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LIAM MCLOUGHLINEDITOR

A new phase for the US

construction materials sector?

The US construction market and its associated sectors, including quarrying and aggregates, could be entering a new phase with a rebound in growth.

Research from the United States Geological Survey (USGS) on US aggregates production, and from data and analytics provider Dodge Construction Network on US construction activity, both suggest this may be the case.

The USGS estimated that 441 million metric tonnes (Mt) of crushed stone were used or sold in the US market in the third quarter of 2025, a seven per cent increase year-on-year from the third quarter of 2024.

The Dodge Momentum Index of US commercial and institutional non-residential construction projects for January 2026 increased by 29 per cent year-on-year compared to January 2025. The commercial segment was up 26 per cent, with data centres contributing heavily to this gure.

A total of 33 projects valued at $US100m or more entered planning throughout January.

The largest commercial projects included the $US500m Amazon Data Center in Jeffersonville, Ohio, and phase one of the Hunter’s Ridge Data Center in Mclean, Virginia. The largest institutional projects to enter planning were the $US407m Memorial Hospital expansion in Colorado Springs, Colorado and the $US300m AdventHealth Hospital expansion in Parker, Colorado. Our US market report in this issue picks through this data and nds plenty of other positive indicators.

Major industry manufacturers have made recent moves strengthening their US focus. Cement technology and equipment company Fuller Technologies (formerly FLSmidth Cement) con rmed it would relocate its headquarters to Allentown, Pennsylvania, while continuing to maintain its existing of ces in India and Denmark.

The return to the Lehigh Valley, where several major cement plants are located, is a key part of the company’s new era.

Mineral processing equipment manufacturers such as Sandvik are expanding their digital technology capabilities in line with changes in US customer demand. Sandvik last year acquired the computer-aided manufacturing (CAM) business

of MLC CAD Systems. The Texas-headquartered reseller provided computer-aided design (CAD)/ CAM solutions in the Mastercam network and will now become part of Sandvik’s Mastercam business unit.

Also in 2025, John Deere announced its acquisition of a Pennsylvanian-based construction technology company, Tenna, which provides asset-tracking solutions such as its integrated technology platform, which provides near-realtime information on equipment operations, trends and maintenance.

With investment in the US is occurring on the factory oor, our manufacturing feature in this issue, nds that this investment is moving handin-hand with greater employment. The latest US Labour Department job report released in February showed 130,000 jobs were added to the US economy, with the construction sector accounting for 33,000 of those.

“Construction continues to be a powerful engine of economic growth,” Association of Equipment Manufacturers president and chief executive of cer Megan Tanel said.

“Strong hiring re ects sustained infrastructure investment, private development activity and longterm con dence in the build environment.”

In this issue, we report on how a horizontal triple screen from McLanahan is helping longestablished Minnesota aggregates producer McNamara Contracting improve both tonnage and separation at its sand-and-gravel pit.

I write this editor’s letter shortly before heading off to ConExpo-Con/Agg 2026 in Las Vegas for the year’s biggest gathering of construction and quarrying industry professionals. The event provides fascinating insights into the latest industry trends in the US and beyond. The 2026 iteration features around 2000 exhibitors across 2.9 million square feet of exhibit space and 50 educational sessions, including the sector’s biggest manufacturers and distributors. The May-June edition of Aggregates Business America will feature a full report from the show with news, product launches and interviews with industry gures. LM liam.mcloughlin@primeglobalpublishing. com

Celebrating success

The NSSGA has highlighted the achievements and careers of the industry’s best and brightest at its national convention in Las Vegas.

The National Sand, Stone & Gravel Association (NSSGA) has kicked off a busy year in the quarrying and aggregates sector with its 2026 annual convention in Las Vegas, which was attended by more than 700 professionals.

The event, held in conjunction with the National Ready Mixed Concrete Association’s (NRMCA) annual convention, included committee meetings, breakouts and receptions and a joint general session with keynote speaker and famed football legend Terry Bradshaw.

“Our annual convention is an ideal opportunity for members to connect and learn from others in the industry,” NSSGA president and chief executive of cer Michele Stanley said.

“Holding this meeting jointly allows us to be ef cient and shape a united policy message to take back to Washington, DC.”

Over the three days, several key NSSGA events were held, including the NSSGA board of directors’ meeting and the annual membership meeting, the approval of NSSGA leadership, and award presentations. Attendees also enjoyed a keynote speech from arti cial intelligence expert Jon Lake sh.

McLanahan and Eagle Iron Works vice president Mark Krause was recognised with the 2026 Barry K. Wendt Memorial Commitment Award during the annual membership meeting.

NSSGA’s Manufacturers & Services (M&S) Division established the award in 1998 to annually recognise an industry professional who exempli es the dedication

of Barry Wendt, both in commitment to the industry and to the community in which they live. This award is the most distinguished individual award presented by the NSSGA.

“I was lucky to have some great mentors in my early years, with Barry Wendt being my biggest in uence. To receive this award, which carries the name of Barry Wendt, is a true honour,” Krause said.

Krause has worked in the aggregates sector for more than four decades across several roles, including production, dealerships and manufacturing.

NSSGA immediate past M&S chair Craig Lamarque said Krause’s passion for the NSSGA was unmatched as was his role as an educator and mentor within the sector.

“Mark is a leader in the industry known for his commitment to innovation and the continuous improvement of equipment and processes,” he said.

“His [Krause’s] dedication and ability to connect with others of all levels have made him a respected gure in the industry.”

Also, during the annual membership meeting, Zach Green was announced as the 2026 chair of the NSSGA board. Green has 26 years of leadership experience across the Colas Group. He has guided major divisions, including Barrett Industries, Reeves Construction, HRI, IA, and Delta Companies, leading large civil-infrastructure operations across multiple states. Outgoing board chair Ted Baker II of Blue Water Industries handed over the gavel to Green after presenting the 2025 State of the Association.

“It’s an honour to serve as NSSGA’s next board chair,” Green said.

“This association matters, not just in Washington, but back home in every state and community where our members operate, employ people, and supply the materials that quite literally build America.”

The NSSGA’s M&S Division announced that Superior Industries’ Kristen Randall would be its new chair in 2026. Rich Evangelista of Bunting Magnetics Co was announced as the 2026 M&S vice chair.

Randall takes over from outgoing chair Lamarque, who presented her with the gavel during the M&S members’ dinner.

Randall joined Superior Industries in 2023 to lead the launch of OptimizeU, the company’s industry learning and development initiative. She previously held a senior marketing role at Haver & Boecker and brings more than 20 years of experience in the aggregates industry. Randall helped to establish the NSSGA M&S workforce development subcommittee through her involvement with the M&S executive committee over the past few years.

“Our M&S members are a vital part of our association’s success. They develop innovative processes and build key relationships, which increase our industry footprint,” Stanley said.

“I am con dent that Kristen’s industry experience and leadership background will help the division grow to new heights.”

Later this year, NSSGA members will convene for another key event, the NSSGA Legislative & Policy Forum, in Washington, DC, from September 20–23. AB

For more information on upcoming NSSGA meetings and events, visit www.nssga.org.

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Under construction

New data paints an interesting picture of the US construction market and associated sectors as companies position themselves for the next chapter of growth.

The US construction materials market is an ever-evolving landscape as companies jostle for a foothold in one of the world's largest markets. A new phase could be underway in the US market, with recent data showing a rebound in 2025 compared to the slower 2024. With the market on track to rebound across the coming months, companies seem to be positioning themselves to take advantage of the next building cycle in the US.

Dodge Construction Network released its Dodge Momentum Index (DMI) for January, which underscored the rebound. In yearover-year terms, the DMI increased by 29 per cent compared to January 2025. Drilling down into that, the commercial segment was up 26 per cent, with data centres contributing strongly to the topline.

The DMI is a forward-focused indicator for construction spending.

The monthly measure is based on the value of non-residential building projects entering the planning stage and can indicate future construction spending patterns over 12—18 months.

“Data centre projects continue to lead the way, but after elevated activity in late 2025, most nonresidential sectors are now easing into a more sustainable growth pattern,” Dodge Construction Network associate director of forecasting Sarah Martin said.

The United States Geological Survey (USGS) estimated that 441 million metric tonnes (Mt) of crushed stone were used or sold in the US market during the third quarter of 2025. Compared to the corresponding period of 2024, this was a seven per cent increase. Construction sand and gravel sold is estimated to have increased from 260Mt in the third quarter of 2024 to 262Mt in 2025. The consumption rate of construction aggregates was up by ve per cent over this timeframe, with similar increases estimated for Portland cement (four per cent).

Production rates in the third quarter of 2025 also seemed to lift across several key quarrying and aggregates segments.

The production rate of crushed stone increased in seven of nine geographic regions included in the USGS’s data spread. Further increases were also seen in the construction sand and gravel and construction aggregates segments (both six of nine).

It does point to initial signs of resilience within the construction sector, which has traditionally owed on to associated sectors, including construction materials.

In a manufacturing sense, many within the sector would have noticed major shifts that have repositioned existing brands within the US market. Fuller Technologies made its biggest statement about its US focus since it was acquired by the private equity rm Paci c Avenue Capital Partners in late 2025.

The company con rmed it would relocate its headquarters to Allentown, Pennsylvania, while maintaining its existing of ces in India and Denmark.

The return to the Lehigh Valley, where several major cement plants operate, shapes as a key part of the company’s new era.

“Fuller Technologies is proud to be a global company, while returning to its deep roots in Pennsylvania's industrial heritage with the relocation of its headquarters to the USA,” Fuller Technologies chief executive of cer Dennis Cassidy.

“Our engineering and manufacturing locations in Europe and Asia are integral to delivering our products and services to a customer base that is truly global and will remain so.

“As we develop our base in Pennsylvania, we are also committed to growing our presence and technical expertise in key markets around the world.”

Alongside revealing the new location for its headquarters, Fuller is set to invest in its workforce at its manufacturing facility’s in Northampton County. This will support the company’s plan to grow in the cement market alongside complementary segments, including lime, minerals and bulk materials handling.

“We are committed to creating quality employment opportunities here in Pennsylvania, as we expand our operating presence in the key American cement market,” Cassidy said.

“With many manufacturers facing challenges in attracting skilled workers, workforce development is a strategic priority for us.”

Fuller has not been alone in shoring up its position in the US, with Terex also making signi cant announcements in recent months.

The original equipment manufacturer nalised its merger with REV Group in February 2026, with the deal set to form a new “specialty equipment manufacturer” that will have an extensive manufacturing footprint in the US.

Simon Meester has become the president and chief executive of cer of the combined company.

Meester said the new entity is wellpositioned to take advantage of the growing demand in the domestic market.

“This transaction represents a transformative step for both companies. By combining our complementary portfolios and leveraging our collective strengths, we are creating a large-scale, diversi ed industrial leader well-positioned to capitalise on longterm secular growth trends,” he said.

“The transaction will unlock signi cant value for both Terex and REV Group.

“The merger positions the company quite uniquely to accelerate pro table growth with a much more resilient top line.”

Manufacturers growing their digital technology capabilities in line with customer demand in the US market.

John Deere acquired Tenna in 2025.

Sandvik acquired the computer-aided manufacturing (CAM) business of MLC CAD Systems in early 2026.

MLC CAD Systems, a Texas -headquartered reseller, provided computeraided design (CAD)/CAM solutions in the Mastercam network and will now become part of Sandvik’s Mastercam business unit.

“This acquisition supports our growth ambitions within digital manufacturing as it strengthens the direct sales channel of our software solutions, our regional presence and our capabilities to support our customers,” Sandvik chief executive of cer Stefan Widing said at the time.

In 2025, John Deere struck a deal to acquire Pennsylvanian-based construction technology company Tenna.

The latter has made its name as a provider of asset-tracking solutions, including its integrated technology platform, which provides near-real-time information on equipment operations, trends and maintenance.

It remains to be seen whether this growth can continue throughout 2026, but many stakeholders will be intently watching the dynamics of the US market.

If demand remains stable, the data indicate that companies will continue to seek opportunities to grow in one of the world’s largest construction materials sectors through innovation and adaptation. AB

Heavy equipment plays an important role in the quarrying and aggregates sector

Manufacturing momentum

Major manufacturers have invested significantly to expand their manufacturing and remanufacturing operations in the US market.

Investment is occurring on the factory oor throughout the US.

Across the US market over the past two to three years, manufacturers have made investments to strengthen their manufacturing capacity and capabilities.

As automation and digital technology change the face of modern manufacturing, these investments offer insight into the thought processes of the world’s biggest manufacturers.

Against the backdrop of this spending is the latest US Labour Department’s job report released in February. The latest data showed 130,000 jobs were added to the US economy, with the construction sector accounting for 33,000 of those.

Association of Equipment Manufacturers president and chief executive of cer Megan Tanel said the increase in hiring was going hand in hand with equipment investment.

“Construction continues to be a powerful engine of economic growth. Strong hiring re ects sustained infrastructure investment, private development activity and long-term con dence in the build environment,” she said.

“With hiring accelerating, contractors are increasingly investing in advanced equipment, digital tools and workforce development strategies to scale ef ciently and safely. We continue to see a clear connection between economic momentum and innovation.

“As demand grows, the industry is responding with smarter equipment and new training pathways to ensure projects stay on track, in budget and with safety as a top priority.”

Investing in the future

In addition to manufacturing facilities, manufacturers are also showing an increasing willingness to invest in the next generation of the manufacturing workforce.

Advocacy groups, including the Associated Builders and Contractors, have highlighted that a potential shortfall could occur in the US construction sector if the issue is not addressed in the short to

The trade group estimated in a recent report that the construction sector will need to employ around 456,000 new workers by 2027 to meet future demand. It is no small feat, with the number more than 30 per cent higher than the current sector gap.

“Failing to do so will worsen labour shortages, especially in certain occupations and regions, placing further upward pressure on labour costs,” ABC chief economist Anirban Basu said.

Companies, including Caterpillar, have begun taking proactive steps to address this issue through increased investment.

In 2025, Caterpillar announced it would invest $US100 million in workforce development initiatives over the next ve years, with Indiana among the rst states to receive funding from the manufacturer.

Caterpillar is committed to spending $US5

Caterpillar has invested significantly in Indiana.

initiatives in the state, with more workforce funding to be announced for other states.

“The future workforce will need skills for what comes next,” Caterpillar chief human resources of cer Christy Pambianchi said.

“We have our experts working on innovative training and resources to help skill and inform the next generation on how to navigate the worksite of tomorrow, and we’re excited to be starting here in Indiana to enable US workers to enter high-quality jobs in the American manufacturing industry.”

The announcement was made at Caterpillar’s large engine manufacturing facility in Lafayette, Indiana, which has also been the subject of further investment from Caterpillar. In 2024, the company locked in $US725 million for an expansion of the site, which the company labelled “one of the largest single manufacturing investments” in its history.

The multi-year investment aims to increase capacity for manufacturing new engines and aftermarket parts. This includes the capability to build and test products like new engines, genset packages, aftermarket components and refurbished components. Caterpillar estimated the investment would create 100 new jobs in addition to the existing 1900 employees that work at the Lafayette site, which opened in 1982.

“Many of the engines manufactured here in Lafayette will support power generation customers by providing reliable power –keeping operations running during outages

and helping meet the growing energy needs driven by [arti cial intelligence], data centres, and other critical infrastructure across America and around the world,” Caterpillar energy and transportation group president Jason Kaiser said.

Remanufacturing

Other manufacturers, including John Deere, have committed to investments in recent years as a means of increasing their manufacturing capacity.

The US-headquartered manufacturer announced in late 2024 that it would expand its John Deere Reman Core Centre facility through a $US13.5 million investment.

will be around 400,000 square feet once the 120,000-square-foot expansion is nalised.

It continues John Deere’s remanufacturing legacy, which began almost three decades ago as a joint venture with Spring eld Remanufacturing Corporation, which John Deere later acquired.

“This is a signi cant milestone for us and shows John Deere’s commitment to the [remanufacturing] business and to the local community,” John Deere remanufacturing manager Kevin Schrag said.

“Our dedicated employees, with their focus on keeping our customers running and commitment to the remanufacturing business, have made this investment possible.”

The project broke ground in 2025 and is likely to be completed later this year.

The site, based in Strafford, Missouri,

As modern manufacturing continues to shift, investment is helping companies capitalise on the next era of growth. AB

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Tonnage and separation

Upgrading its screening circuit increased throughput and improved material separation for Minnesota’s McNamara Contracting, after installing a triple-deck horizontal screen from McLanahan.

As one of the longest-established original equipment manufacturers in the quarrying and aggregates sector, McLanahan Corporation has spent more than 190 years developing processing solutions.

Over time, its crushing and screening equipment, supported by an extensive dealer network, helps quarry and aggregates operators produce materials for America’s infrastructure, roads, and more. Its proven designs consistently meet the challenge.

Now its history in creating eld-ready solutions is helping McNamara Contracting increase production at its operation in Minnesota. McNamara Contracting, a third-generation contractor in Rosemount, Minnesota, supplies aggregates for asphalt

McNamara Contracting has been impressed by the McLanahan tripledeck horizontal screen.

and base, and offers civil construction services. The Minnesota-based business needed to upgrade its screening equipment after the shaft and bearings on its previous screen deck failed, prompting the contractor to seek a more dependable, higher-capacity screening solution.

Looking for a replacement, McNamara rented a triple-deck horizontal screen from Viking Aggregate Equipment, the manufacturer’s regional dry processing dealer. The dealer supported the installation and commissioning of the screen, ensuring the unit was tuned for the application before production began.

The triple-deck solution features McLanahan’s triple-shaft mechanism with an aggressive oval stroke, adjustable settings,

and an end-tensioned bottom deck for easy maintenance, with access holes for screen media replacement.

The unit was installed on a portable chassis and includes wide walkways, dualaccess ladders, and a sliding discharge chute to improve access and simplify maintenance.

The horizontal screen was installed as the nal screen in the crushing circuit, separating material from the primary and secondary crushers into three nal products used in McNamara’s asphalt mix.

“It handled a lot more material, and just the way everything was set up on it with the sliding chute and the accessibility to get to the screens, everything worked really well with that screen deck,” McNamara crusher operator Joseph Adelmann said.

Material too large to pass through screen openings moves along the screen to discharge onto the product conveyor. Oversized material is returned to the crusher for further reduction until it passes through the screen and is sent to the stockpile.

Material is fed onto the screen decks where it is separated by size as it moves across the screening surfaces.

Oversized material that cannot pass through the screen media is discharged and returned to the crushing circuit for further reduction before being processed again.

Since introducing the horizontal screen, McNamara has seen an increase in both production capacity and screening performance compared with its previous unit.

Adelmann said the new screen allows the operation to process a higher volume of material while maintaining product quality.

“It shakes a lot more to where it’s able to sift a lot more and handle a lot more material to where we can put more out,” he said.

The improved screen capacity has also enabled the operation to upgrade other parts of its processing circuit to support higher throughput.

“Since the horizontal screen is able to handle more, we were able to get a new conveyor that could pour more material to that screen deck, so we’re not wasting space,” Adelmann said.

Maintenance accessibility has also been a major improvement compared with the company’s previous screening unit.

The horizontal screen features an end-tensioned bottom deck, designed to simplify screen media replacement.

The sliding discharge chute also allows operators to quickly access the screening surfaces for maintenance.

McNamara has already replaced the screen media on the bottom deck twice since installing the machine, and Adelmann said the process has been signi cantly easier than with the contractor’s previous screen.

“Our last screen, you had to unbolt a hundred-pound plate at the end and put that off to the side, and that’s how you got into the screens,” he said.

“It’s really nice to slide that chute back to where you can get in there and get everything, and then I really do like the end-tensioned screens.”

In addition to simplifying maintenance tasks, the machine’s design has improved safety and accessibility around the screening unit.

Wide walkways and ladders on both sides of the screen make it easier for operators to carry out inspections and service work.

Adelmann said these practical features have made a noticeable difference for the team operating the plant.

“Everything is way nicer with the McLanahan Horizontal Screen,” he said. With increased throughput, improved separation performance and easier service access, the triple-deck horizontal screen has become a key part of the contractor’s portable crushing and screening operation. AB

New leadership

Major appointments and departures have occurred in the US quarrying and aggregates

sector.

The US construction materials sector continues to be a hive of activity with several companies and organisations announcing key executive appointments in recent months.

Aggregates Business America examines the key changes across the US market.

Leading the charge

Josh Cage is set to play a key role in establishing CheckProof’s operation in America after taking on a new role as the US country manager.

Cage will be providing support to CheckProof’s customers in the US as well as managing commercial growth in the important market.

The new role signals CheckProof’s intent to grow in the key quarrying and aggregates market after establishing CheckProof US in 2024 and opening its of ce in Houston in 2025.

Cage said he is looking forward to the new role which will see him relocate from the UK to Houston.

“I’m excited to relocate from the UK to Houston and work even more closely with our US customers and our US team on the ground as we grow,” he said.

From his past experiences, Cage said he understood the bene t that CheckProof’s solutions could offer US customers.

“I rst used CheckProof in quarry operations, where follow-up was often fragmented across paper, spreadsheets, and shift handovers,” he said.

“Once inspections and actions became digital, traceable, and tied to real frontline processes, the day-to-day impact was immediate: safer execution, simpler compliance, and fewer issues slipping through the cracks.”

CheckProof vice president of sales and customer success Sanne Wiman said Cage had the right skillset to be successful in his new role.

“Josh has a rare combination of credibility from years in operations and the commercial discipline needed to scale,” Wiman said.

“He’s delivered strong results and earned trust quickly by staying close to the realities on site. With Josh moving from the UK to Houston, we’re reinforcing our commitment to the US and making it easier for customers to work with us – faster decisions, tighter collaboration, and a sharper focus on measurable outcomes.”

Successful tenure

The American Cement Association (ACA) is on the hunt for a new chief executive of cer after Mike Ireland announced his decision to retire.

The longtime president and chief executive of cer of ACA has stepped away from the top job after eight years.

His tenure included the organisation’s rebrand from the Portland Cement Association to the current ACA moniker as well as industry campaigns on carbon emissions and public awareness initiatives.

“It has been an absolute honour to work with the many wonderful people in this industry, which carries the unparalleled responsibility of not only facilitating everyday life for people around the world, but for making modern-day society possible,” he said.

“I’m humbled by the signi cant strides ACA has made during my tenure in raising the cement industry’s pro le from one that quietly helps provide the literal building blocks of America, to a recognised, leading voice in the construction arena, whose opinions are sought after and greatly valued

by Washington’s decision-makers. I deeply appreciate the opportunity I’ve had to represent this illustrious industry.”

The ACA has established a committee to nd Ireland’s replacement.

“ACA appreciates Mike’s leadership, spirit of collaboration, and the unique sense of humour he is famous for to help navigate the industry through its many successes and challenges over the past several years,” ACA board chair Monica Manolas said.

Family transition

Civil construction and construction materials company Allan Myers has revealed its new leaders following a leadership transition.

The family business con rmed Ross Myers is its new executive chairman after previously serving as its chairman and chief executive of cer for more than four decades.

Aaron Myers has been promoted from executive vice president to CEO as Ross’ successor. This marks the fourth generation of Myers in the family business alongside chief operating of cer Brock Myers and chief growth of cer Seth Myers.

“This is a remarkable time in the trajectory of our company. It has been a dream of mine for decades to be able to continue the family legacy of leadership at our company,” Ross said.

“I am overwhelmingly con dent in Brock, Aaron, and Seth continuing to partner with our other company leaders, building on our collective successes.”

The company also con rmed that Ray Bond is now its executive vice president and chief nancial of cer. Bond takes over from Denis Moore, who has become the director of special projects for the Myers Group. AB

Aggregates

Contact:

Without flow aids, accumulation of material is common throughout cement manufacturing, from quarry to load-out of the finished product.

The clogging conundrum

Martin Engineering global air cannon product manager

Brad Pronschinske shares his insights into best practices for preventing clogging in silos and hoppers using flow aids.

Despite the enduring desire to keep materials owing throughout the process, there are always parts of a cement plant where materials must be held, stored, and funnelled into the next stage of production. Even well-designed systems can succumb to the problem of materials clinging to the inside walls of silos, bins, and hoppers.

Once coarse material starts to stick, the build-up is generally fast and dense. This slows the ow of material, causes spillages and secondary blockages, and eventually results in unscheduled downtime.

The temptation to nd a quick way to remove the clog- without the proper risk assessment, safe access, tools or training- can create unnecessary risks. This is where ow aids come in. Flow aids are devices speci cally engineered and installed to promote material ow, clear buildups, and prevent clogging, avoiding costly downtime and reducing risk.

The rst step to selecting the right ow aid is understanding how, where, when and why clogs are happening in a particular vessel.

The next step is designing a system with the right ow aids that removes any worker involvement in clearing the blockages.

Characteristics of clogging

Silos are typically designed to store a certain volume of material, while hoppers generally exist to consolidate and then direct material  ow.

In all cases, understanding the function and maximum load of a vessel is important, as is an appreciation of the properties of the materials passing through, including considerations such as potential moisture content and temperature, plus the effect of atmospheric conditions.

Wide variations in the size and shape of particles also affect the ow characteristics. Failure to consider these and other factors can lead to suboptimal designs that increase the likelihood of build-ups and clogging.

If a hopper is not designed to carry the right material load at full capacity, then a sudden surge of material or a clog can lead to potential dangers. And even if a hopper or silo is engineered properly, repeated abrasion from loading over the years can cause the vessel walls to wear thin, which decreases their capacity to contain the weight.

This can also potentially affect the hopper or silo’s structural integrity, which can increase the risk of a serious event.

There are numerous reference guides that explain vessel loading in order for the right design to be determined, such as the American Concrete Institute’s (ACI) structural standards, which describe differing loads in storage vessels:

•Dead load: The total weight of the structure, including attached components and equipment supported by the structure. •Live load: Forces exerted from the stored material, including high and low pressures

caused by ow, plus anything independent of the structure such as snow, positive and negative air pressure, wind or seismic load, and any forces from materials stored against the external wall.

•Thermal load: Caused by temperature differences between the inside and outside faces of the wall.

•Settling load: Forces from uneven settling of the structure.

So the weight, size and type of material, load velocity, plus direction and distribution, structural design of the vessel, as well as factors like weather, can all play a part in clogging and overloading. And the moment the clogged material is discharged, the force of the surge can also overwhelm the structure, gate, skip or conveyor onto which it is owing, so understanding the weight of the material in the clog itself is important too.

Hopper geometries and discharge points

Discharge points come in varying shapes, depending on the vessel and the material ow characteristics [Fig 1]. Cement plant manufacturers carefully choose discharge point shapes based on a series of load and ow factors. Spouts that are narrow, such as those found on conical or pyramidal shapes, direct ow in a vertical column either into a chute or a speci c loading area. Slotted spouts, like those found on the wedge or transition shapes, typically distribute material in a narrowly de ned line for loading onto

conveyors or into containers. The shape of a vessel should match that of the discharge point or it will be prone to clogging.

The slope angles in discharge point geometries can also contribute to clogging, depending on material characteristics, the speci cations of the application or the placement.

Discharge points can feature gates or grates that stop or help to separate the material. Gates, for example, halt material ow for incremental lling of rail cars or a truck body. Grates can be used to slow or direct the ow of material when loading onto a conveyor. Either way, operators often nd that these devices can exacerbate clogging by stopping or slowing material at the structural choke point of the vessel.

Unsafe practices

Once a clog has been detected, there are several unsafe practices that, at the time, may seem like a quick and harmless solution, but frequently cause injuries and are even known to cause fatalities.

One unsafe but common method is beating the vessel walls with mallets or other heavy objects to loosen adhered material. Besides the health and safety risks, over time, the more the walls are pounded, the worse the situation becomes, as the bumps and ridges left in the wall from the hammer strikes will form ledges that provide a place for additional material accumulations to start.

Another hazardous yet popular practice is poking or lancing underneath the clog at the discharge point. This can result in a sudden surge of falling material, burying or crushing the worker(s) below. Physical lancing from above is also common, often with makeshift platforms that allow access but provide little protection should a worker slip and fall into the vessel.

Air lancing the clog from the mouth of the vessel at the top can be an effective option, but only when guardrails are tted or a safe access platform is used. Of course, the reach of the lance and the pressurised air stream must match the size of the vessel and the clog. And again, unless a harness is worn, workers could still fall in trying to get the lance down to the clog, even if guardrails are present.

Perhaps the most prevalent cause of worker injuries is entry into the vessel.

Along with potentially sinking into the material, especially in the centre, the silo or hopper contents could be ‘bridging’ and suddenly release. If a worker enters the vessel and stands on the fragile bridge or on a buildup to the side, a sudden discharge could pull the worker into the cavity, causing serious injury or engulfment.

These unsafe situations and behaviours can be avoided by introducing ow aids to the vessel to mitigate clogs, promote material ow and reduce downtime.

Productivity

As the term implies, ow aids are components or systems installed to promote the ow of materials through a silo, bin, hopper or chute, whilst controlling buildups, dust and spillage.

Flow aids come in a variety of forms, including rotary and linear vibrators, highand low-pressure air cannons and aeration devices, as well as low-friction linings and optimal chute designs, to encourage the most ef cient ow of bulk materials.

These solutions can be combined in any number of ways to complement one another in an integrated system to improve overall productivity. Flow aid devices can be used for virtually any bulk material or environment, including hazardous duty and extreme temperatures.

When employing ow aids, it’s critical that the hopper or silo structure is sound and the ow aid device(s) are properly sized and mounted, because their operation can exert additional stresses on the structure.

A well-designed and maintained vessel will not be damaged by the addition of correctly sized and mounted ow aids.

It’s also important that any ow aid device is used only when discharge gates are open, and material can ow as intended. By far the best practice is to use ow aids as a preventive solution to be controlled by timers or sensors to avoid material buildup, rather than waiting until material accumulates and begins to restrict the ow. Using ow aid devices in a preventive manner not only reduces the chance of clogging but also enhances safety and can even save energy.

Engineered vibration

The age-old solution for breaking loose blockages and removing accumulations from chutes and storage vessels was to pound the outside of the walls.

A better solution is the use of “engineered vibration”, which supplies energy precisely where needed to reduce friction and break up potential accumulations to keep material moving to the discharge opening, without damaging the chute or vessel.

The technology is often found on conveyor loading and discharge chutes but can be effectively applied to other processes

One of the main advantages of flow aids is that plant operators gain a level of control over material flow that is not possible any other way.

and storage vessels, including silos, bins, hoppers, screens, rail cars, feeders, cyclones and heat exchangers.

Productivity with a blast

Another highly effective solution for eliminating material accumulation in chutes and vessels is the low-pressure air cannon, pioneered and patented by Martin Engineering in the 1970s. It uses a cement plant’s compressed air system to deliver a powerful and carefully timed blast to dislodge build-ups. Air cannons can be mounted on metal, concrete, or even wooden surfaces, as long as the surfaces are structurally sound.

The basic components include an air tank, a fast-acting valve with a trigger mechanism, and a nozzle that distributes the air in the desired pattern to clear the accumulation most effectively. The sudden blast of air released by the valve on an air cannon is directed through a specially designed nozzle, which is strategically positioned in the chute, tower, duct, cyclone or other location.

Often installed in an array of several air cannons and precisely sequenced for maximum effect, the devices can be timed to best suit individual process conditions or material characteristics. The air blasts help break down material accumulations before they become problematic, allowing materials to resume normal ow.

To customise the air cannon installation to the service environment, speci c air-blast characteristics can be achieved by adjusting the operating pressure, tank volume, valve design, and nozzle shape.

In the past, when material accumulation problems became a recurring issue in hardto-access areas like the pre-heater system, processors would have to either limp along until the next scheduled shutdown or, more likely, endure expensive unplanned downtime to lance the clogged buildups. That used to cost businesses hundreds of thousands of dollars per day in lost production.

A series of air cannons can be programmed to deliver preciselytimed discharges for maximum benefit.

1. Rotary vibrators supply energy best suited to keeping fine, dry materials moving.

2. Air cannons deliver a controlled burst of compressed air to dislodge material buildup.

Think clean

Given the demands and complexities of cement production, material clogs in silos, hoppers and other vessels should be banished with engineered solutions such as vibration, air cannons and other ow aids. The key to success lies in selecting the appropriate ow aid technology based on material properties, vessel design and operating conditions.

Moreover, the proactive and preventive use of these solutions, rather than reactive measures, has been shown to help maintain optimal performance and can even extend the lifespan of storage and transfer equipment. As cement plants continue to prioritise ef ciency and worker safety, investing in well-designed ow aid systems is a necessity. By embracing such innovations, producers can achieve smoother operations, maximise throughput, and create a safer working environment, ensuring that materials move through the process without unnecessary interruptions. AB

A loaded Cat 735 truck transporting material on a quarry site.

Generational shift

After Caterpillar’s fourth-quarter announcement in 2025 on the launch of four next-generation articulated trucks for global customers, the manufacturer gave the full lowdown on the new models, including how they are designed, manufactured and assembled.

Michael Miller is enjoying watching Cat 735 and Cat 730 nextgeneration articulated trucks working with a Cat 350 excavator during a trade media trip to the off-highway machine manufacturer’s demonstration and testing quarry, just off the busy A1 highway in County Durham.

Miller, a strategy manager for Cat Technology, hails from nearby Peterlee, which is home to Caterpillar’s nine-building articulated truck manufacturing and assembly facility, the only one of its kind globally. Miller has worked at Caterpillar for 25 years, after four years as an engineering and parts-purchasing contractor.

He is also the second generation of his family to work at Caterpillar Peterlee, following his father, who worked there for 20 years as a shop oor welder and fabricator. Multi-generational employment and long-service milestones are common at the Peterlee facility, with several employees sharing the same dedication to the company.

“It’s great to see the steel coming in one end and nished trucks coming out the other. It’s also great to see the trucks here working in the quarry,” Miller said.

“My role is to give customers the technology they need to extract information from their machines, enabling them to get the most out of them. They want to know how their eet is being utilised, answering questions like ‘what are the cycle times?’ and ‘is this machine being overloaded?’. There could also be leading safety indicators that technology can help identify.

“Perhaps an alarm on a machine is being repeatedly triggered, and you want to determine when and where it occurs on-site. We can also help customers with their servicing and maintenance task planning.

“We are always working to advance Caterpillar machine technology on our products. That’s been the case with ‘Operator Coaching’ for the next-generation articulated trucks, which is already available for the latest Cat excavators.”

After talking to Miller, Aggregates Business was taken around a section of the demonstration and testing quarry in a next-generation Cat 735 by Scott Thomas, a Caterpillar product application specialist for articulated trucks, who was demonstrating many of the new features and bene ts available in next-generation Cat articulated trucks. The machines were launched in the fourth quarter of 2025 and are scheduled to enter full production in rst quarter of 2026.

“We’re very blessed to have this just a 25-minute drive from the [Peterlee] facility. We have an excavator out here loading the truck, and we can do everything the truck would be expected to do on a jobsite. It’s unique to have such a site so close to a manufacturing hub. It helps so much,” Thomas said.

In addition to its four new next-generation articulated trucks, Caterpillar also produces three larger-platform models: the Cat 740, with a 40-tonne payload and a Cat C15 engine; the Cat 740EJ (ejector body),

with a 42-tonne payload and a Cat C18 engine; and the Cat 745, with a 45.2-tonne payload and a Cat C18 engine.

Earlier in the day at Caterpillar’s vast 1500-employee Peterlee articulated truck facility, Caterpillar global product application specialist Sherrie Williams, Caterpillar director of product value stream for articulated trucks Adam Freeman, and Thomas, had given presentations on the next-generation Cat articulated truck range and the Caterpillar Peterlee site and its linked demonstration and testing quarry.

“Any Caterpillar articulated truck you see anywhere in the world was built right here,” Freeman said.

As Thomas said, Caterpillar’s 725 (24-tonne payload), 730 (28 tonne), 730 EJ (27.1 tonne), and 735 (32 tonne) models feature a ‘smarter’ articulated truck design, with a range of automatic features integrated into the trucks. The upgraded interior puts control at your ngertips, with all functions accessible through a sleek touchscreen or a smooth, responsive keypad. The touchscreen is easy to navigate using the integrated jog dial for added convenience.

New push-to-start with operator ID stores up to 50 operator IDs to quickly get to work and safeguard against unauthorised use.

The new Cat C13 engine powers the latest trucks with ratings from 257–316 kilowatts (kW), depending on the model.

Designed to meet global emission standards – including US EPA Tier 4 Final, EU Stage V, Japan 2014, and Korea Stage V – the C13 features a compact, lightweight design that requires no exhaust gas recirculation.

The machine is available in con gurations suitable for all regions worldwide, ensuring reliable performance across a wide range of applications.

Williams said there were several improvements of the next-generation Cat articulated trucks compared to the current range: 725 (14 per cent more productivity, 10 per cent more fuel ef cient); 730 (12 per cent less fuel burn, 16 per cent more fuel ef cient); 735 (10 per cent less fuel burn, 11 per cent more fuel ef cient).

Freeman said most of those gains are attributable to improvements in engine and drivetrain ef ciency and to technological advances that enhance operator performance.

With no operator input required, the advanced automatic traction control on the Cat next-generation articulated trucks prevents wheel slippage in poor underfoot conditions, providing maximum traction and productivity. The new engine overspeed control works seamlessly with Automatic Retarder Control (ARC) to manage braking

response, and building con dence for newer operators in challenging conditions. Machine speed limiting supports safe operation by allowing the operator to set ground speed in service mode, ideal for uneven terrain, high-traf c areas, or sites with strict speed regulations. Additionally, the integrated body height limiter promotes safety by helping ensure the machine operates within a jobsite’s height restrictions.

Williams said the Cat 725, 730, and 735 models’ redesigned dump bodies offer easier loading than previous designs and help to maximise payload. The redesigned body features a rerouted exhaust heat system that helps minimise material carryback, improving load ef ciency and reducing cleanup time.

Improved payload technology enables operators to view real-time load weights on the integrated display, thanks to the system’s updated software and sensors.

External payload indicator lights alert the loading operator when the rated payload is approached and when the target payload is reached. Thomas said that Caterpillar’s innovative Dynamic Rollover Protection feature supports rollover prevention and works in parallel with the eld-proven Stability Assist feature, which prevents hoisting on uneven terrain.

Con gurable to material and jobsite conditions, this new feature monitors conditions to detect when the truck is experiencing high lateral acceleration, provides a visual and audible alarm, reduces fuel and then nally the machine will cut off fuel supply to the engine and apply the service brakes automatically if no corrections are made manually by the operator.

It reduces the risk of machine rollover during high-speed cornering, helping minimise downtime and safety repairs. Additionally, Stability Assist software reports information via VisionLink to increase awareness of when an event has occurred.

“For me, of all the features we’re introducing with our next-generation articulated trucks, Dynamic Rollover Protection is the most exciting and provides the most value in terms of safety,” Freeman said.

“It lives up to the level of safety we want to provide to our customers and also highlights the level of systems integration we have. The fact that engine, transmission, and driveline controls are all designed and built by Caterpillar gives us the ability to better control potentially dangerous situations by incorporating features like Stability Assist with Dynamic Rollover Protection and Automatic Retarding and Traction Control, to name but a few.”

Thomas said that Auto Wait Brake (AWB), another next-generation truck feature, reduces operator fatigue by automatically applying the service brakes when the shift lever is in any position other than park and the ground speed reaches 0 kilometres per hour. The service brakes apply within one second of the truck stopping, and after eight seconds, the transmission shifts to neutral with AWB engaged. Simply using the throttle re-engages the transmission and releases the service brakes. This new feature eliminates the need to shift to park for short-duration stops and saves fuel when shifting to neutral. This feature also works with the truck’s Hill Assist by applying the service brakes to prevent rollback.

Thomas said a new dump body height limit feature for next-generation Cat 725, 730 and 735 models allows the bed raise height to be set to meet jobsite conditions.

The operator can quickly increase the height limit by raising the bed to the desired height and holding the keypad button. Alternatively, it can be set through the display service mode to meet site-wide limits. This feature helps prevent the dump body from contacting overhead objects and increases cycle time by limiting full-body travel.

The Cat 730 EJ is an ejector model.

This means trucks can be emptied without raising the body, helping maintain machine stability. This unique design allows load dispersal on inclines, side slopes, and in very soft underfoot conditions, such as those found on land ll sites. By virtually eliminating material that can stick to the body, the truck can operate in areas with low overhead clearance, such as around overhead lines or in tunnelling and underground operations.

Thomas said with faster cycle times, the versatile 730 EJ can eject and spread material on the go, reducing the need for additional spreading and dozing equipment.

Safety is a key advantage of the ejector body models, as the truck body’s hydraulics push the material onto the ground as the operator passes. This is ideally suited to lighter materials that can be left in the truck body during body tipping.

Providing front- and rear-proximity detection, all next-generation articulated trucks offer an optional object detection and multiview camera via a separate secondary monitor. Thomas said the system’s radar sensors, mounted fore and aft, provide visual and audible alerts when objects are within the truck’s travel path.

Four discrete camera views, con gurable to the operator’s preference, are mounted at the front, rear, and sides to enhance the operator’s view around the truck.

Williams demonstrates how the onboard, optional interactive training tool, Operator Coaching, measures and reports on individual operator behaviours that affect ef ciency, safety, and machine health. Operator Coaching identi es opportunities to improve operating behaviour for both inexperienced and experienced operators by monitoring 14 activities. Tips are available on a summary page on the main touchscreen display, while animated video tutorials provide operator instructions. For eet managers, the GPS feature includes maps that show where tips are triggered during the work cycle. Among the 14 coaching tips are: Hoisting without articulation; Hoisting with transmission in neutral; Hoisting on level ground; Reducing cornering speed; Using a lower gear when retarding; Reducing speed in rough conditions; Approaching grade in lower gear.

Freeman said that the story of articulated truck manufacturing in Peterlee dates back to 1972, when David John Brown (DJB) began developing articulated truck concepts to improve traction, otation, and manoeuvrability on tough job sites.

“He did it using Caterpillar truck engines, transmissions, and axles, with the trucks branded DJB. In 1973, DJB started manufacturing trucks at this facility [in Peterlee]. We celebrated 50 years of [articulated truck] production here a couple of years ago,” he said.

In 1985, Caterpillar and DJB entered a formal business partnership, creating Artix Limited (Artix). The launch of Caterpillarbranded articulated trucks soon followed. Caterpillar bought the Peterlee site from the Brown family in 1996, with the rst machine built under Caterpillar ownership being a D400, 36-tonne truck.

Over the years, the lineup expanded to include multiple three-axle models, with innovations such as the 740 EJ for ef cient unloading. Continuous design improvements in power, capacity, and operator comfort mean the factory is well on its way to achieving a key build milestone of 70,000 trucks in the rst half of 2026.

“Our articulated truck range continues to evolve towards offering the best cost per tonne of material moved for our customers,” Freeman said.

Stuart Plant, senior quality manager and a second-generation Caterpillar professional with nearly four decades of experience, and Caterpillar Peterlee director of manufacturing operations Jason Maw lead the tour.

Plant’s journey from apprentice to senior leadership re ects the factory’s commitment to nurturing talent and passing on deep technical knowledge. His team oversees more than 100 quality checks across two assembly lines, ensuring that every truck meets Caterpillar’s rigorous standards before leaving Peterlee. Three thousand tonnes of steel are cut and processed each month, producing 75,000 articulated truck parts. A third of the factory's employees are welders/ fabricators, and the site also houses 20 robotic welding machines. More than 150 miles of sheet metal are welded each month.

After walking through the factory’s large front- and rear-frame assembly section, the tour reaches the paint plant. Dump truck bodies are robotically spray-painted, in part, Plant said, to protect staff health and safety and ensure consistency. Components are manually spray-painted. The assembly line uses between 12,000 and 15,000 litres of paint per month. More than 100 production aspects are analysed on the two assembly lines. Sub-assembly of certain components is performed in other on-site buildings and delivered to the assembly line.

“Our assembly line engineers work in pairs, and we try to keep those pairs together so that they form a partnership over many years. It takes around three months to become fully certi ed to work as an assembly line operator,” Maw said.

Each fully-assembled articulated truck is driven 12 laps, around nine kilometres, around the Caterpillar Peterlee test track before undergoing further static tests.

After a thorough wash, the articulated truck undergoes a comprehensive pre-delivery inspection before being booked for dispatch to its purchasing customer.

There is a well-staffed research and development centre on the Peterlee factory site, staffed by Caterpillar engineering talent from around the world.

Caterpillar Peterlee has an active apprentice recruitment programme dating back to DJB’s ownership of the site.

More than 50 apprentices are currently part of the programme, which combines practical work at Peterlee with university-based learning over a three to four-year period.

Plant joined the site through the apprenticeship scheme 39 years ago, working his way up the seniority ladder to a role on the senior management team.

“Workers like Stuart who have had a successful career at the company are a symbol of deep expertise and commitment - understanding every step of the process and the level of detail required to produce a world-class product,” Maw said.

“Our dedicated operatives are always striving for excellence in our processes, understanding the importance of what we produce for our customers.”

Those nal thoughts are fully echoed throughout the visit, including by Caterpillar’s Michael Miller.

It is safe to say his father would approve of them, too.

“End-to-end quality and attention to detail are at the heart of the factory’s work,” Plant said. AB

A big global aggregate world

The eighth GAIN Meeting brought together aggregates associations from around the world to discuss key industry issues.

The need for even greater industry collaboration, widespread dif culties in obtaining site operating permits, including access to essential virgin aggregates, the increasing role of technology in modern global aggregate production, and rising sustainability-focused demand for lowercarbon and recycled aggregates were among the key topics highlighted and discussed at the eighth GAIN Meeting in Córdoba, Spain.

Comprising a voluntary network of national aggregate associations, with a mission to share industry best practices and promote a more sustainable sector globally, GAIN (Global Aggregates Information Network) has 20 members spread across all six continents, representing 75 per cent of global aggregates production.

Key outtakes from the meeting:

The key role of aggregates associations in championing local industry needs – and, indeed, in forming or revitalising a national association where needed.

Economic conditions vary widely, from the prosperity of the United Arab Emirates and Singapore to the signi cant challenges faced by Argentina and South Africa. In all cases, national associations can play a crucial role in convincing governments of the bene ts of promoting the aggregates sector, which can lead to a ve-fold increase in downstream construction, ultimately bene ting society by delivering housing, social buildings, and infrastructure.

Everywhere except China, access to resources is a fundamental common need that authorities must understand, as well as the essential role of these raw materials in societal well-being. This is particularly important in recognising aggregates as

either an essential raw material or a critical raw material, as is the case in New Zealand. A gradual decline in production tonnages is observed in most GAIN member countries, with the global total decreasing from 44 billion tonnes in 2019 to an estimated 38.6 billion tonnes in 2025. This decline appears to be due to geopolitical factors and a negative economic outlook.

In developing regions, informal industry production can comprise up to 30-40 per cent of the total output (maybe 15-20 per cent globally), which the responsible industry, represented by GAIN, is actively addressing. The European-led initiatives focus on decarbonising aggregates production and increasing energy ef ciency at all stages of the process. The parallel initiatives in water usage minimisation and in fostering restoration, reclamation and biodiversity, where the industry is playing an extremely positive role. The rapid evolution and modernisation of the industry in China, with world-class plant and machinery design, are rapidly embracing arti cial intelligence (AI) in automation and autonomous operation.

The parallel, highly innovative projects (such as DigiEcoQuarry, ROTATE, and SCIMIN) currently underway in Europe are bringing tangible bene ts to the application of AI/digitisation.

At a global level, while there is a commitment to safety performance, there is unfortunately still a high incidence of fatalities, indicating a need for refocus.

There is an ongoing focus on further reducing employee health risks; however, a need for regulatory pragmatism is evident in some new legislative proposals that may overreach. There are labour shortages across the industry globally, which can be addressed through campaigns to improve work-life

balance, as well as more training and career development initiatives, allowing GAIN members to develop common approaches.

Imagining the future opens the mind towards rapid industry evolution that lies ahead. GAIN has now come of age and can con dently move forward, successfully sharing best practices and proudly promoting them on the global stage.

State of play USA

NSSGA represents over 90 per cent of crushed stone and 70 per cent of sand and gravel (S&G) production in the US, sourced from 9000 quarries. The rst half of 2025 aggregate production in the United States decreased by 4.9 per cent, with an estimated decline of around 5.5 per cent expected in the second half of 2025, primarily due to weakness in the residential and commercial construction markets. The high infrastructure spending expected under the Big Beautiful Bill Act has not yet kicked in. There are also various permitting and regulatory challenges.

CANADA

APAC continues to coordinate several provincial associations across Canada, effectively serving as a ‘Canadian GAIN’. Production has dropped by ve per cent in 2025, despite big housing demands, though usage averages over 10 tonnes per capita (t/c). Ontario represents 40 per cent of the national market. The biggest challenges are access to resources, environmental constraints and labour shortages.

EUROPE

In Europe, aggregate production trends vary by country, partly due to the ongoing war in Ukraine.

Additionally, the industry faces signi cant challenges: permitting procedures remain slow and complex, and access to local resources is becoming increasingly constrained. Regulatory and societal expectations regarding environmental and social performance continue to rise. Aggregates Europe continues to advocate strongly at the European Union and national levels.

ARGENTINA

While in ation is now only two per cent per month, the construction economy has stalled, with the use of aggregates reduced to only 0.7t/c. The Córdoba region is faring better than in Buenos Aires. It is hoped that the midterm election result will stimulate growth.

BRAZIL

ANEPAC represents approximately 80 per cent of the market, which is around 680 million tonnes, or just over 3t/c. The year 2025 is expected to be slightly down, but with anticipation of restored growth in 2026, driven by major infrastructure projects.

The Brazilian aggregates sector is facing regulatory challenges, land-use issues (with urban development encroaching on quarries), and rising costs. SMEs, which predominate in the industry, are particularly hard-hit by these challenges. ANEPAC continues to lobby strongly on behalf of the industry.

COLOMBIA

While the GDP per capita (GDP p/c) continues to rise in Colombia, construction is down by some 22 per cent compared to 2019, due to economic uncertainty and a political refocus on other sectors. Accordingly, predictions of aggregate production to 2030 vary widely from the current 105 million tonnes to (optimistically) to 125 million tonnes in 2030, then 2.5t/c. While there are some major infrastructural projects, such as the Bogotá metro, very signi cant challenges remain in the lack of access to resources, due to high biodiversity, complex permitting procedures, delivery logistics (most supplies are by road), and above all, informal extraction (addressed by the ‘Buy Formal, Build Legally’ campaign). ASOGRAVAS is addressing these issues.

COSTA RICA

Costa Rica, like Colombia, is biodiversityrich, meaning that most aggregates tend to come from river extraction. Permitting restrictions and urban development are also making extraction increasingly dif cult, as well as urban encroachment, thereby resulting in longer transport distances. Current aggregate usage is 2.5t/c, which is expected to increase with the need for infrastructural development.

PANAMA

CAMIPA is the Mining Chamber of Panamá and was welcomed for the rst time in this GAIN meeting. Panamá has a relatively high GDP/c, encouraging strong infrastructural development.

The event in Córdoba, Spain, consisted of two meeting days, divided into eight modules that were packed with presentations and informal discussions.

The of cial aggregate production gures, however, do not appear to align with cement production statistics.

Like in Colombia and Costa Rica, there have been signi cant changes in weather patterns attributed to climate change. CAMIPA is dedicated to responsible extraction, particularly in tropical forest areas.

CHILE

While Chile is over 4000km long and only 200km wide, 49 per cent of aggregate production is concentrated in the Santiago and Valparaiso regions, predominantly owned by cement and concrete producers. High interest rates have deterred housing construction, and the economy heavily relies on the mining industry's output; current aggregate usage is only 1.9t/c.

SOUTH AFRICA

South Africa continues to suffer from economic turbulence, indicating a further decline in production in 2025 (though the of cial gures probably signi cantly underestimate total production).

ASPASA works very actively towards achieving a better regulatory framework more appropriate to the SMEs in the aggregates sector.

UAE

The construction industry in the UAE is powering ahead with $875 billion of infrastructure projects currently underway, including the development of new islands off Abu Dhabi. Stevin Rock operates north of Dubai in Ras Al Khaimah, with its largest quarry supplying 80 million tonnes/year, much of which is exported.

CHINA

China has experienced a rapid transition to modern technology over the last 10-15 years; however, major infrastructural development has slowed, resulting in a reduction in annual aggregate demand from 20 billion tonnes pre-COVID to 14.5 billion tonnes in 2025. Unlike other regions, obtaining new permits in China is relatively easy, although it comes with strict environmental conditions attached.

New quarries are now typically 5 million tonnes/year capacity, with most products transported by river to the major cities.

Some 30 per cent of aggregate products in China still come from river extraction. The 15th 5-year programme is being developed, which gives helpful certainty in the industry outlook.

INDIA

India is the second-largest aggregates market globally, with the fastest growth at six per cent per annum, estimated to reach 6.4 billion tonnes by 2025, just over four tonnes per capita. The market is characterised by major infrastructural investment across the country, yet the aggregates industry remains highly fragmented.

MALAYSIA

The MQA is the best-organised association in SE Asia (apart from China), with widespread engagement with government authorities, employee training and education, local and international cooperation, good public relations, and strong community and social interaction. Construction moves forward steadily on major infrastructural projects, with consumption at 5t/c.

SINGAPORE

All aggregates are imported as Singapore no longer has any indigenous sources (beyond recycled materials). AAS connections with these countries may help attract new GAIN members in Southeast Asia (e.g., Indonesia, Vietnam, and Thailand). The economies of the ASEAN region remain very strong.

AUSTRALIA

The current outlook is positive, with an annual aggregate demand of 135 million tonnes (8t/c). However, increasing challenges of access to resources, especially around Sydney, are leading to aggregate transport distances exceeding 240km.

The country’s manufactured sand and recycled aggregates are growing.

NEW ZEALAND

Demand is at, yet good at 9t/c, driven by the need for infrastructural development and climate/weather adaptation.

A signi cant positive was being included on the critical materials list, which can facilitate the delivery of permits at a national level. AB

Indeco makes durable and reliable equipment.

Tackling tough challenges

The HP 7000 from Indeco has been a valuable addition to Donato Coricciati Srl’s operations in Salento, Italy.

In quarrying, there’s no doubt that dolomitic limestone poses a tough challenge. Its hardness and abrasiveness can test equipment and demonstrate just how tough it truly is.

Donato Coricciati Srl, based in Martano, Salento, has made its reputation by extracting dolomitic limestone from its reserves since 1974, with operations supported by a eet of equipment that excels in this application.

When it comes to rockbreakers, Donato Coricciati Srl has been a longtime Indeco customer since the early 1980s, thanks to Indeco’s high-quality performance and durability. Company founder Salvatore Coricciati was involved in testing Indeco’s rst hydraulic hammer models, including the HB 27. The partnership has gone from strength to strength ever since, with Donato Coricciati investing in multiple Indeco

hydraulic hammers ranging from the HP 1500 model to the HP 4000 and HP 5000 models.

The strength of the partnership was underscored by Donato Coricciati’s decision to invest in an HP 7000 hydraulic hammer from Indeco for daily operations.

The Italian-based operation has equipped the HP 7000 hydraulic hammer to a Volvo CE 480 excavator, which works in conjunction with a Volvo wheeled loader and an Astra dumper.

Average production across the veday workweek reaches 700—800m3 of aggregates, used to support concrete and bitumen applications, as well as railway ballast and construction work.

All the material is certi ed and classi ed in accordance with current standards.

“After evaluating several alternatives, Donato Coricciati Srl reaf rmed its preference

for the Indeco brand, valuing not only the quality of its products, but also the reliability and customer focus of its prompt, professional support service,” Indeco said.

Tips and tricks

A hydraulic hammer can be a valuable addition to any quarrying and aggregates operation, especially for handling tough materials.

As with all quarrying equipment, a hydraulic hammer is a strategic investment for a quarry, but nding the right one goes beyond compatibility with machinery.

Businesses need to consider material type, production output, durability and ef ciency. Indeco outlines key considerations for operators when evaluating its hydraulic hammer models.

Fuel savings

One key advantage is Indeco’s hammers’ Fuel-Saving system, which can save up to 20 per cent on fuel compared to similar hammers in its class.

This ef ciency is achieved through a streamlined hydraulic system that operates at very low pressures, reducing revolutions per minute and improving overall ef ciency. As a result, operating costs decrease, and the machine becomes more environmentally friendly. Indeco hydraulic excavator hammers feature a system that automatically adjusts Indeco’s equipment can withstand harsh applications.

the hammer’s power and frequency according to the hardness of the material. This reduces energy waste and enhances productivity.

Reliability

The Hardox steel construction on moving parts reduces wear and extends hammer life. The Anti Blank Firing system protects against blank ring, preventing damage to the hammer and excavator boom.

Indeco offers a wide range of hydraulic hammers, from small- to large-scale, heavy-duty models that are suited to different applications.

Small hammers

Designed to be paired with a 0.5–14tonne excavator, Indeco’s small hammer models are used in road construction, light demolition work, building recycling, and foundry maintenance.

These models are easy to manoeuvre, with a compact yet powerful design suited to con ned spaces and residential areas.

Medium hammers

The medium-scale models (6.5–32 tonnes) of Indeco hydraulic hammers are versatile additions to many job sites.

These models are de ned by their powerto-weight ratio and a streamlined design.

These hammers have been used in various applications, including building demolition, ground breaking, secondary breaking in quarrying, ditch excavation, and industrial maintenance.

These models have even been used underwater when combined with a specialised kit.

Large hammers

Indeco’s large hydraulic hammer models (21–140 tonnes) combine power and output, enabling them to work in challenging applications.

These hammers have been used in primary breaking applications in the quarrying sector, excavation works in construction, railways and road tunnels, as well as large-scale industrial demolition works. AB

KEY CONSIDERATIONS

• Weight of the excavator

• Oil flow rate

• Hydraulic pressure

• Intended use

Refer to the technical data and consult Indeco experts to make a safe, informed choice. With the right combination, your excavator becomes a powerful, e cient, and cost-e ective demolition tool.

Bright future ahead

Astec and Telestack are ready to meet regional and global demands in the quarrying and aggregates sector with a big year on the cards.

Astec managing director for Europe Damian Power is a straight-talking, highly experienced executive in the off-highway equipment world.

Power has witnessed global product demand rise and fall over several decades and has played a hands-on role in the technical evolution of machines to meet customers’ increasingly bespoke application needs.

Power told Aggregates Business that while 2025 was a challenging one for off-highway original equipment manufacturers (OEMs), he is optimistic about market opportunities in 2026. These opportunities include some of Astec’s latest machines which were produced at the its Omagh facility in Doogary, and showcased at the ConExpo/Con-Agg 2026 event in Las Vegas. There will also be another exhibition at Hillhead, the UK’s largest quarrying, construction, and recycling equipment show, taking place 23-25 June 2026.

“Everything we will have at Hillhead this time around we’ll be able to take an order from UK and European market customers,” Power said.

“We’ll have a story to tell on the tracked mobile equipment we’re launching at Hillhead, and we’ll also be there talking about our modular crushing and screening offering, and our washing offering. We are keen to do more in that sector.”

Power said Astec is not new to delivering wash plant solutions for quarrying, construction and other industry customers.

“We have a strong US market presence in wash plants, and we want to enter the European market, promoting our rich, strong heritage in America,” he said.

“We also have the European launch of a new model from our Peterson product line [horizontal grinders, disc and drum chippers] at the IFAT show in Munich in May, so 2026 will be an extremely busy year in terms of new product launches for the European market.”

Astec has been remarkably busy in recent years. The 44,000ft² expansion of the Astec Omagh facility in 2023 brought its total footprint to 100,000ft².

A comprehensive range of new Astec mobile tracked crushing and screening plants is being introduced to the quarry and aggregates market throughout 2026 and 2027, with more to come in 2028.

The new model lineup is the result of a signi cant research and development program involving machine design and engineering teams based in the US, Northern Ireland, and South Africa, leveraging Astec’s strong engineering legacy.

“We are going to have a comprehensive range of tracked nishing screens, scalping screens, tracked jaw- and horizontal shaft impactor crushers, horizontal screens and four or ve new washing products,” Power said.

“All of those new machines will be made here [Astec Omagh]. We already have customer orders for units and expect to build momentum through 2026.

“In addition, we are taking two of the tracked jaws and a cone crusher from our existing portfolio and certifying them for the European market. They are not on the list of new products. These are popular and proven models in the US and other regions worldwide. We’ve tested them in the UK in a controlled environment, and they have performed really well. We believe we can gain market traction with these, as they are high-performing and robust units.

“We’re entering the European market and know there’s a lot of very serious competitors out there who have been in the market for a long time. We have high con dence in the performance of our new products, given our legacy and the

proven nature of the screens and crushing chambers at the heart of the machine. All new products have been designed to meet the latest [European] standard, in addition to [Conformité Européenne standard].

“We are excited about the range we are bringing to the market. We believe we have some products that are going to stimulate a bit of interest, including our proven multi-frequency screen and our new varifrequency technology.”

Astec launched its vari-frequency technology in the fourth quarter of 2025. This innovative feature is now integrated across its horizontal screen range - a nextgeneration design engineered to elevate screening performance. Built to reduce material binding and maximise uptime, the new patented system offers producers a smarter, more dependable way to keep operations running ef ciently and effectively. The eight-foot model will be among the standout Astec products featured at ConExpo/Con-Agg 2026.

“We will also be making a bit of noise about the multi- and vari-frequency technology at Hillhead,” Power said.

“It is a patented technology, and there’s a great story to tell about how it works.”

As part of the company’s extensive ‘From Rock to Road’ exhibition lineup showcased last year at World of Asphalt and AGG1, the Astec A50 jaw crusher offers several safety and maintenance bene ts.

A patented cheek-plate design joins the upper and lower cheek plates, allowing them to be easily released as a single piece from the crushing chamber and replaced. The jaw chamber is offered with a fully hydraulic toggle setup, perfect for recycling applications, or a new patented mechanical toggle, well-suited to crushing rock. Both are directly interchangeable. The A50’s new frame features a bolted-and-keyed design, incorporating an anti-vibration mount and a new bolt-on jaw feed, making it a more exible product that can be easily integrated into an existing material processing site footprint. This jaw chamber will also be offered on one of the new tracked jaw plants being developed for international markets, which will be built in Omagh.

Astec has a presence in several key quarrying and aggregates markets.

Power said Astec’s global research and development (R&D) program has been key to several crusher-chamber and material- ow enhancements found on the new product lines. The team includes a couple of Europebased PhD researchers who work within the Astec Digital Group.

“We are continuing to build the team out here in Northern Ireland, and we are con dent with our manufacturing footprint that we’ve got what we need for the next 36 months, at least,” he said.

“We’ve done a lot of prep work in 2025, and 2026 is de nitely going to be a moving year for us, with a lot of products coming through.”

Equally, Telestack had a busy 2025. Among Telestack’s recent European market installations is an integrated three-unit mobile system comprising an HF Hopper Feeder, a TL18 Link Conveyor, and a TB Shiploader, supplied to Bristol Port, a major player in the UK’s maritime infrastructure market. The setup is enhancing Bristol Port’s quayside operations for loading aggregates and nes into coastal vessels.

The port aims to increase vessel turnaround speed, lower operational costs, and minimise reliance on wheeled loaders.

Achieving average loading rates of 800 tonnes per hour (tph) consistently while handling peaks of 1000tph, the Bristol Port system incorporates extensive dustsuppression measures. This includes an overband magnet to remove tramp metal, dust covers on all conveyors, a spray bar, and a rubber sock chute to ensure clean loading.

The reduction in mobile plant traf c on the quayside also contributes to a safer and more organised working environment.

The inherent mobility of each unit enables Bristol Port to adapt its setup for different materials or berth con gurations.

“We’re still leading the market for mobile conveyors, pushing the boundaries with the continued support and investment from Astec

in Europe. At the next Hillhead, with Astec products there, too, we’ll be part of an even bigger showcase,” Donnelly said.

“We continue to expand and innovate to keep our dealers engaged and to remain a leader in our market. We have a 27-foot-long hopper feeder coming out, among other new products.”

Donnelly said another innovative solution, unveiled by Telestack in the latter half of 2025, is the TCL2031 tracked mobile conveyor, which is one of the largest-capacity conveyors of its kind on the global market.

Designed to meet the demands of highcapacity material handling with unmatched versatility and strength, the TCL2031 is a heavy-duty tracked stacking and linked conveyor engineered to transform highthroughput material handling on mobile sites.

The TCL2031 has been developed following the success of many installations of the existing TCL1031 tracked-mounted stacker, which handles applications up to 1000tph and 0–300mm primary jaw-crusher operations.

The new TCL2031 is designed for higher-capacity applications, ranging from 1500 to 2500tph.

Donnelly said Telestack is also seeing its conveyor solutions being deployed in the offshore energy sector.

The company has supplied two mobile shiploading systems to DEME, a marine engineering and offshore energy group, as part of the Coastal Virginia Offshore Wind (CVOW) project.

As the largest offshore wind project in the US, CVOW represents a pivotal step toward clean energy and carbon emissions reduction, with Telestack’s innovative shiploading equipment playing a vital role in its success. CVOW, developed by Dominion Energy, is designed to deliver 2.6 gigawatts of renewable energy – enough to power approximately 660,000 homes at peak output.

The project involves constructing 176 wind turbines, three offshore substations, and undersea cables, along with onshore infrastructure to deliver renewable energy to the grid.

Telestack’s two mobile shiploading systems have seamlessly integrated into the project's material handling, ensuring ef cient loading of large-grade armour rock into exible fall pipe vessels.

Telestack has supplied two AP 1500 D3 wheel-mounted apron steel feeders and two TB 52 radial telescopic shiploaders to load rock material onto DEME’s specialised rock installation vessels at a high loading rate.

“As well as the recent project with DEME, we are working in Europe with Dutch and Belgian companies in this area of the market, including Van Oord, Boskalis, and Jan De Nul Group. When you add DEME, they are very much the big four [for offshore energy],” Donnelly said.

“Large global [offshore wind] projects are happening with all those companies.

“There are also offshore wind installations planned off the west coast of Ireland, and companies need to transport armour rock from ports to those sites to lay their foundations.” AB

The rise of recycled materials

Recycled materials represent a growing area of interest in the quarrying and aggregates sector and could be a cornerstone of a more sustainable future.

In recent years, the global aggregates sector has undergone a steady shift toward the use of recycled and secondary materials. For producers in the quarrying and construction materials industries, this change presents both opportunities and complexities.

As sustainability goals become increasingly stringent and infrastructure investments surge worldwide, understanding how to balance virgin and recycled supply has become a critical competitive factor.

The landscape

Aggregates – sand, gravel and crushed stone – remain the foundation of the world’s construction supply chain. Yet the structure of this market is evolving as recycled materials gain a stronger foothold.

According to the United States Geological Survey (USGS), recycled asphalt and concrete are being increasingly substituted for virgin aggregates in infrastructure projects across the US. Globally, the recycled concreteaggregate market was reported to be $US4.7 billion in 2024 and is projected to surpass $US12 billion by 2034, re ecting a compound annual growth rate of nearly 10 per cent.

In Europe, this shift is even more pronounced. The Mineral Products Association (MPA) reported that the United Kingdom produced 74.3 million tonnes of recycled and secondary aggregates in 2023,

representing 31 per cent of the domestic market. Such results highlight the maturity of recycling practices in established markets and point to the growing potential for other regions to adopt similar models.

For producers, this trend brings both opportunity and urgency. As virgin resource extraction faces increasing cost, regulatory oversight and community scrutiny, the availability of recycled feedstock presents a means to meet sustainability targets without compromising output.

Aggregates producers who diversify early stand to gain from emerging demand in low-carbon infrastructure and circulareconomy construction, reshaping the very economics of quarrying and materials supply.

The key drivers

The rise of recycled aggregates is underpinned by converging pressures across multiple domains — economic, regulatory and technological. The following scenarios illustrate why recycled aggregates are attracting more investment worldwide.

Prime aggregate deposits are becoming increasingly dif cult and expensive to access, prompting producers to explore alternatives such as construction and demolition (C&D) waste and quarry byproducts. These materials, once viewed as waste, are now valuable feedstocks in sustainable construction.

Circular-economy policies are reshaping construction waste management.

The United States Environmental Protection Agency underscores that recycling C&D materials reduces land ll use and offsets the environmental impact of virgin extraction.

Market demand

Clients in both public and private sectors are demanding lower-carbon materials.

Recycled aggregates align seamlessly with this agenda, offering quanti able sustainability bene ts that support greenbuilding certi cations and eligibility for infrastructure funding.

Technology

Recycling technologies now make aggregates from concrete and asphalt more reliable, yet under nine per cent of materials are reused, while raw extraction drives water stress, biodiversity loss and global emissions. Expanding recycling capacity helps producers stay competitive and align with circular economy goals.

Other perspectives

The adoption of recycled aggregates varies signi cantly across global markets, in uenced by diverse regulatory pressures, infrastructure priorities and access to technology.

In North America, growth has been steady as recycled asphalt and concrete gain traction in state and federal infrastructure projects.

The United States Infrastructure Investment and Jobs Act has provided fresh momentum for integrating sustainable materials, while producers in Canada are investing in regional recycling hubs to reduce transportation emissions and dependence on raw materials.

Europe continues to lead the transition, with the UK and several Western European countries operating well-established circular economy frameworks that prioritise the recovery of construction and demolition waste.

The MPA reported that recycled and secondary aggregates already account for nearly one-third of the UK’s total supply, indicating how policy alignment and technological readiness can accelerate market transformation.

In contrast, Asia-Paci c markets are in earlier stages of adoption while rapidly building capacity. Countries such as Japan and South Korea have implemented strict construction waste recycling mandates, while emerging economies like India and Indonesia are experimenting with public-private partnerships to scale up the production of recycled aggregates.

Meanwhile, developing regions in Africa and Latin America represent the next frontier for the use of recycled aggregates.

Although formal recycling systems are still limited, rising infrastructure investment and the abundance of construction and demolition waste create a strong foundation for localised recycling initiatives.

By combining community-level collection systems with small-scale processing, producers in these regions can lower material costs and reduce the environmental footprint of new construction.

The global picture reveals a sector in transition. Mature markets are re ning circular models, and emerging economies are beginning to integrate recycled aggregates into mainstream construction.

The pace of adoption may differ, but the direction is clear — recycled materials are steadily moving from an environmental preference to an operational necessity across the world’s aggregates industry.

Strategic pathways

For producers adapting to this changing landscape, several strategies can help align business performance with circulareconomy goals:

•Diversifying material portfolios: Integrating recycled aggregates into a business’s core offerings reduces exposure to volatility in virgin-resource markets and positions producers to serve sustainability-driven markets.

•Investing in processing infrastructure: High-quality recycled aggregates require modern sorting, crushing and washing facilities to ensure optimal condition.

•Maintaining stringent quality control: Concerns about the durability of recycled aggregate can be addressed through robust testing and certi cation processes, ensuring compliance with both engineering and environmental standards.

•Optimising supply-chain logistics: Urban recycling facilities located near demolition hubs can reduce haul distances, emissions and costs. Collaborating with wastemanagement partners enhances ef ciency and feedstock consistency.

•Monitoring regulation and incentives: Policy measures, such as land ll diversion targets, recycled-content mandates and green procurement requirements, will continue to shape market dynamics.

•Building a sustainability-focused brand: Transparent sustainability reporting and life-cycle assessments can strengthen brand reputation and secure long-term partnerships with environmentally focused clients.

Managing operational challenges

Even as recycled materials gain traction, aggregate producers must carefully manage several operational challenges to ensure reliable performance and pro tability.

One of the most critical issues is maintaining feedstock consistency. Construction and demolition waste can vary signi cantly in composition and quality, requiring strict input controls and strong relationships with suppliers to produce uniform aggregates.

Balancing economic considerations is another challenge. While recycling reduces dependence on virgin extraction, the processing, sorting, and quality-control steps can be capital-intensive. Achieving economies of scale through partnerships or regional collaboration helps keep operations cost-effective.

At the same time, the economics of recycling are becoming increasingly attractive. With aggregate purchase and disposal costs now averaging $US30 per tonne — and up to $US50 in some cases — on-site crushing and recycling can deliver signi cant cost savings. Portable crushers capable of processing just a few thousand tonnes of material can already pay for themselves, underscoring how localised recycling can enhance pro tability while advancing sustainability goals.

Regulatory and technical compliance also play a major role. In many regions, infrastructure projects still specify virgin aggregates by default. Producers can address this by engaging with regulators and engineers to update the acceptance criteria based on veri ed performance data from recycled aggregates. Environmental management adds another layer of responsibility, as issues such as potential leachate or pH imbalance from reclaimed concrete must be controlled through environmental monitoring and treatment processes. As more companies enter the recycled-aggregate segment, competition is intensifying. Producers will need to differentiate themselves through consistent quality, transparent sustainability reporting and proven technical reliability.

Recycled materials is a growing segment of the quarrying sector

Those who manage these operational challenges effectively will be best positioned in the evolving global aggregates market.

Action framework for the transition

Producers should adopt a structured approach that is market ready and operationally capable.

•Conduct market and regulatory scans: Assess local and regional regulations, construction codes, and sustainability targets in uencing demand.

•Audit feedstock availability: Map available C&D waste streams, quarry by-products and industrial residues to determine viable sources.

•Upgrade or retro t facilities: Evaluate plant capabilities for handling recycled feedstock and plan investments in modern processing technology.

•Develop and test product lines: Implement rigorous testing and quality control systems to ensure consistent performance across recycled aggregate grades.

•Forge supply-chain partnerships: Collaborate with demolition rms, waste haulers and municipalities to secure a reliable material pipeline.

•Engage customers and stakeholders: Educate clients about the structural reliability and sustainability bene ts of recycled aggregates through transparent communication and data-sharing.

•Track nancial performance: Monitor production costs, yields and margins to re ne operations and guide investment.

Forward thinking

The rise of recycled aggregates marks a signi cant shift in the global materials supply.

The coming decade will be de ned by how effectively producers integrate circular practices into their core operations.

The most successful producers will be those that view recycled aggregates not as a compliance measure but as a core growth strategy within an increasingly circular global marketplace. AB

Renewing for the future

Steve Nendick investigates the future of hydrogen combustion engines within the engine manufacturing sector.

Hydrogen combustion engines are seen as a green alternative to traditional diesel power as the industry looks to reduce carbon emissions and address climate change. The remote nature of quarries and higher duty cycles of the machinery on-site positions green hydrogen-powered equipment as a viable solution.

We have been using gas combustion in cylinders for over two hundred years to generate power, with the rst hydrogenpowered combustion engine developed by François Isaac de Rivaz in 1806. The rst commercially successful internal combustion engine (ICE) was created by Étienne Lenoir around 1860, and the rst modern internal combustion engine, known as the Otto engine, was created in 1876 by Nicolaus Otto. The rst functional diesel engine, called the Motor 250/400, was designed by Rudolf Diesel and built by Maschinenfabrik Augsburg in Germany.

So, over two hundred years of development and accumulated expertise, alongside advances in design, component technology and electronic controls, have

resulted in extremely capable modern internal combustion engines (ICE). While there are challenges using hydrogen as a fuel, there should be no doubt that modern hydrogen combustion engines (H2ICE) can deliver a very good zero-carbon option for industrial applications. They t where current diesel engines t and deliver equivalent power and torque, making them suitable for quarrying, where high-power output is critical to operations. H2ICEs have equivalent durability and reliability and follow the traditional service and repair practices. Being adapted from existing engine technology should make them a simpler and more affordable option when moving on from diesel.

Hydrogen engine design

Hydrogen combustion engines are gaseous-fuel spark-ignited and differ from diesel combustion, which is liquid-fuel compression-ignited, but share many commonalities with natural gas combustion. As with all combustion engines, cycle ef ciency is poor, as a considerable amount of the energy is lost. It is less than diesel (45 per cent ef ciency) and more closely aligned to natural gas (40 per cent ef ciency).

Hydrogen has a wider ammability range (4–75 per cent), and higher ame speed compared to other fuels, making controlling combustion more challenging.

This can lead to issues like pre-ignition and knocking if not effectively managed.

Engine components must be designed to withstand higher combustion temperatures to maintain the engine’s durability and lifespan.

Hydrogen is so much lighter than equivalent fuels such as natural gas, and you need approximately three times the volume of hydrogen to get the same amount of energy. To get the same productivity out of hydrogen-powered machines, there is a need to increase the pressure of the fuel supply or increase the volumetric ow of hydrogen.

While hydrogen combustion engines produce next to no carbon dioxide emissions, they are not entirely emission-free. The combustion process is hotter than that of equivalent fuels, producing oxides of nitrogen (NOx) emissions. Advanced aftertreatment systems, such as selective catalytic reduction (SCR), are required to minimise NOx emissions. These are equivalent to what is seen with today’s advanced diesel engines.

Hydrogen production

For the H2ICE to be truly green, the hydrogen used must also be “green” and created using sustainable resources such as solar or wind power. Currently, there are many forms of hydrogen production, with most being produced through natural gas reforming. Known as “grey” hydrogen, the production process emits a substantial amount of carbon dioxide, taking away any of the bene ts gained from using hydrogen as a fuel.

Using electrolysis to split water into hydrogen and oxygen will produce hydrogen, and electricity needs to be produced carbon-free from renewable energy, such as wind, solar or hydro, to be truly green and sustainable. The high cost and energy requirements associated with electrolysis are a current barrier to adoption. Also, there is an extremely limited supply of green hydrogen production capability. With most focused on power generation and manufacturing. This limits availability for other industries such as quarrying and construction.

Hydrogen storage and distribution

Storing hydrogen poses its own set of challenges. Being the smallest and lightest molecule, it substantially increases the potential for leakage. Imagine footballs being red into a football goal; the net will catch all of the balls. Replace the footballs with tennis balls red into the same net, and you can visualise the challenge. As hydrogen has no smell or colour, quarry sites will need to install equipment to detect potential leaks.

This requires the hydrogen to be stored at extremely high pressures, up to seven hundred bar, or at extremely low temperatures as a liquid. Both of these would require advanced and costly storage solutions. The safe and ef cient storage and transport of hydrogen is still underdeveloped, which adds to the complexity and cost of using hydrogen as a fuel on a quarry site.

Packaging hydrogen fuel on a machine also creates challenges for the equipment manufacturers. Hydrogen’s low energy density means that substantially larger tanks are needed to ensure the equivalent productivity as diesel power or require more regular refuelling. The high-pressure tanks are also heavier than equivalent diesel tanks. These changes will impact the machine’s stability and manoeuvrability. The rugged environments of quarries and construction sites mean that heavy vibrations, shocks, and potential impact from debris increase the risk of leaks. These challenges would point to a signi cant redesign of the machine frame and balance.

The current fuel distribution infrastructure is predominantly designed for liquid fuels like gasoline and diesel. Transitioning to hydrogen would require a complete overhaul of any site’s infrastructure to accommodate the unique properties of hydrogen. This would include hydrogen refuelling stations and managing safety standards to prevent leaks and explosions. The cost and logistics of developing this infrastructure are substantial and present a major hurdle to the widespread

There is increasing interest in hydrogen as a potential fuel source.

OEM UPDATE

JCB has showcased its advancements in H2ICE. Its fully operational four-cylinder hydrogen combustion engine has been developed over three years with an investment of £100 million. More than 130 evaluation engines have been produced to power backhoe-loaders, telescopic handlers, and generator sets. JCB has overcome some governmental concerns around H2ICE, securing approvals from 11 European licensing authorities to enable commercial deployment across various industries.

Yanmar has unveiled two hydrogen engine concepts based on its 3.8-litre 4TN101 diesel platform, with a power output of up to 70kilowatts (kW)/94horsepower (hp).

These demonstrate the feasibility of adapting existing engine platforms to use hydrogen fuel. Also presented was a hydrogen-powered generator based on its 0.4-litre YDG5500 engine.

Liebherr has introduced its first large wheel loader (L566H) powered by a hydrogen combustion engine. It operates on green hydrogen produced from renewable energy, ensuring zero emissions. The prototype will take part in a two-year trial at STRABAG’s Gratkorn quarry in Austria, aiming to reduce CO₂ emissions by up to 100 tonnes annually. Although the release doesn’t confirm, this is probably powered by Liebherr’s H9X4 compact nine litre four-cylinder hydrogen engine.

Perkins is promoting its “Project Coeus,” a collaborative initiative with Loughborough University and Equipmake, to focus on hydrogen engines. This initiative is supported by UK Government funding of £11.14M from the Advanced

adoption of hydrogen combustion engines for quarrying and construction.

Hydrogen costs

The current cost of producing and maintaining hydrogen combustion engines is higher than that of traditional diesel engines. This is due to the high cost of hydrogen production, storage, and distribution, as well as the specialised materials and components required for the engines. It will take time for these costs to come down and enable them to compete economically with conventional engines and other alternative fuel technologies such as battery electric. The adoption of hydrogen combustion engines is less limited by the performance of the product but more by the economics of the fuel.

Propulsion Centre UK (APC). Coeus will develop a seven-litre Perkins 1200 Series industrial power unit with hybrid-electric components and advanced controls to enable operation on hydrogen. The three-and-a-half-year project is underway at Perkins’ global engineering headquarters in Peterborough, UK. Equipmake are developing the epowertrain technology with Loughborough University, assisting with advanced engine analytics and emissions controls.

Caterpillar have presented a hydrogen engine testing exhibit, emphasising its ongoing research into hydrogen-fueled engines. The company is developing a transient-capable hydrogen-hybrid system based on the new C13D engine platform, aiming to match the performance characteristics of traditional diesel engines in o -highway applications.

Denyo has unveiled two mobile power solutions: a hydrogen fuel cell generator and a 100 per cent hydrogen engine generator. These products cater to the growing demand for clean, portable energy sources in construction and remote operations. Based on their 45kVA diesel generator, power comes from Kubota’s 3.8 litre 85kW (114hp) hydrogen engine. Cummins continues to showcase its HELM fuel-agnostic 15-litre engine platform, capable of operating on hydrogen and clean diesel. This next-generation heavy-duty X15 engine is a clean-sheet design that reflects Cummins’ strategy to provide flexible, low-emission power solutions adaptable to a number of fuels. This 15-litre hydrogen engine has directinjection with lean-burn combustion and will be available with ratings from 298-395kW (400-530 hp) and a peak torque of 2600Nm.

Hydrogen adoption

Even though off-highway emissions regulations have been around for over 25 years, CO2 emissions have never been included. The key focus has been on particulate (PM) and oxides of nitrogen (NOx) emissions for air quality and smog improvements. It is understood that CO2 limits could be included in the potential European Stage VI regulations, but these are not expected until at least 2030. So, given the additional running costs, major capital infrastructure investment, and staff training required, it will likely take further government regulations and grants for companies to adopt H2ICE as a major power source. AB

Powering on

much of the long, repetitive work they previously had to undertake.”

The integration of robotic welding and automation systems to enhance manufacturing ef ciency and precision is part of a broader transformation of Powerscreen’s new global headquarters. The site, located on Dungannon’s Coalisland Road, now also includes an 8500-square-foot of ce space and a range of energy-saving enhancements to reduce carbon emissions.

Powerscreen’s new global headquarters is the latest in a series of strategic investments by Terex to modernise its operations and bring its facilities into the digital age.

Additionally, implementing job tracking and digital shop- oor information systems has streamlined work ow management.

At the same time, data capture technologies leverage valuable insights to support continuous improvement and material management systems, optimising inventory levels and reducing waste.

While robotics continues to transform welding operations, the human element remains at the heart of the Powerscreen brand. Few embody this more clearly than James McLaughlin, the site’s team trainer and a long-serving member, whose warmth and knowledge are immediately evident.

“I joined Powerscreen in 1979 straight from school. I began as a tter and welder and worked on the shop oor until 2016, when I moved into the training role. Over the years, I’ve witnessed steady, incremental change as the business has evolved,” he said.

“The most signi cant shift came when Terex acquired Powerscreen in 1999.

“Terex brought global technical expertise and introduced stability to our working patterns. Before that, we might work three days a week in winter and six or seven days a week in summer.

“By the 2000s, we were consistently working ve or six-day workweeks yearround. Terex also introduced a much more advanced safety culture – they were far ahead of us in that regard.”

McLaughlin begins the tour in a large, multi-wall area lined with message boards, several of which focus on workforce safety. Safety, in fact, emerges as a recurring theme throughout the visit.

“Above all else, it’s essential that everyone goes home safely every day. Safety isn’t just a noticeboard slogan; it’s part of our identity and how we operate,” he said.

After pausing at a world map marking Terex’s global manufacturing and parts facilities, McLaughlin goes to the sheet steel cutting shop, where recent investment has strengthened its capabilities.

“We process a substantial volume of sheet steel here in Dungannon, and when demand peaks, our Ballymoney site supports us,” he said.

“We use advanced plasma cutters for speed and consistency, while Ballymoney operates laser cutters for high precision components. Logistics are critical to maintaining ef ciency, so planning is everything.

“In addition to the cutting technology, we’ve added a new drill saw line for section steel, bringing even more capability in-house. It’s a signi cant investment and re ects Terex’s ongoing commitment to innovation and growth within Powerscreen, something I’m proud to see after so many years with the brand.”

As the tour continues, McLaughlin stops beside a striking photograph of the Mark I screen, the rst machine produced by Ulster Plant in March 1966. The business adopted the Powerscreen International name in 1970.

Powerscreen offers a broad portfolio of mobile crushers, including jaw, impact, and cone crushers, and screeners,

including horizontal, vibrating grizzly, trommel, and conveyor units. Designed for quarrying, demolition, recycling, and mining, the machines feature tracked mobility, high throughput, and, increasingly, hybrid and electric power options across models, including the Premiertrak jaw crushers, Trakpactor impact crushers, Maxtrak cone crushers, Chieftain screeners, and Warrior scalpers.

McLaughlin said there had been a shift toward alternative power systems.

“Transitioning to hybrid-powered machines has required some adjustment within the manufacturing facilities,” he said. “At the moment, demand for hybrid power is outpacing fully electric plants.”

Past the parts sub-assembly line, McLaughlin goes into two large halls equipped with conveyor systems for the tting-out of crushers and screeners.

“We operate a four-stage build process, and maintaining lean practices is essential. Each hall has a dedicated manufacturing engineer overseeing operations. At the end of each build, there should be nothing left in the parts trolley. If there is, the engineer is noti ed, and corrective action is taken,” he said.

In the screen box installation hall, McLaughlin told Aggregates Business about a long-standing tradition.

Powerscreen utilises the latest production processes at its manufacturing facility in Dungannon.

At Powerscreen’s global HQ, the bench that greets visitors was designed and manufactured in memory of esteemed colleague Pat Mallon, the friendly voice who went the extra mile for customers and dealers worldwide.

“Every screen box carries the name of the person who built it. That signature represents pride and ownership. A screen box that isn’t perfectly balanced can cause vibration that affects throughput, so precision is critical,” he said.

“Many of our team members have spent years perfecting this craft. When you see your name on that nished product, it re ects your skill, your commitment, and the level of quality customers expect from Powerscreen.”

Quality is not just something Powerscreen talks about, it’s visible everywhere in its manufacturing facility.

“The goal is simple: don’t accept, don’t make, and don’t pass on a defect. If everyone does that, we deliver machines that meet the highest standards. It’s about pride in what we do and making sure the customer gets the best,” he said.

As Powerscreen marks its 60th anniversary, one thing is clear: its manufacturing facility is built on continuous investment and innovation.

Every process and enhancement re ects a commitment to excellence and safety, ensuring Powerscreen remains at the forefront of mobile crushing and screening worldwide. AB

Bodarwé has been a longstanding Liebherr customer.

Loading the future

Quarry and aggregates operations are turning to powerful loading machinery and equipment to elevate their performance.

The Bodarwé company has been based in eastern Belgium for nine decades, with its family roots shaping its past and present.

Over the years, things have shifted in quarrying and earthmoving, but Bodarwé has stood as a testament to the value of longstanding partnerships and a values-driven approach to business.

“Respect for our employees is at the centre of everything we do. It is the guarantee of high-quality work in a healthy and familiar environment,” Bodarwé company director Stéphane Bodarwé said.

“The pleasure of working together is of central importance.”

Bodarwé has transformed remarkably since Jean Bodarwé founded the company in 1937. It has more than 250 employees, eight subsidiaries and activities in road construction, earthworks, quarrying and civil engineering.

Supporting its works across these important sectors is a range of key partners that support Bodarwé’s operations with machinery, spare parts and customer service.

Bodarwé purchased its rst Liebherr machine in 1989. Ever since, the company has been a regular Liebherr customer for its earthmoving machines which deliver high levels of performance and fuel ef ciency.

Ever since Bodarwé invested in its rst R 900 crawler excavator, a steady stream of Liebherr equipment has joined its eet.

Underlining the extent of its partnership, Bodarwé’s R 984 crawler excavator, which it purchased for its quarry in Waimes, Belgium, was only replaced in 2019 with a R 9100 mining excavator after several thousand hours of operation.

“Liebherr is a supplier with a broad and comprehensive product range that ts in perfectly with our various elds of activity. The machines are high-quality and reliable. In addition, our drivers agree that they are easy and intuitive to operate and offer a high level of working comfort,” Bodarwé company director and fourth-generation representative Jean Bodarwé said.

The overall eet across all of Bodarwé’s operations is around 400 machines and vehicles, including 28 Liebherr machines: 14 wheeled excavators, eight crawler excavators and six wheeled loaders.

As the company’s activities range from quarrying and earthworks to road construction and more, any addition to its eet must be versatile and capable of high output.

With so many machines and projects underway, maintenance is also important.

“The easy maintenance and monitoring of Liebherr machines is also an important factor that enables us to ensure the success of our teams on the construction sites,” Bodarwé machine manager Roger Bungart said.

A key differentiator of Liebherr machinery is the power-split travel drive, which comes as standard on all XPower wheeled loaders.

It combines the bene ts of a hydrostatic and a mechanical drive into one machine, delivering impressive performance while reducing fuel consumption.

“Robust machines are essential for our various activities, but we also attach particular importance to the machines' low fuel consumption. In this respect, the L 566 XPower and L 580 XPower wheel

Liebherr machinery supports Bodarwé’s quarrying operations.

loaders con rm our decision every day. The partnership with [Liebherr’s of cial sales partner in Belgium] SOMTP is also of crucial importance,” Jean Bodarwé said.

“Together with Liebherr, we always nd suitable solutions.”

Stronger networks

Komatsu has strengthened its dealer network in France with the original equipment manufacturer con rming that BIA Group will become one of its newest distributors.

Under the terms of the deal, BIA Group will be the of cial distributor in the territories that were previously covered by BPM Construction. The announcement follows con rmation that BIA Group would acquire BPM Construction.

Komatsu Europe con rmed it would undertake a structured transition that would see existing teams, operational structures, and on-the-ground operations remain in place.

“This evolution marks a new step in the deployment of our European strategy. By entrusting BIA with the distribution of our products in the territory currently covered by BPM Construction, we are bringing together the experience of two strong and complementary partners,” Komatsu Europe chief executive of cer and managing director Tadashi Maeda said.

“Our priority is to provide our customers with even higher-performing support, both commercially and in after-sales service.

“We warmly thank BPM Construction for many years of collaboration and development, and we are con dent that BIA will continue this momentum by delivering signi cant added value to the French market.”

Komatsu Europe has also made a strategic change to its distributor network in Germany, which will see Schlüter take on an expanded role in the region. Schlüter has taken over the territory that was previously covered by Ritter & Schwald (R&S) as part of a transition that will see the latter become an authorised dealer operating under Schlüter.

This means Schlüter will manage all sales, service, and support activities in the former R&S region, while R&S will operate as a dealer partner under Schlüter.

“We’ve given the new 6015 class-leading tool carrying capacity and heavy-duty undercarriage protection to deliver reliable and productive operation in the most demanding conditions,” Caterpillar product value stream manager Ryan Mitchell said.

“With its 14.6-tonne bucket payload, the shovel provides proven pass match ef ciency with Cat 773, 775 and 777 haul trucks operating in the 55- to 90-tonne-class range.”

The new-generation pilot pump con guration can deliver variable, on-demand hydraulic oil ow in response to control lever movements. This means that when simultaneous movements occur, the ow rate increases; when the joysticks return to neutral, the oil ow decreases, lowering the system’s heat generation and reducing component wear. According to Caterpillar, this system can improve fuel ef ciency by 5.5 per cent.

The 6015’s updated standard bucket linkage autolube system eliminates the need for manual lubrication. To ensure smooth operation and enhanced durability, the new

1. The Cat 6015 hydraulic mining shovel can be used in quarrying applications.

2. Caterpillar has launched the Cat 6015 hydraulic mining shovel.

slew bearing features a triple-roller design. Additionally, the larger grease tank capacity extends service intervals to 500 hours.

A new Cat PPPC hydraulic system improves operator ef ciency by adjusting hydraulic ow with joystick movement, ensuring smooth, predictable operation.

The 6015’s four-pump system dedicates three pumps to implement and travel, and one to swing. Pressure and ow compensation deliver only the necessary ow, and automatic ow proportioning ensures precise multifunctional operation.

The new shovel links to Cat MineStar Solutions via Product Link Elite, using cellular or satellite, with MineStar Health offering improved condition monitoring and reporting for eet operations. The Cat Electronic Technician platform helps technicians diagnose, maintain engines, and monitor the pilot pump system pressure.

Mitchell said the Cat 6015 hydraulic mining shovel was very versatile.

“It delivers exible and productive loading ef ciency across a full spectrum of applications, including mining, quarry and aggregate, heavy construction, and industrial,” he said. AB

“We are con dent that this evolution will enhance our proximity to customers and optimise our support capabilities across the region,” Maeda said.

“Schlüter’s leadership in the German market and R&S’ long-standing relationships will together reinforce Komatsu’s service excellence.”

Increased uptime

Caterpillar has of cially launched its new Cat 6015 hydraulic mining shovel with several design tweaks to help customers achieve a lower cost-per-tonne in their operations.

The mining shovel has a new pilot pump system with variable hydraulic oil ow, a triple-roller slew bearing, and a new standard bucket linkage autolube system, compared to previous models.

Powering productivity

Hauling equipment manufacturers have made major moves to consolidate their operations and expand in key areas.

By any de nition, the Austrian Alps are a tough operating environment. The gradients can reach 40 per cent, and the winter conditions are brutal, but it is also the backdrop for one of the more ambitious renewable energy projects of recent years: the Kühtai 2 power plant.

The power plant is no small undertaking. The project includes a new reservoir with a rock ll dam, a tributary tunnel with six water catchments, and a modern storage power plant. The scale of the job required durable and reliable machinery which could handle the conditions, day after day, which is why, in April 2025, Volvo A45 haulers were added to the existing eet of Volvo haulers ranging from the A25 to A60 at the renewable energy project. Immediately, ve of the new generation A45s from Volvo Construction Equipment (Volvo CE) were put into operation, and very quickly, drew rave reviews from operators.

“In the steep terrain, the Volvo machines are top-notch. They come up the steep mountains,” Swietelsky articulated hauler operator Maik Jacobi said.

“The comfort in this dumper is quite good. Riding the 45mm body is simply ne because it has air suspension.”

The A45s have been put to work in a wide range of roles, including transporting ller materials from the quarry up towards the rock ll dam. This task sees the A45s forced to navigate challenging terrain with more than 2100 metres of elevation as gradients reach around 35–45 per cent. The repetitive nature combined with the undulating environment makes this a tough task but one that the A45s have handled with ease.

It is also where key design features on the Volvo machines have played a signi cant role in ensuring safe operation.

The A45’s cabin, with wide windows and a relatively short hood, provides clear visibility for operators, while the modern LED headlights illuminate the operating path. In a challenging environment, including navigating around other equipment in tight spaces and changing weather conditions, operators can carry out their tasks with precision.

The Kühtai 2 power plant is designed as a gateway to a more sustainable future.

The realisation of this ambition is being powered by Volvo CE’s machinery load after load in extreme conditions with skilled

operators and a trusted service partner in Ascendum Baumaschinen Austria.

Ascendum Baumaschinen Austria has supported the project with on-the-ground service for the entire Volvo eet. This has included preventive maintenance and the provision of spare parts for the Volvo eet to maximise uptime.

“The Ascendum technicians who are working in Kühtai are excellent. They do their job at the highest level,” Jacobi said.

Expansion

Volvo CE has further strengthened its capabilities after completing the acquisition of Swecon from Lantmännen.

The European Commission gave regulatory approval in January 2026, which provided the green light to Volvo CE to nalise its deal for the Swecon and expand its construction machinery capabilities.

The deal includes the full extent of Swecon’s business: products and services, Entrack, rental operations, aftermarket services, of ces, workshop facilities and its 1400 employees.

Swecon had a presence in Sweden, Germany, Estonia, Latvia and Lithuania.

Head of Volvo CE Melker Jernberg said the deal would strengthen Volvo CE in key markets with improved retail operations.

“We are excited to [be] welcoming all employees from Swecon to Volvo and we believe that together, we will be stronger and better equipped to continue to enhance the support to our customers in their transition towards more sustainable and productive solutions,” he said.

Following Volvo CE’s announcement of the acquisition of Swecon from Lantmännen, Tomas Kuta was con rmed as the new head of Swecon, with Tomas Börjesson retiring.

“By joining forces, Swecon combines its market expertise with Volvo CE’s innovation power, while customers continue to receive the same trusted support, services, and points of contact – now strengthened to help them succeed today and tomorrow,” Börjesson said.

Wide appeal

Caterpillar has unveiled the latest addition to its hauling line-up in the new Cat 707 widebody truck.

The new model features a fully integrated Cat powertrain, including a Cat C13 engine, a Cat automatic transmission, a proprietary Cat axle and a maximum 66-tonne payload. The new 707 wide-body truck offers parts commonality with other Cat machines, including a common C13 engine, CX31RT transmission and cab.

“We have engineered our new wide-body truck with a unique philosophy. It’s built to be rebuilt, offering consistent mechanical availability and longevity through a second lifecycle, which can help lower operating costs,” Caterpillar global product specialist Angel Gonzalez said.

“With its foundation of reliable operation and a cost-effective rebuild option, the new 707 wide-body has been engineered, manufactured and eld-tested using the latest technologies to ensure the truck is ready for work. This is the rst Cat wide-body truck model in a new product family that broadens the Cat hauling systems portfolio.”

Reman on the mind

The growth in demand for remanufacturing options has been underlined following Komatsu North America’s decision to signi cantly expand its capabilities via its latest acquisition.

The company has acquired SRC of Lexington, a North American business that specialises in distributing remanufactured components to operations in the construction and mining sectors.

According to Komatsu North America, its remanufacturing business has seen signi cant growth in recent years, with a fourfold increase in transaction volume from 2010–24.

Komatsu’s international remanufacturing network has grown to encompass around 45 locations across 16 countries.

“North America is one of Komatsu’s most important markets for both construction and mining equipment,” Komatsu North America vice president for parts and infrastructure Danny Murtagh said.

“This acquisition allows us to deepen our reman capabilities closer to customers, improve responsiveness, and support dealers and end users with high-quality, cost-effective solutions throughout the equipment lifecycle.”

SRC Holdings president Tim Stack said his company was looking forward to its new chapter as part of Komatsu.

“This agreement re ects a shared commitment to remanufacturing excellence, technical expertise, and long-term support for customers,” he said.

“Just as important, it re ects our responsibility to do what is right for our people. Becoming part of Komatsu allows the Lexington team to build on over three decades of remanufacturing strength, while providing the investment, long-term support and opportunity needed to carry that legacy forward into its next chapter.” AB

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Power and precision

Versatile crushing and screening equipment is increasingly in demand as operators seek to achieve high production levels from their machines.

When it comes to operations, there is little Matt/MPX does not cover.

The Brazilian-based company operates quarries and asphalt plants but also has a line of business in civil engineering and road infrastructure with a broad range of clients including the public and private sectors.

With such a wide scope of activities, Matt/MPX has come to appreciate versatile solutions that suit its mobile operations, including the Kleemann plant it recently invested in. With a jaw crusher, cone crusher and screen plant, Matt/MPX has partnered the plant with its Ciber mobile asphalt mixing plant for a one-two punch that offers incredible exibility to its operations.

The MOBICAT MC 110 EVO2 jaw crusher handles primary crushing while the MOBICONE MCO 90 EVO2 mobile cone crusher provides shaping capabilities in the secondary crushing stage before the MOBISCREEN MSC 953 EVO mobile screening plant ensures the necessary classi cations are achieved in the processing stage.

“We have already had excellent results with the Ciber asphalt mixing plant. That’s why we also wanted to invest in a material

processing plant that is easy to transport and offers us greater exibility,” Matt/MPX co-founder Douglas Matt said.

“Working with Ciber over the past few years has clearly shown that it pays off when the machines can be moved around the quarry, the plant and the job sites and then positioned exactly where they are needed.

“This simpli es our logistics considerably, saving us countless lorry journeys and huge costs.”

The success of the mobile machinery has led Matt/MPX to re-think what is possible for job site logistics across many of its projects.

The Brazilian out t sees the Kleemann plant as being complementary to its quarrying operations, with the capacity to support its asphalt plants and regional jobs.

The company’s quarry can be found in Passo Fundo, where basalt is extracted. The most popular materials are gravel in various sizes and macadam.

The Kleemann plant has already earned plenty of fans among the quarry workers for its production and low fuel consumption.

The MOBICAT MC 110 EVO2 consumes 12 litres an hour, the MOBICONE MCO 90 EVO2 a maximum of 25 litres, and the MOBISCREEN MSC 953 EVO consumes around nine litres per hour.

“I must admit, I was sceptical when the new plant train was delivered. It’s an entirely different technology from what we’re used to with our stationary plants,” Passo Fundo quarry manager Jean Cleber Dall’Alba said.

“The production output of the new machines is very impressive. We produce over 2000 tonnes of material per day in an eight-hour operation – and the plant is only running at 70 per cent of its potential capacity.

“These are very affordable fuel costs, which makes production extremely ef cient.”

A key part of the transition to the Kleemann plant has been the control system. The intuitive spective connect platform lets operators see key machine data from anywhere on site, making it easy to manage operations and make informed decisions.

“As I said, I was apprehensive about the new technology. But my concerns were completely unfounded. The operation is extremely clear and intuitive,” Dall’Alba said.

“I am impressed by the plants’ robust design and good accessibility.

“Everything is so straightforward. No complicated settings or ground mountings are required. Just simple levelling –and off you go.

“I introduced some of the guys here to the handling of the plant. They picked it up very quickly. In fact, they virtually fell in love with the machine.”

But potentially none of this would have happened if not for Matt/MPX’s decision to

invest in another piece of equipment from a fellow Wirtgen brand, the mobile asphalt plant known as the Ciber iNova 1500.

Matt said the asphalt plant’s production levels gave the company con dence that equipment from the Wirtgen Group – which includes Kleemann and Ciber – was the real deal.

“With the Ciber iNOVA 1500, we produce 75 to 150 tonnes of asphalt per hour. The plant can be transported on just two transport vehicles, making it signi cantly more compact and easier to move than conventional plants. This is ideal for use on changing job sites,” he said.

“We have always been impressed by the exibility, ef ciency and ease of operation of the Ciber plant.

“It is a real step forward for us that we now also have all these advantages in material processing with the new plant train from Kleemann.”

The success of its recent purchases has all but ensured that Matt/MPX will be repeat customers of Kleemann in the future.

“When it comes to new purchases in the future, we will de nitely continue to operate within the Wirtgen Group universe,” Matt said.

Expanded presence

Metso has con rmed changes to its distribution network in Europe and North America, which will strengthen its services and support for customers in key areas.

1. MATT/MPX operates a Ciber asphalt plant.

2. Metso and Mellott have enjoyed a successful partnership in the US.

3. Metso has expanded its partnership with Fischer-Jung.

Fischer-Jung has been assigned a new territory in Germany, which will support customers in the north and east of the country. The company has been a long-time distributor for Metso, with more than three decades of association with the crushing and screening manufacturer.

“Expanding into Northern Germany is a logical step in the development of our long-standing partnership with Metso, and it strengthens our distribution presence in the German market,” Fischer-Jung chief executive of cer Thorsten Plew said.

Fischer-Jung will be responsible for delivering local access to Metso’s products, including wear and spare parts, as well as aftersales support, in its assigned territories.

“In today’s demanding operating environment, customers need more than high-quality machines, they need a partner who understands their challenges,” Metso director of capital sales (EMEA north) Adam Benn said.

“At Metso, we truly believe that our strong partnership with Fischer-Jung, and their technical knowledge, eld experience, and commitment to maximise uptime and productivity will continue to be a key differentiator in the success of our customers.”

Metso has also expanded its presence in the North American market, where the original equipment manufacturer announced an expanded agreement with Mellott.

Under the new deal, Mellott will be the authorised Metso distributor for Florida and its existing territories in the southeastern US. It will continue to support Metso’s crushing and screening equipment, spare and wear parts, and services offerings to quarrying and aggregates producers and contractors.

Key features in the new A50 include:

• Keyed and bolted frame: Eliminates high-stress welded joints for long-term durability

• Solid side plates: Removes weak points and cutouts in the mainframe’s side plates

• Cast swing jaw and angled wear plate: Prevents material bridging and strengthens high-stress zones

• Longer liners with improved nip angle: Maximises material grip and crushing e ciency, and reduces wear

• Interchangeable fixed and swing liners: Extends the life of wear parts

• Patented interchangeable toggle assemblies: Hydraulic and mechanical options eliminate heavy wedges and side plate cutouts

• High inertia flywheels: Heavy-duty flywheels for reduced horsepower requirements

• Engineered isolation mounts: Rubber mounts isolate crushing forces, reduce stress on chassis frames and mounting structures

“We are thrilled about this expanded partnership with Metso, as it enables us to deliver even greater value to our loyal Florida customer base that has trusted us for over 30 years,” Mellott president Nick Ecker said.

Metso vice president for distribution management (Americas) Steve Cianci said the agreement further strengthens Metso’s ability to deliver high-quality solutions and customer outcomes.

“Mellott has a strong track record in customer satisfaction as a Metso distributor, and they have been recognised with Metso’s distributor awards for their sales and service performance and capabilities,” he said.

“It is essential that we work with distributor partners who are willing to invest alongside us to ensure the best possible customer experience.

“Mellott has demonstrated a clear ability to scale its business with Metso through disciplined investment, operational excellence, and a strong focus on customers.”

Additional crushing

Astec has expanded its extensive range of crushing solutions with the A50 jaw crusher, which is the rst model in a new series of jaw crushers. Astec said the new A50, the rst of its A-series line, was the “beginning of a new era” for the manufacturer,

with several product launches as the full line-up is introduced over the coming months and years.

“The A50 jaw crusher is a true representation of what we can achieve through our OneASTEC NPD strategy,” said Astec vice president of product management Stephen Whyte.

“By bringing together the best engineering expertise and proven designs from across our legacy brands, we’ve created a machine that represents both our legacy and establishes a new benchmark in future jaw crusher design.

“The A50 sets a new standard in crushing performance and is the start of an exciting new chapter in crushing technology.”

The A50 builds on Astec’s long history in crushing equipment, which includes developing the Pioneer, Telsmith, and Osborn jaw crushers. According to Astec, the new series includes features that balance highlevel production with enhanced safety.

“Astec has created a crusher that delivers the durability, ef ciency, and performance producers demand today while laying the foundation for the future of the A-Series line,” the company said in its release

“With the launch of the A50, Astec honours its legacy while delivering safer, easier operation and maintenance, helping customers lower their cost per tonne.” AB

Taking a global perspective

The quarrying and aggregates sector is set to enjoy some of its biggest trade shows throughout 2026.

MAY 6–9

SaMoTer 2026

Organiser: Veronafiere

Telephone: +39 045 11176091

JUNE 23–25

Hillhead 2026

Organiser: The QMJ Group

Tel: +44 (0)115 945 4367

JULY 1–2

PNG Expo Organiser: Prime Creative Media Tel: +61 03 9690 8766

SEPTEMBER 2-5

SteinExpo 2026

Organiser: GEOPLAN GMBH Tel: +49 7229 606-30

OCTOBER 6–8

IQA National Conference Organiser: Institute of Quarrying Australia Tel: +61 (02) 9484 0577

ENEWS WEB PRINT

Flexible. In performance and applications.

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