With municipal water costs exceeding $100,000 per month during droughts and “walking leaks” from slurry injection threatening active mining operations, the Franklin Quarry was under mounting pressure.

Additional constraints also pushed Vulcan to find a more economical and sustainable solution at its operation in Franklin, Tennessee.

“The city water supply only provided 50 to 75 gallons per minute, but we use 2,000 gallons per minute at the wash plant,” says Aneesh Kona, an engineering project manager within Vulcan’s Central Division. “We filled a pond overnight to use the next day, but the pond collected dirt – and cleaning it every three to four years cost $500,000 to $1 million.”

Ultimately, Vulcan invested in a fines recovery system that turned an active risk at the Franklin Quarry into a resource stream recovering saleable material. The system also enables Vulcan to recycle more than 90 percent of its process water.

“It’s a blueprint for how modern quarries can balance production goals with environmental stewardship,” Kona says.

Blueprint for growth

Franklin Quarry’s fines recovery system, which has been running since September 2025, is a closed-loop mechanical circuit featuring a 40-ft. high-rate thickener and a three-meter, four-roll belt filter press that replaces traditional slurry pond disposal.

According to Kona, process water slurry is treated in a high-rate clarifier for rapid liquid-solid separation. Recovered fines are dewatered into a stable, stackable “cake” for stockpiling, while clarified water is immediately recycled back into the plant.

Vulcan says the system achieves a 99 percent reduction in municipal water costs. It also recovers 3 percent of total fines – or about 40,000 tpy. The system blends fines at a 6 percent ratio into saleable products.

“The recovered product is a stable cake – exceeding 36 percent solids – with a median particle size of 12.7 micrometers,” Kona says. “It meets TDOT (Tennessee Department of Transportation) Type 2 skid-resistant specifications and is blended internally into commercial base aggregate.”

The system represents a $5.1 million investment by Vulcan, which made the case to shareholders by targeting a $500,000 annual reduction in utility water expenditures along with eliminating the safety risks associated with subsurface slurry migration.

The company’s exploration of such a system began in early 2023.

Among the technical hurdles Vulcan cleared on the project was a foundation for the system. In the end, a stable foundation was engineered on a 25-ft.-deep washout pond using specialized shot rock fill to support more than 3.25 million lbs. of equipment.

The system itself uses a centralized PLC architecture with in-line turbidity and mass-flow sensors for automated polymer dosing, which maintains performance despite geological feed variability.

“It’s essentially a water treatment plant – a thickener and a belt press,” says Kona, noting that the thickener is from McLanahan Corp. while the belt press is from BDP Industries. “We pump process water into the thickener, add flocculant to settle solids and recover clean water.”

System at work

Kona says the Franklin Quarry’s system is the first of its kind in that the operation’s use case was water. Other Vulcan sites have experience with such systems, he adds, but their needs are rooted in fines recovery.

“This case study serves as a blueprint for sustainability by converting an environmental and safety liability into an economic asset through a ‘circular economy’ approach,” Kona says.

Related: Vulcan Materials expands footprint with Brannan assets

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According to Breedon Group, Falling Springs is a highly automated quarry with 185 million metric tons of limestone reserves located in Dupo, Illinois. The operation is situated about 15 minutes from downtown St Louis.

“The acquisition of Falling Springs Quarry represents an attractive bolt-on investment, which strengthens our U.S. platform with a premium aggregates asset in an exceptionally strategic location,” says Rob Wood, CEO of Breedon Group. “The business is well-invested, highly cash generative and extremely complementary to our existing operations in the St Louis area, supporting our long-term growth ambitions in the United States.”

On its latest top 100 crushed stone producers list, the U.S. Geological Survey ranks Casper Stone Quarry/Falling Springs Quarry as the No. 89 producer in the U.S. Breedon Group says the quarry produces more than 2.2 million metric tons per year.

The operation will now be integrated with Breedon’s existing operations in the region.

Related: How Southern Stone is surging under Five-S

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Peter Kilmurray was named North America sales manager at Consep, an Australian engineering solutions provider whose specialties include mineral processing.

Kilmurray previously served at Haver & Boecker Niagara.

Consep is parent company of SizeTec and Heath & Sherwood, which both have ties to aggregates and mining. While SizeTec specializes in vibrating screening equipment, Heath & Sherwood supplies a line of standard and custom-designed samplers used for feeding process control analyzers, metallurgical accounting and inventory control requirements.

“Whether you are looking to meet process requirements in dewatering, desliming, scalping, or wet or dry sizing, you can rely on SizeTec products for all your screening and sizing applications,” Kilmurray says.

Related: Selecting the right screen media for the job

<p>The post Consep names Kilmurray North America sales manager first appeared on Pit & Quarry.</p>

Kobelco Construction Machinery USA launched the SK850LC-11 crawler excavator.

Weighing about 186,000 pounds, Kobelco says the new machine offers a combination of power and stability for large-capacity applications. The SK850LC-11 features a 512-hp. Isuzu Tier 4 Final engine, providing operators with the power and torque needed to lift heavy loads and operate large tools.

According to Kobelco, the SK850LC-11’s hydraulic system minimizes fuel consumption while maximizing power. The company says it delivers a smooth response to operator input, a digging force of 90,598 pound-force and an arm force of 61,148 pound-force.

The excavator can perform multiple functions while traveling – lift, swing and carry – due to its independent travel function. This feature allows the operator to dedicate one hydraulic pump to the travel system and one to all other functions.

A selection of features is inside the cab of the SK850LC-11 that Kobelco enhance operator ergonomics and safety. A seven-way adjustable, heated air-suspension seat moves together with the armrests, and hydraulic controls aimed at reducing operator fatigue provide shock absorption and offer comfort while riding.

Menu screens are accessible on a 10-in. color monitor, displaying information such as work mode, maintenance intervals and fuel consumption, as well as a 270-degree view from the machine’s three-camera system.

Related: John Deere launches pair of wheel loaders

<p>The post Kobelco debuts latest excavator model first appeared on Pit & Quarry.</p>

Komatsu is expanding its customer support and infrastructure in the Western U.S. with the planned opening of a new parts distribution facility in Mesa, Arizona.

The new location is intended to strengthen regional parts availability, improve delivery responsiveness and help dealers and customers maximize equipment uptime across the region, according to the company.

Among the investments Komatsu is making in the Mesa facility are automation, storage systems and operational enhancements. These investments will position inventory closer to customers and streamline delivery, Komatsu says. The center is currently under development and is expected to become operational by the end of 2026.

The 270,000-sq.-ft. distribution hub is expected to help support Komatsu’s customer base in the region with capabilities including:

• Stocking parts for construction, mining, forklift and forestry equipment

• Improving regional parts availability through localized inventory

• Reducing freight distance and transportation requirements

• Enabling next-morning delivery to many Western dealers

“This investment reflects Komatsu’s long-term commitment to strengthening support for our dealers and customers across the Western U.S.,” says Danny Murtagh, vice president of parts and infrastructure at Komatsu. “With expanded distribution capabilities and greater inventory availability positioned closer to our customers, we can respond faster, improve equipment uptime and deliver a better overall support experience.”

Related: Komatsu opens new mining hub in Illinois

<p>The post Komatsu to open parts distribution facility in Arizona first appeared on Pit & Quarry.</p>

Vulcan’s acquisition includes a rail-connected quarry with reserves in Lamar, Colorado, and a new distribution yard in the Dallas-Fort Worth market.

“These portfolio actions align with our aggregates-led growth strategy by expanding our reach into southern Colorado and strengthening our distribution network in Dallas-Fort Worth to meet growing customer demand with high-quality aggregates,” says Ronnie Pruitt, CEO of Vulcan Materials.

In Colorado, Brannan Sand & Gravel has aggregate plants in Brighton, Central City, Denver, Fairplay, Fort Lupton (two plants) and Platteville. The company has five asphalt plants in Colorado along with seven ready-mixed concrete plants in the state.

Brannan Sand & Gravel ranks No. 46 on the U.S. Geological Survey’s latest list of the nation’s top 100 sand and gravel producers. The list was made available in early 2025.

Related: Early-year trends emerge in first-quarter earnings

<p>The post Vulcan Materials expands footprint with Brannan assets first appeared on Pit & Quarry.</p>

CDE appointed Brent Wilde as business development manager for Canada to support the company’s growth across the country. 

With more than 20 years of experience in the construction industry, Wilde has held various roles across business development, operations, construction management and project management.

In recent years, CDE says Wilde has been involved in advancing soil washing and resource recovery opportunities within the Canadian market, contributing to project development, operational planning and business strategy related to contaminated soil remediation and sustainable materials recovery.

“I’m really excited to be joining CDE,” Wilde says. “This is a really exciting time for CDE and the natural processing and waste recycling sectors in Canada, and I’m eager to help customers find sustainable solutions for their materials.

“Our goals are very much aligned,” he adds. “We are both passionate about finding creative ways to unlock value from materials traditionally viewed as waste, and I look forward to sharing CDE’s innovations in resource recovery across Canada.”

Wilde’s appointment follows CDE’s addition of Chad Greenfield as vice president of sales for North America and Latin America.

Related: CDE debuts ModaLine for modular sand washing

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That’s not a shock. In the safety world, regulatory change often arrives with disjointed rhythm: hype, anticipation, public comment and then a staggered implementation that can feel uneven at best.

But none of that changes the reality in the field. A pause in enforcement is not a pause in exposure.

A few summers ago, I was in West Lebanon, New Hampshire, talking with a team in the shop when this really came into focus. The haul road ran just uphill from their bays, and every time a truck came through, dust would drift down and settle into their workspace.

What stood out was this: The team in the shop – nowhere near the crusher – was dealing with more day-to-day dust exposure than some of the folks working directly in production. There was no dramatic fanfare – just steady, quiet exposure.

That’s the part we must stay ahead of. And in this case, a properly used water truck made all the difference.

Protecting our lungs from the known impacts of silica remains critical.

As an industry, we don’t get to rest on our laurels. We have a responsibility to stay vigilant and proactive.

Whether MSHA is enforcing today or tomorrow, the expectation should remain the same: protect the people doing the work.

Rather than revisiting the standard or repeating the controls we’ve already discussed in this column, let’s shift the lens a bit. Here are a few everyday areas – often overlooked – that can have a meaningful impact on keeping our team’s lungs clean.

Hidden sources

■ Haul roads. When most people think about silica exposure in a pit or quarry, they picture crushing operations or blasting. That makes sense, as it’s visible and obvious. But spend a few hours on-site and you’ll see a different story.

Haul roads and travel ways can generate significant amounts of ambient dust, especially during dry conditions. Every pass of a truck adds to the problem. Over time, that dust becomes part of the environment everyone breathes.

Two factors make a measurable difference here: water and speed. Consistent water truck use is one of the most effective controls available. Target dry, high-traffic areas, and don’t wait until visibility becomes an issue. By then, exposure has already occurred.

Speed is the other lever. Faster travel equals more agitation, which means more dust in the air. Consider simple, practical controls:

■ Clearly posted speed limits

■ Speed monitoring signs or feedback boards

■ Direct communication with drivers and haulers

None of these are complicated, but together they reduce dust generation in a meaningful way.

■ Air filtration. Most buildings, vehicles and pieces of mobile equipment are equipped with some form of air handling or air conditioning system. These systems are designed to protect the operator, but only if they’re maintained.

Filters don’t stay effective forever. If they’re clogged, bypassed or simply forgotten, they stop doing their job. That turns what should be a controlled environment into another exposure point.

Build filter checks and replacements into your routine maintenance systems – not occasionally, but systemically. A clean cab with a functioning filtration system can be one of your strongest defenses against airborne contaminants.

■ Confined spaces. These already demand a high level of attention, and most teams are well-trained on entry procedures. But it’s easy to overlook how quickly air quality can degrade in these environments.

Limited air movement, poor natural ventilation and the potential for contaminant buildup create a perfect storm for respiratory exposure. In these situations, the margin for error shrinks fast.

A few reminders that matter:

■ Follow your confined space entry procedures, every time

■ Ensure proper ventilation before and during entry

■ Use appropriate PPE and respiratory protection when needed

■ Inside a confined space, what you breathe matters even more – and the consequences show up faster

Commitment beyond compliance

MSHA may be pausing enforcement, but our responsibility doesn’t pause with it. Our job is to protect the people doing the work and make sure they go home safely, every day. Clean lungs are part of that promise.

If you have silica-reduction ideas that are working in your operation, I’d love to hear them. Let’s keep sharing what works.

Steve Fuller has worked over the past 20-plus years with a variety of industries – including aggregates – in operational and safety leadership roles. Now representing Steve Fuller Company, he can be reached at steve@stevefullercompany.com.

Related: Assessing the cost of ‘just this once’

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Boreal is based in Fermont, Quebec, and serves operations across the Labrador Trough.

Through the agreement, Boreal Mining Equipment will represent Haver & Boecker Niagara’s full range of screening technologies – including vibrating screens, engineered processing plants, condition monitoring systems and aftermarket services.

“We are excited to welcome Boreal Mining Equipment to our dealer network,” says Steve Dery, vice president of sales at Haver & Boecker Niagara. “Their strong industry knowledge, commitment to customer service and technical capabilities make them an ideal partner. Together, we are well-positioned to deliver innovative solutions that help customers optimize performance and reduce downtime.”

Related: Smarter screening, stronger plants with Haver & Boecker Niagara

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