Liberty University in Lynchburg, Virginia built a new state-of-the-art natatorium that would measure up to 75,000 square feet. The facility is unique to the campus as it holds the largest diving platform in the United States and would be hosting USA swimming programs and national meets. Any crack in a pool is detrimental because a pool is meant to contain water and cracking can compromise the high-quality look and feel to it. PREVent-C provides controlled expansion resulting in volume stability creating 90

Major expansion of cheese processing facility in Juda, Wisconsin. The general contractor partnered with Dalmaray Precast Concrete to produce the three-part, 8,000-gallon holding tank and manholes.

Blue Ridge Beverage Company, Inc., is one of the largest, full-service wholesale beverage distributors in Virginia. When Blue Ridge Beverage Company built a 40,000 square-foot warehouse expansion at its Salem headquarters, the goal was to extend the joint spacing beyond the traditional 15’ to match the column lines.

Blue Ridge Beverage Company, Inc., is one of the largest, full-service wholesale beverage distributors in Virginia. When Blue Ridge Beverage Company built a 40,000 square-foot warehouse expansion at its Salem headquarters, the goal was to extend the joint spacing beyond the traditional 15’ to match the column lines. 

Modera Coral Gables is a 237-unit luxury apartment mid-rise building in Miami, Florida, located on an urban infill area and only one block south of Coral Gables’ Miracle Mile, a pedestrian-friendly entertainment and retail hub. The building is LEED Silver-certified and has six residential floors above three levels of parking. A large pool is situated on an expansive elevated deck on the fourth floor. Originally, a bentonite mat was specified for the foundation. Because excavations were five feet below the water table, it became impossible to eliminate enough water to install the mat. Cemex, the ready-mix supplier, worked with Penetron on a solution. PENETRON ADMIX was mixed into the concrete for all below-grade structures (and also the three-level parking garage and the fourth floor pool structure), allowing placement of the concrete into the waterlogged site.

The expansion of the Oyster Creek propylene production facility in Freeport, Texas, was a key part of Dow Chemical’s multi-billion-dollar investment (Gulfstream) program to take advantage of low market prices for locally-produced shale gas. The massive scope of construction made easy application and reliability of the concrete treatment solution a priority. PENETRON ADMIX SB was specified as a robust waterproofing solution for all concrete used for the water containment tanks – each with a capacity of 1.5 million gallons (5.7 million liters). As an integral waterproofing protection, it prevents penetration of water and aggressive agents into the concrete and also features a self-healing capability. Delivered in pre-measured soluble bags, the admixture simplified accurate dosage during batching and saved time in the construction schedule.

The expansion of the Canpotex Marine Terminal 5 in Portland, Oregon, enlarged the facility’s capacity to process and ship white potash to overseas markets. Initially, a membrane solution was specified to protect the concrete piers, tunnel and building foundations. However, the project owners opted for an integral solution, thanks, in part, to many contractors who said they saved time and reduced construction costs when switching from a traditional surface applied waterproofing to a Penetron crystalline solution for projects located in a marine environment. Penetron worked with Cal Portland to design an optimal concrete mix that met the demands of the marine environment. PENETRON ADMIX was used to waterproof all new concrete. PENETRON slurry and PENECRETE MORTAR were applied to the tie holes and to patch previous honeycombing and defects.

The expansion of the Canpotex Marine Terminal 5 in Portland, Oregon, enlarged the facility’s capacity to process and ship white potash to overseas markets. Initially, a membrane solution was specified to protect the concrete piers, tunnel and building foundations. However, the project owners opted for an integral solution, thanks, in part, to many contractors who said they saved time and reduced construction costs when switching from a traditional surface applied waterproofing to a Penetron crystalline solution for projects located in a marine environment. Penetron worked with Cal Portland to design an optimal concrete mix that met the demands of the marine environment. PENETRON ADMIX was used to waterproof all new concrete. PENETRON slurry and PENECRETE MORTAR were applied to the tie holes and to patch previous honeycombing and defects.

The South Cobb Tunnel Lift Station in Austell, Georgia, was the largest expansion project and deepest tunnel construction undertaken by the Cobb County Water Authority (CCWS), and it was completed a year ahead of schedule. Part of a comprehensive sewage and wastewater treatment system, the 5.5-mile-long tunnel was built through hard rock at a maximum depth of 400 feet. The project also included a 130 million gallon/day lift station to transport wastewater flows; the height of the station is about 212 feet. PENETRON ADMIX was used to ensure the concrete structures, tanks, foundation slaps and containment structures could resist the high levels of water pressure remain watertight. The admixture was also added to the concrete lining used to support areas of fractured rock and groundwater inflow.

The South Cobb Tunnel Lift Station in Austell, Georgia, was the largest expansion project and deepest tunnel construction undertaken by the Cobb County Water Authority (CCWS), and it was completed a year ahead of schedule. Part of a comprehensive sewage and wastewater treatment system, the 5.5-mile-long tunnel was built through hard rock at a maximum depth of 400 feet. The project also included a 130 million gallon/day lift station to transport wastewater flows; the height of the station is about 212 feet. PENETRON ADMIX was used to ensure the concrete structures, tanks, foundation slaps and containment structures could resist the high levels of water pressure remain watertight. The admixture was also added to the concrete lining used to support areas of fractured rock and groundwater inflow.

Liberty University in Lynchburg, Virginia built a new state-of-the-art natatorium that would measure up to 75,000 square feet. The facility is unique to the campus as it holds the largest diving platform in the United States and would be hosting USA swimming programs and national meets. Any crack in a pool is detrimental because a pool is meant to contain water and cracking can compromise the high-quality look and feel to it. PREVent-C provides controlled expansion resulting in volume stability creating 90

Major expansion of cheese processing facility in Juda, Wisconsin. The general contractor partnered with Dalmaray Precast Concrete to produce the three-part, 8,000-gallon holding tank and manholes.

How Much Does It Cost To Operate a Crusher? By Chris Nawalaniec Crushing equipment is the heart of an industrial material-processing system. The size reduction choice you make will have a profound impact on the profitability of your business. When the right choice is made, you should expect many years of profitable operation. How do you make the right crusher choice? Crushers are not glamourous. They are brute force workhorses and what they do is simple, really. Size-reduction equipment in all forms is adding energy to a material to make big pieces smaller. Simple, right? Cost versus Value What does it cost or what is it worth? Producers need to keep that simple equation in mind. We all have to keep our eye on the ball and stay focused on profitability. What are Crushing Costs? Capital acquisition cost Base machine Structures and chutes Motors, drives, guards Energy consumption per unit produced Electricity Compressed air Wear parts cost Normal maintenance Planned downtime Lubrication costs Oil Grease Major repairs Infrequent maintenance Unplanned downtime Labor Normal maintenance Special or unique tools required When the above costs are all accounted for, they are used to quantify the production costs related to size reduction and are expressed in cost per unit of measure production. For example, $0.50 per tph. What Does Value Mean? There are always opportunities to buy a machine at a lower upfront cost. This usually translates into paying higher operating costs over the life of the equipment. Higher service labor cost. Higher wear parts costs. Higher energy costs. Often there is a justifiable case to spend additional capital dollars for the better machine. When evaluating crushing equipment suppliers, crusher manufacturers should quantify both costs: purchase price and operating costs. Before you purchase, ask for reference customers to visit. Selecting Equipment Why are there so many types of equipment? Our team brainstormed this question, and we came up with more than 50 tools or machines that are used for size reduction. What we are addressing here is industrial size reduction of dry, solid materials, which are grown, mined or chemically synthesized, and need to have a physical dimension alteration to be put to use. Customers are asked five questions to begin the equipment selection process. What is the material? What is the moisture content? What is the maximum size going into the machine? What is the size range desired after crushing? What is the desired production rate of finished product? When it’s time to dive a bit deeper to define the problem, we ask some additional questions. How long do you expect to operate the plant? Are you looking at mobile, skid-mounted or fixed installation? Are there electrical limitations or special power requirements at the plant site? Is the system open or closed circuit? Do we need to consider future expansion plans now? The variables above all affect your costs. Let’s take the first question as an example. How long do you plan to operate? There are times when mines reserves, stockpiles, permits, project contract terms affect expected life. If a project is limited by any factor, then “good enough” could be the best choice. As long as the equipment is safe and there are machine wear parts and service available, then going “cheap” may be the best choice. Another factor to consider with low-cost is limited post-sale assistance if there is some process change or major equipment problem. You don’t want to be hung out to dry. Aggregate producers typically expect to be running and profitable for many years. Always buy a crusher from an established company, develop a relationship, and expect ongoing service and personal contact. Ask before you buy about how they approach post-sale parts sales and service. Ask the company quoting how they intend to offer service for their crusher. How many field service people do they have? Are they local, regional or too far away? Not having responsive suppliers will have a significant impact on your plant profitability. Summary Investing in the best size reduction equipment for your specific needs is a big decision. The above should give you a lot to think about so equipment solutions can be objectively analyzed. Chris Nawalaniec is vice president of sales and marketing at Stedman Machine Co.

Teamwork Helps Integrate Design, Manufacture and Installation of Size- Reduction Systems By Eric Marcotte, Inside Sales Manager, Stedman Machine Company Designing and deploying size-reduction systems takes experience. Many people can collect and install some of the pieces they feel are needed to create a working system, but experience with the interrelationships between components is harder to find. And to ensure safety and performance, crushing, screening, storage and handling systems need to be professionally engineered. A system is always more than just a collection of parts; they must work together whether it’s a properly designed chute or an elaborate processing plant. Retrofitting new crushers, conveyors, screens or other pieces of equipment is also not always an easy process. Even if drawings and specifications no longer exist, plant designers need to make sense of what is there and know what it takes to make new pieces fit in an existing puzzle. If continuing production during the upgrade is required, system bottlenecks will need to be prevented. For example, raw material or finished product stockpiles may be required to keep downtime to a minimum. Also, access and space requirements need to be confirmed and double-checked. First - Assemble a Team Engineering and expertise in a variety of areas are required to develop size reduction systems, including: crushing, screening, structures, conveyors, chutes, hoppers, dust collection and storage, whether for a small equipment retrofit or a large turnkey facility. CAD and process design software applications are must have. Limit multiple layers of personnel. Work directly with the engineers and personnel to select the equipment and design the system. Project management, installation, scheduling and tracking experience will be needed. Be sure supervisors and installers are MSHA trained and have experience in fieldwork. Second - Process Design While most projects present new challenges, a widely experienced team will bring in ideas from other industries. Typical projects involve the following processes and types of equipment. industrial crusher Load out and material receiving This can be a feed hopper with an apron feeder, belt feeder, vibratory or screw feeder, truck dump or railcar unloading system. Bulk material transportation Designing, building or procuring belt conveyors, stackers, apron conveyors, screw conveyors, and pneumatic handling conveyors. Crushing Crushing is the basic building block of a size-reduction system. Experience with a large range of crushing equipment offers many solutions. Properly feeding material into the crusher greatly increases its efficiency, contributes to even wear and maximizes wear metal costs. Bulk material storage Specifying, providing and installing a range of silos, hoppers or other bulk storage solutions. aggregate crusher Screening Experience with many screening manufacturers to include the right screening solution into the system. Dust Collection Including the proper dust collector and dust collection system is a key component to allow a crushing system to work properly. Experience with many dust collection vendors will facilitate properly sizing, connecting and installing the best dust-collection system solution. Controls and Electrical Components To make sure that all components of a system work together, work with control system engineers, panel builders and electrical contractors to create a working, integrated system. Buildings, Foundations and Structure Design, procurement and specifications for buildings, foundations and structures for the equipment supplied on any system. Third - How to Do It Every project has a different set of circumstances that are unique to it. Try to follow a simple checklist to ensure the best possible solutions to the problems. Initial project team meeting. Crusher and screening testing as required. Define required scope for the system. Create preliminary concepts and drawings. Review with operators and supervisors. After receiving feedback, fine-tune the drawings, concepts and put forth a detailed proposal. Set up kick off meetings as required. Proceed with the purchase of major components. Proceed with a detailed system arrangement. Detail major assemblies. Assemblies put out for detail drawing creation. Drawings are self-checked and then crosschecked for accuracy. Assemblies are re-entered into system layout from detail assemblies to verify fit. Approval drawings sent out as required. Vendor drawings checked and approved. Items checked as they are received. Work with vendors and shipping to verify shipment accuracy. Pictures are taken of all shipments for record purposes. Installation supervisor works with install crew to identify, locate and erect items as needed. As installation finish date nears, begin check of motor rotations, sensors etc. Final customer acceptance – formal reviews to finalize “punch list,” follow up items and document the system is performing as specified. Example - Typical Quarry Expansion A limestone quarry running since the 1950s and producing 500,000 tons per year wanted to increase yearly production capacity up to 1.5 million tons with a new automated plant. The new design needed to have the capability to stockpile hundreds of thousands of tons of finished product. The focus was on creating a state-of-the-art plant with designed-in flexibility to do different product sizing. The automated plant needed to have the ability to run production all day as well as to be able to change the product sizes within 10 minutes. The design and fabrication of a new plant may take up to two years to complete as each idea is considered and "wish lists" are sorted out. You don’t want to come back and say we should have done this or done that. Get the very best of everything you can get into the plant for longevity. The project will include numerous conveyors, sensors, controls, vibrating screens, feeders and other equipment. size reduction machine Installed electronics and control systems feed a programmable logic controller. Each conveyor at the plant is equipped with terminal strips that are all wired to communicate information to one main processor, bringing all of the information together in one place to make it easy to operate. All of the feeders and conveyors are monitored to collect all of the information required to operate the plant. With the ability to monitor the speed of the conveyors and feeders, the quarry can keep an eye on production and troubleshoot maintenance issues. The reason for having an automated control system is that if something goes wrong on one of the conveyors, you’ll see it fast enough to prevent a catastrophe that might require digging out a conveyor. If something does go wrong, the computer can take over and begin dropping conveyors, discharging material and shut the feeder down. Since the quarry can now monitor the conveyors moving, the speeds and the tons per hour, limitations can be set to help catch problems before they become too serious. If something is going wrong, say conveyor 2A is slowing down, you can put limits on how much you want to allow it to slow down before the feeder is paused and then limit how long that feeder stays paused. In the end, the quarry was able to more than double their production capacity with the help of the automated plant. The plant was built, delivered and installed as planned with no problems. This is an ideal situation if a quarry is sitting on huge reserves of limestone and plans to operate the crushing plant well into the future. Projects such as this are successful when the customer’s needs are defined and understood, and the project team – including the customer and all supplier partners work to accomplish the project goals.

Liberty University in Lynchburg, Virginia built a new state-of-the-art natatorium that would measure up to 75,000 square feet. The facility is unique to the campus as it holds the largest diving platform in the United States and would be hosting USA swimming programs and national meets. Any crack in a pool is detrimental because a pool is meant to contain water and cracking can compromise the high-quality look and feel to it. PREVent-C provides controlled expansion resulting in volume stability creating 90 percent fewer cracks on average compared to standard concrete. Eight months after the project was completed, the results showed there were zero cracks.

In this training module, Performance Associates International (PAI) covers the characteristics of a gyratory crusher that’s designed to be the first stage in the size reduction of run-of-mine ore. A gyratory crusher receives ore from a mine and crushes the ore between a gyrating main shaft and stationary liners called concaves. This module explains the gyratory crusher’s principle of operation and provides detailed descriptions of the major components and the role that each component plays in its operation. You'll learn how the drive system operates, the details of the dust sealing system, the importance of the various lubrication systems, and the two functions of the main shaft positioning system, or MPS. We’ll also explain the operation of the balance cylinders and how they’re designed to prevent oversize boulders from causing damage. We’ll also cover the apron feeder, which conveys the crushed ore from the crusher to a downstream discharge conveyor belt. The principle of operation and detailed descriptions of the components of the apron feeder—including the drive chains, pans, rollers, and an electric or hydraulic motor—are illustrated. This is one of many plant area modules that is covered in a typical PAI operations training module.

With increasing challenges of lower grade ore bodies, more complex mineralogy, and stricter environmental regulations, mining companies need the tools to help evaluate and optimize their investment. FLSmidth's state-of the-art ore characterization & process mineralogy labs provide metallurgical services, to assist with exploration, mine site geology, expansions, feasibility studies, plant support optimization, and environmental work. Read more about these services by downloading the brochure.

After a period of intense mining project development, driven by increased emerging market consumption of building-block commodities such as coal, copper, and iron ore, the mining industry now finds itself in a period of cost cutting and capital preservation. Between 2005 and 2015, mining firms worldwide constructed and started up more than 1,230 greenfield mines representing total investment value of $265 billion. The mining boom, which included greenfield mine construction and expansions of existing mines, really peaked in 2012, but significant spending for major mining projects continued in 2013 and 2014, albeit at a lesser rate, as large projects that had started in earlier years reached peak construction.