How we made our choices
When we ask readers how we can best help them keep track of changes in the products and services they use to produce aggregates, almost everyone wants an annual short list of the really important stuff.
No wonder. The sheer volume of introductions is overwhelming. Aggregates Manager covers numerous products each year in its RollOuts departments and Supply Lines features and offers even more product coverage through its website and newsletters.
So each year, our staff reviews all the product introductions we’ve covered for the past year to pick out those that we believe are worth further review. Our priorities are new concept products, which are rare; new series/new generation products in categories that relate to the aggregates industry; and other rollouts which serve our readers’ interests by increasing competition in a product category. We also consider reader engagement through website and social media traffic.
Inevitably, we omit deserving products, either because we just didn’t understand the significance of the product or because the announcing company didn’t communicate what was special about the product, or both. In either case, we apologize in advance for these omissions.
Atlas Copco
Remote-control drilling
The Atlas Copco SmartROC T40 is one of the first surface drill rigs from the manufacturer to offer the option of radio remote-control operations by upgrading the rig with a SmartROC radio remote-control kit. The T40 drills hole diameters of 3 to 4 1/2 inches, to a maximum depth of 92 feet. The rig is designed with a low center of gravity and a high ground clearance so it can operate safely on rough terrain. It is fitted with a 33.5-horsepower Cop 2560 rock drill. A boom reach of 25 feet in height for horizontal drilling and 18 feet forward for vertical drilling offers flexible operations. Atlas Copco | www.atlascopco.us
Brigade Electronics
Radar detection for portable plants
Brigade Electronics released a line of radar obstacle-detection systems for mobile plants. The Backsense radar system divides a specified detection area into five zones and provides a visual and audible warning when objects enter the hazard area. The cab display includes five LEDs corresponding to each of the five distance zones from the vehicle. A warning buzzer has an adjustable sound level of 65 to 90 dB. The manufacturer says the sensor is impervious to water, dust, and mud. The system controls the radar beam pattern, so the spread of the beam can be restricted to the desired width to minimize false alerts. Detection areas up to nearly 100 feet are available. Brigade Electronics | www.brigade-electronics.com
Case
Aggregates duty loader
Case Construction Equipment introduced the Case 1221F wheel loader, the newest and largest model in its F Series wheel loader line. Designed with an 11.9-liter Tier 4i engine that delivers up to 355 horsepower, the unit is built for aggregates and mining applications. Enhancements to the engine and transmission at maximum travel speed allow for increases to productivity of at least 18 percent and fuel efficiency of at least 8 percent. The unit is powered by a cooled exhaust gas recirculation engine with diesel oxidation catalyst and diesel particulate filter. The wheel loader has an operating weight of 66,800 pounds, with buckets ranging from 6.3 to 7.8 cubic yards. With a 6.8-cubic-yard bucket, the breakout force with tilt cylinder is 55,730 pounds. The machine is available with Z-bar and extended reach configurations. Four programmable power modes save fuel and increase available power. Case Construction Equipment | www.casece.com
Case
First SCR dozers
Case Construction Equipment introduced its M Series of dozers. The largest unit in the line, the 2050M, has 214 horsepower. Key features include increased horsepower rating, the first selective catalytic reduction technology built into a dozer, fuel savings of up to 14 percent, industry-leading visibility, versatile controls, and a pressurized cab for comfort. The engine is built by Fiat Powertrain Technologies and is said to offer advantages in terms of maintenance and fuel efficiency. Case says SCR is well suited for dozers because it lets the engine run at peak performance under variable loads without compromising the power or drawbar pull that achieves the force required for earthmoving. Case Construction Equipment | www.case.ce.com
Caterpillar
More powerful artics
The Cat 730C articulated dump truck features a new engine with more power, advanced transmission control, enhanced operator amenities, new serviceability features, and automatic traction control. The design centers on customer requests for increased productivity, lower operating costs, superior availability, long-term durability, added rimpull/retarding capability, ease of operation, and high resale value. The 730C is rated at 31 tons and is powered by a Cat 13 ACERT engine rated at 367 horsepower. It is available in Tier 2, Tier 3, or Tier 4 Final configurations. A diesel particulate filter and selective-catalytic-reduction system provide exhaust aftertreatment for the Tier 4 Final model. Compared to prior models, the 730C has nearly 16 percent more power and more than a 30-percent gross torque improvement. To control speeds on downhill grades, it employs a new engine-compression brake that provides 60 percent more retarding power than predecessor models. Caterpillar | www.cat.com
Caterpillar
Wheel loader bumps payload
Cat’s 990K wheel loader offers more power and increased payload for improved productivity and fuel efficiency. It features a redesigned cab that delivers a sleek operator interface and quiet environment, as well as several features to promote operator and maintenance technician safety and performance. Designed as a loading tool for the 773, 775, and 777 trucks, it has a rated payload of 17.5 tons, up from its 16.5-ton predecessor, the 990H. New Performance Series Buckets promote fast filling and full buckets; they are available in sizes ranging from 11.25 to 13 cubic yards. The Cat C27 ACERT engine powers the unit and delivers an 11-percent increase in power compared to the earlier model. A total of 699 horsepower helps increase production without a corresponding spike in fuel consumption. Additional fuel-saving features include ECO Mode (on-demand throttle), engine-idle shutdown system, and engine-idle kickdown/auto-resume mode. Caterpillar | www.cat.com
Deister
High-volume screen
Deister Machine Co.’s BFO-11224-EX2 Mine-Duty Screen represents the next generation in machine size and production output. The 12-foot by 24-foot, horizontal single-deck unit is said to deliver day-to-day reliability and high-volume capacities in a variety of hard rock mining and mineral processing applications. The unit features the new Deister EX Series of geared exciters, which are designed to create the force output required to drive large screens. Geared exciters feature all-steel components, specially coated bearing inner races to deter wear on shafts, and shafts that are case-hardened and ground for minimal wear.
Deister Machine Co. | www.deistermachine.com
Doosan Infracore
Rugged excavator
The Doosan DX350LC-3 excavator features a 281-horsepower engine, a 7,603-pound operating weight, and a 41,667-pound arm digging force. Built for the most rugged conditions, this excavator features significant power and performance increases to go along with its Tier 4 Interim status. A new boom float option allows the boom to move freely up and down without hydraulic flow, while a temporary reset button offers the ability to momentarily disengage the float, allowing hydraulic flow to activate the boom.
Doosan Infracore | www.doosaninfracore.com
JCB
Tier 4 Final loader
JCB debuted the 457 wheel loader with the all-new JCB CommandPlus cab. The machine is the first to show off the completely new cab structure, engine cover, and rear counterweight design which are said to contribute to improved visibility, lower noise levels, increased cab room, and an enhanced working environment for the operator. In addition, the 457 is the first large JCB wheel loader to meet Tier 4 Final emission standards. An MTU diesel engine contributes to fuel savings of approximately 16 percent, compared to the previous model. It meets emission standards without the need for a diesel particulate filter. JCB | www.jcb.com
Kleemann
Tier 4 Final cone plant
Kleemann says its MCO 9i S EVO mobile cone crusher offers high-productivity secondary or tertiary crushing in a fuel-efficient, Tier 4 Final emissions-compliant machine. It provides a discharge conveyor-mounted final classifying screen with oversized aggregate return conveyor that permits a closed material cycle and production of final particle sizes without a standalone screen. The oversize can also be discharged via the swivel-mounted return conveyor at the side. The unit’s diesel-electric drive provides low fuel consumption in a compact design. Optional crusher anti-spin and automatic lubrication functions make for high crushing capacities and durability. Its power plant generates 332 horsepower at 1,500 rpm, and the optimized crusher housing design permits more than 287 horsepower to be continuously available to the crusher. The cone diameter permits a raw feed capacity of 287 tons per hour, with a feed size maximum of 8 1/4 inches. Kleemann | www.wirtgenamerica.com
KPI-JCI
Jaw update increases energy
Significant changes to KPI-JCI and Astec Mobile Screens’ new generation of Vanguard Plus Jaw Crushers are said to reduce maintenance and increase energy and performance. Operator investment is protected through replaceable wear parts such as the jaw die seats and barrel protector plate. Maintenance is simplified with a new jaw die wedge design that holds the jaw die in place. The manual shim adjustment method was eliminated as the closed-side setting is now adjusted through the use of hydraulic cylinders. New design components — including increased stroke, toggle angle, and flywheel inertia — enable operators to increase performance. The 4450 features a 1 1/2-inch stroke that opens wider and compresses material more to get material through the jaw quickly. It can crush up to 816 tons per hour.
KPI-JCI and Astec Mobile Screens | www.kpijci.com
Liebherr
Excavator for harsh conditions
With its kinematics and hydraulic power, the R 956 crawler excavator, from Liebherr, is designed with increased breakout and digging forces for tough operating conditions. The unit weighs in at 117,945 to 123,020 pounds, depending on configuration, and is powered by a 322-horsepower, Tier 4 Interim engine. An automatic idling system helps to optimize fuel consumption, along with two-stage turbocharging with intercooler, which increases power at low revs. A “Regeneration Plus” function allows for accelerated lowering of the boom without sacrificing power.
Liebherr | www.liebherr.us
Martin Engineering
Self-adjusting belt skirting
Martin Self-Adjusting Skirting is designed to fit any conveyor while reducing maintenance and increasing efficiency. By creating a tight seal to the belt, it prevents spillage and equipment breakdown caused by fugitive material. The skirt requires only 1.25 inches of free belt area, making it suitable for conveyors with chutes close to the belt edge. The rubber-sealing strip is 0.75 inches wide and provides 2 inches of wear life at speeds of up to 700 feet per minute. The sealing strip is available in continuous lengths of up to 100 feet. Maintenance is streamlined with a simple rubber clamp so that no tools are required for assembly.
Martin Engineering | www.martin-eng.com
Major Wire Industries Ltd.
Crown deck adapter
Major Wire Industries Ltd. introduced crown deck adapters for modular decks. The adapters allow operators to convert a flat screen deck into a crowned deck on pin- and grooved-type screen decks. The adapters were developed for operators with flat decks who were limited to using modular type screen media, but wanted other options.
Major Wire | www.majorwire.cc
McLanahan Corp.
Re-engineered jaw crusher
McLanahan Corp. spent two years engineering its Freedom Series jaw crusher, which is designed for high-performance primary crushing. Safety lock pins and hydraulic assist for wear parts change-out make maintenance safer. Adjustments to the closed-side settings are now simpler. Hydraulic rams are isolated from crushing action, allowing longer life and full automation, while nearly eliminating toggle migration. The attack angle and crushing stroke pattern were re-engineered to increase capacity by up to 15 percent. The 250-horsepower 4250 can produce up to 1,240 short tons per hour with a 14-inch closed side setting. As a primary, McLanahan says it is designed to deliver the lowest cost per ton in the market.
McLanahan Corp. | www.mclanahan.com
Metso
Track-mounted combo plant
Metso says the Lokotrack LT220D is the most compact track-mounted combination of a cone crusher and screen ever made. The combination plant is said to reduce operational costs in several ways, most notably by lowering fuel consumption and reducing the need for maintenance. Both units are run with a single Cat C13 diesel engine, while an efficient power transmission boosts operating power. Fewer units to transport offer a quick set-up job and allow operators to consider smaller contracts that may not have otherwise been profitable. Cone options include the HP200 or the GP220.
Powerscreen | www.powerscreen.com
Michelin
Dump truck tire to debut
Michelin Earthmover introduced a re-engineered X-Super Terrain articulated dump truck tire. New features are said to improve service capabilities, and the tire size range will include 23.5R5. Uptime is optimized through the use of C2 technology, which has robust casings with less shoulder mass that leads to longer tread life. The self-cleaning tread design provides better traction and promotes additional sidewall protection.
Michelin | www.michelin-us.com
Nesco
Dust control for track plants
Nesco’s DustPro Series H spray system is designed for hydraulically driven track-mounted plants. It includes a high-pressure pump with hydraulic motor, control panel, and wireless remote. The pump module features two output lines, each with a solenoid valve. One line supplies nozzles at the feed hopper to control dust when the plant is charged, the other supplies nozzles at strategic locations throughout the rest of the plant. Spray nozzles at the hopper also can be automated by installing an optional presence detector. Wireless remote operation allows the loader operator to control the spray system by using spray nozzles only when and where they are needed.
Nesco | www.drdust.com
Powerscreen
Mobile jaw crusher
Powerscreen’s Premiertrak 300 jaw crusher is said to excel at higher fuel efficiency and lower transportation costs. The unit uses a 40-inch by 24-inch jaw chamber and can produce up to 308 tons per hour. Options include a vibrating grizzly feeder or a large fully independent hydraulically driven pre-screen. An optional hydraulically folding extended side conveyor, with a stockpile height of 10 feet, 2 inches, is available with the pre-screen feature. A bypass chute design incorporates a flap gate to allow operators to switch between using the side conveyor or sending material to the main belt without the need to fit a blanking mat on the bottom screen deck. A hydraulically adjustable closed-side setting can be adjusted quickly and without tools, while the new hopper design incorporates a complete hydraulic fold-and-lock system to eliminate the need for manual wedges. It is powered by a 275-horsepower Tier 3-compliant Cat C9 ACERT engine or a 272-horsepower Tier 4 Final compliant Scania DC9 engine.
Powerscreen | www.powerscreen.com
Sandvik
Primary and secondary crusher
Sandvik Construction continued to expand its Prisec line with the introduction of the CI531 primary and CI532 secondary Prisec 3 horizontal shaft impact crushers. As with the rest of the product line, the HSI crushers can be configured into either a primary or secondary crushing mode. In addition, single-stage crushing is also an option with the ability to recirculate material to the primary versions of the crushers. A new crushing chamber design is said to allow for impressive reduction ratios through the use of two uniquely designed curtains, which have traditionally required a three-curtain configuration crusher. The maximum feed size is 39 inches in the primary configuration and just under 14 inches in secondary operation. Throughput ranges from 441 to 772 tons per hour as a primary and 276 to 441 tons per hour as a secondary.
Sandvik Construction | www.construction.sandvik.com
Superior Industries, Inc.
Chevron pulleys
Superior Industries, Inc. offers a new longer-lasting model of its chevron pulleys, which are v-shaped wing pulleys designed to deflect fugitive material. Made from special high-tensile steel, the new AR Chevron Pulley model is designed for conveyor owners who require extra high performance and guaranteed uptime with their material handling applications. The pulleys are available in Mine Duty and Super Duty models, with diameters ranging from 10 to 42 inches and face widths from 12 to 75 inches.
Superior Industries, Inc. | www.superior-ind.com
Telsmith
High-capacity cone crusher
With 402-horsepower performance and a crushing capacity output range of 150 to 600 tons per hour, Telsmith’s T400 Cone Crusher boasts the largest-in-class clearing stroke and highest-in-class crushing force. The cone features a large clearing circuit, which is engineered to safely and quickly allow any uncrushable material to pass. With a maximum feed opening of 12 inches, it has a 52-inch diameter head and a 54-inch receiving hopper. To minimize downtime and reduce inventory costs, the crusher enables the use of a single bowl for all liners over its range of operation. It also features a new and improved patent-pending anti-spin feature that prevents head spin to extend manganese life. A patent-pending concave (bowl liner) retention system — consisting of a specially designed and positioned lipped ring that centers the bowl — achieves retention without the use of hammers or hand tools. The unit also features the largest-in-class, patent-pending hybrid bearings.
Telsmith | www.telsmith.com
Terex MPS
Modular jaw plant
Terex Minerals Processing Systems’ (MPS) MJ47 primary jaw crusher module is said to increase the application capabilities and crushing capacity of its existing modular product range with its largest jaw module to date. Designed for large quarries or contractors who want a stationary type design without the complexity of a typical stick-built plant, the module features a 36- by 48-inch Terex Jaques ST47 jaw crusher. Other key features include the Terex Simplicity 51-inch by 24-foot heavy-duty, double-deck vibrating grizzly feeder; large capacity truck dump hopper; discharge conveyor; extra heavy-duty galvanized/painted I-beam frame; wrap-around maintenance access platform; stairs; and guardrails.
Terex MPS | www.terexmps.com
Terex Washing Systems
Modular scrubbing system
Terex Washing System’s AggreScrub 150 is designed to separate stubborn clay material that cannot be removed by rinsing or screening alone. The system can work as a standalone unit or in conjunction with Terex’s AggreSand plant. The modular plant includes a web frame chassis design that supports a scrubbing hull, a 6- by 2-foot trash dewatering screen, a 12- by 5-foot two-deck rinsing and sizing screen, and has an integrated sump and pump. Galvanized walkways are said to provide unprecedented levels of access to all areas of the plant. The control system used on the AggreSand plant has been adapted for this plant. Radio control of all main functions is available as an option, as well as remote telemetry, which enables data to be sent to the plant owner remotely, through email or SMS alerts.
Terex Washing Systems | www.terex.com
Volvo
Fuel-efficient excavator
The Volvo EC250E crawler excavator delivers a 5-percent improvement in fuel efficiency compared to past models. The gain is attributed not only to the Tier 4 Final Volvo engine, but also to a range of features that optimize flow and minimize pressure losses in the hydraulic system, including ECO mode, which automatically reduces fuel consumption without any loss of performance in most operating conditions. In addition, the excavators can be equipped with automatic idling and auto-engine shut down systems as optional equipment. All operator interfaces — including joysticks, keypad, and LCD monitor — have been ergonomically designed and positioned for comfort and efficiency.
Volvo | www.volvoce.com
Volvo
High ground clearance arctic
Volvo’s A40G articulated haul truck features a new turbocharged six-cylinder Volvo engine that meets Tier 4 Final emission regulations. The drivetrain and inline dropbox are designed for high ground clearance, while the drivetrain delivers high rimpull, lowers fuel consumption, and provides reliability in heavy-duty applications. Oil-cooled wet multiple disc brakes are said to reduce maintenance costs and increase uptime, even on muddy or dusty sites. A retardation system controls downhill haul speeds using wheel brakes and the engine brake. Automatic traction control and differential locks are standard, while an onboard weighing system allows the equipment operator to optimize payload. The machines are also fitted with CareTrack, Volvo’s telematics system.
Volvo | www.volvoce.com