2016 AGG1 Academy
The AGG1 Academy is the one place to go to learn about virtually every aspect of the aggregates industry. The practical knowledge you’ll gain and proven techniques you’ll learn about will enable you to manage your operation more effectively, efficiently and profitably. Targeted topic tracks can help you create a custom education experience that’s tailored to your unique needs.
All AGG1 Academy sessions take place at the Music City Center.
Tuesday, March 22, 2016
It’s 6 a.m., you have a line of customer trucks waiting to be loaded, and do you know where your gradation is? Have you ever had gradation results that you just don’t feel represent the material you are receiving or shipping? What can we do to more closely represent the actual gradation in our sampling and testing program? This presentation gives an up-close look at the variability which occurs when moving material through bins or silos. Also included is a case study of implementation of radar technology to measure levels which increases efficiency and improves sampling methodology. You’ll hear recommended best practices you can take home and implement immediately.
This presentation will give an introduction to alkali silica reactivity (ASR) in concrete and the expansive gels that form as alkaline fluids derived from cement attack amorphous siliceous aggregates. We will discuss how ASR forms, what it does to concrete, how it can be identified and how it can be prevented.
This session showcases innovations which have improved the aggregate ticketing process and optimized customer cycle times. Existing off-the-shelf technologies were enhanced to allow for an automated RFID based rolling check-in, a mobility solution that allows ticketing from stockpile loaders, remote printing, and “signature-less” tickets that allow drivers to stay in their trucks at the scale house. The session will detail key success factors including developing a highly collaborative project team, using formal project management, analyzing plant traffic patterns, reviewing all scale house related business processes, and branding the technology. The project team was able to design a highly customized, reliable, and efficient aggregate ticketing solution.
What do you do when the substance hits the fan and an accident or environmental incident occur at your worksite? This presentation will cover all the critical steps in preparing for effective legal management of an MSHA/OSHA/EPA incident investigation, essential steps in the crisis management process, legal notification requirements, preparation of accident and near miss reports, legal privilege issues, issues surrounding abatement of citations, and the many other areas that must be addressed in both large and small scale emergencies. The session will also explain post-accident debriefing of employees and how to benefit from the results of root cause incident investigations. The speaker is an attorney and safety professional who has helped clients manage approximately 200 accident cases.
In this presentation, experts from Martin Engineering discuss common concerns that arise from the use of belt conveyors in aggregate operations. The presentation will review how and where dust is created, with a special focus on hazards (and regulation) of silica dust in aggregate operations. It will review the mechanisms that create dust in a conveyor transfer point, and discuss changes the user can make to increase the efficacy of dust control measures. A second portion of the program will offer improved transfer point technologies that offer ways to control material flow to centralize loading, improve belt tracking, and reduce the escape of dust.
Key Performance Indicators (KPIs) provide organizations a performance measurement that can be used to evaluate success of particular activities. Companies may have several KPIs, and it is important that a company balance KPIs across several processes. If KPIs are centered only on a singular goal, like production goals, then several other worthwhile goals, such as quality, may be sacrificed. This can lead to unbalanced performance measures and hence unbalanced company performance. This presentation looks at one company’s successful efforts to implement a systematic approach using a Quality KPI to continually assess the performance and risk exposure of their products.
In this session, attendees will learn the proper way to safely and effectively maintain the primary crusher and subsequent equipment, including how to perform daily PMs, how to develop a good maintenance program and how to simplify the troubleshooting process. It will explain proper wear parts utilization, best practices and proper methods to protect the equipment. The session will conclude by articulating the correct way to apply the crusher and to promote maximizing the crusher’s potential, balancing the system and minimizing downtime.
Geotechnical and structural geology are crucial in all aspects of quarry and pit operation and a thorough understanding of the subjects is essential for those working in the extractives industries and those associated with processing. In this session, Julian Smallshaw from the Institute of Quarrying will use the Institute’s retained knowledge of international best practice to help delegates learn about the importance of good pit design to maximize the reserve as well as understanding the importance of slope stability for safety. Aspects of quarry inspection will also be covered alongside design considerations for pits.
Dust emissions arise from four principle sources: (1) paved roads, (2) unpaved roads, (3) stockpiles and (4) material handling and processing operations. This workshop discusses Reasonably Available Control Measures (RACM) to reduce dust emissions from these major source categories. RACM includes operational controls that train personnel to minimize dust, engineered controls to contain emissions, wet suppression systems to prevent dust and dry collection equipment for hazardous emissions. The presentation is designed to enable participants to prepare cost-effective dust control plans that rely upon in-house labor and material to reduce reliance upon more expensive control measures.
Continuous Improvement Engineering is a principle used to staggering effect across all business and sectors. In this session, Julian Smallshaw of the Institute of Quarrying will take delegates through an overview of the approach that led one major aggregates producer to save in excess of $45 million in Europe and Africa. Continuous improvement operates at site and company level to drive improvements in P&L performance by looking at every aspect of an operation and its interface to the next. Not for the faint hearted, Continuous Improvement required the dogged, grinding determination of the Groundhog but can be highly addictive!
This interactive presentation will have two main components. The first part will focus on managing the walk-around MSHA inspection: how to document the facts that will make a difference when citations are issued, and how to maintain a positive relationship with MSHA without making the inspector’s job easier during the site visit. The second part will explore how operators can reflect on the enforcement process and use the experience to build and strengthen their safety culture. These measures, which focus on extending the safety‐focused frame of mind to the miners doing the work, require minimal time and little to no investment, but will pay huge dividends in fewer injuries, fewer citations, and a better relationship with MSHA.
This session will give an overview of the various types of crushers and their application, including a review of selection criteria, basic application, and what can be done by the operator to improve performance. By providing an overview of each type of machine and how they work, the attendee can better understand what tool to select for an application and how to set it up for best performance.
Rogers Group’s success as a 107 year old independent company in aggregates and construction has been astonishing. Over the years, leadership has driven a dynamic culture of excellence in safety, manufacturing operations and people development. The presentation will provide an overview of the cultural differentiators that allow Rogers Group to remain competitive and successful. The session will explore how leaders throughout the company continue to drive profitable growth and develop creative approaches to ensure Rogers Group remains ahead of their competition. A unique culture that allows successful leaders to leave and return to the company (the boomerang employees) will also be discussed.
At most mining operations, blast vibration levels are kept well below established criteria, yet compliance with the regulations does not always solve the conflicts arising from blasting operations. Mine operators often resort to random changes in blast design searching for a solution to mounting neighborhood complaints. This presentation will discuss an integrated, scientific approach toward identifying, understanding and solving blast vibration problems.
By using the right metrics, both quantitative and qualitative, a company can systematically build a solid customer base that minimizes its risk while maximizing its overall profit. This session will discuss a variety of metrics that can be used to measure sales as well as the strengths and weaknesses of each. You’ll learn how these metrics support the sales process and lead to overall profitability. Some of the metrics will include: Average sales price (ASP), volume, revenue, margin, customer contacts, and win percentage.
Attendees will hear a focused dialogue regarding belt construction, stress and forces on belting, transition distances, operating versus rated PIW, and splicing considerations. This session is designed to be interactive, with the participants contrasting manufacturers’ specifications with their real world experience. You’ll leave this session with a clearer understanding of the cause of events affecting conveyor performance and improved skills to resolve the issues.
Building trust in throughout all levels of your organization is a cornerstone to achieving safety excellent. Although most organizations tell employees to speak up if they see unsafe conditions or other employees committing at-risk behaviors, few have actually trained employees on how to deliver or receive feedback. There are numerous barriers that exist, preventing employees from speaking up. Too often many employees withhold their safety concerns because they’re afraid of the consequences of speaking up and many of us misconstrue concern as criticism. This presentation will teach the fundamental steps of effectively giving and receiving safety feedback.
Fine products cost producers the most to make, can have very tight specifications that are difficult to achieve, and can generate excess fines—oftentimes at a low overall production rate. This presentation will discuss the generation of fine aggregate products and how to do it efficiently and cost-effectively using vertical shaft impactors and high frequency screens without generating excess fines. The audience will walk away with a better understanding of how to implement these technologies into their operation and will give them a better idea of how to make these products more profitable for their organization.
With more technology options competing for your time and budget, where should you start? How does it help me make money? Which technology will help to manage your aggregates operations and what’s the right for your operation? This session identifies the key processes within your operation where technology can make a significant difference and then help you to decide what’s right for you. Learn which costs can be affected by today’s latest technology, what benefits to expect, and how to calculate the impact for your own specific operation. After this session, you will have a framework for thinking about the different ways technology can affect your top and bottom lines, and some tools to do your own calculations.
Online interactions have changed the way we communicate, get information, and stay connected. Social media has been offered as a solution to improve community engagement because of its capacity to connect with thousands of people in a relatively short amount of time. Using social media and proper risk management tools, we will show you how to bridge the gap between your operation and the community.
As quarries progress into their reserves, operations are processing material with a higher level of clay and silt. While some materials may require only rinsing, others require scrubbing to remove clay and other deleterious materials. Topics in this course include aggregate washing techniques, maintenance routines, classifying tanks, screws versus screens, troubleshooting common washing problems and consequences of wrong-sized equipment.
We will give a comprehensive overview of an effective screening operation and will discuss the appropriate application of various types of screens, how to measure the effectiveness, and an overall evaluation of the condition of the screen and structure. Specific topics that will be discussed include screen types, stroke profiles, g-force, screen efficiency, sampling protocols, screen axis movement, structure movement and examples of improvements. The performance evaluation section of this presentation will include a case study with an existing aggregate producer.
This seminar will provide information on the pre-work that can be done to ensure that portable crushing and screening operations are shipped, erected, and commissioned as quickly and efficiently as possible.
Is your existing ERP and CRM technology working for or against you? Attend this session to learn about the most important technology decision that aggregate companies are facing today. Learn about technology innovations affecting the aggregates industry in the near term, and how you can make sure you’re prepared technologically to handle them in the future. Find out the tough questions you have to ask your technology vendors to make sure they’re helping you innovate and preparing for the future.
Wednesday, March 23, 2016
There is a balance between safety and economic viability as mines get deeper and continue to experience slope stability issues. Innovations in engineering controls are an effective means to guard against rockfalls, unstable ground, and challenging geologic conditions. To assist in developing these engineering controls it is imperative that mines continually collect geotechnical information beyond the initial mine plan to improve its design strategy to guard against hazards such as slope and ground failures. Using engineering controls such as slope reinforcement and rockfall containment systems can be a viable solution to safeguard your operation.
This presentation will cover the reasons, methods and equipment required for washing and scrubbing coarse aggregate. Most aggregate plants have some level of contaminant in their coarse aggregate and this will offer solutions to resolving that problem.
In this session we will explore the different styles of thickeners (or clarifiers) commonly used in the aggregate industry and what applications are best suited for each. We will also review the primary purposes for using a thickener and what containment facilities or further processing are required downstream of a thickener.
This presentation will discuss potential size reduction methods for production of aglime, including an explanation of the relative advantages and disadvantages of different types of size reduction equipment in this application in terms of particle size capability, energy, maintenance, and capital expenditures.
Mature companies often fight, or surrender, to the idea that “the way we’ve always done it is the only way.” While this can be an asset in regards to company values, people, and commitments, when it comes to utilization of IT technology this mentality can quickly become a liability. Pine Bluff Sand & Gravel is an organization whose leadership has placed a continuous commitment to maintaining age old values in the way they treat their people, while equipping them with the right technology to keep them safe and productive. This presentation will explore how they do this.
In order to attain and sustain excellence in safety, an organization has to move beyond safety efforts that focus solely on compliance. This presentation will focus on the Six Levels of Safety, which is a roadmap for success, and provide real-life examples of how one aggregate producer is developing a culture of safety.
This presentation will look ways to improve safety for those who must work on and around belt conveyors. This presentation will start with the various hazard points of the conveyor system, and what can be done to mitigate those hazards. It will then turn to work practices including lockout/tagout as well as housekeeping standards and maintenance procedures. And finally, the presentation will look at the benefits of employee training to improve conveyor safety for those who work on or around belt conveyors and for those or who manage the performance of belt conveyor systems.
Metal detection in the aggregates industry can be a troublesome, frustrating experience. When metal detection works, it can save thousands of dollars in lost revenue, repairs, and man-hours. When it doesn’t work, well… Metal Detection 101 is geared specifically for plant and maintenance managers. It offers a light-hearted introductory look at the science of metal detection, highlights how the detector actually works, and things to consider when purchasing, installing, and operating a detector in an aggregates plant. Attendees will come away with a better understanding of the limitations of the detector and knowledge of how to better integrate metal detection into their operations.
In our ongoing efforts to streamline our operations, Haley & Aldrich converted all of our field forms to electronic “eforms” using mobile devices and rugged tablets. In doing so, we realized significant savings from reducing data management steps, eliminating transcription and duplication errors, and improving data storage and management options. We subsequently offered this service to our Construction Materials and mining clients who have to conduct routine air, wastewater, waste and stormwater inspection and compliance services at numerous facilities. Our clients found that using eforms significantly reduced compliance efforts while improving costs and environmental performance at the individual facilities.
MSHA has many categories of citations and orders which it can issue to mine operators and contractors, but what are the different classes of issuances? How should companies respond to each type differently? This presentation will outline the distinct types, and potential ramifications of receiving citations and orders, such as 103(J) and 103(K) Orders, 104(A) Citations, 104(B) Orders, 104(D)(1) and (2) Citations/Orders and 107(A) Imminent Danger Orders. Furthermore, the presentation will prepare mine operators and contractors to properly react to the issuance of any citation or order and to contest to each issuance in a timely manner.
W63 The New Standard for Corporate Conservation: Embracing Accessibility, Enhancing Credibility and Driving Change
Margaret O’Gorman, Wildlife Habitat Council, Hilary Johnson, Oldcastle Materials and Tim Bent, Bridgestone (retired)
Wildlife Habitat Council (WHC) engages with corporations – in the aggregates industry and beyond – their employees and community members to recognize and encourage wildlife habitat projects for conservation, education and recreation. Presenters will discuss on-the-ground conservation programs that enhance biodiversity and promote corporate goals, including those related to social responsibility, sustainability, employee engagement, community relations and STEM education. Attendees will benefit from the panel’s experience in aligning their voluntary sustainability standards with contemporary conservation priorities and actions, and how they use data and results allow for evaluation of impact.
When you are proposing a controversial mining application, the best thing you can do to prepare, from a political and community perspective, is to try to put yourself in the opponent’s position. This session will address the topic of community outreach from that perspective. The session will be an interactive session with the audience taking on the role of the angry constituents. At the beginning of the session, we will distribute talking points and the specifics of the proposed greenfield quarry that we will be presenting. The audience will be broken up into groups, and each of these groups will have a specific agenda. These separate groups will strategize on how best to attack the proposal that is being put forward while we conduct a fictitious public hearing.
What is ‘Big Data’, and how can your company harness it to manage stockpile inventory? This session will explore how new technologies are making it possible to realize big value from big data, geospatial data, and 3D data in construction, mining, paper and DOTs across the world. Attendees will hear examples of real world case studies using 3D data for business from the iPhone, aerial and UAV. The audience will be challenged to rethink how existing business problems can be solved in new ways, with low cost camera systems and massive image sets.
Join Dolese Bros. Co. President Mark Helm to discuss why he has invested and believes so much in telling the Dolese story not only to his employees, but to the general public as well. This session will overview the need for companies both big and small to develop a communication and community strategy to help operations and develop relationships with policy leaders and elected officials and improve employee morale. Maybe it is a simple “quarry tour” with school children (Dolese calls their tours KIDS ROCK) or just inviting the local mayor to see your operations, or even more, maybe a simple Facebook page with pictures of your operations and employees – if you are not telling your story, someone else will.
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.
Over the past 5 to 10 years there has been increasing focus on the elimination of settling ponds. Some producers are looking to eliminate settling ponds in order to avoid covering up existing reserves with ponds while others are looking to replace them in order to save the costs or eliminate the hazards associated with settling ponds. This session will present one or more case studies involving the selection and installation of a filter press to dewater tailings from washing sand or aggregate products, recycle the water in a closed loop system, and completely eliminate the need for an existing settling pond. The audience will learn the budgetary costs of using a filter press versus settling ponds as well as the land space, time and water savings.
Thursday, March 24, 2016
Traditional methods of delivering MSHA Annual Refresher Training—lectures, overhead projectors, PowerPoint presentations, and videos—limit participant involvement, and research has proven that “retained” learning from these methods ranges from only ten to 30 percent. Several Oldcastle Materials Group staff, in an effort to improve participant involvement and knowledge retention, developed a training process which relies heavily on small group interaction and a creatively-designed MSHA Safety Education Workbook, while keeping the use of PowerPoint slides to a minimum. Post-training survey results indicated that participants gained new safety information and retained more information as a result of actively participating in the learning process. In this session, attendees will hear about the successes Oldcastle saw from delivering MSHA Annual Refresher Training in this innovative format, and will learn about how to facilitate the training in their own operations.
The workplace examination regulation at 30 CFR 56/57.18002 is rapidly becoming a major focus of attention for MSHA inspectors as the agency attempts to grapple with a recent upswing in the number of fatalities in the metal/nonmetal sector of the mining industry. This presentation will analyze the workplace examination regulation, and focus on the particular language in regulation where MSHA enforcement activities are increasing. In addition, the presentation will review current cases before the Federal Mine Safety and Health Review Commission which may impact how MSHA inspectors evaluate the effectiveness of an operator’s workplace examinations.
While haul trucks and wheel loaders had long been the standard for material handling and transport, rising fuel, maintenance and labor expenditures began adding significantly to costs per ton. This course will explore modern material handling systems and their impact on product quality and operating expenses. In addition, we’ll cover styles of conveying equipment and their applicational uses, common maintenance concerns and related solutions and tips to maximizing uptime of conveying equipment.
Learn how mining companies are using drone aerial images to automatically get perimeter, volume and weights of their aggregate stockpiles, in significantly less time.
Can integration really make a difference in your supply chain? This session explores a variety of options for integrating various aspects of your bulk materials supply chain from dispatch, into transportation, point of sale, delivery and billing. Increase efficiencies and reduce delivery cycle times by tracking your trucking costs in real time.
Attendees will hear a practical guide to help aggregate producers measure and manage their bulk raw material inventory. Reliable and accurate measurements actually increase the bottom line. But managing inventory is not just about having an accurate number. We will discuss the value of a full service provider who can help you reconcile your inventory from production to financial reporting. This means it is not just about measuring a stockpile – it is about understanding and tracking how materials move through the operation from the ground to the piles to the sale. When you have better information to work with, you can make better business decisions.
This session will use the Prisma project as a case study to answer the questions: 1) What is the “Internet of Things” really if you take away the hype? 2) How much data is enough and how do you select the important vs. the “nice to have?” 3) What does this mean for aggregate customers and OEMs? 4) Where Metso sees the benefits and what comes next.
Using your annual audiometric testing results, with your noise exposure data, and your employee work histories, you can effectively measure how well your hearing conservation efforts are working over time.
This session will provide aggregates producers with important updates on the status of new standards ISO 14001 (Environmental) & ISO 45001 (Safety). You’ll hear an overview of changes made to the standards and the trends that we are seeing in the planning and implementation of the standards, as well as valuable suggestions for your company to plan for and implement the new standards. There will also be a Q & A section.
In an ever-changing world, what are the pros and cons of dedicated fleet maintenance programs? What types of maintenance programs retain technicians better? What key areas do customers gain from going to a dedicated contract maintenance program? This session will provide the key differences in programs: keeping in house or outsourcing to OEMs or to a dedicated fleet maintenance company.
This session will present a case study where a mine operator has had a major disaster with employee injuries or fatalities. Those first few hours and days are critical in maintaining control over the situation from both an internal management standpoint and a legal standpoint. This presentation will discuss best practices in dealing with and responding to regulatory agencies, conducting your own internal investigation into what happened, responding to employee concerns and questions, and also being mindful of any future litigation concerns.
The aggregates industry is getting more and more competitive every day. Operators have to monitor their operations closely in order to be profitable and manufacture products efficiently. Smart quarries are taking advantage of cloud reporting tools to find the competitive edge, and maximize production. This session presents real-world case studies from quarries around the world and how they make use of reporting technology in crushing and screening operations. You’ll get the inside story on how they increased quarry efficiency across America, in Australia, New Zealand, Sweden, England and France. Examples include large aggregate companies, small quarries and contract mobile crushing operators.
MSHA’s proposed rule for the assessment of civil penalties contains a substantial list of proposed changes to the current penalty assessment criteria and procedure. Whether it’s attempting to reduce the Federal Mine Safety and Health Review Commission’s authority and autonomy over contested assessments, or reducing the options inspectors will have to evaluate gravity and negligence, the new rule is likely to have a significant impact on how our operators handle inspections and post-inspection contests, both informal and formal, of citations and orders. Learn about the major impacts that the new rule could make on an operator’s business.