AGG1 Academy

Tuesday, February 16, 7:30-9:00 AM

T41 The "Sweet Spot" - Technology, Techniques and Procedures to Establish and Maintain it Within Your Operations
Alan Bessen, Quarry Tools, Inc. and Gregg Webb, The Olen Corporation

There is a point in every operation that yields the highest percentage of quality product at the lowest cost with the least amount of waste. This presentation illustrates the use of available technology to obtain and evaluate current operating data to establish the acceptable range of performance for each process variable needed to define and achieve "The Sweet Spot" within which optimal profit can be achieved.

T42 Behavior-Based Safety
James Veneskey, Aggregate Industries, Inc.

This presentation outlines practical insights on the human side of the way in which leaders can genuinely lead an organization and its people toward a culture of safety. This is focused on observations of behavior, confronting challenges, continuous improvement, understanding, and reviewing the entire task. Attendees will come away with a heightened appreciation of the critical role of a company's culture in determining it's overall safety performance.

T43 Screening and Screen Media Selection 101
Joe Schlabach, Deister Machine Company, Inc., and Jeff Beck and Charlie Young, Hoyt Wire Cloth

This session covers basic concepts for novice plant design personnel to understand screening options. Screening is the critical "cashbox" of each operation. This overview will cover items like stratification, separation, bed depth, and the effects of stroke, amplitude and speed. You will glean nuggets on to help your existing screening operations while gaining an understanding for future plant expansions. Different types of media and their application will also be covered.

T44 Methods of Underwater Excavation
Andy Haumesser, The Melvin Stone Company and Damon Gonzales, Dredging Supply Company

The presentation is divided into two sections, mechanical dredging and hydraulic dredging, which provide basic information on the different types of dredges, on comparing operating costs and productivity in deposits with differing sediment compositions, sizes, and compactions.

T45 Tire Monitoring
Jack Dutcher, Bridgestone Americas OTR Tires, and John Deere representative

Tire cost is a significant contributor to the overall operating cost of off-highway equipment. Bridgestone will provide an overview of tire maintenance and the procedures companies can use to monitor use, maximize tire life and anticipate future tire demand. John Deere will provide an overview of the capabilities, limitations, and benefits of a current on-board tire pressure monitoring system.

T46 The Orca Quarry: A Win-Win Partnership With Local First Nations
Mike Westerlund and Ken Palko, Polaris Minerals Corporation

Polaris Minerals Corporation has developed the Orca Quarry, a new construction aggregate quarry on Vancouver Island, BC, in partnership with local First Nation communities. This presentation gives practical examples of how relationships were forged with the First Nations, and the tangible benefits of these relationships in permitting, construction and operations.

T47 Aggregate Technology 101: Session I
TBD

Session I will focus on aggregates used in concrete and concrete pavements and will address how aggregate properties effect strength, slump, durability and other performance attributes. The panel will respond to questions and share their research experience in meeting design specifications and resolving construction challenges.

Tuesday, February 16, 9:30-11:00 AM

T51 Pros & Cons of Contract Drilling & Blasting
Ed Svec, Austin Powder Company and panel TBD

This panel covers the criteria that a company can use to determine whether or not to hire a contractor for its drilling and blasting services or to handle them in-house. Also, the session covers the best practices a company can use to choose a good contractor.

T52 Energy Management in a Quarry: Getting Payback
Dave Noble, Granite Construction, Inc.

Energy management begins with the premise that "You can't manage what you can't measure." Through careful selection of metering devices and data collection points the first step toward energy savings is developed. Optimal use of "intelligent" load controlling devices constitutes the second step in managing energy consumption. The last step involves the shrewd selection of billing plans and power rates and taking maximum advantage of incentives, grants, and other rebate programs offered by utilities.

T53 Managing Multiple Priorities
Carol Kivler, Kivler Communications

Have you ever been in a position where you had so many things to do but couldn’t decide which to do first? Setting priorities is the first step to improving your productivity and getting the most out of every day. But setting priorities in today’s complex organizations can be difficult. Issues like multiple bosses, greater workloads, and higher expectations have made setting priorities more complicated than ever. Categorizing your tasks in a way that allows you to distinguish those important and urgent tasks that must be dealt with promptly, even if you don’t particularly enjoy doing them from those tasks that can wait is the first step to managing your time. In this fast-paced, interactive program learn to maximize your "prime time," manage your multiple priorities, eliminate your time invaders, and take control of your time.

T54 Everything You Wanted to Know About Crushing but Were Afraid to Ask: The Sequel
Mark Krause, Lafarge

"This presentation addresses flow analysis and the hows and whys of crusher selection including ownership consideration, operating cost consideration, particle shape consideration, fines production consideration, and future requirements. Attendees will learn: 1) there are many things to consider when deciding on what crusher to use; 2) just because there is a certain kind in the application today, another machine might be a better fit and 3) how does operating cost versus ownership cost enter into the equation?

T55 How Clamshell Dredges in the Cincinnati Area Changed the Way Producers Mine Sand and Gravel
Ted Carman, ROHR Corporation and producer TBD

This discussion and overview with several producers from the Greater Cincinnati Area focuses on how they have adapted their Clamshell dredges to the challenges of their deposits and how they have used modern efficiencies and technology to take advantage of existing reserves. ROHR Corporation touches on the history of clamshell dredges, the advantages using a clamshell dredge for the extraction of sand and gravel, and the recent advances in clamshell dredging. Questions from the audience will follow the presentation. A panel discussion with produces concludes this interesting topic.

T56 Starting an Underground Mine
Michael F. Dunn, Shelly Materials, Inc.

Factors involved in a new underground mine start-up are discussed through case history examples of decisions regarding site characterization, mine layout and dimensions, and operational considerations including use of contractors. Mine geometry, geologic effects, equipment, production rate, and future use must be considered together from site characterization to training so as to operate a safe mine. This discussion "walks" through all the milestones as underground mines go from concept to production.

T57 Aggregate Technology 101: Session II
TBD

The performance of asphalt and aggregate base are significantly influenced by the properties of aggregates. Extensive industry research funded by AFTRE has demonstrated the appropriate use of aggregates to ensure performance. A panel of experts will translate highly technical topics in terms that are understandable to a non-technical audience and focus on the use of aggregates in flexible pavement systems including design and construction considerations.

Tuesday, February 16, 2:00-3:30 PM

T61 Aerial Photography for Topographic Mapping and Volumetric Inventory Reporting
Greg Lemke, Air Land Surveys

This presentation provides the attendee with a general understanding of aerial photography and three dimensional mapping from aerial photography. Examples of aerial photographic products, topographic mapping in a variety of electronic CAD formats and orthorectified aerial photography will be presented in addition to a discussion about the horizontal and vertical accuracies that can be achieved using aerial topographic mapping. Attendees will learn the benefits of using an aerial approach to mapping vs. ground based methods.

T62 Overcoming Community Opposition
Christopher Hopkins, The Saint Consulting Group

This session provides guidelines for gaining community acceptance through dialog, community relations programs, community involvement at various governmental and non-governmental levels and the local media. The material is based on NSSGA's best-selling Community Relations Handbook: A Guide to Building Trust and Credibility in the Community. Overcoming community opposition is never easy, but can be done if you understand that it is an ongoing and political process. Learn how to develop relationships with local and state elected officials to assist in developing the "reservoir of good will" essential when the road gets rocky.

T63 Mining the Benefits of Sustainability and Making it Core to Your Operations
Margie Flynn, BrownFlynn, Becky Andrews & Mike Melton, Fairmount Minerals, Geoff Boraston, Granite Construction Inc.

Businesses are increasingly integrating sustainability into their operations for a number of key reasons—reducing costs, motivating employees to innovate and find ways to maximize revenues, creating customer and brand loyalty, reducing risks, creating competitive advantage, or strategically expanding its role in their communities. By adopting it as a core value and integrating it into the full cycle of business processes, sustainability will become integral to a business' culture and the company will integrate it into every business decision.

T64 Contesting MSHA Citations
Adele Abrams, The Law Office of Adele Abrams

This compelling presentation highlights key procedural considerations within a strategy for successfully contesting MSHA citations. Accordingly, this dynamic presentation includes strategies for research, informal conferences, proceedings for administrative law judges, appeals, and settlement negotiations. Attendees will glean keen insights on how to position the company for fairest possible outcome when dealing with MSHA enforcement personnel.

T65 Dry Processing of Manufactured Sand
Clarence Kreiser, Buell Div. of Fisher-Klosterman, Inc.

This presentation reviews and compares the several options available to dry process a manufactured sand product to reduce the minus-200 mesh material to meet federal, state or local specifications. These include the high frequency screens, dynamic (rotary) air classifier and the static air classifier. It also presents comparative data of field results achieved by each method and review how moisture content in the feed material will affect processing of the manufactured sand product. In addition, it demonstrates the importance of evaluating both the final enhanced manufactured sand product and the fines material being removed.

T66 Blending and Load Out Systems
Thomas Woehrl, WOHWA Distribution North America, Inc.

This presentation demonstrates blending and feeding technology from WOHWA shown on an actual project installed on Vancouver Island: Polaris Orca Plant. The audience will learn that loading out with a load out system can save costs, increase the product quality, decrease long term investment costs and prevent from overloading trucks.

Wednesday, February 17, 7:30-9:00 AM

W41 Small Projects, Big Profits
Jessica Sparks and Matt Etheridge, Etheridge Automation

Even during times when budgets are shrinking, labor and energy costs are increasing and product and safety standards are tightening, automation is the best solution for efficiency and production increases. You don't have to have a huge budget to get huge benefits from automation by doing smaller, segmented projects. These include single circuit automation, multiple circuit process automation and automatic load outs. Learn how these smaller projects maximize plant efficiency, lower cost per ton, reduce downtime and provide a more consistent product without the large capital expense of full blown automation.

W42 The Accidental Boss

Effective leaders, now more than ever, must wear many hats. Yes, your hard hat is very important. But you also need to wear your business, company advocate and employee advocate hats too. Come and explore tactical and practical leadership reminders on "blind spots", signs, and hazards. Rediscover how some basic techniques can significantly improve the commitment, effort, and loyalty of your workforce.

W43 Storm Water Compliance Strategies for EPA's Enforcement Initiative in the Aggregates Industry
Joel Nickel, Aggregate Industries, Inc.

EPA has a three-year storm water enforcement initiative underway in the aggregates and ready-mixed concrete industry. EPA has been aggressive in their efforts to inspect and cite non-compliance at these facilities. As EPA develops compliance assistance tools for the industry, industry must get its own house in order by creating, updating and maintaining Storm Water Pollution Prevention Plans, storm water permits, erosion control devices and Best Management Practices. This session evaluates EPA's current enforcement status as well as review industry compliance strategies that include how to implement training, and how to implement this into your Environmental Management System.

W44 Washing 101
John Bennington, Greystone, Inc. and Jeff Wendte, Kolberg Pioneer, Inc.

This presentation overviews the basics of this easily misunderstood portion of operations. Topics include washing techniques, classifying tanks, dewatering screws versus dewatering screens, cyclones and separators. With the ever-increasing need for sand, especially manufactured sand, gaining this insight is invaluable.

W45 Dealing with Clay in Dredge Deposits
John Morgan, Hilltop Basic Resourses

This presentation familiarizes attendees with geological terms found in boring logs and soil classification charts that describe clays and how they affect mining in a submerged deposit. This brief discussion precedes two case studies, one mechanical and one hydraulic, that demonstrate some of the techniques and what are the additional operating costs necessary to excavate and capture materials in various different types of clay.

W46 Slope Stability
Jay Kaczmorowski, Continental Placer, Inc.

As quarries cover more area and become deeper, the potential for slope failures increases. Most operators in aggregates have no experience with slope failures. This presentation will provide attendees with the tools to help keep their employees safe below highwalls using photographs and three-dimensional perspectives. Helps provide the "fix" for a major failure.

Wednesday, February 17, 9:30-11:00 AM

W51 Setting Up a Belt Scale Calibration Maintenance and Program
Sheldon Shepherd, SIEMENS Process Instrumentation

Dynamic weighing devices like belt scales require routine calibration. For best results, it is important to have an ongoing calibration and maintenance program that includes record keeping. Many issues are a result of problems with the conveyor, commissioning, or improper calibration. Belt scales respond to vertical forces, both desired and undesired. Understanding these forces will help identify issues. Careful evaluation of the application, proper installation, calibration and routine maintenance will yield many years of continuous and reliable service.

W52 Clean Decisions on Capital Budgets: ROIC for Plant Managers
Rick Everist, L.G. Everist, Inc.

Today's plant managers and superintendants are increasingly better educated, yet typically lack the economic background to make good "return on investment" decisions. This course focuses on how to analyze and measure your plant with a critical eye on real per-ton productivity.

W53 A Model and Process for Assessing the Value of a Company's Environment, Health and Safety Programs
David Carroll, Lafarge

This seminar is an interactive learning and evaluation process designed to help a company assess the value created by its existing ESH program elements, the incremental value of going beyond mere regulatory compliance and assessing whether a company is a true industry ESH leader. The model and process involves an easily completed questionnaire, self scoring of the responses and an open discussion that identifies potential areas for improvement.

W54 Selection of a Primary Crushing Option
Randy Sandrik, Martin Marietta Materials

This presentation is a case study of the selection of a primary crushing option at the North Troy Quarry in Oklahoma. Started up in 2005, the site is an 8 million-ton/year limestone aggregate operation that operates year-round and produces a full range of crushed stone aggregate products including concrete aggregates, hot mix asphalt aggregates and flexible base and sand. Prior to start up, several studies were conducted to determine the optimum primary crushing scheme for quarry development, initial mining, and long-term production. These studies, and the actual results with both portable in-pit crushers and a large fixed in-pit crusher, present real data for the industry to use.

W55 Conveying 101
Rob Mullen, Superior Industries and Larry Goldbeck, Martin Engineering Company

Aggregate production involves three key processes – crushing, screening, and conveying. This discussion focuses on the operation and safety of conveyors found in today’s aggregate operations. We will discuss the basic operation of belt conveyors, identification and function of idlers, pulleys, drives, and take-ups, characteristics of bulk materials, and conveyor belt construction. Conveyor safety is a primary responsibility for all maintenance, planning and operating personnel. Our discussion will include accident statistics, E-Stop PM, guarding requirements, stored energy, and accident analysis. This session is an excellent introduction to conveyors and safety and will further enhance existing knowledge.

W56 Quarry Blasting and Community Relations
McRoy Sauls, Sauls Seismic/NOMIS Seismographs and John Babcock, South Technical Services, LLC

This presentation provides quarry personnel working in the areas of management, land acquisition, and governmental affairs with tools needed to address negative perceptions and complaints about quarry blasting. Presenters discuss the evolution of safe blasting standards in the U.S., how to design effective vibration and airblast monitoring programs and manage seismograph measurements, and assess the real impacts of blasting on surrounding structures. Elements of a Good Neighbor Policy as a means to communicate your safe blasting practices are described.

Wednesday, February 17, 2:00-3:30 PM

W61 De-dusting Crusher Screenings into Saleable Product
Perry Miller, Polydeck Screen Corporation

This presentation demonstrates how Polydeck has achieved success for multiple customers by using small opening, anti-blinding synthetic screen media to dry screen on conventional vibrating screens, thus reducing the amount of minus #100 and #200 mesh in the crusher dust. This has been accomplished without washing and without air classification, which were methods that were previously used. The success with synthetic screen media on conventional screens has shown that, in many cases, washing is not required to reduce the quantity of fines in a waste product to create a manufactured sand product, and this method eliminates many of the disadvantages of air classification, particularly cost and allowable moisture content. Along with a customer partner, the presenters will outline the steps taken to achieve these significant results.

W62 Productivity Improvement without Breaking the Bank
Todd Creasy, Bridgepoint LLC

Mining professionals are inclined to believe that capital investment is the only road to sustained productivity improvements. Applying the scientific management techniques of Lean and Six Sigma, mining professionals are reaping tremendous improvements in production while reducing equipment and labor expense at the same time. These approaches, perfected in the manufacturing sectors and since tested and proven in the mining industry, offer some profit centered alternatives for improving plant efficiency and effectiveness.

W63 Groundwater Occurrence and Impacts to Your Bottom Line
Richard A Hisert PhD, H2H Associates, LLC

Hydrogeologic settings vary and have a dramatic impact on operational costs. Fundamental geologic and hydrogeologic concepts are discussed and outlined for various settings so that producers understand the potential risks to their operation relative to ground and surface water resources. Specific examples will be discussed within a variety of geologic settings.

W64 Web-Based Safety
Valerie Cantrell, Caterpillar, Inc.

As times change, we look for alternative ways to communicate "safety" with the ultimate goal being to change behavior so people will get safely home. Caterpillar® has taken a large step to bring safety awareness to the masses. Learn the challenges and triumphs that one large company has endured in the creation of an internet safety program SAFETY.CAT.COMTM. Gain knowledge of what customers are saying and how this site is used for regulatory compliance. Enhance your company's safety communications with new ideas and insider tips.

W65 Blasting Perception Through Blast Design
Jeff Straw, GeoSonics, Inc.; Doug Rudenko, Vibra-Tech Engineers and Joyce Watson, Oldcastle Materials

Blasting operations are usually one of the top five issues raised in objection to greenfield or expansion permitting. Vibration limits and the science behind ground vibration and airblast measurements to establish safe criteria, advanced analysis techniques such as using large arrays of seismometers within the community, structure response studies, and the use of crack monitoring instrumentation provide an operator with tools to demonstrate the effect blasts have upon structures. A proactive approach to managing this community concern follows two paths, one internal to the operation, the other external in the community.

W66 Selection of Excavation and Support Equipment for Sand and Aggregates Operations
Steve Kirk, Martin Marietta Materials andDarryl Lanker, Mid Ohio Materials Inc.

The safety, efficiency, and profitability of a sand operation or an aggregates quarry are based largely on using the proper equipment to excavate and haul the material, as well as the correct support equipment. Too often equipment selection is based on the operator’s knowledge of certain types of equipment; equipment which may or may not be optimum for a given property. This presentation analyzes the factors to consider in equipment selection, and the methods to determine the proper excavators, haulage units, and support equipment for the specific property.

Thursday, February 18, 7:30-9:00 AM

TH41 Using Basic Statistical and Fragmentation Analysis to Improve Blast Results and Crusher Throughput
Dave Lilly and Lawrence J. Mirabelli, DynoConsult, a division of Dyno Nobel, and Ran Tamir, Lafarge NA

Digital fragmentation analysis from blast photographs and video is becoming an essential tool to analyze blast results and determine the success of changes to blast design. The Lafarge Ravena plant is using digital fragmentation analysis to optimize rock size and productivity. This presentation details ways to statistically relate the results of blast fragmentation analysis to changes in blasting parameters such as powder factor and pattern (burden and spacing) changes. Methods using Excel spreadsheets to relate fragmentation analysis to crusher and loader productivity are described.

TH42 Do's and Don'ts for Conducting Environmental Site Assessments and Compliance Audits at Aggregate Operations
Dave Ruetz, GZA GeoEnvironmental, Inc

Topics include a discussion of the requirements of the ASTM and federal standards for environmental assessments, the CERCLA exemptions from environmental liability associated with conducting an environmental site assessment, tips for conducting such assessments efficiently, reliance letters and Phase I ESA issues unique to aggregate facilities. Environmental Compliance Audit topics covered include a discussion of federal and state audit privilege laws, how to conduct such an audit under the attorney/client/work product privileges, preparing audit protocols for aggregate facilities, transferring the knowledge gained from the audit into an environmental management system, and auditing issues that are unique to aggregate facilities.

TH43 Surface Mine Rescue Training
Anne Kelhart, Martin Stone Quarries, Inc.

The issue of mine rescue has become one of the most important elements of a safety strategy. This presentation includes discussion of such key items as pre-planning, overview of hazards, ground control, combined hazards, and certificates. Attendees will learn how to implement a comprehensive program of mine rescue for surface operations.

TH44 Maximizing the Aggregate Circuit
John Googins, Aggregate Consultants LLC

Balancing the production to the sales demand is more important then production itself. This presentation shows how to analyze the customer product demand and design the plant, equipment and flow to maximize the mass flow balance, product quality, and proportions to reduce the cost of goods sold.

TH45 Site Assessments Review—Key Elements to Lower Your Cost Per Ton.
Dick Martin, Caterpillar Mining Consultant

This is a review of common areas of opportunity that have been found by performing detailed site assessments across large mining and aggregate operations across the world. With more than 150 site assessments completed around the world, Caterpillar has found common "low hanging fruit" that can typically be applied across most aggregate and cement operations. These assessments are typically two-to-three-day, in-depth reviews focused on site operations and maintenance and repair evaluations and provide benchmarks for comparisons. Dick Martin, a Virginia Tech Mining Engineer, has 30-plus years of global experience in the coal fields and most recently as a mining consultant working directly with Caterpillar's largest aggregate end users.

TH46 Motor Efficiencies Law
Baldor Electric

The U.S. Department of Energy-mandated Premium Electric Motor Efficiencies are coming into law in 2010. The 2010 Energy bill not only increases the efficiency requirements of motor manufacturers; it expands the number of products that are to be included and may also offer incentives for conversion by companies to the new, more efficient product. This seminar outlines the impact of this new law on your organization, defines the list of motor products included and reviews any incentives that the government may include in the final bill to help you get there in terms of 2010 Electric Motor Efficiency requirements.

Thursday, February 18, 9:30-11:00 AM

TH51 Dust Control in Crushed Stone, Sand & Gravel Operations
Rick Felde, Dust Control Technology

Dust control is an important part of stone and gravel processing, transfer and storage operations. The presence of dust can pose a health risk to workers, be a nuisance to neighbors, increase equipment maintenance costs, and impair visibility. Dry collection and wet suppression are commonly used in the aggregates industry. This seminar focuses on the applications and costs associated with each technology; discuss the most effective control strategies for optimum performance.

TH52 Safety & Health Management Systems
Steve Boydston, DNV Business Assurance

Increasingly, companies are looking to systematize their approaches to safety, and doing so in as strategic a manner as possible. For this reason, development of a safety and health management system is seen by many industry leaders as vital. This presentation discusses various approaches, such as ANSI Z-10, and instructs on such key elements of a system as training, accountability, measurement, and continuous process improvement. The presentation discusses potential obstacles to creation and implementation of programs, and ways to avoid those challenges. Attendees will come away with a deeper understanding of the ways in which strategic systems can enable more successful management of safety and health issues.

TH53 Washing: Texas Style
Brian Bailey, Vulcan Materials Company

Blend new and old technology to build today's wash plant. By combining new and old technology, Vulcan has designed and built their sand systems including tanks, screw washers, dewatering screens, separators, and fines recovery systems. Where they fit in the system will be shown by actual field case studies using Vulcan's Texas operations as an example.

TH54 Maximizing Plant Productivity by Benchmarking and Evaluating Performance
Bob Bartok, Paschal Associate Sales, Inc. in conjunction with George Fox, Luck Stone Corporation; Phillip Gosnell, Rogers Group, Inc. and Dan Humpal, Martin Marietta Materials.

The presentation demonstrates the advantages gained by establishing plant performance benchmarks and tracking actual changes or simulating proposed changes to determine the impact on productivity. The theory and practical application will be demonstrated using real-life before and after operating results. Elements include establishing benchmarks in new and existing plants, reviewing plant data and performance through field samples, evaluating process equipment performance, identifying bottlenecks and inefficiencies, attaining the highest degree of accuracy, monitoring performance and comparing that to established benchmarks, making informed investment and replacement decisions and maximizing plant productivity and profitability.

TH55 Rail Transportation of Aggregates
Robert Pickel, National Steel Car

Changes in aggregate production locations and consuming markets have dramatically increased the role of rail transportation of aggregates. Higher oil prices have benefitted rail versus truck-haul of product. This phenomenon has been complemented by an emerging market of increased demand of aggregates for scrubber stone in coal-fired electric power plants. These events have had a dramatic impact on the way aggregates are handled by the railroads, the equipment (railcars) that hauled the product, and the handling of such traffic at origin and destination by producers and consignees. Transportation and attendant logistics can and often do cost more than the aggregate product itself. Therefore, every effort should be made to improve the economics of moving the product, and rail has gained an increasing role in this area.

TH56 Tier III Engines and Beyond
Caterpillar, Inc., John Deere Worldwide Construction & Forestry Division, and DA Lubricant Company

This topic explores the Tier III compliant engines with special emphasis on lubricants and impact/performance of low-sulfur fuels, and then consider the next step, Tier IV engines. The intent of this session is to prepare producers for the cost and effort that will be required to meet these new engine requirements and to provide some guidance on steps to take prior to enactment of the regulations.

Cost (does not include admission to World of Asphalt & AGG1 Exhibits or other training)