Reports from around the world by industry specialaists

• construction • demolition • quarrying • mining

Volume 1 No 3

Tough working conditions for Van Oord in manipulating heavy mast sections during construction of offshore wind farm

Reports from:

• BRAZIL

• BELGIUM

• GERMANY

• “Building Business Confidence” - CEA Conference

• Technology is the Future

• Bauma 2010 - A Show of Optimism

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CONTENTS

8 BELGIUM Major wind farm makes progress. Dutch contractors, Van Oord, overcome challenges of working on the world deepest, furthest offshore wind farm.

10 BRAZIL New Alcoa Bauxite mine at Juruti in Brazil selects single supplier of equipment and support services to minimise risk and maximise productivity.

12 GERMANY Challenging formwork requirements at German product facility with attention to quality finish and alignment of joints.

FEATURES

14 Crusher buckets win world recognition More contractors are beginning to recognise the benefits that crusher buckets can bring to many construction sites.

16 “Build Business Confidence” Speakers at the annual CEA Conference explain the need to rebuild business confidence as being integral to the recovery from the economic situation. 19 Manufacturers evaluate technology for improving efficiency Roger Lindley looks at the way in which some companies are evaluating what technology is suitable for the next generation machines.

21 Merlo readily embraces new technology Roger Lindley reports from Merlo facilities in Italy on how the company is increasing markets by innovative engineering and use of technology.

Technology at Work - Bauma 2010

24 Sandvik to show innovations made possible by group synergies

26 Technology is changing the way the construction industry works

28 Engines, Components and Technology

LATEST VIDEO ADDITIONS

Topcon IP-S2 video - 3D mapping in high definition

Topcon 3DMC³ - Technology enabling high speed precision dozer grading

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Caring About Others in the Construction Industry Roger Lindley - Publisher/Editor, Contractors World magazines.

It has been said on many occasions that construction is one of the most accident prone industries in which to work. Although methodology, equipment and site practices have significantly reduced the opportunity for accidents, it is worth reflecting on the fact that, based on reported statistics, some 7 people will die EVERY HOUR today as a result of work related accident in the construction industry.

Do not think that the high risk of reportable accident is only found in developing countries. Although there is serious cause for concern about the lack of proper procedures and regulations in many parts of the world, there is still an unacceptably high level of incidents found in countries with well regulated health and safety procedures

"...in a typical decade about 1,500 people are killed on construction sites in Great Britain and 25,000-30,000 more are recordable injuries." one reports in the UK says.

Too many people believe that accidents only happen to other people until it is too late. Apart from the pain and suffering series accident can inflict, there are also the social ramifications - loss of income, the burden of debt, etc.

This is where the Lighthouse Club steps in. Founded in 1956 by Edward Ward and his colleagues, the charity has recently celebrated £10,000,000 ($15,000,000) in assistance through the Lighthouse Club Benevolent Fund, to individuals and families struggling to survive the economic effects of serious accidents.

Although primarily a UK based charity, it is the aim of the Trustees to expand its work around the world. There are already groups in various parts of the world but there is room for more.

The word is being spread, together with the organisation’s aims and objectives, primarily by UK expats taking overseas positions - permanently or on a temporary basis. Contractors World magazines firmly support the aims and objectives of this charity.

Roger Lindley says "With the hardship of the current recession impacting severely on the construction industry, never has the cry for help been so loud. The Lighthouse Club has yet to establish activities in the USA but it is a similar story in parts of the world where they are active. They need all the help they can get because only then can they help those facing unforeseen hardship.

As the publisher of Contractors World magazines, for 2010, I am pledging a minimum of 7.5% of advertising income to the Lighthouse Club. We will also make space within our magazines available to promote the club and its events, internationally as well as regionally. "

Enjoy Yourselves While Helping Less Fortunate Colleagues The Lighthouse Club is not just about assisting those going through difficult times. It is also about socialising, sharing common interests and participating in enjoyable events which, in turn, raise the urgently needed funds for the Benevolent Fund.

Don Baldry, a name familiar to many with a long career in the industry and an active member of the Lighthouse Club says

"Here in the U.K. annual membership is £20($30), an application form is downloadable from our web home page. That has to be a bargain! It guarantees a response, on any subject, from any one of the many email addresses listed in the score or more of web pages devoted to the Club here in the U.K. and Ireland.

For today’s 'Œtravelling man' that small membership and a roam around the web pages devoted to Lighthouse Clubs Overseas can be an introduction to friends gathered in the Member’s Stand at Happy Valley or Molly Malones Bangkok or Harry’s Bar Singapore, and the monthly get togethers in Kuala Lumpur, Manila, Phuket, and Pattaya. Members in Dubai have the Offshore Sailing Club, in Abu Dhabi, The Club at Mina Sadiyatt.”

Support the Lighthouse Club - become or member or help by making a donation. Do it now.

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Editorial Comment

As soon as this issue of Contractors World is published, I will be heading for Munich, Germany to spend 8 days at the world’s largest event for the construction industry with an estimated 500,000 other visitors.

For those unfamiliar with Bauma, it is a daunting and challenging task to see everything, even with so many days in which to do it and with colleagues to help.

I have been to every Bauma since the beginning of the 1980s and have seen it grow event by event. Changing venues in the 1990s because it had outgrown the central city location.

Held every three years, there is always something to excite you, no matter what your involvement in the construction, demolition, mining, quarrying or recycling industries. It is recognised as the show to be seen at - reason enough for over 3,000 companies to participate.

This year, I have already noticed more and more emphasis on technology. Measuring systems for surveying and mapping now use GPS and laser technology as a matter of course, but 3D mapping is opening up a completely new market. There is also evidence of a recognition of the benefits that full integration of information technology could bring. This was brought home to me at the World of Concrete where I had discussions with business development managers from Microsoft who are working with partners to enable a seamless interface throughout all departments and operations of companies. I will be reporting on this in the next issue.

It does not take much imagination to envisage quarries loading highway trucks at the face. On-board systems would tell the loader operator how much material has been loaded. This will be confirmed by the on-board system in the truck. The data is then fed back through the quarry operation for localised management, it can then be fed through to administration for issuing of invoice and notification sent direct to the customer to confirm that delivery is in progress. The highway truck having been loaded will similarly involve the transport company and processing of data can take place.

What other information can be gleaned? The loader operator will tell the mobile crusher what grade material to process. The productivity of the loader operator, the hours the work and system monitoring will indicate performance and servicing needs such as fuel bowser. Technology has to be paid for, but in this example, the weighbridge and staff are eliminated, administration functions are fully automated. Servicing is only done as and when necessary. Early diagnosis of part failure can reduce downtime and repair costs if the service engineer knows what the problem is and can ensure that the appropriate parts are available.

Of course, there is always the risk of information overload. This was a complaint when computer technology was first being introduced because there was no uniformity or common platform to collate and process the data. This close integration is possible today and it is now essential that OEMs ensure that their systems comply with a standard protocol.

Published by VVV Limited Content compiled and edited by: Roger Lindley MCIM Nick Johnson

©VVV Ltd. 2009 All Rights Reserved

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GERMANY Potains for Hamburg tower blocks German contractor, Höhns-Bau GmbH & Co. KG is using Potain tower cranes in building a multi-use block in the German city of Hamburg’s Hafen City harbour area.

The development is one of the largest European urban make-overs at this time. Two Potain cranes, an MDT 218 and an MDT 268, arrived on site in July 2009, and are expected to work together on the project until April 2010.

Jens Höhns, Managing Partner and engineer at Höhns-Bau, said using topless cranes gave more flexibility on the project.

“We started with an MDT 218 on this project, but as the schedule accelerated, it was clear we would need to erect another crane,” he said. “There were two options available to us. Either we could erect a larger crane, farther away from the project that could swing over the construction. Or we could erect a topless crane with a shorter jib that would swing underneath the crane that was already erected. We chose the second option.”

Potain topless cranes do not have a cathead above the jib and can be operated in closer proximity to other cranes on site. This design makes them especially well-suited to the Hamburg site.

Once it was decided to use two topless cranes on the Hamburg project, transportation was easy. Höhns-Bau opted for the Potain MDT 268 for the optimum combination of lift strength and ease of erection. The heaviest elements for the mobile crane erecting the MDT 268 were the 8.7 t counterjib and the 8 t revolving platform.

Jens Höhns said he was impressed with getting both cranes in the air on the project. “The MDT 268, including the base, 95 t central ballast, 25 m jib, 13.8 t counterweight and over 50 m of mast, was easy to transport on eight articulated trucks. The crane can be moved economically with a light assembly load that gives a real advantage when calculating the costs of construction. We also like the counterjib on the crane, which can fold for transport.”

The first Potain crane on site, the 8 t capacity MDT 218 A J8, was erected with a 40 m jib giving it a jib end lift capacity of 4.6 tonne. The crane was mounted on a 4.5 m x 4.5 m base with 1.6 m x 1.6 m mast sections. Height under hook for the crane is 55.7 m.

The second crane, the MDT 268 J12, was assembled farther away and above base level. The MDT 268 is able to rotate under the MDT 218 as it is installed with a 52.4 m height under hook, and its base is 2.5 m lower on the job than the MDT 218. As the distance between the mast of the two cranes is just 30 m, the MDT 268 is working with a 25 m jib. It has a 12 t maximum capacity, and at its jib end can still lif t 9.4 tonne. “The components we’re lifting weigh up to 9 t, so with the combined lift ability of 20 t, there is plenty of flexibility,” he said. “They work really efficiently together even though they are operating in a tight space.”

PPPPPANORAMAANORAMAANORAMAANORAMAANORAMA

Potain

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AUSTRIA See through ice - the world's largest mobile borer miner in action Earlier this year, the Sandvik Mining and Construction cutting competence center in Zeltweg, Austria presented the world’s largest and most powerful mobile underground mining machine to potential customers from Canada, the US, Poland, Russia, Germany and the UK.

The MF420 Borer Miner has an operating weight of 250 tonne.. The total installed power is 1550 KW (2,000 HP). The machine being demonstrated was the first of a total of seven units to be delivered to the Canadian potash producer PotashCorp during the period April 2010 to April 2011.

During prototype tests, the machine cut a 10-m-long tunnel through a specially constructed concrete block that was 10 x

10 x 10 m in size. Following the cutting test, the machine was given a new challenge.

For the first time ever, the machine cutting process would be filmed from the perspective of the rock.

To make this possible, a large ice block was built in the entrance of the test tunnel. The Austrian-based company ICEANDART was contracted to design and build this ice wall.

Sandvik Mining & Construction

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SOUTH AFRICA Maeda at World Cup 2010 The Moses Mabhida Stadium in Durban, South Africa, one of the many new stadiums built in South Africa in preparation of hosting the 2010 Soccer World Cup, is complete.

This stadium has a unique “Arch” feature which starts on the South with two structures joining at the top and going down in the North side as one structure. It is said that this symbolizes the unity of the country. A “cable car”

has been incorporated to travel up and down the North side of the arch to give visitors a panoramic view of the city of Durban and its coastline.

On the Southern part of the arch a stairway has been constructed on each of the two structures allowing the more energetic visitor to walk up the arch and enjoy this panoramic view.

Amongst the equipment used in the final stages of cosntruction were two Maeda MC405 mini crawler cranes supplied through ANE Equipment Rental and Sales.

The machines were used by TSI Glass & Aluminium for a period of two months, for the installation of sheets of glass throughout the stadium. A suction glass-handler attachment was utilized to aid the lifting and positioning of the glass panels.

Maeda

BELGIUM Major Wind Farm Makes Progress. The Dutch specialist marine contractor, Van Oord, is actively progressing the works on the contract for the engineering, procurement and construction of the first part of the Belwind offshore wind farm project. The wind farm is being constructed on the Blight Bank, 46 km off the coast of Zeebrugge, Belgium where the sea depth is between 15 and 37 m.

The developer and client is Belwind nv - founded by a number of Dutch and Belgian investment companies. The contract value amounts to some Euro 280 million and is one of the largest current projects for Van Oord. The project is scheduled for completion in November 2010. As offshore wind farms go, the Belwin is unique in being the furthest out to sea and in the deepest water.

Pieter van Oord, CEO of Van Oord: ‘Since 2002 Van Oord has been involved in building offshore wind farms in North West Europe. This is Van Oord's second EPC (Engineering, Procurement and Construction)

contract. Earlier we completed the Princess Amalia wind farm project off the coast of IJmuiden, the Netherlands. Our knowledge and experience is concentrated in our Offshore Wind Projects business unit .”

The activities involve the construction of the foundations and erection of 55 wind turbines, all infield subsea cables in between the wind farms, the subsea export cable, a 165 MegaWatt offshore high voltage station and placement of 55 turbines. By 2011 the first phase of the Belwind project will annually provide 165,000 families with environment-friendly power.

Belwind monopiles installed Ballast Nedam’s heavy lift vessel Svanen was commissioned by Van Oord to drive 56 steel piles for the foundations. In February 2010 Van Oord

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installed the last of 56 monopiles. Each monopile is 5 m diameter, weighs between 300 and 500 tonne and is 50 to 70 m in length. They were transported from the fabricators by coasters to the strorage site in Zeebrugge, Belgium. In addition, there were 56 transition pieces, which were manufactured in Aalborg, Denmark, and also transported to Zeebrugge, Belgium.

By mid-February, Van Oord had successfully installed 50 of the transition pieces using the self -elevating jack-up platform, JB-114, equipped with a Favco PC 300 HD offshore crane. The crane has a capacity of 280 tonne at 22 m. Van Oord finalized the installation works at the beginning of March 2010.

The installation of the 55 turbines started in the second half of March 2010 by a jack-up platform. The wind turbine generators are being erected by Vestas.

The 52 km inter-array cable laying work is planned to start in April 2010, and will be executed by the 1,082 gross tonnage, Van Oord cable laying vessel, HAM 601. A supply barge will be used to bury the cable.

In the spring and summer of 2010 the export cable installation, scour dumping and installation of the Offshore High Voltage Stations will be in progress.

With the installation of the 56 monopiles completed, Van Oord began installing the last of the 56 transition pieces (TPs). One of these transition pieces is for the Offshore High Voltage Station.

Each transition piece weighs 160 tonne and is 25 m long. The foundation of each wind-turbine consists of a monopile and a TP. Total weight is 410 - 660 tonne in total and is between 65 to 90 m long. With these in place, work began installing the turbines.

By the end of March, Van Oord began the transport and installation of the 55 wind generator turbines of 3 MW each (165

MW in total) and it did not take long for the first turbine to be successfully installed. This first V90 Vestas turbine was positioned using the jack-up platform, JB 114, which departed from Zeebrugge to one of the most difficult locations on site.

Each turbine has three, 45 m long, blades mounted to the nacelle located on top of the tower with a height of approximately 73 m from sea level. Completion of the installation of 55 turbines is expected at the end of September 2010, according to programme.

Van Oord

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[top] A jack-up barge installs the first of the wind turbines.

Handling the large dimensioned transitional elements in deep, unpredictable North Sea water required not only specialised equipment but also highly-skilled engineers prepared for the many challenges.

Alcoa chose Metso for the reliability and effectiveness of its solutions already present in bauxite mining operations.

BRAZIL Alcoa launches a new mine in Juruti with Metso equipment Alcoa's bauxite mine in Juruti, located on the banks of the River Amazon, in western Pará, Brazil which opened in September 2009 has bauxite reserves estimated at 280 million of tonnes. The initial production of the mine is calculated at 2.6 million tonne/year. Operating with such significant quantities of ore requires specialized engineering to the conveying systems, processing and loading. After evaluation, Alcoa invested in Metso's car dumpers, apron feeders, stackers, reclaimer, belt conveyor systems, ship loader and vibrating screens. The equipment is installed throughout the complex formed by the mine, processing plant, railroad and port.

The package of included equipment, commissioning, erection supervision; start up, assistance of the operation and training for the Alcoa operators from Metso.

Metso's Sales Manager, Silvino Marcos Garcia, says: "Due to the difficulties arising from the project location, Alcoa required a supplier that had a strong presence in Brazil, not only with respect to quality and reliability of its products and services but also the ability to provide technical assistance and parts supply to meet the challenging conditions in Juruti".

Considering the need for advanced management, planning accuracy and logistic capabilities, Alcoa also preferred having only one supplier that was able to offer a complete package, instead of working with several different companies. Having multiple supplier could have hampered the management of the project and would also require greater resources for the coordination of technical interfaces.

The bucket wheel reclaimer supplied to Alcoa is one of the most technologically advanced pieces of equipment ensuring the reliable and efficient shipment of the bauxite. This equipment benefits from automated operation, allowing precise movement forwards and backwards and boom slewing to reclaim bauxite from the stock pile in various benches. This versatility increased the rated capacity of the project.

Another important piece of equipment is the ship loader which has the ability to travel along the quay and, by means of boom slewing and extension, reach all the holds of vessels. The ability to easily move the loader provides for fast and efficient loading of vessels in the shortest possible time. The rapid turnaround of ships reduces costs and additional payments of demurrage by Alcoa.

A demand from Alcoa was that the equipment had to ensure operational reliability, high availability and good durability. Metso were able to assure Alcoa that the equipment would, to a large extent, work automatically following a detailed commissioning program, which enables greater operational efficiency and safety with fewer operators.

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"There is a monitoring system that provides extensive resources for operation and supervision of the entire process in a simple, versatile, effective and safe manner that further minimizes operational errors and enables monitoring and proceed production analysis", says Equi.

The Juruti operations, which are part of the Alcoa World Alumina and Chemicals (AWAC) joint venture with Alumina Limited consist of a port facility, a mine and a 50 km rail system to the port.

Bauxite from Juruti will be shipped to the Alumar alumina refinery in Sao Luis, Brazil which is undergoing a 2.1 million tonne per year expansion program that will bring total production there to 3.5 million tonne per year.

“We have taken steps to make the Juruti project the best mining project in the world - world-class in terms of efficiency and our commitment to sustainable development principles,” said Franklin Feder, President of Alcoa Latin America. “This mine will serve our operations in Brazil and lower our costs. At the same time we will mine bauxite and return the area to the same, if not better, condition than when we initially arrived. Our commitment is to deliver on both the business efficiency and the stewardship of the region.”

The Juruti Project will mine, and re-vegetate, a total of 6,000 hectares over a period of 40-60 years. That is equivalent to one day’s worth of the current deforestation in the Amazon according to the latest data published by Brazil’s Ministry of the Environment.

Recognizing that no permanent deforestation is acceptable, Alcoa has already been working with NGOs and reforestation experts to ensure that the mined-out areas will be totally re-vegetated with native species. For every Brazil nut tree removed during the mining process, Alcoa will replant 10 trees. And for every other species of tree impacted during the process, Alcoa will replant 2 trees for each tree removed. In total, Alcoa estimates it will plant 15 million trees over the next 50 years in the Juruti region.

The Juruti Mine is located in the West of the State of Pará, right in the very heart of the Amazon rain forest. Juruti is an old township, dating back some 125 years, and according to data from the Brazilian Institute of Geography and

Statistics (IBGE) 2007, it has 34,000 inhabitants, of which 60% live in the 150 rural communities that predominate in the region.

Its economy has been traditionally based on the growing of manioc, fishing, livestock farming and gathering from nature.

With reserves of around 700 million metric tons of top quality bauxite Juruti has one of the largest deposits in the world, material that is going to be necessary to meet growing demand and which has also made it possible to expand Alumar (Aluminium Consortium of Maranhão) in São Luís (MA). Initial production at the Juruti Mine will be 2.6 million tonne.

Metso Minerals & Construction

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Ship loader is able to move along the quay for faster turaound of ships there by reducing costs.

Truck cars carry the reclaimed material to the coneyor system for the ship loaders.

GERMANY Complex formwork solutions for high fair- face concrete quality

There is fair-face concrete wherever you look on the multifunctional extension of the production facility of the medical technology and pharmaceutical company, B. Braun Melsungen AG, at its parent site in Melsungen, Germany.

For this project, the contractor Ed. Züblin AG, is having to form top-quality concrete surfaces with a defined joint layout. The required custom forms are being designed wall-for-wall by Harsco Infrastructure (formerly Hünnebeck) Project Development in Ratingen. These then have to be approved by architects and then fabricated precisely to specification.

The composite building fabric (cast-in-situ concrete, partially precast slabs and steel structures) of the new production plant for infusion pumps and dialysis machines is to be erected in just 16 months. The complex comprises a production shop, workshops, clean rooms, laboratory, an office wing, a canteen and a multi-level parking garage. Some of the one- to four-story purpose-built building units have basements, while others rest on ground-level foundations. Access to all areas is provided by six continuous staircases and various lift shafts.

The project will demand about 23,400 m³ of cast-in-situ concrete and is scheduled for completion in September 2010. This means plenty of work for the fabric constructors who have to shutter roughly 60,000 m² of wall and slab surfaces. The foundations account for 3,700 m², the slabs approximately 12,000 m², and all this is joined by 6,600 m² of support for partially precast slabs, 1,000 m² of column formwork and 3,500 m² for floor bearers, upstand beams and parapets. These are tough formwork tasks for which Züblin is relying on planning services and materials from Harsco Infrastructure.

Wall surfaces amounting to 32,300 m² account for the largest share of the required formwork - and technically they are very demanding. Whatever the surface - helical parking garage ramps, staircases or the exterior walls of the above-ground structures - Class 3 fair-face concrete is demanded throughout, i.e. concrete surfaces of a high design quality.

The building fabric of the new production plant for B. Braun Melsungen AG is to be completed in only 16 months. Wall surfaces amounting to 32,300 m² are accounting for the majority of the required formwork - and technically they are very challenging. Whatever the surface - helical parking garage ramps, staircases or the exterior walls of the above-ground structures - Class 3 fair- face concrete is demanded throughout.

The ready-to-use prefabricated large-area elements made of H 20 beams, perimeter planking and ribs are a sophisticated customized solution for the shuttering of the curved parapets. The elements are set up on ID 15 towers and serve initially as slab stopends. The fair- face concrete parapet is created in a second concrete pour.

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The choice of formwork systems has been dictated not only by the need for an extra smooth surface, but also by a rigidly defined pattern of joints and ties. The formwork systems employed consist of large-area elements (based on H 20 timber beams) which Harsco Infrastructure has prefabricated and supplied ready-for-use to the construction site.

For every single wall surface, the project developers have designed the required formwork elements, drawn elevations and submitted the tie and joint pattern to the architects for approval. The outcome of this elaborate formwork planning process is over 150 elevation, fabrication and assembly plans in A0 format to ensure that all the concrete surfaces are constructed precisely as desired.

As a result of the teamwork, the fabric constructors under the supervision of Züblin senior foreman Rainer Knödler have been achieving the demanded high quality and also complied with the narrowly defined deadlines.

Formwork elements for Class 3 fair-face concrete The central demand for the straight wall surfaces (façade and staircases) is the creation of a continuous joint through

all parts of the building (top edge at 2.77 m). However, this is only possible with elements of entirely different heights, varying from 2.5 to 6 m.

Because no infill strips are allowed, the formwork elements had to be additionally constructed with customized widths. The formwork elements are lined with a plastic ply, with a preferred panel size of 1.5 x 3 m. During the placement of the outer wall, another special factor to be considered was that the façade is perforated. Harsco Infrastructure is also responsible for the precision fabrication of the window blockouts required during pouring. Once they are installed in the fair-face concrete formwork on site, concrete placement can start.

Another highly challenging formwork task is the construction of the helical parking garage ramps (inner cylinder diameter 10 m) with their parallel entrance and exit lanes. This is another case for custom-built large-area formwork elements, but this time curved ones made of H 20 beams and perimeter planking.

The 3.5 m high formwork stands on a folding scaffold and climbs in three lifts. The projecting 3.8 m wide ramp lane slabs are being shuttered with Topflex timber beam slab formwork and poured in parallel in a staggered process.

For the underside of the ramp lanes and for the entire helix, Class 3 fair-face concrete is demanded. The soffit, for instance, has a radial pattern. The Harsco Infrastructure custom formwork department has supplied precision-cut formply for this. The all-round curved parapet adopts and continues the radial pattern of the underside of the slab and thus demands further custom formwork.

Overall, Harsco Infrastructure has supplied 110 custom formwork elements (600 m²) in 30 different variations for the curved fair-face concrete structures.

With over 75 percent of the cast-in-situ parts of the complex completed on time, Züblin project manager Stefan Sigler says “We're making good progress and the quality is excellent as well."

Harsco Infrastructure

In terms of the formwork required, the construction of the parking garage helices (inner cylinder 10 m) with their parallel entrance and exit lanes is extremely exacting.

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CRUSHER BUCKETS WIN WORLD RECOGNITION In an increasing number of environmentally conscious countries, more restrictions are being placed on the amount of building and demolition debris that can be removed from sites. This factor, coupled with the increasing cost of landfill is leading to more on- site materials recycling.

As more builders and contractors are pressurised into having to recycle brick and concrete waste on site, so there is increasing scope for contractors to use appropriate equipment. And, if the demand is insufficient to justify investing in a dedicated crusher, an attractive alternative is to add a crusher bucket to the fleet and gain more utilisation from an existing excavator.

There are also many situations where there is a need for substantial crushing but where it is impractical to transport to and from a crusher. For instance in agricultural applications or localised road construction and remediation often far from centre depots.

In rural and extreme remote areas such as found in Africa and India, the ability to crush and size excavated material for immediate reuse is not only efficient use of material but also highly productive in terms of equipment utilisation and workers.

Crusher buckets for excavators are not new but, as landfill taxes rise in more countries, they can now offer a good way of turning waste concrete and brick debris back into usable fill material on site. So the use of these attachments is on the increase and this has resulted in a wider choice of buckets becoming available for not only standard sized excavators but also midis and larger minis.

A good feature of crusher buckets on excavators is that they are simple to use. The excavator operator simply scoops up the material and curls up the bucket to retain it. The crushing mechanism is then activated and the crushed material soon starts to flow out through the open heel of the bucket.

Once all the crushed material has fallen to the ground, any other remaining debris, such as rebar, can be swung around and tipped out onto a separate pile.

Another positive feature of crusher buckets is that they can be tipped upside down to quickly free any blockage that might occur. This is a major safety advantage as the one-man operation of the crusher bucket is controlled entirely from within the well-protected excavator cab.

A US contractor has found crusher buckets the ideal solution for processing demolition material during ground clearance in preparation for a large housing project at a US Military base.

In New Zealand contractors have found multiple uses for MB crusher buckets - from crushing concrete railway sleepers, processing rotten rock in a quarry or even in recycling facilities where they are proving ideal for glass

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According to MB (Meccanica Breganzese) of Vicenza in Italy which claims to be the world leading supplier of crusher buckets, more and more contractors are realising the efficiency that crusher buckets bring.

“For maximum productivity, it is essential to size the crusher bucket to the excavator. With the right combination, it is possible to achieve throughput of up to 50 m³/h, depending on the hardness of the material.

And, simple adjustment to the jaw setting allows sizing material for different requirements. The MB crusher bucket range can process material between 9.1 mm and 50 mm.”

Global Recognition of Benefits Although used extensively on smaller, more job-specific applications, more and more contractors are also recognizing crusher buckets as a tool for larger construction and demolition projects.

In South Africa, the construction company, Liviero Civils used MB crusher buckets in ground clearance applications during construction of the largest stadium for the 2010 World South Africa, with a capacity for almost 100,000 people.

In the USA, a specialist contractor is using crusher buckets for construction of 1635 houses and the revitalization of an additional 443 residential units for the families of the US military forces. This is the largest project involving the development of privatized military lodging in the country since 1996.

The 2084 units will be erected on the Joint Base McGuire-Dix-Lakehurst, N.J, from which transport aircraft, aerial refuelling aircraft and one of the most recognized tactical fighters of the modern day, the F15, are regularly deployed.

In New Zealand, Mike Earl Contractor is using a MB BF 70 on a 18 tonne Doosan excavator in a small quarry with rotten rock where, with jaw setting at 50 mm, he is achieving a throughput of 30 m³/h.

Another contractor in New Zealand demonstrated how well the BF60 and the BF70 could crush concrete railway sleepers. “We found that with the BF70 we could crush two sleepers side by side in under 30 seconds. The smaller BF60 was set up on our Sumitomo SH120 and this was crushing the sleepers also.

The BF70 was used on a Komatsu PC200. We set this digger up in under 2 hours. Loading the crushers in a face shovel fashion we could crush over 100 sleepers per hour.

There is about 8 kg of clean steel in every sleeper, so there could be some money in recycling the steel alone not to mention selling the crushed product.”

MB currently produces four sizes of jaw-action crusher buckets suitable for use on excavators weighing from 8 to over 28 tonne.

The company also makes a bracket mounted magnetic separator for use on its crusher buckets in order to collect rebar and other steel from the construction and demolition waste.

Contractors have been busy building new stadia in South Africa for this year’s World Cup. Contractors working on the largest stadium have found MB crusher buckets the ideal solution for localised crushing and processing of material.

MB Bucket Crushers

Markets have changed dramatically over the past few years. Western markets have declined markedly while China and India have maintained growth.

Roger Lindley reports from the CEA Annual Conference where key people from industry and Government gave their outlook for the future.

Building Business Confidence Every year the CEA (Construction Equipment Association) holds a one-day conference to review the challenges facing the industry.

This year, the conference was particularly well attended, probably because many in the industry are still looking for guidance on where the economy is going and where, in the world, will recovery begin.

As is usually the case in such instances, there are clear indicators of where future growth will come from, but they, in turn, raised further questions.

David Phillips, Managing Director and founder of Off- Highway Research set out the global position and trends in his very matter of fact approach.

The figures left no one in any doubt as to the seriousness of the situation facing manufacturers with unit demands down by as much as 80% and little sign of any rapid recovery.

David Phillips said “One year ago, when I was addressing the same conference, we really did not know how bad it was

and how bad it was going to be. Now we can see.” However he took a pragmatic approach, which has also

been voiced by many; not only in the construction industry but in general economic terms.

The fact is that we got used to the words ‘Never had it so good’ - markets were in growth, money was readily available and everything was positive. But, in reality everyone knew that it could not be sustained, but most had anticipated a fall back, not a total collapse of market confidence.

The pace of growth was too fast and it was time for the brakes to be applied. As we now know, the brakes were not applied but the engine stalled just when we needed the power.

“We will never go back to 2007 - it was a wonderful dream,” says David Phillips. With this in mind, he showed that taking out the highs of recent years, the severity of the current position does not appear to be so bad.

Of course, it is still having a devastating affect on the global economies trying to return to a more ‘normal’ market demand situation (if there is anything such as normal). As David put it “demand is ultimately based on building market confidence.”

Manufacturing Will Move East David drew attention to two markets where growth has been maintained - China and India. Both large countries with vast populations and a need to

develop infrastructures in order to enable economic growth.

India has ambitious plans to develop infrastructure with rail tracks and highspeed roads but such projects have a tendency to get delayed by excessive bureaucratic procedures.

China, on the other hand, has been able to compensate for decline in export markets by stimulating domestic demand. As an example of the speed at which China implements programs, David Phillips said there was a 2000 km long highspeed rail link between two cities that would be completed in 2 years. Most other countries would require that much time simply for discussions and planning stages alone.

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The changing values of the different geographic regions shows the changes and the forecast growth.

That is not to say that China’s sometime seemingly ruthless approach to development is always the right one. But the fact remains that when necessary, China takes the appropriate measures to stimulate domestic demand.

This could have serious repercussions for western markets, where manufacturers generally are reducing investment, employing less people and slowing down product development.

By comparison, Chinese manufacturers are benefiting from the high domestic demand to develop new products and build new, more efficient manufacturing facilities.

For example, Zoomlion is to open a factory with a capacity to build 20,000 hydraulic excavators a year. Further evidence of China’s ambitions will be at Bauma.

David Phillips advised “Watch China at Bauma 2010, where they are very strong and very determined.”

He also said that Chinese manufacturers have recognized their weakness - the ability to provide a viable after-sales support service - and are looking for European companies to acquire who can provide essential quality product and service levels.

Future Stability Although Off-Highway Research is confident that the Chinese economy will continue to grow, there are those that have serious concerns about their ability to sustain growth.

Even Chinese authorities are voicing concern according to The Daily Telegraph newspaper in the UK. The newspaper recently reported that:

China risks social melt-down within five years because of the stresses provoked by its economic boom, government officials were warned yesterday. The country was now in a "yellow-light" zone, the second most serious indicator of "social instability", according to an official report focusing on the growing gap between rich and poor.

"We are going to hit the red-light scenario after 2010 if there are no effective solutions in the next few years," said the report commissioned by the labour and social security ministry.

Outside of China and India, demand is becoming more positive but is at very low levels, and, as David Phillips confirmed, the demand is actually higher than unit sales indicate. Unfortunately, units cannot be delivered because of the lack of affordable financing from the banks.

“Making finance more readily available would stimulate demand’” said David Phillips in answer to a question from Contractors World. Off-Highway Research is not forecasting a rapid recovery in the Middle East other than confirmation that the markets will recover to a lower level with Oman being the market to watch for future development.

Markets will never be the same The world has to recover from the effect of a massive seismic shock. The restructuring will create a market place significantly different from those of the past. As the markets goes through a metamorphose the result will place greater emphasis on technology.

The economic crisis will further accelerate the integration of technology into machines and beyond to provide a seamless interface of information to the project management and administration functions.

In summarising, David Phillips said: • Europe: is now at its lowest level since 1993 Modest growth of 2% in 2010. Sales will be 127,500 in 2014 • North America: now at its lowest level since 1992 Sales will be 125,300 in 2014

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Recovery will take place over the next few years but will remain substantially below those of 2007, according to

Off-Highway Research forecasts.

According to Off-Highway Research forecasts, market demand will change by geographic regions and also by

type of equipment.

Page 18

• China: will peak at 277,000 in 2011 44% of global sales; largest market in the world • India: the next big market for expansion from 29,000 in 2009, to 60,000 in 2014 • Production will move from West to East • Regional production will continue, but will be rigorously assessed • China and India will be the winners in inward investment • Component production will follow shifts in OEM production. China is now

producing 50% of global demand

JCB responds to market challenges To show the way that forward thinking companies are responding to the challenges, David Bell, Chief Corporate Development Officer for JCB told how the company was investing in the future.

JCB is investing not only in new plants and facilities, but in developing people skills also. In recent years the company has invested heavily in new engine technology and a purpose built large excavator plant.

“There is a severe skill shortage. Nobody wants to be an engineer today” said David Bell. “To provide a skill pool in the future, JCB, together with other companies such as Rolls Royce aero engines at Derby, the Toyota car plant in Derbyshire and train maker Bombardier, has created the JCB Academy.”

The $33 million academy is in Tutbury Mill, a historic Grade II listed building on the outskirts of the Staffordshire village of Rocester - the home of JCB. It will provide specialist education for 500 students in all aspects of engineering and features advanced technology such as 3D modelling. The emphasis in the academy will be on learning by actual projects. David Bell said “For the students, self-belief is crucial.”

The academy opens in September 2010 and is already fully subscribed - proof that, given the right tools and motivation, there is still an interest in engineering.

Infrastructure the driving force According to Paul Skinner the Chairman of Infrastructure UK “Infrastructure will be the big investment over the next 20 years with energy scheme to lower carbon trajectory, railways and road”. This division of the Treasury Department for the British Government set out three objectives.

• developing priorities • enabling long term investment • bring focus on importance of infrastructure development. The Government has already announced an urgent need to replace rapidly aging nuclear power generation

facilities and inefficient coal fired power stations. There is a proposed highspeed railtrack planned, initially from London to Birmingham - a distance of 193 km.

Once completed the line could then be extended further north, eventually all the way to Scotland. In announcing the scheme the Government spokesman said that the project would create 10,000 jobs and would

cost between $24 and $26 billion. Unfortunately for the depressed construction industry, work on the rail link will not commence until 2017.

Paul Skinner said “We want to set a new course for infrastructure UK.” However, in answer to Contractors World’s questions, Infrastructure UK indicated that there was no way to speed up decision making and all projects had to follow normal studies for social, economic, environmental and other concerns. While we agree that consideration is essential, as a stimulus for economic recovery it pales in to insignificance when compared to China’s response of 2000 km of highspeed rail track in 2 years - not that we are advocating China's model.

Compliance essential Rob Oliver, Chief Executive for the CEA, speaking on behalf of UK construction equipment manufacturers, emphasised the need for all governments to recognise the importance to economic wealth and development, of the construction industry and the manufacturers supplying it.

Other speakers also emphasised the importance of compliance with the various directives. Although sometimes a little misguided, all directives are well intended to protect the environment and the safety of operators and other people working on and around machines.

There is no room for complacency even though compliance can add to the cost of machines. The use of non- compliant machines cannot be justified. However, it is one thing forcing manufacturers to ensure that machines are compliant with market demands. It is another policing the use of non-compliant machines. This should be part of the health and safety policy of every contractor. What is the point in ensuring people wear appropriate protective clothing - boots, hardhat, gloves, goggles, high-visibility jackets but, at the same time, allowing non-compliant machines to work on site?

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David Bell, Chief Corporate

Development Officer for JCB

Manufacturers Evaluate Technology for Improving Efficiency Manufacturers face a never ending battle to win and maintain customer loyalty. All are require to make massive investment in research and development in order to ensure that product lines comply with various regulations - which can vary from market to market.

In Europe, North America and other parts of the world, regulations tend to be focused on environmental issues and safety. The cleaner burning engines provided in the first phase of Tier IV engines bring benefits but at a significant cost. Most manufacturers when looking at meeting compliant needs take a holistic approach and maximise on the potential the refinements can deliver.

New engines can be more fuel efficient, thereby offsetting the initial cost by reducing operating and owning costs. If operating costs can be further reduced by improving the interface between the engine management systems and hydraulics to deliver power where and when it is required, then there is scope for greater benefits. Load sensing hydraulics provide the opportunity for additional cost reductions as well as increasing productivity.

Long gone are the days of the simple steel seat. Operators today benefit from advanced cab designs, which are designed to be comfortable, better support for reducing back injuries, offer all-round visibility for safety of other people on site, controls that are conveniently placed and mainly electronic (pilot) based for more precise, faster, smoother operation and a conditioned environment enable working in all conditions. Diagnostic communication with computers speedily identify faults for shorter downtime and service intervals have also been significantly increase.

Because of the high investment cost in developing Tier IV engine compliant engines, and the current economic state, there has been a tendency to put other emerging technologies onto the ‘back-burner’ for the time being. However, there is evidence that the development in this area is now coming to the forefront once more. A few years ago, at major exhibitions, many companies showed ‘futuristic’ ideas or early prototype a new technology driven machines - hybrid technology.

Japan leads the way with hybrid technology The growth in this area is being driven mainly by the Japanese who are really showing their green credentials. Not only

are the Japanese automotive manufacturers leading the world in hybrid technology, the construction equipment manufacturers are now doing the same.

Komatsu has recently introduced it first hybrid technology driven excavator, the PC200-Hybrid in the North American market and it is going to be introduced into Europe at Bauma 2010. Kobelco has also recently introduced into the Japan market, a small excavator that uses hybrid technology to eliminate energy waste and lower fuel costs. Little is known of this machine at this time as it is only available in Japan.

In other areas, companies are evaluating electric power. For instance, Caterpillar is currently in the middle of evaluating an electric rigid dump truck. Such trucks have been around for many

years, but Caterpillar appears to have taken the technology to a new, more efficient level.

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Six tonne Kobelco tracked excavator using hydrid technology to reduce fuel consumption by as much as 60%

Roger Lindley takes a glance at what to expect from companies as they evaluate the use of technology for everything from engines through to control systems, measuring and management of information.

JCB

Kobelco

Terex has a clearly defined strategy for developing technology into its range of ADTs. It is also working to keep unit costs down by investing in more efficient production methods. ADTs of the future will be much more intelligent and smarter says head of engineering, Alan Clark.

Acceptance of technology growing by stealth Almost growing by stealth, because we find we are using it more and more without realising the full extent, is computer aided technology using wireless (WiFi) and GPS technology to provide a seamless interface throughout an organisation in which information is transferred automatically from one system to another. For instance, a machine on hire can report back actual hours usage to the plant hire depot where the data can be automatically fed into the administration function and invoices issued electronically without any human interface. The same data can be fed to the service department to monitor usage for scheduling of service time. At the end of the specified hire time, commands can be sent to the machine to prevent its operation.

Roger Lindley recently took the opportunity to meet with senior executives from two very different companies, but involved in global marketing and with an input into product development.

High on the agenda at Terex Alan Clark, Head of Engineering - Heavy Construction Machines, in the UK said “Expectations from dealers and customers today is extremely high. They want more productivity, increased reliability and lower costs.” He then went on to explain that it is rarely possible to lower unit cost, but there are significant steps that can be taken to reduce lifetime costs.

“Naturally, we evaluate all new technology and look at what competitors are also doing. And, if it can be demonstrated to deliver positive benefits to customers then we will introduce it.” Terex work closely with suppliers in ensuring that development of key components such as engines and transmission meet Terex’s demand for “quality components that have the durability to cope under harsh conditions with the necessary reliability”.

“There is definitely scope for developing hybrid technology in such machines as articulated dump truck. It is not imminent but obviously something we are evaluating,” says Alan Clark, “The potential is there, but the question is how best to harness it because it has to be reliable and robust.

As excavator manufacturers are doing, there is scope to recover energy from the hydraulic cylinders. Energy is wasted through the cylinders when lowering the dump body. Energy can also be recovered from the braking system. However, Contractors World got the impression that Terex is looking more at electronic technology. “Improving wireless total machine diagnostic system monitoring will enable much better service management and reduce maintenance times. Linking all the different systems together is getting closer allowing effective collection of data.” Terex has a plan on how it will develop its range and significant new technology introductions can be expected over the next three years. “New generation trucks will be more intelligent and smarter” says Alan Clark.

Companies can also reduce costs by investing in manufacturing facilities. Terex is continually upgrading and modernising its facilities in Motherwell, Scotland. JCB has also invested many millions of pounds in its facilities in recent years - a new heavy excavator production unit, advanced engine test beds and production and logistics management. JCB is also now investing in people by being one of the lead sponsors for the JCB Academy which will provide

engineering education to over 500 students each year.

Caterpillar

Komatsu

Terex

An archimedes screw weighing

13.5 tonnewill be used in harnessing

water power from the adjacent

millrace to turn a turbine to create power at the new

JCB Academy

Page 20

Some new innovation or technology undergoing testing at the Merlo facility in

Cuneo, Italy.

Merlo readily embraces new technology If one company is going to embrace new technology and deliver innovative and well engineered products it is the Italian company Merlo. During a recent visit to Cuneo, in northern Italy, Contractors World took a look at the company’s facilities and discussed with Maurizio Ganio-Mego, Director, Export Sales, just where Merlo is heading. Always inquisitive, and with an eye on the future developments, the company’s founder Amilcare Merlo also intervened to add his comments during the conversations.

It was soon obvious that Merlo is well advanced in evaluating its latest customer aid. Merlomobility is a new computerised system for fleet management that shows real-time location of several vehicles using GPS technology and cell-phone networks. The system makes it possible to monitor important information on vehicle parameters as well as receiving and processing alarm calls.

Undergoing evaluation in Italy, the system combines GPS, GSM/GPRS/UMTS telephone networks, WiFi and the Internet to provide a fully integrated system that does not require installation of any complex software or extensive user training. It readily interfaces with existing data-processing software such as Microsoft Excel. The data can even be read on small devices such as a PDA.

Being able to monitor equipment to such an extent has many obvious benefits to utility companies, local government and plant hire companies. In Italy, the system is already being used to manage and monitor vehicles used for refuse collection and for street cleaning.

Merlo is not only investing in peripheral use of technology but is also looking to implement it in the new products under development. One example of this is the company’s EcoPowerDrive system. This is an innovative electronic control system that manages both a machine’s hydrostatic transmission and the diesel engine.

Simultaneously management enables full optimization of energy generation to improved operating efficiency, lower sound levels and, potentially, lower service costs.

Thirty percent fuel saving At a time when diesel costs are at record high in most parts of the world, any contribution to reducing this saving fuel will be most welcome. Merlo claim that its

Using a variety of communication systems,

Merlo has developed a ‘real-time’ fleet

management system

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The EcoPowerDrive system from Merlo provides optimum power between the engine and hydrostatic drive for smooth, effortless travel - even on steep gradients.

By producing as many components as possible in-house and investing in the latest production technology, Merlo has very efficient manufacturing facilities. Investing in people is also important and the company continues to increase workforce when other companies are reducing theirs.

EcoPowerDrive (EPD) system can reduce fuel consumption by as much as 30% - that amounts to two day fuel saving in a six-day week. External noise is reduced by up to 2.5 dB(A), selected travel speed is more easily maintained and maximum tractive force is available, even when the engine is idling, for safer operation on steep gradients.

Merlo admits that the system does have some disadvantages but these are more than offset by the benefits. The management system uses complex algorithms to determine the best engine speed and the hydrostatic ratio. The driver defines the required travel speed via the accelerator pedal, the management system does the rest.

However, as the travel speed is not fixed, but depends on load, it is necessary to accelerate the engine to almost full speed in order to get maximum thrust such as when used as a loader. The EPD system, by reducing fuel consumption, also means lower emissions as the engine is working less. There is also said to be a noticeable improvement in manoeuvrability and precision working.

Using one of three modes - Fine, ECO or Full - the operator can set a basic parameter for the EPD to use. With proper instructions, operators can

be made aware of the benefits of selecting the appropriate mode. Unfortunately, if mode selection in hire industry hydraulic excavators is any indication, operators invariably leave the selection in High or Heavy duty mode.

Ongoing technology development A more logical approach would be for the EPD to become intelligent enough to determine the best mode automatically and, it is possible that this is under investigation in the Merlo R&D facilities. The P55.9 CS heavy duty telehandler is the first machine in the Merlo range to have EPD transmission fitted as standard.

The EPD will be progressively offered across the range but only where it meets Merlo’s ethos of meeting customer expectations. Although the strategy is to retain market position by developing new technology, Merlo also appreciates the value of its workforce, and, for the company, investment in people is as important as that into R&D.

Investment in people and marketing Merlo remains a family concern, with daughter Silvia, already with many years experience in the company, and others there to ensure continuity whenever the charismatic Amilcare Merlo decides to retire. There is no indication of when this might be as he is still full of enthusiasm for the latest developments.

Like other companies, it has seen a dramatic decline in demand for products in all markets but that made the company more determined than ever. When other companies were reducing number of employees, Merlo has been increasing its workforce - last year by over 2%. It has also continued an aggressive R&D program and making further investing in their facilities.

As Mr. Merlo told Contractors World, “Without dedicated people there is no future.” By comparison to many companies, Merlo is young. The company was only founded in 1964 but today has over 1,000 people worldwide. It has facilities of more than 150,000 m², achieved net sales in 2008 of 395 million Euros of which 79% was from exports. Today, Merlo is the market leader in rotating telescopic handlers and in hydrostatic transmission telehandlers. Investment in R&D has increased year on year and reached almost 30 million Euros in 2009.

As Maurizio Ganio-Mego told Contractors World. “Exports are very important to Merlo and we carefully monitor the various markets - geographically and by application, see what is required and then implement the necessary measures to satisfy that demand.”

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A tracked telescopic unit with dozer blade and bucket - not yet named but to be

unveiled at Bauma 2010 by Merlo.

He explained that, although technology has its advantages, it is not necessarily a benefit in some parts of the world where the quality of fuel and ability to service advanced machines is not always available. “We have to ensure that we can adapt our products and services to meet local conditions to ensure customer satisfaction.“

Once example of this strategy working is in North America where cooperation with one of Canada’s largest rental companies in French Canada lead to the rapid acceptance of European style Panoramic telehandlers, which is now spreading throughout the country.

The new, larger P50.18 machine was developed specifically to compete with the larger US machines such as from Skytrak and Lull.

This is another reason why Merlo, as a company, manufactures as many components as possible for its machines. “We can better control quality and more speedily adapt to changing requirements. With outside suppliers you have to constantly monitor quality, delivery times and costs said the company.

He emphasised one of the core strengths in the Merlo vision - to listen to customers who are the people facing up to the challenges of changing market demands. Their knowledge can be vital to the future development of machines.

Mr. Merlo, when asked about hybrid technology, talked enthusiastically of the possibilities and, as an engineer, he could see many opportunities - even beyond where many people are currently looking. Hybrid technology depends on achieving a means of storing energy otherwise going to waste without adding additional weight or negatively impacting on performance.

Obviously in many of Merlo products there is a significant potential to recover energy from releasing pressure on hydraulic cylinders and braking. Couple this ability with the advances already achieved with the EcoPowerDrive system and we may see the way in which Merlo is thinking. As battery technology improves this is another area from which more of Merlo’s smaller products will benefit. It is already used on smaller Cingo access platforms. Obviously one to look out for in the future.

Latest innovations on show at Bauma 2010 Merlo will be showing and explaining in more detail its latest innovations at Bauma 2010. Such is the amount of new equipment, that the company has is taking more space at a time when others are reducing theirs. Among the products that Contractors World knows about are the MPR15 and MPR18 - a revolutionary concept in access platforms. The MPR concept offers the combined benefits of a large area access platform associated with scissor lifts with the mobility and versatility of a truck mounted access platform. The 4 m x 2 m platform hydraulically rotates through 180º in both directions through its vertical axis and features power supply outlets and a hose through which air or water can flow. The ability to travel at 40 km/h and reach heights of up to 18 m makes the MPRs suitable for street light and gantry, bridge, tunnel and other applications where ease of transport and generous working envelope are

required. The Panoramic telehandlers, which are proving

so successful in Canada, will also be on show including the new P25.6 and the P50.18.

There is also the new Roto 60.24 MCSS with the unique Merlo rotary coupling system allowing the turret to rotate continuously.

Some other new introductions are firmly under wraps until April 19th, 2010 when Mr. Merlo will show his company’s ability to lead in technological innovations.

Merlo SpA

Maurizio Ganio-Mego, Director, Export Sales with Amilcare Merlo, the founder and head of Merlo SpA

Among the array of new equipment Merlo will introduce at Bauma 2010 is the MPR roadable, large working area access platform (in foreground.).

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Our associate publication - CP&E - Contractors Plant & Equipment - is featuring in-depth previews of plant and equipment to be seen at Bauma 2010 in current issues.

Roger Lindley takes a look at some of the technology and innovations coming through at Bauma 2010 that will either have an immediate impact on the way things are done or on how they will be done in the future once the technology is integrated in to machines.

Sandvik to show innovations made possible by group synergies One of the biggest areas to benefit from technology in recent years has been the mining and quarrying sectors where even the smallest step in reducing material handling costs can, over the course of a year or more, lead to significant savings. In some instance, it is the difference between a viable and nonviable operation. It is a pity to see so many long established brands now lost to greater corporate brand stamping without, it would seem, concern for brand-customer loyalty and market perception. Names such as Tamrock, Rammer, Extec and Toro, for instance were world-famous brands, once recognised for pioneering engineering and innovations in tough applications. Today, these famous names are now integrated into the massive Sandvik brand and have, unfortunately, virtually disappeared.

However, mergers and acquisitions have brought many benefits. Sandvik today can focus of system solutions rather than individual products or applications. By providing a range of systems that can be mixed and matched to provide optimum solution to specific quarrying and mining activities, they have enabled managers to significantly reduce operational costs. And any mine or quarry manager will tell you that the better the system integration the more productive is the processing.

Some products are difficult to improve upon, a jaw crusher is a jaw crusher which ever way you look at it. However, there is technology that can be applied to more efficient operation, more durable components and easier replacement of wear parts. Sandvik will unveil several interesting examples of applied technology at Bauma 2010. The first of a new range of mobile tracked crushers, QI240 tracked impact crusher, for instance. Designed specifically for the construction, aggregates, demolition and recycling industries, it is the result of over two years research and developments benefiting from Sandvik’s recently acquired mobile crusher expertise and the group’s materials technology and manufacturing capabilities.

There is little information available on this other than that it is a single unit designed for mobility, productivity, transportability, minimal environmental impact and ease of use. The QI240 uses Sandvik impactor technology and based

on the chassis of the well-proven QJ240 tracked jaw crusher.

The new Sandvik LHD - Electric Power Technology Underground mines will be wanting to take a closer look at the latest in the LHD range from Sandvik which many diehards still refer to as Toros. At Bauma, the group will show the new electric-powered 14 tonne electric LHD that brings together higher productivity, lower operating costs and reduced environmental impact with all the strengths of diesel machines.

The LH514 electric-powered LHD incorporates key features of the recently launched diesel machines, such as upgraded cabin design and Vehicle Control and Management system (VCM). The electronic control system incorporates a an advanced user interface with improved diagnostics and a platform

Page 24

Sandvilks’ new electric drive LDH - the LH514 to be shown at Bauma 2010

Technology At Work

Page 25

for Sandvik’s Automine technology, plus an upgraded electric system that are designed to for optimum interface with the electronic control system.

The latest LHDs have upgraded electric and hydraulic systems and improved tramming capacity deliver excellent productivity, reliability and performance. Four hundred 400 meters of cable allows then work in applications where the hauling distance is short and operations are repetitive.

Higher productivity is achieved because of the electric motor’s peak torque, resulting in faster bucket filling and better acceleration. The electric model features 14,000 kg of tramming capacity, buckets ranging from 4.6 m³ to 7.0 m³, three-phase, squirrel-cage 45 kW pump and 132 kW drive motors with Dana 5000 series gearbox and Posi Stop axles.

Compact breaking power receives global launch Breakers have been progressively enhanced over the years and today generally offer faster breaking with low vibrations to the operator and reduce noise levels. Sandvik will launch a new range of Compact breakers at Bauma what it is describing as ‘a revolutionary range of breakers combining simplicity and cost effectiveness, with a class leading power to weight ratio, optimized for production in demolition and recycling applications’.

The new range, available in three sizes designed to match carriers in the 0.8 to 4.0 tonne range, benefits from a sturdy and a compact shape to suit applications in confined spaces, while constant blow energy maximizes the impact energy regardless of oil flow.

Capable of accepting a wide range of oil flows, excellent back pressure acceptance and flange top mounting, the new models can be used on a wide range mini-excavators, skid- steer loaders, and other compact carriers.

With just two moving parts, maintenance is minimized which means lower owning and operating costs. They require no periodical gas recharging, and can be resealed in just 45

minutes, while the integrated single lower tool bushing can be replaced in just 10 minutes for both faster servicing.

More technology breakthrough from Sandvik It will be interesting to see if Sandvik makes any further announcement on their use of hybrid technology which they first announced last November for double roll crushers.

The Sandvik CR800 series of hybrids combine the advantages of a classic double roll crusher with sophisticated sizer technology.

Their compact design means minimum space requirement but a high capacity (up to 12,000 mtph (13,228 stph)) make them efficient crushers of limestone, overburden, coal and ores in primary and secondary crushing stages.

What makes the CR800 different is that they are equipped with flywheels that store excess energy which is then available to compensate for energy peaks during operation. This allows use of a smaller drive motor with resulting energy efficiency.

If this technology can be used in this type of crusher, there are obvious opportunities in other crushing and screening applications.

Sandvik Mining & Construction

The new range of Compact breakers from Sandvik are cleverly designed to minimise number of moving components. They have obviously retained Rammer’s original engineering innovation.

Sandvik has used hybrid technology to store excess energy

in roll crushers for when it it required. Is this an indication of the way the company is moving?

Bucyrus + Terex = ? Little has been said by Bucyrus since their acquisition of Terex Mining business other than to say that it is natural additional to their existing product range and enables them to be a much bigger player in the mining and quarrying industries.

Prior to the acquisition, the company indicated what it was planning for Bauma 2010, with many examples of technology at work for the mining industry. Not surprisingly, the company will use scale models for its display including a 1:50 scale replica of the latest rotary blasthole drill for hole sizes between 251 and 405 mm. There will also be a 1:50 scale 8750 D3 walking dragline - a monster of a machine with bucket capacities in excess of 168 m³.

The electric shovel range is benefiting from ‘revolutionary HydraCrowd technology’ that uses a crowd/retract cylinder to move the electric shovel handle into and out of the bank automatically thereby eliminating the need for crowd and retract ropes. Other advances reduce major scheduled service times to every 2 years.

However, the big question is - what will the company show anything from the former Terex mining equipment line up or will they be able to tell more of what their plans for the future are.

Bucyrus

Technology is changing the way the construction industry works. Construction sites today are much different to those of 25 years ago, when computer technology was in relative infancy, the Internet was yet to be born as we know it today, WiFi and cellular phones was something people dreamed about. What a different a few years makes.

Today few business can exist without computers, mobile phones, the Internet and all that this technology has enabled. Leading the way in advanced technology in the construction and related industries are the traditional instrument providers such as Topcon, Trimble, Sokkia - companies who first established a reputation for manual theodolites and similar tools of yesteryear. How things have changed, and Bauma 2010 will see some interesting advances.

Topcon make major advances First introduced at the World of Concrete earlier this year, Topcon will demonstrating just where technology is taking us with several advanced innovations.

Mark Contino, Vice President of Product Marketing told Contractors World “The recession will bring about changes in the way people do business. Construction will be a more technology driven industry as we recover from the recession. More technology to increase efficiency and productivity. “ However, he issued a caveat to technology development “The technology exists - the challenge is to make it affordable.”

Topcon Europe Positioning (TEP) will feature a new machine control system - 3DMC² - which can increase dozer speed for grading up to 200%, or even more, while providing unprecedented smoothness. Ray O’Connor, Topcon president and CEO, called the 3DMC² breakthrough “as tearing down the last barrier in regard to increasing job site productivity - speed.”

O’Connor said, “There’s never been anything like this in construction machine automation. Topcon’s 3DMC² technology speeds up the position calculation by a factor of 10 from today’s systems. This allows for faster positioning in real time, which means the machine can be controlled to design grade at much faster speeds than any other system.

“With Topcon’s GPS+GLONASS technology, productivity was dramatically increased due to precise positioning and accuracy. With 3DMC² increasing a dozer ’s operating speed, there’s yet additional savings in time and money on every job.

“This is not a technology that just any company can do. Any company can use sensors and think of the concept of getting a dozer to go faster with increased accuracy. What’s different here is that Topcon used the proper algorithms, satellite signal filters, the proper arithmetic formulas and the scientists and engineers at the company’s global technology centres, all working together, to accomplish yet another world’s first construction development.”

“Topcon was the first company offering contractors the option of going stakeless at every phase of the job with 3D GPS machine control systems.”

“This new addition to the Topcon family of machine control products will drastically change the role of dozer operation on a typical job site. Of course, as the speed increases, we can do more work in less time. That means less operating time, less fuel, less wear on a machine and most importantly, more time that can be spent on other work in other areas.”

Tangible Construction Site Management Visitors to Bauma will be able to see a live demonstration of their Topcon construction site management capability. Strategic partners RIB and TOPCON will be showing a construction machine linked wireless via TOPCON’s SiteLink server to RIB’s STRATIS software booth. Visitors will be able to look at the office/machine interaction outside the building as well as at the TOPCON booth.

“The presentation in Munich is intended to introduce the benefits of the system by highlighting the effects of changes and the prompt reaction potential on the construction site enabled by the integrated solution,” explains Achiel Sturm, Construction Business Unit Manager of Topcon Europe

Andreas Dieterle, Product Manager Sales at RIB, adds: “Cross-section data is directly transmitted from the fair booth to the machine working outside. As soon as the machine has done its job, the information is sent back on-line to our software system via SiteLink. Exact actual-target comparisons are possible at any time. Whenever there is a change of plan, the machine is given the necessary data direct and can initiate its new working processes immediately.”

Another example of just how advanced technology has gone is the company’s Ip-S2 highspeed total mapping system. How simple can it get? IP-S2, a vehicle-mounted, mobile 3D precision mapping and survey system.

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The IP-S2 combines dual-frequency GNSS signal tracking and positioning and inertial measurement to integrate laser scanning and digital imaging.

Using 3D laser scanners, LIDAR, and/or cameras, the data collected is integrated, time- stamped and geo-referenced. The customer can then quickly and accurately combine LIDAR “point cloud” and digital imaging data to build 3D models of the areas driven.

Industry-leading sensor integration creates unlimited applications for the technology in GIS, construction, agriculture, mapping, and machine control — all areas where Topcon has market leadership.

Ray O’Connor, TPS president and CEO, said, Topcon’s Inertial Positioning System (IPS) “makes it possible to track motion through 3D space, creating an instant solution to myriad asset management and data collection applications.”

With its high accuracy scanning and inertial measurement capabilities, its ability to support a variety of sensors and its 360-degree hemispherical digital video camera system, O’Connor said, “The IP-S2 can gather accurate measurement data in extremely difficult conditions, such as tunnels, under bridges, in heavily wooded areas or urban canyons.

“The applications for the IP-S2 are limitless,” he said. “Whatever you can conceive of in the areas of asset management, data collection on precise location of virtually any subject, using digital photography capabilities, as well as laser scanning options, with its on-board tools the IP-S2 can do the job.”

Collecting field data for GIS applications has always been a time-consuming task, usually taking several years to fully accomplish. As a result, many databases are incomplete, preventing managers from utilizing their full potential. Safety has also been an issue, requiring personnel to stand in highly travelled road corridors where most assets are located.

Eduardo Falcon, senior vice president and general manager of Topcon’s Emerging Business Unit, said, “The IP-S2 revolutionizes the way in which GIS field data can be collected. One pass of an area at normal vehicular travel speeds provides a complete dataset of highly accurate position information and high resolution imagery.”

He added “Using new software tools, GIS operators can easily identify features, assign attributes, and then export them to geospatial applications. The reduction in cost and improvement in safety are exponential compared to traditional ground survey methods.”

Topcon

Trimble also promote total information integration Indicating the way technology is revolutionising the way the construction industry of the future will work, Trimble will use Bauma 2010 to demonstrate its ‘Connected Site’ systems to show how such systems are transforming the way design engineers, contractors, and job-site crews can tackle their grading and excavation jobs. What used to be done manually can now be completed more efficiently and accurately with a mix of GPS, construction lasers, total stations, wireless data communications, the Internet and application software.

Trimble’s theme at Bauma 2010 is “DO THE MATH” focuses on how Trimble Connected Site solutions allow technologies to work seamlessly together to provide even greater benefits to the contractor—lower operating costs, optimization of personnel and machines, increased productivity, higher accuracy, increased safety, and insight for greater operational intelligence.

Technology is not only for larger companies. Small companies can also find that it enables them to do much more by removing what has traditionally been time consuming tasks. Because most information technology systems are based on modules, systems such as ‘Connected Site’ solutions offer multiple points of entry.

Trimble

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Topcon IP-S2, a vehicle-mounted, mobile 3D precision mapping and survey system

Trimble will use Bauma 2010 to deomostrate its ‘Connected Site’ systems

Engines, Components and Technology Bauma 2010 will see an abundance of Tier IV engines from all the leading manufacturers. Engines have to meet every exacting emission standards and component manufacturers then have to modify their products to ensure optimum benefits are derived from the new engine technology.

This domino effect eventually ends with the plant manufacturers who only too quickly claim credit for the performance enhances, increase productivity and other benefits that has only been made possible by the key-component developments. Looking at these developments can give an indication of what to expect from machines in the future.

Perkins Perkins will be unveiling the new 854 Series compact, four cylinder 3.4 litre engine. The 854 Series builds on Perkins’ strength and ability to tailor power solutions for individual customer needs. Significantly the new model will allow Perkins to offer customers greater power density and compactness to suit their precise requirements, whatever the application.

Offering more power and torque from a smaller package, customers will now be able to move seamlessly through the power bands as the 854E produces 45kW (60hp) up to 86kW (115hp).

The 854E range benefits from a common rail fuel injection system, smart waste- gated turbocharger and aftercooler, all regulated by full authority electronic controls to ensure world-class performance and fuel consumption.

Starting from 2011, the engine, which develops a peak torque of up to 420Nm, will be available in the 2,200 to 2,500rpm speed range.

In keeping with all Perkins’ Tier 4 Interim / Stage IIIB product range, the 854E has been developed using extensive “voice of the customer” research. To meet these requirements, the range features a strong emphasis on power density, fuel consumption and performance, giving OEMs choice and support if downsizing is desired.

“The increased torque, power density and performance of the 854E, complements Perkins’ Tier 4 Interim / Stage IIIB product range which we are confident will meet customers’ requirements. The power and performance provided by the new engine offering also supports downsizing which could help OEMs minimise the need for machine redesign in this cost sensitive climate,” said Allister Dennis, Perkins’ new product marketing manager.

Deutz Deutz will be showing a new generation of technology to meet the future EU emissions standard IIIB/US EPA Tier 4 interim. The new engines cover a broad performance range from 25 – 520 kW, and combine increased power density with high economic efficiency and proven Deutz quality.

Marked improvements in engine performance were achieved for all of the engine types. In particular, the response times of engines undergoing dynamic load changes were reduced by up to 50 per cent. This feature is being seen in new machines that claim a significantly higher productivity in construction equipment.

Deutz has tried to engineer in to the new engines more cost-efficiencies. They have been able to do this through simplifying installation, increasing service life and extending service intervals, as well as low fuel and oil consumption. Acoustically optimized components also ensure that costly additional insulation is virtually unnecessary for damping purposes.

With the new engines conforming to the IIIB / Tier 4 interim exhaust gas standard, equipment can be equipped with smaller engines than has been the norm. An improved common rail fuel injection, optimized turbocharging and basic engine components that are designed to far higher power densities are the key enablers.

Kubota Also pushing the boundaries in engine technology, Kubota sets a standard with its new 07 engine series - the V3307-Turbo (3.3l).

Although extremely compact, it has a high performance density. Features includes a variable PTO with up to 80% of the power being taken off; 4-valve technology for lower exhaust emissions; no intercooler required and designed with electrically controlled injection for the next emission standard (EPA Tier IV final) Engine output is up to 75 kW.

Design considerations in the engine is to enable compact exhaust treatment possible. The better raw emission of 4-valve engines has a positive effect on exhaust treatment.

Catalytic converter and particle filters can be smaller ins size, thereby reducing the cost of treatment.

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COMPANIES FEATURED Contractors World Vol. 1 No 3

Ballast Nedham

Bucyrus

Caterpillar

Deutz

Favco

Harsco

JCB

Kobelco

Komatsu

Kubota Engines

Maeda

MB Crusher Buckets

Merlo

Metso Minerals

Off-Highway Research

Perkins

Potain

Sandvik

Terex

Topcon

Trimble

Van Oord

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Heart Of Mary Villa Appeal Fund

An Appeal from David Phillips founder of Off-Highway Research

In April 1999, my wife and I adopted Hanna, an 11 month old baby from the Philippines. She had been born into typical third world poverty, but was fortunate enough to have been found by nuns at the Heart of Mary Villa, a charity that devotes itself to caring for orphaned and abandoned babies, and ensuring that they find safe homes for the future.

In 2000, I visited the orphanage after a typhoon. Great damage had been done; babies had to be evacuated by boat, many of the facilities were underwater and there was great risk of disease. The cash starved government could do little to help, so who could? So the 'Heart of Mary Villa Appeal Fund' was founded.

With the recent typhoon hitting very badly, the orphanage has been devastated once more: the flood waters reached the second floor of the nursery, and all 27 babies had to be rescued by ladders, boats and general ingenuity. The latest reports are that everyone is safe, but all clothes, food and medicines, and everyone’s property have been destroyed.

Off-Highway Research has sent a sum to meet immediate needs to ensure that life returns to some sort of normality as soon as possible: food, drinking water and medicines, but it is the longer term that we need to plan for, and for which we need money.

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A $20 donation will keep a baby looked after for a week - food, care, medicines and the administrative work to help find new parents. Not very, but enough to make a big difference for the future of a child. Think about that when you next go to a restaurant.

What Could You Do To Help? Please give as much (or as little) money as you can spare, either by check to me (made payable to 'Heart of Mary

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My best regards

David C A Phillips Off-Highway Research

Heart of Mary Villa Appeal Fund, 35 Great James Street, London WC1N 3HB, England

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