telling us what needed to be done
little bit before you get to that point. cerned. They’re not just cranking out to make this happen.” •AMJ•


Call Bob Meyers at Telsmith: 800-765-6601 or 262-242-6600 • E-mail:

The automated plant controls were supplied by the Controls Division of Astec Industries. Not only can the
operator keep track of exactly what is happening at the plant by viewing the on-screen displays, but the
control system can be quickly and easily serviced by Telsmith. The control system is linked by telephone
to Telsmith in Milwaukee and to Astec’s Controls Division in Chattanooga. Because of this linkage, if there
is ever a problem, it can be serviced remotely—any time of the day or night. The plant can actually be run
from either of the two remote locations.

Volume 2, Number 1 — Page 5

Moving hundreds of miles between
two or three locations four times a year

It is likely that you have heard of—or at The answer to their problem came in the would have to move,” said Hindman. “We
least seen—some of the products that are form of commercial crushing equipment. realized that if we could utilize just one
made by the Dallas, Texas-based Pavestone They discovered that the right crusher could power unit to move the entire unit, that
Company. That’s because Pavestone is a reduce the concrete blocks back to rubble so would make it much more accessible.”
leading manufacturer of segmental concrete they could be reused—or recycled—back
into the manufacturing process. Hindman said that they went back to KPI
products, including paving stones and
and told them how they wanted their recy-
retaining-wall blocks. These products are Bobby Hindman, the vice president of cling program to work: One crushing unit
utilized by a number of markets, ranging transportation with Pavestone, said the would be moved back and forth between
from contractors and commercial builders company began its recycling program by two or three different facilities, possibly as
to do-it-yourself weekend warriors. acquiring a portable crushing unit from often as once every three months.
Pavestone Company operates 18 regional Kolberg-Pioneer, Inc. (KPI) and setting it
up at its facility in Dallas, Texas. They soon “Our core business is not crushing,” said
manufacturing facilities across the United
realized that the concept was going to work Hindman. “This was a substantial capital
States. Several years ago, the company
well. They hoped to use one machine to investment for a company of our size. So
took a look at its manufacturing process
service several different facilities in differ- we needed to share that investment with a
and identified an area that they thought
they could improve. With every batch of ent locations, but the original crushing couple of different facilities.
paving stones or retaining-wall blocks that unit they purchased did not prove to be as “That’s when KPI went back to the drawing
portable as they preferred.
was produced, a few would come out with board to see if they could come up with a
defects that made them inadequate for “The first piece of equipment that we got piece of crushing equipment that was
sale. Pavestone wanted a way to be able to was mobile, but there was a disadvantage contained in one unit. They actually did it.
reuse these otherwise wasted products. in that there were several pieces that we And, so far, it’s worked out very well.”

Page 6 —Volume 2, Number 1

The unit KPI designed was a CS4233CC the units were able to go to work with their be cleaned and prepped prior to moving,”
closed-circuit mobile crushing plant. The primary application: crushing the rejected he said. “That takes some time, depending
main body of the plant is based on the KPI Pavestone products. on how frequently the operators were
Fast Trax horizontal shaft impactor (HSI) cleaning it during normal operations.”
According to Tim Harms, sales engineer
crushing plant—but instead of being a track-
with KPI, the crushers are actually pro- Murray said the actual moving is relatively
mounted unit, the CS4233CC is equipped
ducing material with specifications that simple. “We just raise it up off the cribbing,
with tires that make it highway portable.
are outside of their recommended limits. pull the cribbing out, back the stacker out
“It’s a self-contained, stand-alone unit,” However, because of the specific applica- of the way, hook up the truck and the
said Mike Murray, recycling yard process tion that they are performing, the crushers dolly underneath it, and pull it out. That
manager with Pavestone. “It has a radial are able to handle these specifications doesn’t take long at all. It will take the
stacker, of course. But we just leave one without any difficulty. better part of the day to get the entire unit
radial stacker at each facility so we don’t ready to move—but most of that is just
have to worry about transporting that part “The HSIs are being run at 1/4-in. (6-mm)
closed circuit right now, which is outside the cleaning.”
of the unit from one place to another.”
the application envelope we recommend,” After the crushing plant is moved to the
The new KPI portable crushing plant fully said Harms. “They are not recommended new location, Murray said it usually takes
met Pavestone’s needs, so the company to be run in closed circuit any tighter than about four to six hours for the yard crew
purchased a total of four units and had them 1 in. (25 mm). But when they’re crushing to set it up again.
delivered to four different sites where they those paving stones and retaining-wall
are currently in operation. Since then, the blocks, they are able to run it at 1/4 in. (6 “Installation of the cribbing is the critical
company has ordered another CS4233CC mm)—due to the 1/4-in. (6-mm) size of part of the operation,” he said. “You need
crushing plant—and they eventually plan the aggregate that was used in the original to take care during installation in order to
to operate a total of six of these units, in manufacturing process.” make sure the machine is level.”
addition to the original unit that is at their
Dallas facility. Each unit will rotate duty After the material from the manufacturing Overall, Hindman said the new recycling
between two or three different locations, plant’s rejected product has been broken program is working well for the Pavestone
with a total of 15 to 18 facilities being back down into its original form, it can Company at the locations where the KPI
serviced by these six units. then be recycled back into new Pavestone crushing plants are working. And a major
products. The company has reported that part of that success was making sure they
Some of the sites where the new units were with the addition of the recycled material, had the right equipment that would best
delivered were relatively new or rebuilt the finished products are actually stronger serve their needs.
facilities. In some areas, old asphalt parking than they were before the company’s recy-
lots had been torn up, or old buildings had “We expressed our own ideas of what we
cling program began.
been demolished. When the new KPI needed—and KPI worked with us to bring
crushing units arrived, they were initially In addition to meeting production needs, it to reality,” said Hindman. “KPI has been
put to work crushing this rubble stock. Murray said the crushing plant has proven very professional and we look forward to
After this site preparation was completed, to be easy to move. “The machine needs to working with them in the future.” •AMJ•


Call Curt Peterka at Kolberg-Pioneer: 800-542-9311 or 605-665-8771 (E-mail:

Pavestone Company, a nationwide manufacturer and marketer of segmental manufacturing process for new product. The company plans to eventually
concrete products, is using several KPI CS4233CC closed-circuit mobile have six of these units operating. Each of them will rotate between two or
crushing plants to recycle material from rejected paving stones back into the three different recycling locations across the country.

Volume 2, Number 1 — Page 7

This Alabama asphalt producer and paving contractor uses
one Fast Pack portable screening system at three different quarries
The reasoning is really quite simple: Why According to Leon Luadzers, territory For Pope, the actual, day-to-day operation
use three crushing-and-screening plants at manager for KPI and JCI, the acquisition of the plant is its best feature.
three different locations when you could of the Fast Pack system revolutionized
accomplish the same job faster, easier, and the way the company approached its “I like the way it operates,” he said. “You
with more versatility by using only one aggregate production. “Instead of having can tell that somebody put a lot of study
plant—and with only one crew? three sets of stationary plants,” Luadzers and time into designing it. If you look
said, “they could have one highly efficient close, you see certain features that show
It appears to be The New Math. that the people who designed it have had
portable Fast Pack plant—and one very
In any case, sound reasoning was used by good crew.” experience in the field. They’ve been there
Bunn Brothers Material, Inc. when they and done that. And that makes a big dif-
decided to buy a portable crushing-and- The Fast Pack system consists of one ference. Instead of an engineer just sitting
screening plant. Bunn Brothers Material Pioneer Vanguard-style jaw plant as the down and starting a drawing, it looks like
is headquartered in Tuscaloosa, Alabama primary crusher, two JCI three-shaft hori- someone who has crushed rock before
and operates three sandstone quarries to zontal screen plants, two JCI Kodiak 400 provided a lot of input when this machine
produce aggregate primarily for its parent HP cone plants (one as a secondary and was designed.”
company, S.T. Bunn Construction Company, one as a tertiary), and any number of
Inc., a producer of hot-mix asphalt and a Kolberg conveyors, equipped as required. The Fast Pack portable plant is being used
paving contractor. Bunn Brothers Material has only begun to by Bunn Brothers Material to produce
realize all of the benefits of the plant’s four different sizes of rock. Pope explained
For years, Bunn Brothers Material had that the stone is an extremely hard sand-
used stationary plants to crush and screen portability. Since they acquired the plant,
it has only been moved twice. But Glenn stone that is excellent for use in rip-rap,
its aggregate material. The company’s base courses, and hot-mix asphalt.
three active quarries in Alabama—one Pope, area supervisor for Bunn Brothers
near Tuscaloosa, one in Marion County, Materials, said he expects the process will “It’s a hard, hard sandstone,” he said. “This
and another near Berry—each required its go faster each time. type of sandstone doesn’t deteriorate. If
own stationary crushing-and-screening “It took us three to four days to change you watched the way it goes through these
plant. Operating three stationary plants locations,” said Pope. “For example: We crushers, you’d swear that it was a regular
meant having three operating crews. tore it down in Marion County on Friday; limestone aggregate.”
Bunn Brothers realized there had to be a it rained on Saturday; and we cleaned it
better way to get the job done. Despite the tough material that comes
on Sunday to get all the rocks off before from their quarries, the Fast Pack crush-
The answer to their problem came in the transporting it on the highway. Then on
ing-and-screening system has apparently
form of the Fast Pack® portable system Monday we started moving six pieces at
proven itself to be quite a versatile and
manufactured by Johnson Crushers a time from Marion County to Berry—
efficient producer.
International, Inc. (JCI) and Kolberg- about 65 miles (105 km). We were set up
Pioneer, Inc. (KPI). The portability of the and ready to run rock around dinnertime “We have had a number of people come
plant meant that Bunn Brothers could on Wednesday. That wasn’t bad. But next to our quarries to see this plant while it is
quickly and easily move it from one of time, I don’t think it will take that long.” operating,” said Pope. “When they ask
their quarries to another, wherever and The manufacturer designed to plant so it about it, I tell them that it’s a good oper-
whenever the work was needed the most. can be set up in only four hours. ating plant. Very user friendly.” •AMJ•


Call Curt Peterka at Kolberg-Pioneer: 800-542-9311 or 605-665-8771 (E-mail:

Page 8 —Volume 2, Number 1

Bunn Brothers Material of Tuscaloosa, Alabama
is owned by brothers Terry and Sonny Bunn.
After a great deal of consideration, they came
up with the idea of replacing the stationary
crushing-and-screening plants at each of their
quarries with a single portable system. The unit
they picked was the Fast Pack® system shown
in the photograph above.

The Fast Pack crushing-and-screening system

was designed to be a high-tonnage plant that
could be quickly and easily moved from one
location to another. After arriving at a new site,
the system can be set up in about four hours.
The system consists of a Pioneer Vanguard-
style jaw plant as the primary crusher; two JCI
three-shaft horizontal screen plants; two JCI
Kodiak cone plants (one as secondary and one
as tertiary); and as many Kolberg conveyors as
may be required by the producer.

Volume 2, Number 1 — Page 9

In the summertime, Lancaster Quality Stone keeps this
Fold ‘n Go portable screening plant busy 16 hours a day

Lancaster Quality Stone bought a Fold ‘n Go portable screening plant in May of 2004. They keep the unit working long days.
For example: At one point, they stacked up 22,000 tons (20,000 tonnes) of sand in only seven days of production.

Page 10 —Volume 2, Number 1

As you listen to John Rutkowski talk Screens Fold ‘n Go® 2612D screening equipped with easy-to-use hydraulic level-
about the stone products that his company plant in May of 2004. During the one ing gears and hydraulic operator controls
produces and the pace of its operation, you production season that the company has for setup and angle adjustment. High-
get the distinct impression that Lancaster had it in operation, the new screening impact areas are protected, reducing
Quality Stone is a high-energy company. plant stepped up to the task and achieved maintenance costs and increasing the
So it only makes sense that the company all of the company’s goals. machine’s operating life. Easy-to-reach
would be using the most efficient, most engine controls and grease points also
versatile equipment it could find. “When this machine runs, it’s gotta run,” simplify routine maintenance procedures.
said Rutkowski. “In the summertime, we And while the machine is operating, no
John and Jeff Rutkowski, co-owners of were running it from 6 a.m. to 10 p.m.
Lancaster Quality Stone in Lancaster, standby operator is required. The Fold ‘n
Last fall, we were able to pile up 22,000 Go 2612D is mounted on rubber-tired
Wisconsin, entered the aggregate business tons (20,000 tonnes) of sand in just seven
in 1998. Prior to that, the company was wheels, making it mobile inside the quarry
days of production. The Fold ‘n Go is a and easy to move from one site to another.
trucking aggregate for local construction very good unit!”
companies—which is a service the firm “In my opinion, this unit is well-engineered
continues today. But after more than ten In addition to speed and efficiency, the and well-built,” said Rutkowski.
years of hauling other people’s aggregate, Fold ‘n Go screening plant also has to be
able to produce a wide variety of product “Plus, it is really, really quiet! We used to
they realized they could better serve their
for the company. Lancaster Quality Stone rent machines from other manufactur-
customers if they began crushing their own
uses the Fold ‘n Go screening plant to ers—and those things were just noisier
rock instead of buying it from others.
produce a 0.5-in. (13-mm) asphalt chip than all get-out. This machine runs so
“We were hauling the rock 20 to 25 miles for base material; a limestone winter quiet that when an inspector from the
(32 to 40 km),” said John Rutkowski. “We abrasive used by municipalities as a safer Mine Safety Health Administration came
finally decided that we had to get our own alternative to sand to control ice on road- by, he was really impressed. He said, ‘I
quarries and do it ourselves.” ways; agricultural lime; and a sandstone can’t believe how quiet this operation is
Today, the company operates five quarries product that is used by farmers in the running!’”
and two sand pits. The market area they area as cattle bedding. Rutkowski said he has been impressed
focus on includes all of Grant County in with the service he has received from the
“We use this machine for a wide range of
southwestern Wisconsin. manufacturer of the Fold ‘n Go screening
products,” said Rutkowski. “We keep it
With the harsh winters in Wisconsin, the plant, Astec Mobile Screens.
busy, that’s for sure.”
company chooses to shut down operations “The people at Astec Mobile Screens
The Fold ‘n Go model is designed to be
between December and April. That means have been excellent,” he said. “They are
cost-efficient, easy to use, and extremely
Lancaster Quality Stone’s equipment must always there with answers to any questions
portable. It can be configured with PEP
work harder in order to meet the firm’s we might have or with any technical sup-
Vari-Vibe®, PEP Duo-Vibe®, or Kolberg
needs throughout the production season. port that we might need.
screen boxes to meet application demands
To handle that requirement, Lancaster and to ensure maximum productivity. “From what we’ve seen, they’ll do almost
Quality Stone acquired an Astec Mobile The Fold ‘n Go 2612D screening plant is anything to help us.” •AMJ•


Call your Regional Sales Manager at Astec Mobile Screens: 800-545-2125 or 815-626-6374 • E-mail:

Prior to purchasing the portable screening

plant described in this story, Lancaster Quality
Stone was operating another piece of screening
equipment that they bought from Astec Mobile
Screens: a PTSC 2618VM mobile unit (photo
on the right) that they use to process man-sand
and ag-lime.

Volume 2, Number 1 — Page 11

An effective equipment fleet kept the project on schedule
during demolition of Old Terminal 1 at the Toronto airport
Here is a job requirement that will sound perform some specialized work at the areas. Consequently, the old terminal must
familiar to any contractor: Toronto Pearson International Airport in be completely razed.
Meet production goals while working Toronto, Ontario, Canada. In April 2004,
Part of the demolition of Old Terminal 1
within a tight set of specifications. the Toronto Pearson International Airport
involves the floor-by-floor leveling of a
opened its New Terminal 1, a 42-gate
Most jobs have their own unusual set of nine-story parking structure. Because of
facility that is a key part of a ten-year
circumstances that invite—or sometimes weight restrictions on the structure, the
development and improvement program.
even demand—the contractor to think in demolition approach is to break out the top
new and innovative ways. And to employ But after the opening of the new terminal, four parking levels using mini-excavators
equally innovative technology. the Old Terminal 1 posed an obstacle to and skid steers equipped with hydraulic
the growing airport. While it still stands, breakers. After removing these levels, the
This was precisely the situation that not all aircraft can reach the new terminal crew will be able to work from the ground
Priestly Demolition, Inc. encountered when building—meaning that passengers have with excavators that are equipped with
the company was awarded a contract to to be shuttled to and from aircraft staging shears and larger hydraulic breakers.

Page 12 —Volume 2, Number 1

“This project must take no longer than
three weeks per floor,” said Ryan Priestly, One of the challenges in a 500 ft/lb (350 m/kg) class on the same
size skid steer,” said Creighton. “The BTI
president of Priestly Demolition. “That’s
not a lot of time to break out the 100,000
was to meet TB285ME breaker is a 750 ft/lb (500 m/kg)
breaker and it only weighs 760 lb. (345
square feet (9,290 m2) of concrete and
182 support columns on each level. We
production goals kg). So if the skid steer can handle it,
then it is certainly better to purchase the
really had to take a look at how we could
effectively expand our equipment fleet to
without exceeding more powerful breaker, primarily
because that additional power will allow
handle the job.” the weight restrictions you to increase your production.”
Priestly Demolition is a family-operated Creighton went on to explain that Priestly
contracting business that was founded in on the structure. Demolition gets more value out of the
equipment it uses by carefully balancing
1971. The company’s headquarters are in
Aurora, Ontario. Their stated mission is They needed the inventory that it owns outright and
the equipment that it rents for special
to supply the best available equipment for
unique project requirements. Priestly
a small excavator occasions. For the Old Terminal 1 demo-
lition, for example, Priestly Demolition
Demolition’s equipment inventory lists
more than 100 large machines and vehicles,
with a big breaker. rented two 8.25-ton (7.5 tonne) Link-Belt
as well as smaller tools, attachments, and excavators, each fitted with a BTI
TB625QA hydraulic breaker in the 1,500
specialized equipment.
ft/lb (1,000 m/kg) class.
As they approached the airport project, “They are getting better productivity by
Priestly Demolition’s fleet included two renting newer-model excavators and
high-reach excavators, one of which was breakers. In addition, their downtime is
equipped with a Breaker Technology, Inc. almost nonexistent because they maintain
(BTI) TB2080X hydraulic breaker in a a proper mix of owned versus rented
10,000 ft/lb (6,700 m/kg) class, and the equipment,” said Creighton.
other with a BTI TB2580X hydraulic
Priestly Demolition also gets as much
breaker in a 13,500 ft/lb (9,100 m/kg)
versatility out of its equipment as possible
class. With these tools, Priestly Demolition
by utilizing interchangeable tools on the
was in good shape to handle the breaking hydraulic breakers. “We use a chisel-point
and downsizing of concrete from the tool when we have thicker beams to go
lower floors of the parking structure. But through,” said Priestly. “And we use a
they needed to find the best option for the ‘slab buster’ or ‘elephant’s foot’ when we
smaller, lighter equipment that would be are working on slabs.”
used on the upper levels of the structure.
Priestly went on to explain that the
Priestly consulted with Creighton Rock so-called “elephant’s foot” is a blunt-end
Drill Ltd., an Ontario-area equipment tool that vibrates and breaks concrete
dealer. In the end, they chose to purchase from steel reinforcement, rather than
a BTI TB285ME hydraulic breaker in the piercing the concrete as do the narrow-
750 ft/lb (500 m/kg) class. The unit was profile or chisel-point tools.
then mounted on a Bobcat skid steer so it By using the BTI breaker equipment,
could be used on the project. Priestly Demolition realized a number of
“My biggest priority on this job,” said benefits. First, the 21-model line of the
Priestly, “is meeting the production goals The terminal-demolition project at the Toronto
TB Series of hydraulic breakers have
while not exceeding weight restrictions Pearson International Airport involved the use been simplified to eliminate downtime.
on the structure. So we needed a small of several BTI hydraulic breakers. Among them The TB Series breaker design incorpo-
were two TB625QA breakers mounted on Link- rates only two internal moving parts and
excavator with a big breaker. The BTI
Belt excavators (above and in the photo on the fewer total parts than most other break-
breaker offers a better weight-to-power ers. Also, an increased oil-flow working
facing page). There was also a TB285ME breaker
ratio, and you can apply it on the smaller range allows the contractor to mount the
that was mounted on a Bobcat skid steer.
excavator. This is the biggest breaker that same breakers on a wide variety of
we have ever put on that size of machine. eration, the BTI TB285ME really was the equipment to suit numerous applications.
The production is great enough that it best fit for this project’s special needs.
has reduced our overhead by allowing us “Priestly Demolition was excited by the
“We recommended that Priestly could go simplicity of the BTI design,” said
to do the job with fewer units on the with a more powerful breaker on their Creighton. “The design features fewer
structure that is being demolished.” skid steer because the BTI breakers are a moving parts. That, of course, means less
Al Creighton, sales manager for Creighton little lighter than comparable models. time and money in maintenance and much
Rock Drill, said that after careful consid- They had been using a competitive model easier day-to-day operation.” •AMJ•


Call Tom Witt at Breaker Technology, Inc. (BTI): 915-369-0878 • E-mail:

Volume 2, Number 1 — Page 13

Just a few miles from Santo Domingo,
there is a beautiful Caribbean vacation
destination called Boca Chica. One of
the growing businesses in the area—
Constructora Bisono—needed a reliable
and productive aggregate-processing
plant. They decided to get the entire
plant from a single source: Telsmith.
Constructora Bisono’s new plant con-
sists of a Telsmith 3042-PP-VGF
crushing plant with a roller-bearing jaw
crusher and a 4 x 20-ft. (1.2 x 6.1-m)
vibrating grizzly feeder. There is also a
Telsmith SW620 FD-SM screening
plant and a secondary crushing plant
featuring a Telsmith 5252 HSI. The plant
also has a Model 5044-32T twin-screw
classifier. The processed material is
moved to storage piles with a series of
Telsmith conveyors and stackers.
According to Rafael Bisono, owner of
Constructora Bisono, the plant has
exceeded his expectations in terms of
both quality and production. •AMJ•

The People’s Republic of China is in the middle of a massive program

to build dams that will control flooding and provide hydroelectric power
The work is in progress right now: Ten
large- and medium-size hydropower sta-
tions with a total installed capacity of 8.5
million kilowatt hours will eventually be
operating in the People’s Republic of
China. In addition to providing electric
power for expanding economies in their
respective areas, the hydropower stations
will also serve to dramatically reduce the
flooding that these rivers have produced
over the centuries.
Two of the massive building projects—
the Goupitan Hydropower Station on the
Wujiang River and the Xiluodu Hydropower
Station on the Jinsha River—are using
vertical-shaft impactors (VSIs) as crushers
to help in the production of cubic sands
that are subsequently used to make high-
quality concrete for the construction of
the dam. There are a total of five VSIs on
these two jobs that were supplied by
This photo shows the three KPI 4500-EVTA vertical-shaft impactors (VSIs) that are currently being Kolberg-Pioneer, Inc. (KPI).
used on the Xiluodu Hydropower Station construction project on the Jinsha River in the upper reaches
of the Yangtze River in the People’s Republic of China. Two other KPI 4500 VSIs are in operation on According to the manager of the Goupitan
the Goupitan Hydropower Station project on the Wujiang River. project, the two KPI 4500-EVTH crushers

Page 14 —Volume 2, Number 1

Southern Peru Copper Corporation (SPCC) is one of the world’s largest producers of
copper. They have two large mines in Peru—the Toquepala and Cuajones Mines—
along with a smelter in Ilo, which is located in the southern part of Peru. At the Ilo
operation, SPCC had a production problem in their processing of seashells which are
useful because of their lime content. After processing, the shells are used in the
flotation process and smelter operations. They are produced in two sizes—3/8 in. x 1 in.
(9.5 mm x 25 mm) and 3/8 in.x 1/8 in. (9.5 mm x 3 mm). But seashells are located on
the beach, where there is also an overabundance of sand—and sand can be a detriment
to the smelter process.
SPCC contacted the Astec Aggregate & Mining Group to see if they could assist in
solving the production problems. The processed seashell-sand material would need
the following products: 1 in.+ (25 mm +); 1 in. x 3/8 in. (25 mm to 9.5 mm); 3/8 in.
x 1/8 in. (9.5 mm to 3 mm); and –1/8 in. (–3 mm). The last product, of course, would
be the sand. The company also required a production rate of 165 tons (150 tonnes)
M(Above photo) In order to produce top-quality per hour with little variance in the gradations of the finished product.
material, the owner of Constructora Bisono
specified the installation of a Telsmith twin-screw After discussing the matter with representatives from Astec Mobile Screens, a plan for
classifier and a dust-suppression system. the ideal portable plant evolved. In addition to producing the two finished products
required by SPCC—the coarse seashell and the fine seashell products—the plant would
O(Opposite Page) The company’s aggregate also power three 60-ft. (18-m) stacking conveyors. The plant would continuously move
processing plant is capable of producing up to along the processing-site and would waste the oversize and sand material out the back
300 tons (272 tonnes) per hour) with a range of of the plant as it moved.
products: 1 in. to 3/4 in. (25 mm to 19 mm);
–3/8 in. (–9.5 mm); 3/8 in. to 3/16 in. (9.5 mm to After thorough analysis, engineers at Astec Mobile Screens designed a custom triple-
4.7 mm); and 3/8 in. to 0 (9.5 mm to 0). The pri- deck portable screening plant: the PSP 3618DM (see photo below).
mary crusher is a Telsmith 3042 jaw crusher.
The PSP 3618DM portable screening plant offered a triple-deck screen to include a
There is also a secondary crusher: a Telsmith
5252 horizontal-shaft impactor. 5 x 10-ft. (1.5 x 3.0-mm) scalper top deck; a 6 x12-ft. (1.8 x 3.6-mm) high-frequency
middle deck; and a 6 x 18-ft. (1.8 x 5.5-mm) high-frequency bottom deck. The plant
also has three transfer conveyors and three stacking conveyors for stockpiling the
finished products.
that are being used at his site are working
out quite well, even under the project’s To date, the PSP 3618DM at SPCC has logged more than 12,000 operating hours,
somewhat wet conditions. “This is the with no major mechanical problems. The company’s positive experience with this
best equipment we have ever used for sand plant has led to another project where they are processing seashells to an even finer
manufacturing and processing,” he said degree than anyone originally thought would be possible. •AMJ•
during a recent interview. “The production
rates are very high—and the units have a
maintenance-friendly design.”
A typical application of the VSIs on these
two projects involves feeding limestone
material in sizes ranging from 5 mm to
40 mm and with 3- to 5-percent moisture
content. The goal is to achieve a useable
sand product of -5 mm.
The two 4500-EVTH VSIs on the Goupitan
project feature two electric motors on a
twin-drive mounting. One motor is verti-
cally mounted on each side of the crusher
and both are connected by individual sets
of V-belt drives.
The three 4500-EVTA VSIs working on the
Xiluodu project are similarly equipped, but
are fully autogenous—which means they
can be used for highly abrasive applications.
This is a key factor because these vertical-
shaft impactor units are being used to crush This is the PSP 3618DM portable screening plant that was especially designed by engineers at
basalt materials with maximum compressive Astec Mobile Screens to meet the highly demanding production requirements of Southern Peru
strengths of 270Mpa. •AMJ• Copper Corporation at its smelter location at Ilo in the southern part of Peru.

Volume 2, Number 1 — Page 15

When completed, this hydroelectric project in Turkey
will feature the third-tallest dam in the world
Construction is progressing nicely on the
Deriner Dam and Hydroelectric Power
Plant (HEPP) located on the Çoruh River
near Artvin in northeastern Turkey. When
completed, the Deriner Dam—at 830 ft.
(253 m)—will be the tallest dam in Turkey
and the third-tallest dam in the world.
The project statistics are quite impressive:
❏ More than 2,000 people are
employed on this project;
❏ The amount of rock excavated
will be in excess of 39 million cu.
yd. (30 million m3);
❏ Building the double-curvature
arch of the dam will require a total
of 4.6 million cu. yd. (3.5 million m3)
of concrete.
❏ The dam will create a reservoir of
2.5 billion cu. yd (1,970 million m3).
❏ When finished, the power plant
will be capable of generating 2,300
GWh of electrical energy annually.
The project is being implemented under
the responsibility of the State Hydraulics
Works (DSI) of Turkey and constructed by
a consortium composed of ERG Company
of Turkey; TSE (Russia) as civil contrac-
tors; Alstom Power (Switzerland) and VA
Tech Hydro (Austria/Switzerland) as sup-
pliers of the electromechanical parts; and
Stucky Consulting Engineers (Switzer-
land) as civil engineer. Construction of
the dam started in January 1998.
The first two years of the project were
devoted to the construction of a 15-mile
(24-km) bypass road to replace the state
road along the Çoruh River. In 1999, the
construction of the diversion tunnel was
started. The diversion was put into opera-
tion in early November 2001.

When completed, the Deriner Dam & HEPP will

stand 830 ft. (253 m) tall, making it the third-
tallest dam in the world.

Page 16 —Volume 2, Number 1

The excavation work of the dam area
reached the crest level in early June 2002
and the installation of the cable cranes Here is a schematic layout
was completed three months later. At
present, the dam foundation has been of the crushing and screening plants
excavated, together with the grouting and
drainage galleries on both abutments.
The rock consists mainly of granodiorite
at the Deriner Dam in Turkey
with diabese intrusions (so-called dikes).
The excavation of the powerhouse cavern
and of the adjacent valve chamber, head-
race tunnel, and several access galleries
was completed without major problems.
Assembly of the draft tubes and their
concreting has started.
The excavation of the dam’s foundation
will be completed by the middle of 2005.
The double-curvature arch dam is sched-
uled to be completed in 36 months. The
aggregate necessary for the mass con-
crete will be produced with crushing and
screening equipment that was supplied
by Telsmith and KPI, members of the
Astec Aggregate and Mining Group.
A total of 7.1 million tons (6.4 million
tonnes) of rock will be crushed and
screened for the concrete production in
36 months. The concrete aggregate will
be obtained from excavated granite mate-
rial. The end product of the crushing
plant is 0 to 0.1 in. (0 to 3 mm) crushed
sand, plus four sizes of aggregate: 0.1 to
0.5 in. (3 to 12 mm); 0.5 to 1.3 in. (12 to
32 mm); 1.3 to 2.3 in. (32 to 60 mm);
and 2.3 to 4.7 in. (60 to 120 mm).
a BTI Pedestal-Mounted Boom and Hydraulic Breaker System
Sand will be obtained by crushing the b Model 48-in. x 20-ft. Vibrating Grizzlies (2 each)
rock in Vertical Shaft Impactors (VSIs)
and sizing to the specs by the installed
c Telsmith 3648 Roller-Bearing Jaw Crushers (2 each)
classifying tanks. The production capacity d Telsmith 6 x 20-ft. (1.8 x 6.1-m) Triple-Deck Specmaker Screen
of the plant is 1,100 tons (1,000 tonnes)
per hour. e Telsmith 6 x 20-ft. (1.8 x 6.1-m) Triple-Deck Vibro-King® Screens (3 each)
The crushing equipment was delivered f Electromagnetic feeders (3 each)
by Telsmith and KPI in April 2004. The
conveyor belts and steel structures were
g Telsmith Model 52S Gyrasphere® Crushers (3 each)
manufactured by Pimakina, a manufac- h Telsmith 8 x 20-ft. (2.4 x 6.1-m) Triple-Deck Specmaker® Screens (3 each)
turing division of ERG.
The crushing and screening plant area is
i Kolberg-Pioneer 4500EVT SA Vertical Shaft Impactors (3 each)
currently under preparation and the entire j Kolberg-Pioneer 10 x 40-ft. (3.0 x 12.2-m) Stationary Classifying Tanks (2 each)
plant operation is expected to be in serv-
ice by April 2005. Other site installations k Kolberg-Pioneer 44-in. x 32-ft. (1.1 x 9.8-m) Single-Spiral Sand Prep
required for the concrete work—such as
the concrete batching plant, the cement
l Kolberg-Pioneer 44-in. x 32-ft. (1.1 x 9.8-m) Twin-Spiral Sand Prep
silos, and the aggregate silos—will also m 36 x 72-in. (0.9 x 1.8-m) Vibrating Pan Feeders (3 each)
be ready by April 2005. •AMJ•


Call Eduardo Barrera at Astec Industries: 866-376-1331or 954-438-7747 • E-mail:

Volume 2, Number 1 — Page 17

A Quick Overview of the Massive Display of State-of-the-Art

aInformation Center
Astec Aggregate and Mining Group

bAstec Controls
Plant Automation Demonstration

cAstec Mobile Screens PDF 2618VM

Mobile Screening Plant

dJCI FT300 Track-Mounted

Cone Crusher Plant

eKPI Vanguard ®

Model 3352 Jaw Crusher

fKPI 7000 Series Classifying Tank

and Spec-Select I System

gKPI FT 4240CC Track-Mounted

Horizontal-Shaft Impact Crusher

hKPI Fast-Pack ®System

(Scale Model 1/64 actual size)

iTelsmith 3258 Jaw Crusher

with Hydraulic Adjustment

jTelsmith 52SBS Cone Crusher

with Remote Automation Control

kTelsmith 44CCP Closed-Circuit

Portable Cone-Crusher Plant

Page 18 —Volume 2, Number 1

Art Crushing and Screening Technology at ConExpo-Con/Agg


k b

h e


Volume 2, Number 1 — Page 19

The Kleinkopje colliery in South Africa has expanded its prod
The impressive scope of one of South
Africa’s largest collieries recently became
even more impressive. Osborn Engineered
Products—a South African manufacturer
that specializes in designing and market-
ing equipment for bulk-materials handling
and minerals processing—was selected
to help Anglo Coal’s Kleinkopje colliery
undergo an expansion. The work started
in February 2002. Several years later,
after significant additions, the expansion
has been successfully completed.
The Kleinkopje Colliery is located near
Witbank, Mpumalanga, South Africa. The
facility was commissioned in 1978 to
provide coal for the export market. Today,
the mine produces pulverized coal injec-
tion and thermal coal for export; washed
and sized coal for the domestic market;
and metallurgical coal for use by the local
steel industry.
The recent expansion program was aimed
at meeting the increase in Anglo Coal’s
export allocation, a result of the Phase 5
expansion of Richards Bay Coal Terminal
(RBCT). This expansion will see RBCT’s
annual throughput capacity increase from
the 8.3 million tons to 8.8 million tons
(7.5 million tonnes to 8 million tonnes).
Osborn took on the $8.3 million (USD)
contract to expand the plant at the
Kleinkopje colliery. The project entailed
the installation by Osborn of a ROM
hopper with a capacity of 385-ton (350-
tonne); an apron feeder measuring 72 in.
(1,800 mm) wide and 56 ft. (17 m) long;
a grizzly feeder 78 in. (2,000 mm) wide
and 15 ft. (4.6 m) long; a grizzly screen
to remove undersize material measuring
–4.3 in. (–110 mm); a 12 x 25-ft. (3.6 x
7.6-m) rotary breaker; and a new jaw
crusher with a 550-ton (500-tonne) per
hour capacity. The new jaw crusher will
replace the existing crusher.
In addition, Anglo Coal extended the
mine’s conveyor system by a total length
of about 1 mile (1.6 km) with conveyor
belt widths of 48 in. (1,200 mm), 53 in.
(1,350 mm), and 59 in. (1,500 mm).

This photo shows the new conveyor system

installed by Osborn at the Kleinkopje colliery
near Witbank, Mpumalanga, South Africa.

Page 20 —Volume 2, Number 1

oduction levels to 8.8 million tons (8 million tonnes) per year
Modifications made by Osborn to the
hard-material crushing building included
strengthening the overall structure of the
building; installing an additional feed
conveyor; and installing new chutes that
would receive reject material sized up to
30 in. (750 mm) lump size from two con-
veyors. The modifications to the facility
also included installing the new crusher.
According to contract manager Marius
Prinsloo, the challenging aspect of the
Kleinkopje project was the consideration
that had to be given to the handling of
hot coal from the opencast mine. “In some
cases,” said Prinsloo, “the coal is actually
burning (as it leaves the mine), so equip-
ment and conveyors may be subjected to
extremely high temperatures.”
To assist with cooling down hot coal, an
atomized spray system was installed at
the tip and at the primary crushing area.
Ceramic linings were also fitted to most
sliding portions of the chutes. Rail and This is the new 12 x 25-ft. (3.6 x 7.6-m) rotary breaker installed by Osborn as part of the $8.4 million
(USD) contract to expand and upgrade the production facilities at the Kleinkopje colliery. The contract was
VRN400 liners were fitted to all plate- intended to increase the facility’s annual throughput capacity from the 8.3 million tons to 8.8 million tons
work in the tip area and jaw-crusher feed (7.5 million tonnes to 8 million tonnes).
chutes. In addition, copper head systems
were installed on the jaw crusher and
rotary-breaker bearings to measure heat
and vibration conditions.
“These were all critical elements of the
project,” said Prinsloo, “since the coal
being conveyed is extremely combustible.”
An unusual element of Osborn’s contract
at Kleinkopje was the large run-of-mine
tip. “The mine required that the tip have
a holding capacity of three 140-ton (130-
tonne) bottom-dump haul trucks in a
3CR12 tip bin,” Prinsloo explained.
“Osborn met the mine’s specifications in
this area.”
Prinsloo cited the company’s expertise in
both primary tips and rotary breakers as
factors that qualified Osborn to take on
the challenges of this expansion project. Another key element of the
facility’s upgrade was the
Osborn Engineered Products is based in addition of an Osborn 30 x 55
Elandsfontein, Johannesburg, South jaw crusher that can deliver
Africa. The company is a leading manu- production capacities that
facturer of crushing and screening plants, can reach as much as 550-
and conveyor systems. •AMJ• tons (500-tonnes) per hour.


Call Martin Botha at Osborn Engineered Products: +27 (0) 11 820 7725 • E-mail:

Volume 2, Number 1 — Page 21

At one end of the tripper system, the railcars carrying the incoming
aggregate are positioned over the in-ground hopper. The material
is dumped into the hopper where it is picked up by the feed con-
veyor (above) and moved up to the overhead tripper conveyor
(right). The feed conveyor transfers aggregate from the hopper to the
tripper conveyor at a rate of 800 tons (725 tonnes) per hour.


Unusual circumstances can create unusual The Unusual Problem amount of back-and-forth traffic in a
problems—and unusual problems often Unfortunately, the railroad spur line was plant yard that was already crowded with
call for unusual solutions. Such was the located quite a distance from their HMA haul trucks lining up to get hot-mix.
case with a producer of hot-mix asphalt plant: about 300 yards (275 meters). After The Unusual Solution
(HMA) a few years ago. One thing led to unloading the material from the rail cars The company’s management approached
another: unusual circumstance, problem, and stacking it, they had to use front-end
and solution. Here’s the story: Kolberg-Pioneer to see if their engineers
loaders to move it to where they were might have some input. They were in the
The company is in the business of paving stockpiling the material for the plant. The process of purchasing a new HMA plant
highways and performing other heavy result: a lot of man-hours used, a lot of from Astec, Inc. and they were interested
construction work. Because of the paving hours on the loaders...and a confusing in solving the problem before the new
business, their HMA plant uses a large facility became fully operational.
amount of aggregate on a daily basis.
Together, the two companies worked out
The Unusual Circumstances
a solution that has generated interest from
The unusual part of the operation is that
a number of companies that deal with
there is no suitable supply of aggregate
aggregate materials. The solution involves
nearby in the area where the company
does business. For years, they had either a rail-car unloading facility and a tripper
brought the aggregate in by truck or by conveyor that is used to transport the
rail, depending on its origin. Then they material a long distance and then stack it.
had the opportunity to get their supplies In the past, the material was handled
from a quarry that was an additional 30 numerous times. They moved it out of the
miles (48 km) away—which was simply pit where the rail car had dumped it; then
too far to haul by truck. they stacked it; then they moved it with a
They decided to commit to hauling most loader or excavator and stockpiled it;
of their aggregate in by rail to a spur line then they moved it once more to the
Rail cars deliver aggregate to the plant on a HMA plant’s cold-feed bins.
that was adjacent to their property. In that regular basis—and the material is dumped into
way, they could get all of the aggregate an underground hopper before being moved to But with their new tripper system, the
they needed, when they needed it. the overhead tripper system. material moves automatically from the

Page 22 —Volume 2, Number 1

On the tripper conveyor, the aggregate moves along until it reaches
the spot where it can be discharged to one side or the other of the
conveyor (left). The manual flop gate diverts the aggregate from the
conveyor so it can flow down to the proper stockpile. As you can see
from the photo of the hot-mix asphalt plant (above), the stockpiles
are located conveniently close to the cold-feed bins.


rail-car unloading pit to the stockpiles. unloading station; a tripper feed conveyor; ❏ Stationary tripper conveyor—This
The only time they touch it is when they and a stationary tripper conveyor. Here are particular component is a Kolberg Series
send a loader to fill the cold-feed bins— some of the details: 40 conveyor measuring 36 in. (0.9 m) wide.
and those cold-feed bins are only about The system was built to carry the material
❏ Rail-car unloading station—There is
30 ft. (9 m) away. across five aggregate bunkers for a total
a stationary, underground hopper with a distance of 450 ft. (137 m). There is a
The results have been impressive: top opening measuring 14 x 38 ft. (4.3 x traveling tripper and a manual flop gate
The company was able to reduce both the 11.6 m). The hopper slopes are 60° and chute that allows the material to be dis-
size and activity of its loaders. It was there are hinged, false hopper walls with charged to either side of the conveyor.
vibrators to prevent the aggregate from There is also a special chute at the far end
able to reduce the number of man-hours
hanging up on the walls. There is a 36-in. of the tripper conveyor that allows it to
used in moving material. Traffic around
(0.9-m) conveyor belt that assists in the feed material directly onto the facility’s
the plant was improved dramatically. And collection of the material for subsequent
at the same time, they were able to radial stacker that is located abut 25 ft.
transport to the tripper feed conveyor. (7.6 m) beyond the last bunker.
increase the production capabilities of the This belt was designed to move aggregate
HMA plant. material at a maximum of 800 tons (725 According to a spokesman of the company
that has been using this system for the
Surprisingly, the design of the tripper tonnes) per hour.
past several years, “We gave ourselves
system is unusually simple and straight- ❏ Tripper feed conveyor—This unit is the ability to unload more material at a
forward. It requires only a relatively a Kolberg Series 46 stationary, vertical- higher rate, thus being more efficient. We
small footprint in order to work properly. curve tripper conveyor that is approximate- were trying to reduce our costs—and that
And it could stretch almost any distance. ly 225 ft. (69 m) long. Some of this con- is what we have been able to do.
The Unique Tripper System veyor is underground, although most of it “This is an incredibly efficient operation.
The system designed by Kolberg-Pioneer is above ground level. The tripper feed We’ve been able to store more material
for this company consisted almost entirely conveyor carries the material up to the on a smaller footprint. And that, by itself,
of just three basic components: a rail-car elevated tripper stockpiling system. has been a big advantage.” •AMJ•


Call Curt Peterka at Kolberg-Pioneer: 800-542-9311 or 605-665-8771 (E-mail:

Volume 2, Number 1 — Page 23

Old-fashioned cone crushers face stong competition
from this new design and superior technology
People in the industry may think they know to be constantly monitored during pro- The Kodiak Series of cone crushers from
cone crushers pretty well since those duction; and (4) their need for frequent JCI features improvements in three major
hard-working crushers have been around adjustments to maintain spec material. areas. First, they have higher capacity.
for a half century or so. But a producer who Second, they have a better quality of
The fact is that the modern cone crusher
hasn’t specced out a cone crusher lately aggregate output. And third, they require
manufactured by JCI defies those percep-
may have a slightly outdated perception less human interface.
tions. The Kodiak Series of cone crushers
of this equipment. For example:
offers producers more capacity, better In order to achieve this, JCI redesigned
There have been complaints about some quality of aggregate output, and requires the cone head. Their engineers changed
old-style cone crushers, complaints that less human interface. In short, these new the geometry of the cone head to a steeper
usually called attention to four of their crushers are bigger and better. Here’s a angle compared to that of conventional
major short-comings: (1) their relatively quick overview of how the Kodiak Series cone crushers. Because the geometry is
low producutivity; (2) their struggle to cone crushers have been engineered and steeper, material is forced by gravity
produce cubical material; (3) their need built to redefine cone-crusher quality: through the chamber at a faster rate.

The Kodiak Series cone crushers from JCI are available in a variety
of field installations, including portable crushing plants like the one
shown here. This is a Kodiak K400 cone crushing plant.

Page 24—Volume 2, Number 1

In order to handle the greater crushing load their rotation threads that frequently gall securely holds the closed-side setting of
associated with this higher volume, JCI or weld together. JCI has patented a the cone crusher in place.
increased the horsepower of the machine. brass-thread insert that resists the galling
Kodiak cone crushers are currently avail- ❏ Tramp-iron relief system—The
and welding. (This is a field-replaceable
able in 300 and 400 hp (223,710 and Kodiak cone crushers offer a much more
part, but a JCI spokesman stated that since
298,280 Watts) models—and a 200 hp the Kodiak cone crushers were introduced efficient and gentler tramp-iron release
(149,140 Watts) model is scheduled to be in 1998, not a single set of threads has system compared to older cone crushers.
released later this year. needed replacing.) This design will save wear-and-tear on
the machine over time.
Also, because the material travels through ❏ Internal counterweights—Old-style
the chamber faster due to the steeper cone crushers had counterweights that Finally, the Kodiak Series of cone crushers
geometry of the cone head, JCI increased were mounted in the rock flow. With time, is improved over older, more conventional
the speed of the crushing action to main- those counterweights would wear out. cone crushers by reducing the need for
tain the reduction. The Kodiak Series also Kodiak cone crushers, however, have human interface. In other words, a crew
features increased stroke, making it a more internal counterweights that are balanced member is no longer required to manually
aggressive machine. at the factory—for life. That means there make adjustments to the discharge setting
In addition to these improvements, the is no need to replace the counterweights. as the liners wear. Instead, a simple push
Kodiak Series of cone crushers also come of a button will change that setting on the
❏ Hydraulic locking ring—Instead of
equipped with four patented features that fly. That, in short, means no downtime.
using the traditional clamping cylinders
eliminate some of the problems that old- with hose connections to lock threads in In all, said a JCI spokesman, these unique
style cone crushers presented: features come together to redefine the
place, JCI designed a single hydraulic
❏ Left-hand brass threads—The older- cylinder that provides up to 550,000 lb. productivity and efficiency of the modern
machines use steel-on-steel threads on (250,000 kg) of locking pressure that cone crusher. •AMJ•


Call Curt Peterka at Kolberg-Pioneer: 800-542-9311 or 605-665-8771 (E-mail:

The JCI Kodiak cone-crusher plant is equipped with a number of innovative

features. Some of these include (see corresponding numbers in illustration
above): [1] left-hand brass threads; [2] internal counterweights; [3]
hydraulic locking ring; [4] tramp-iron relief system; [5] aggressive stroke
and chamber; [6] large-diameter mantle bolt; [7] two-piece cone head; [8]
four-sided anti-rotation pins; [9] anti-friction roller bearings; [10] compact
oil reserve; [11] internal oil heater; [12] anti-spin cone brake; [13] massive
full strut base frame; [14] aggressive stroke wedge plate; [15] oil sealing
system; [16] modified “U” seat; [17] one-piece bowl support; [18] dual The 400 hp JCI Kodiak cone crusher (above) has a surprisingly robust base-
closed-side-setting drive motors and precise CSS changes digital-readout frame design. Weighing in at 58,200 lbs. (26,400 kg), this machine is near-
indicator on the control panel. Overall, the plant provides high production, a ly 12,000 lb. (5,450 kg) heavier than the competitive model. And while it is
massive heavy-duty base frame, state-of-the-art controls, numerous fea- sturdy, it is also efficient, producing more product-per-pass as a result of its
tures that make maintenance easier, and low total cost of ownership. precision roller-bearing design.

Volume 2, Number 1 — Page 25


Track-mounted crusher moves producers forward

with improved versatility and efficiency
Mobile equipment just makes good sense. they cover terrain that would be virtually grizzly feeder. The jaw crusher weighs
This rings particularly true for producers impossible for wheel-mounted equipment, approximately 55 tons (50 tonnes) and
who utilize crushing and screening equip- but they can also be moved from one site has a feed capacity of more than 275 tons
ment because, in many cases, it is easier to another with minimal downtime.” (250 tonnes) per hour while producing 5-in.
to take the crushing plant to the material— (125-mm) material.
instead of the other way around. As a To respond to the current industry trend
toward mobile equipment, Osborn recently In addition to its remarkable mobile bene-
result of this fact of life, many producers
launched its first primary jaw-crusher track fits, the company spokesperson added that
are choosing to operate track-mounted
unit, the Osborn Track 3042. This unit also its South African customers appreciate
equipment that can go where the work is.
made history by being the first of its kind the fact that the Osborn Track 3042 jaw
“Track-mounted equipment offers a number to be fully designed and manufactured in crusher is manufactured locally. “The
of benefits to the producer,” said a spokes- South Africa. spares, backup, and service support of a
person with Osborn Engineered Products, local manufacturer is a significant benefit,”
a manufacturer located in Johannesburg, The Osborn Track 3042 features an Osborn he said. “Customers are assured that spares
South Africa. “Track-mounted crushing Telsmith 3042 jaw crusher, a 42-in.-wide and service from Osborn’s engineers will
machines are cost effective and remarkably (1,050-mm-wide) discharge conveyor, be available quickly and easily.” In addi-
flexible in their operation. Not only can and a 42 x 12 Osborn Obex vibrating tion, standard machines and components

Page 26 —Volume 2, Number 1

were selected for the unit in order to fit in
with Osborn’s standard product offering. One of the many products made
This also ensures that parts are readily by Osborn at its manufacturing
facility in Johannesburg, South
available in the South African market.
Africa is the 80 x 60 single-toggle
The market’s needs were also considered jaw crusher shown here. It is a
when Osborn chose the type of jaw crusher popular piece of equipment among
to mount on the Osborn Track 3042 unit. producers in the coal industry.
The Osborn Telsmith 3042 jaw crusher
was selected for the unit because it is the
most widely used size for primary crushing
in South Africa. It features a rugged frame
and optimized toggle seat and nip angle.
It is diesel-driven with a heavy-duty “fluid
clutch”. The crusher’s feed size can be as
much as 24-in. (610-mm). It has a 2.5-in.
(65-mm) minimum closed-side setting.
The Osborn track unit’s discharge conveyor
features an impact bed to minimize belt
damage, head adjustment for ease of
maintenance, and a low-maintenance
electric drum motor. As an added benefit,
the conveyor is completely removable.
The Osborn Track 3042 unit includes an
Osborn 4212 Obex vibrating grizzly feeder.
This feeder features a low-maintenance
variable-speed electric drive and a hard-
wearing steel bin. South African manufacturer offers
The unit’s electric drive uses a 400-volt
generator sized to drive all of the equipment
except the tracks. There is a 220-volt
equipment for any producer’s needs
power socket for connecting tools on-site. A wide range of applications face different One of Osborn’s largest products is also
Diesel power is provided by a John Deere producers today, from coal mines to stone one of the largest manufactured anywhere
6081HF 8.1 diesel engine rated at 230 kW quarries to manganese and chrome mines. in the world. The Osborn Hadfields 80 x
at 1,500 continuous rpm—generating the Each application presents its own list of 60 single-toggle jaw crusher weighs in at
highest torque output in its class. The challenges. One thing material producers 309,000 lb. (140,000 kg). Its strength and
radiator is sized for an ambient tempera- all have in common is the universal need size make this machine popular among
ture of 113°F (45°C). to create as much product as possible— coal producers in southern Africa.
efficiently and economically.
Hydraulics on the Osborn Track 3042 have Traditional rotary breakers handle up to 3.2-ft.
A manufacturer located in Johannesburg, (1-m) coal-lump sizes; but the Hadfields
been minimized to reduce maintenance. South Africa is working to serve that uni-
Its hydraulic system has also been sized can handle up to 6.5 x 5 ft. (2 x 1.5 m)
versal need. Osborn Engineered Products feed size with throughput of more than
for a 113°F (45°C) surrounding tempera- (usually called Osborn), is a leading
ture and it has no heat-inducing flow- 1,750 tons (1,600 tonnes) per hour.
manufacturer of bulk-materials processing
control valves. The unit’s tracks have a plants and equipment. According to For producers working in rock quarries,
20-in-wide (500-mm-wide) shoe with D6- industry observers, Osborn is currently Osborn manufactures a Telsmith 50 x 60-
equivalent parts. Its speed range is from offering one of the most complete lines of in. (1.3 x 1.5 cm) single-toggle crusher.
0.2 to 0.5 mph (0.3 to 0.8 km/h). jaw-crushing equipment on the market. And for those producing arduous ores,
Additional features of the track unit are the “Working with our sister company, Telsmith, the Osborn Hadfields double-toggle jaw
PLC-based plant logic and remote radio Osborn is dedicated to performing the crushers, available in a variety of sizes,
control. A range of optional extras are also research and development necessary to can handle materials up to 600 MPa.
available, including a cross-belt magnet; produce more efficient jaw crushers,” said “Producers in the industry are recognizing
VGF undersize conveyor with hydraulic a company spokesperson. Osborn’s commitment to producing hard-
fold; full electro-hydraulic controls; The manufacturer’s line of jaw crushers wearing, high-quality jaw crushers,” said
hydraulic bin fold, and a hydraulic rock- includes both single- and double-toggle the company spokesperson. “We will
breaker boom manufactured by BTI, machines, ranging from laboratory size continue developing new technology to help
another member of the Astec Aggregate to 5 x 6.5 ft. (1.5 x 2 m). producers meet their needs.” •AMJ•
and Mining Group. •AMJ•


Call Martin Botha at Osborn Engineered Products: +27 (0) 11 820 7725 • E-mail:

Volume 2, Number 1 — Page 27

TAKES THE RIGHT TOOLS Back in 1958, when he was only 18 years
old, Henry “Red” Torromeo set out to
start his own business by hauling dirt for
customers in a single dump truck. Over
the years, that business has grown into
Torromeo Industries, Inc., headquartered
in Methuen, Massachusetts. The family-
owned company is primarily a concrete-
and-aggregate producer, serving an area
from northeastern Massachusetts up to
southeastern New Hampshire. Torromeo
Industries currently operates two concrete
plants. They have a third plant on order.
After going through the process of building
a business from the ground up, Torromeo
has learned to appreciate certain aspects
of equipment that enable people to do
their jobs faster, easier, and cheaper. So
when the company’s existing crushing
plant was not able to meet his customers’
demands, Torromeo took a hard look at
some interesting features of the crushing
equipment that is available on the market
—and he eventually chose a closed-circuit
The Telsmith 44SBS closed-circuit crushing plant owned by Torromeo Industries is highly portable and portable crushing plant made by a com-
highly productive—two reasons why the plant is helping the owner continue to build his business. pany in Wisconsin: a Telsmith 44SBS.

Page 28 —Volume 2, Number 1

“Our other plant just couldn’t keep up with we’ll be moving it to different gravel pits crusher and can produce three different
our production needs for a particular that we operate around the state of New product sizes, depending on the market
product,” said Torromeo. “It seemed like Hampshire. It will be easy to move. I can demands being met by the producer. “It
we always had a lot of oversize material pick up and move and reset this machine has tremendous capacity,” Torromeo said.
to re-crush, so we bought the new Telsmith in almost one day.” “It really produces.”
to pick up the slack.” Another feature of the Telsmith 44SBS Additional features on the Telsmith 44SBS
The Telsmith 44SBS portable plant had a that impressed Torromeo was the accessi- include a powerful diesel engine that pro-
number of attractive design features that bility to the cone crusher. Unlike other vides consistently high performance.
Torromeo appreciated. The most obvious crusher designs, this machine’s conveyor There is also a digital display that shows
feature was the plant’s portability. The can be folded back, completely exposing the operator the status of the crusher set-
company operates one quarry and several the cone crusher for easy liner changes ting. And there is an optional hydraulic
gravel pits throughout the state of New and other routine maintenance. Screen anti-spin system that helps reduce liner
Hampshire. Torromeo wanted to have the decks can also be accessed easily, making wear and offers improved performance.
flexibility to be able to move his crushing wire-cloth changes simpler.
Since the plant went into operation in the
plant from one location to another in “We have direct access to the cone crusher fall of 2004, Torromeo said all of the fea-
order to produce aggregate products where so we can maintain it,” said Torromeo. tures that showed so much promise to him
and when they were needed. With its “From what I know, it’s the only one on while he was shopping for a new crusher
expanded use of hydraulics, the Telsmith the market that has a conveyor that you have come together in a single piece of
44SBS met that requirement. The unit can pick up and move. And that gives equipment, thereby providing his company
includes hydraulically folding feed con- you direct access to the cone. On all the with a hard-working, valuable tool that is
veyors and a 6 x 20-ft. (1.8 x 6.1-m) other crushing machines, you have to take helping him grow his business.
triple-deck screen module that hydrauli- everything apart. This one is quick—so it
“This machine saved my life this winter,”
cally lowers into the chassis for travel. saves a lot of time and a lot of work.”
said Torromeo. “We were very low on
“We will probably move it three or four Torromeo said he was also pleased by the one particular size of stone. But our new
times a year,” said Torromeo in a recent productivity of the Telsmith 44SBS closed- Telsmith crusher bailed us right out. I’m
interview. “It has been in one spot since circuit portable crushing plant. The plant glad we had it—because it has made my
it was delivered last fall, but eventually, is designed as a secondary or tertiary life a lot simpler!” •AMJ•


Call Bob Meyers at Telsmith: 800-765-6601 or 262-242-6600 • E-mail:

Telsmith designed the 44SBS portable crushing plant

so the feed conveyor can be folded back out of the way
to provide easy access to the cone crusher

The Telsmith 44SBS portable crushing plant is the only plant on the market
that lets you fold the feed conveyor out of the way to provide easy access
to the crusher. The drawings to the right show the conveyor folds back to
the rear of the unit for crusher maintenance—and for transport.

Volume 2, Number 1 — Page 29

Illinois-based Carri Scharf Materials
Company has been involved in trucking Carri Scharf Materials’ new screening-and-washing plant includes the following equipment: a
and materials for 22 years. Last year, the Kolberg primary screening tower with a two-deck static scalping velocity feed box; a JCI three-deck
company added its third complete screen- horizontal wet vibrating screen; a Kolberg skid-mounted 12 x 48-ft. (3.7 x 14.6-m) classifying tank;
ing-and-washing plant that was manufac- a Kolberg log washer; a Kolberg skid-mounted wash plant; and a variety of Kolberg stationary and
tured by Kolberg-Pioneer, Inc. (KPI) and radial stackers and conveyors.
Johnson Crushers International (JCI).
Although Carri Scharf Materials has
achieved success with all of its KPI-JCI
equipment, owner Joe Scharf said that on
this third plant, he had the opportunity to
share his experience with the engineers at
KPI-JCI in order to get exactly the speci-
fications his operation needs.
“This time, I was actually able to sit down
with the engineer and go through every
operational detail: from where the material
was coming in to where it was going out,”
Scharf explained. “We were able to look
at every wear point. We were able to put
in removable wear parts instead of taking
off sheets of metal and welding them.”

Work with the manufacturer to get

precisely the performance you need
The screening plant he referred to is cur- The most dramatic addition is an over- Creating this productive equipment called
rently located in Heyworth, Illinois. It is sized velocity box that Scharf designed for collaboration between Scharf and the
a dredge-fed operation that accesses to help prevent flooding the tank and the manufacturer. Scharf spent time with a
underwater deposits of glacial sand and screen deck. By diverting most of the KPI engineer who used a CAD system to
gravel. With two other plants doing similar water, both the tank and screen deck avoid bring to life Scharf’s vision. “We sat there
work, Scharf was able to anticipate key excess wear. with the CAD machine and went over this
areas that receive additional wear. He then thing and developed the details,” Scharf
“It’s basically just another screen, welded recalled. “Next thing you know, they are
specified modifications, including 0.5-in.
inside at an angle,” Scharf explained. “It building the plant.”
(13-mm) urethane coating throughout and
1.5-in. (38-mm) liners on the velocity box. slows down the velocity of the water as it
comes from the dredge. We’re pumping Founded in 1982, Carri Scharf Materials
“You already know what’s going to wear probably 18 cu. ft. (0.5 m3) per second, serves central Illinois. The company
out,” Scharf explained. “So if you put in (but) the velocity box slows it down. At began as a trucking firm and entered the
stock items and make them removable and the same time, it de-waters and takes the materials business in 1993. They operate
replaceable, it makes all the difference in three sand and gravel locations and a
water right straight to the tank instead of
the world. You can make the repairs in 30 recycling plant for asphalt and concrete.
putting it onto the screen deck. So every-
minutes instead of two or three days.” There is also a rail yard for importing
thing that is hitting the screen deck now Indiana limestone. In January, they opened
Installing a rollaway chute on the screen is just wet, coarse aggregate material a barge terminal on the Illinois River.
decks is a good example. Workers can from 3/8-in. (10-mm) up. That enables
simply undo a bolt to roll the chute away the high production.” Scharf’s attention to detail is obviously
from the screen decks in order to conduct part of this success, and his suggestions on
The innovations are so effective that the how to modify this equipment is a good
necessary maintenance. plant consistently produces 750 tons (680 example. “Sure, it costs a little more up
“This equipment is very user-friendly,” tonnes) per hour, well above its expected front,” he noted. “But we’re looking at
said Scharf. “Everything is very accessi- ceiling. “We couldn’t do that without that what it will save us down the road in terms
ble.” He also added a special “C” flume velocity box on there. It’s scalping prob- of labor and downtime. I’m convinced
from the classifying tank, which improved ably 50 percent of the material and all of that we’ll go through the service life of
the flexibility of the plant with regard to the water away from the coarse aggregate this equipment with very little downtime.
the sand products that are produced. side. That’s what makes the difference.” That will make a big difference.” •AMJ•


Call Curt Peterka at Kolberg-Pioneer: 800-542-9311 or 605-665-8771 (E-mail:

Page 30 —Volume 2, Number 1

They were looking for a screen that would like RMC Nevada for a screen that would fines are getting down to the bottom deck
help them get the large, clean rocks onto provide a higher level of productivity by faster, which gives you more capacity
one conveyor and the smaller rocks and increasing feed volume and throughput. through the screen.
dirt onto another conveyor. And one other According to Paul Smith, product manager According to JCI product manager Paul
thing: They were looking for day-to-day with JCI, there was a lot of research and Smith, a lot of producers will want to
production numbers that most screens development that went into the actual split the rock and the sand right after the
could not deliver. design of the Combo Screen. The concept, primary crusher. They will send the sand
“We are a shot-rock quarry,” said Robert however, is really very simple: to a wash plant for wet processing. And
Totman, operations manager at RMC The Combo Screen uses specially designed everything that is retained above the sand
Nevada, Inc. in Reno, Nevada. “Rhyolite multi-angle screens (see photo, below) on will go into a dry processing plant where
is the material here. We use it both for both the top and middle decks. The screens it will be crushed for use as concrete
concrete aggregate and road base material, measure 8 x 20 ft. (2.4 x 6.1 m). aggregate or asphalt chips or some other
depending on how clean it is.” product. Those were essentially the job
When you feed material onto the screen, needs of RMC Nevada when they bought
Rhyolyte is a lightweight aggregate that the inclined section tends to accelerate
only weighs about 1 ton per cu. yd. (1.2 the Combo Screen.
the material to a relatively high travel
tonnes per m3). Consequently, there is going speed. That makes the bed depth of the “It is almost impossible to set a screen so
to be about 25 percent more volume with material quite thin—which in turn allows that it will be effective with both coarse
this material than with other aggregates. the fines to stratify between the coarse and fine material at the same time. But
RMC Nevada’s market is in the Reno to particles so they can get down to the bot- that is exactly what we have done with
Sparks area. The company operates two tom of the material bed quicker. the configuration and performance of the
facilities for aggregate production. One Essentially, what is happening is that the JCI Combo Screen.” •AMJ•
of them is just outside of Reno and the
other is near Wadsworth. The company’s
operation in Reno was growing and they 1
U 2
needed screening equipment that would
allow them to be more productive.
Totman explained that the material coming 3
from the jaw crusher needs to be screened
in order to separate the products.
“What we wanted was a heavy-duty screen
to scalp out our overburden material after
the jaw crusher. The Combo Screen from
JCI was just the ticket. I’ve got a 3-in.
(75-mm) screen on the top deck and a 2-
in. (50-mm) screen on the bottom deck.
I’m taking all of the good, clean, big rock
and sending it over to the concrete side of
our plant. And all the small rock and dirt 4
goes to our base-rock plant. The oversize
rock—3 in. (75 mm) to 6 in. (150 mm)—
goes to our secondary plant where it gets
crushed again.” 5
According to Totman, RMC Nevada keeps
the Combo Screen active. “We work it
seven days a week and ten to twelve hours The multi-angle Combo Screen from JCI earned its name by combining the advantages of an inclined
a day. Last year, we put 1.6 million tons screen and a horizontal screen into a single unit. This illustration shows the different areas of the Combo
Screen, each of which is called out by a number. The feed end of the top deck has a 20° section [1], a 10°
(1.4 million tonnes) of material through section [2], and a flat section [3]. The second or middle deck [4] is similar, except it begins at 15°, then
that Combo Screen. It’s done a good job.” changes to 7.5°, and then changes to a flat section. The bottom deck [5] is horizontal or flat. Extensive
The Combo Screen was developed by JCI research and experimentation proved that increasing the travel speed of material in the feed section tends
in response to requests from producers to reduce bed depth of the material, thereby getting fines through the screen openings faster.


Call Curt Peterka at Kolberg-Pioneer: 800-542-9311 or 605-665-8771 (E-mail:

Volume 2, Number 1 — Page 31

that meets the customer’s needs

The new PDF 2628VM mobile screen plant from Astec Mobile Screens, Inc. that allows material to be fed directly to the screen while oversize material is
features a modified 6 x 18-ft. (1.8 x 5.5-m) double-deck PEP Vari-Vibe® returned to the track crusher. This unit is track-mounted for ease of movement
high-frequency screen. This versatile plant incorporates a direct-feed system on the jobsite. It fits on a lowboy for convenient transport from site to site.

The recirculating conveyor on the PDF 2618VM in this photo is shown feeding This photo shows a PDF 2618VM processing reclaimed asphalt pavement
the track crusher while the fines conveyor transfers material to a radial- (RAP) with direct feed from the track crusher. A heavy-duty receiving hopper
stacking conveyor. A wrap-around catwalk—which is standard equipment— allows for direct feed from multiple angles when in tight operating areas. The
provides easy access to the screen. The plant offers hydraulic screen-angle high-power diesel engine powers all screen functions, as well as three on-
adjustment for various application needs. board transfer conveyors and three off-plant radial-stacking conveyors.

Page 32 —Volume 2, Number 1

Most aggregate producers are always mobile screening plant and it did not have ❏ Fine material passing both screens
looking for a better, faster, or cheaper way a built-in recirculating system to feed comes out the rear of the plant for transfer
to do the job. Some of them even have the oversize material back to a track crusher. to a radial stacking conveyor.
gumption to ask a manufacturer to design The engineering department quickly set
“The really unique thing about this plant,”
a certain kind of tool. out to design a solution.
said Mandrell, “is the way it interfaces with
That’s what happened not long ago when What they came up with is called the PDF other equipment through the direct feed
Granite Construction approached Astec 2618VM track mobile screening plant. system, which allows multiple feed angles,
Mobile Screens, Inc. with an idea. They According to Mandrell, the central part of and the recirculating system for oversize
wanted a mobile crushing-and-screening material fed back to the crushing plant.”
the newly designed plant is the PEP Vari-
system that would take fairly large pieces
Vibe® 2618VM high-frequency screen. “We Mandrell said the unique features include
of reclaimed asphalt pavement (RAP),
had previously built this screen in various its controls. “It comes with a wireless
crush it, screen it, and then return the
stationary, portable, and mobile configu- remote control. Anytime you want to
oversize material back to the crusher for
rations,” Mandrell said. “But never on move it, you can stand almost anywhere
reprocessing. They also wanted it all on
tracks so they could maneuver around tracks. This would be our largest track in the yard and control its movement.”
small-site footprints. And, of course, they screening plant undertaking to date and we
In addition to its mobility in the quarry or
wanted high production capacity. would have to redesign our initial plant
stockpile yard, the unit is also portable
development—from chassis to power
The track crusher was no problem: Kolberg- from site to site on a lowboy trailer. “That
sources to conveyors.” was one of the challenges,” Mandrell said.
Pioneer, Inc (KPI) was going to provide
a standard track-mounted crusher. But The PDF 2618VM plant has a modified “We needed to get everything into one
where would the customer get a track- double-deck, high-frequency screen that transportable package.”
mounted screening plant big enough and is capable of production rates up to 700
Another unique feature is the screen’s
versatile enough to meet their multiple tons (700 tonnes) per hour. In Granite
rotary tensioning device. A feature on all
application needs? Construction’s case, they wanted to size PEP Vari-Vibe® high-frequency screens,
out RAP for their hot-mix asphalt pro- this quick-release system allows very quick
Astec Mobile Screens had the answer. duction operations. The plant provided screen changes, thereby reducing down-
Tim Mandrell, engineering manager for by Astec Mobile Screens efficiently sizes time. Producers can easily change screen
Astec Mobile Screens, was the lead on the the material into three different products: media for various applications needs
plant development. “The customer was ❏ Oversize material carried over the top desired with material separations from 1
familiar with our PEP Vari-Vibe® 2618VM, in. to 30M (25.4 mm to 0.397 mm).
deck goes to a conveyor that takes it back
which is a modified 6 x 18-ft. (1.8 x 5.5-m)
to the crusher; “One last area,” said Mandrell. “We put a
double-deck, high-frequency screen. We
just happened to be developing a track- ❏ Intermediate material passing through large enough diesel-powered engine and
mounted version of the PEP Vari-Vibe® with the top deck but retained on the middle pumps to power three 80-ft. (24-m) radial
this screen. But it was being designed along deck goes to an on-board conveyor for stackers. This plant will certainly do the
the lines of our popular PSP 2618VM transfer to aradial stacking conveyor; job as requested!” •AMJ•

Now you can get a screening plant with a detachable feed bin
One of the newest product innovations away from the bin (shown in the bottom
offered by Astec Mobile Screens is to be photo). The hopper for the conveyor
found in the Fold ‘n Go 2512KDT track- swings easily into place. When it is in
mounted screening plant. For the first this configuration, you can feed the unit
time, you can have a portable screening with a conveyor from multiple angles
plant that can be fed by either conveyors for small footprints.
or by loaders and excavators.
The Fold ‘n Go 2512KDT is equipped
The 2512KDT can be equipped with a with a 60-sq.-ft. (5.5-m2) Kolberg screen.
detachable feed bin and a hopper for
conveyor feed. Here’s how it works: According to the manufacturer, all of the
Fold ‘n Go plants are driven by high-
❏ When using it in a stand-alone oper- power diesel engines and have hydraulic
ation, you attach the feed bin and feed operating controls. There are wrap-
the system with a loader or excavator around catwalks on the units for easy
(shown in the top photo). access during operation. Each plant has
❏ When you need it for in-line process- an innovative folding mechanism for the
ing with a crusher, you just detach the on-board stacking conveyors that allows
feed bin and track the body of the unit total set-up in under 15 minutes. •AMJ•


Call your Regional Sales Manager at Astec Mobile Screens: 800-545-2125 or 815-626-6374 • E-mail:

Volume 2, Number 1 — Page 33

Tips on how to eliminate primary-crusher downtime
and get a smoother flow of material to the secondary
The use of breaker systems to reduce
oversize material at the primary crusher
has become a standard industry practice,
no matter whether the equipment is a jaw
crusher or an impactor, no matter whether
it is portable, track, or stationary. They all
receive the same benefits from a breaker
system: increased production, greater
profits, and a higher level of safety.
Breaker systems are made up of several
components: a hydraulic breaker; a boom
that will position the breaker so it can
reduce oversize material to eliminate
bridging; an electric-hydraulic power
pack; and a control system that is usually
remotely located.
There are several obvious advantages to
be gained through the use of this kind of
equipment. The elimination of primary-
crusher downtime that is caused by over-
size material is one advantage. So is the
reduction of oversize before it enters the
crusher. So is the breaking up of material
bridges. But there are some other, more
significant benefits:
❏ You are assured of more tons-per-hour
of sized material to the stockpiles with the
boom and breaker raking material into
the primary to ensure a steady flow to the
secondary crushing operations.
❏ You benefit from a steadier, smoother
flow of material from the quarry face.
Since the breaker easily handles oversize,
most owners find they no longer need to
sort the oversize at the face. This results
in faster loading and smoother delivery
of material to the primary. Some owners
report that they have even been able to
reduce the number of haul trucks.
(Top photo) An overall view of what is usually considered to be an ideal installation for a breaker system.
The boom can position the breaker to reach the feeding area—or even directly into the crusher should the
❏ The elimination of jammed crushers is
need arise. The operator’s station is opposite the boom, giving a good view of the entire operation. also a major safety factor. If a breaker
system is in place, there is no need for
(Left photo) The breaker-system controls can be either electro-hydraulic or radio-remote. anyone to think about using a potentially
(Right photo) A properly mounted boom allows the breaker to be positioned directly into the jaws of the dangerous method to dislodge a rock that
crusher. This allows the breaker to be used to free up any jams, instead of someone thinking about climb- is jammed in a crusher. When properly
ing into the crusher to dislodge the jam. installed, a hydraulic breaker can reach


Call Tom Witt at Breaker Technology, Inc. (BTI): 915-369-0878 • E-mail:

Page 34 —Volume 2, Number 1

all areas of the feeder. On jaw crushers, it
is often necessary for the breaker to reach
directly into the crusher. A REALLY BIG HYDRAULIC HAMMER
Taunton, Massachusetts is located right with the TB2580XC, then we use our
If you are considering the installation of
a breaker system, there are five factors in the middle of the state where there is smaller hammers to reduce them again
that need to be addressed: plenty of rock—most of it hard granite. to a size that is suitable for processing
And that situation is an opportunity for in the crushing plants.”
1) What is the size of the breaker that the entrepreneur.
would be required for your operation? By smaller hammers, Lopes meant the
“Some of the stone up here just south company’s 7,500 ft/lb (5,000 m/kg) BTI
2) What is the boom size and reach that of Boston is probably the hardest in the hydraulic breakers. They operate three
you would need? Northeast,” said Gil Lopes, Jr., the of that particular size, along with another,
3) Where would the boom be located? This president of G. Lopes Construction, Inc. smaller BTI breaker that is in the 5,500
will help determine the size and reach. “We do a lot of mining at construction ft/lb (3,700 m/kg) classification.
sites. And some of our day-to-day tools
4) What are the specifics of the power When asked, Lopes said they do not use
are hammers or breakers.”
pack? This must be balanced to the size the really big hammer every single day.
of the breaker and model boom. His company has been in business since “We did when we first bought it because
1964 and has used hammers for most of we needed it for a particular job. But now
5) What will be the type and location of
that time. “The first Breaker Technology we only use the big one between 500 and
the breaker’s control system?
hammer we bought must be six or seven 800 hours a year. But the other hammers
Obviously, good planning is necessary to years old now,” he said. “We’ve rebuilt and breakers? We work them all the time
determine the correct installation of a it several times—and it’s still working.” on a variety of different applications.”
breaker system. At Breaker Technology,
But it is the company’s newest hammer In addition to construction-site work, G.
Inc. (BTI), application engineers will—
acquisition that really attracts attention Lopes Construction also does quite a bit
upon request—make a site survey before
on the job site: It’s a TB2580XC from of road construction and trenching work.
final recommendations are made about a
Breaker Technology, Inc. (BTI). And it is
system. In such a survey, the engineers And then there is the concrete recycling.
a really big hammer by any definition.
will provide the producer with drawings The TB2580XC from BTI is big in its
that show where the breaker should be “It’s rated at 13,500 ft/lb (9,000 m/kg),”
dimensions. Its overall height measure-
located and what type of structure would said Lopes. “We have it on a 350 Cat
ment is 11.8 ft. (3.6 m). The tool itself
be required for its installation. excavator and we’ve used it to break up
measures 7 in. (175 mm) in diameter.
boulders. Big boulders. We’re talking
The location of the controls is vital to an And the operating weight of the hammer
boulders that measure up to 30 ft. (9.1 m)
efficient system. The operator must be assembly alone is 10,195 lb. (4,624 kg).
in diameter. After we hit those boulders
able to see all areas of the feeder-crusher Any problems with the unit? “Not at all.
while at the controls. He must also be
able to see the breaker. Controls for the
breaker are generally combined with those The hydraulic breaker shown
for the crusher and conveyor so that one in these photos is being used
by G. Lopes Construction. It is
person operates the entire primary system.
a TB2580XC that is rated in
The positioning of the power pack is not the 13,500 ft/lb (9,000 m/kg)
as critical, but it should be reasonably classification.
close to the boom/breaker to avoid long
hydraulic lines and provide easy accessi-
bility for maintenance.
When you are shopping for a breaker,
look for a manufacturer who can provide
a diverse selection of hydraulic breakers.
This will let you pick one that closely
matches your requirements.
You should also make sure the boom has
been designed especially for the specific
job you want it to do. For example: An
adapted backhoe boom will not stand up
on the job because it will spend more time
raking material into the crusher than it will
breaking oversize. As a result, it will be
subjected to constant sideloads that can
shorten its service life. The boom you
want is one that was designed and built
to withstand the rough environment of
working at a primary crusher. •AMJ•

Volume 2, Number 1 — Page 35