Fulton Hogan’s Canterbury quarrying operation has been given a lift in productivity and efficiency with the addition of three new crushers from Kleemann. By MARY SEARLE BELL.
FULTON HOGAN HAS been in the quarry industry for more than 80 years and processes rock and aggregates at around 45 different sites throughout New Zealand and Australia to supply to civil construction projects.
Naturally, each region of the country is unique, and the treatment of the rocks differs according to their particular qualities. For Fulton Hogan’s Canterbury branch, the alluvial plains mean that much of the rock processed there is what Quinn McNab, retail and portable operations manager, describes as “nice material”.
However, following the Kaikoura earthquakes, Fulton Hogan took its portable crushers into the Clarence and Hapuka Rivers, where the rocks are larger and present a bigger challenge to crush.
“We were crushing boulders, much bigger than what we’re used to,” says Quinn.
Unsurprisingly, the existing gear struggled with the challenge. So, to meet the challenge, the company opted to buy a new Kleemann jaw crusher, from Kleemann supplier Wirtgen New Zealand.
The Kleemann MC110Z EVO jaw crusher soon proved it was an ideal unit for the job in the Clarence River.
“It can monster all the boulders we can throw at it,” say Quinn. “If the digger can lift it, the jaw can crush it.”
The spec sheet has the crusher’s inlet opening at 1100mm by 700mm, with a maximum feed capacity of 330 tonnes per hour.
“When the NCTIR [North Canterbury Transport Infrastructure Recovery, pronounced ‘nectar’] work finishes, it will fit well into the Fulton Hogan operations in Canterbury, and further south.
“A unit like this future-proofs the company for new projects, especially in hard rock settings across the South Island, where the feed material is typically less consistent than in Canterbury.”
Fulton Hogan is also operating a Kleemann MR110ZS EVO2 impact crusher and a Kleemann MCO9S closed circuit cone crusher.
“We had the impact crusher working in the Clarence River in tandem with the jaw crusher. The jaw would crush the rocks to 100mm and then they were fed into the impact crusher to break them down and screen out an M4 AP40 product.
“We trialled it at our Lake Hood Quarry just out of Ashburton, and in the Ashburton River. It’s quite challenging as the material is really, really small with a high percentage of fines and it’s hard to get the required broken face percentage while still meeting the grading specification,” says Quinn.
However, it seems the MR110ZS is equal to the task.
“It’s doing well, as it has the ability to scalp out the fines with its live independent pre-screen, which allows for the machine to do more crushing with less wear,” he says.
“It’s ideal for this as it can turn out huge volumes of M4, AP65, AP40 and AP20, without additional gear.
“It’s effectively a one-man operation. One guy can grab a loader and feed the impact crusher, and away it goes.”
As for the new Kleemann MCO9S cone crusher, it is still up in the Clarence, working in conjunction with the jaw crusher.
“We’re currently making railway ballast and this has quite specific specifications,” says Quinn. “Ballast is required to be a 65mm product with zero fines.
“This gear is an ideal operation for us, because, like the impact crusher, the Kleemann jaw has the same ability to pre-screen out all the fines in the feed material. This means anything less than 40mm is taken out and everything larger goes to the cone. The cone gives a final crush to ensure the largest sizing is 65mm and helps give shape to the product.”
For Quinn, the other standout feature of the Kleemann products is that everything is enclosed.
“Fulton Hogan is big on safety and the units are well designed with optimal guarding and access points for maintenance. This means there’s no extra guarding required. You just roll it off the boat and use,” he says.
“What is also great about Kleemann, is that you can link all the gear together via an interlinking cable – the machines will adjust if one crusher is not keeping up, automatically running at the optimum level, which ensures our operation is working efficiently.
“And it’s a nice looking piece of kit too!”
Overall, the team at Fulton Hogan is very impressed with their new equipment; “it’s been very reliable”, says Quinn.
On top of this, the support they have received from Gary Payne at Wirtgen has been very good, particularly with training around the new gear.
“Gary has been excellent about running new guys through how it all works,” says Quinn.
“We’ve had no teething issues.”
This article was first published in the April-May issue of Q&M.