A heavy-duty mobile solution to a crushing problem

In 2014 Canyon Rock acquired its second quarry to provide material for rip rap and stone for the Sonoma–Marin Area Rail Transit project, a 113km long rail and bikeway that crosses the region.

The family-owned company’s reputation for operating with optimal efficiency was at stake, so it was essential it chose the right primary crusher, one that could handle heavy-duty quarrying applications easily and for many years to come.

The essential problem for Canyon Rock, and many other such companies, is that the market for track-mounted heavy-duty jaw crushers is flooded at present. Many of the crushers available are excellent pieces of equipment but complicating matters is the fact many are not.

Fortunately, Canyon Rock was informed about the capabilities of the Sandvik Construction UJ440i tracked mobile jaw crusher.

“The UJ440i is a step up,” Canyon Rock co-owner Jonathan Trappe said of the machine’s strengths. “The chassis, the frame, the belt – everything is sturdier. We were looking for something that would last a lot longer than a regular contractor’s primary jaw, something that would run well and last for 15 to 20 years.”

The fact the UJ440i crusher could efficiently turn out two finished products from the quarried rock was the real clincher for Canyon Rock.

“The jaw can handle major openings,” Trappe said. “We can open it up and make finished rip rap. Other jaw crusher manufacturers say the jaws can be opened to 200mm but even that is pushing it.”

This is not surprising, as the UJ440i possesses a jaw size of 1200mm x 800mm, and has proved capable of reducing large volumes of rock at high rates of production – up to 700 tonnes per hour. Push buttons operate the hydraulic closed side setting, which can squeeze the opening down to 100mm from 275mm. Additionally, its conveyor belts are 1350mm wide and sit on hydraulic drive units that can be reversed as needed.

The UJ440i is powered by a 317kW Volvo diesel engine that directly drives the crushing processes. The engine can operate without critical loss of power while consuming a meagre 30 litres of fuel per hour. {{image2-A:R-w:350}}

“The fuel consumption on the Volvo engine is absolutely phenomenal,” said Martin Keegan of Interval Equipment, Sandvik Construction’s distributor for mobile crushers and screens in the area.

“We saw one working in Europe on our factory visit and even when the customer changed the closed side setting on the jaw from 150mm down to 75mm on a very hard competent granite, the fuel consumption only jumped by two litres an hour. I have never seen such a productive unit compared to the fuel consumption.”

Practical deployment and use of the UJ440i is enhanced through an 1135-litre fuel tank, which enables the crusher to process rock all day without interruption for fuelling.

Yet should the need to interrupt the operation arise, emergency stop buttons are located at several appropriate places on the frame of the machine. This is of major importance to a company as safety conscious as Canyon Rock.

Before finally settling on its new crusher, Canyon Rock received many promises from various other crusher manufacturers.
Sandvik was so confident of the UJ440i, the company decided to invite the Trappe brothers Jonathan and James to the UK to see the machine in action.

“It meant a lot to receive an invitation from Gareth Orritt [Sandvik Construction] to tour a Sandvik factory,” Jonathan Trappe said. “We met with the engineers who designed the UJ440i. It was key for us to see one in action, and after seeing how well one was running after 10,000 hours of operation, we knew it was what we were looking for.”

One of the features of the UJ440i that really impressed Canyon Rock was the pre-screen, which enabled it to make legitimate splits of the rock material. The separate pre-screen is located between the pan feeder and the crushing chamber, measuring a mere 1125mm x 2100mm. It is topped by the stepped grizzly section, with a maximum aperture of 100mm.

“The pre-screen on the UJ440i is a superb addition for eliminating the fines quickly,” Sandvik Construction business line manager Orritt said.

“Because of the large screening capacity up to 150 tph, and the large screening area, it ensures that Canyon Rock puts only clean rock into the jaw. This allows the screening plant further down the line to be so much more efficient in making the coarse rip rap products that Canyon Rock needs to supply its customer base.”

When the Trappe family began quarrying some 70 years ago it was as a sideline to its dairy business, which Wendell Trappe’s father (grandfather of the current managers/operators) began operating north of San Francisco.

From a small quarry on the dairy farm, the Trappes hauled occasional truckloads of rock to larger quarry companies. In 1972 the family began quarrying rock seriously when it bought an operational quarry near Forestville, which is managed now by Jonathan Trappe.

What began as an excavation site is now a full service operation, featuring a complete line of aggregate and recycled material, as well as an auxiliary division offering ready mix and concrete products.

The acquisition of the Cazadero quarry, however, created the need for a new approach to material production, using equipment that could produce rip rap and allow Canyon Rock entry to the market for the sub-base and erosion control material.

During its previous operations, the Trappe family had become familiar with Allis-Chalmers aggregate equipment, considering them to be good crushers. {{image3-A:L-w:300}}

Sandvik subsequently purchased and upgraded the Allis Minerals product line, later named Svedala, and the family purchased a Svedala H4800 cone crusher and then a Sandvik CH660 cone from ACS, the local Sandvik Construction dealer for stationary crushing and screening equipment.

Despite the excellence of the Allis-Chalmers, Svedala and latterly the Sandvik Construction static crushing and screening equipment, when it came to purchasing a new crusher Canyon Rock knew it required a mobile unit.

Not only is a mobile jaw crusher able to follow the contour of the quarry face under its own power as the quarry is blasted away but it is also essential when there are drops and increases in the operating areas of the quarry.

All these elements are easily accomplished due to the 74-tonne UJ440i travelling on its 500mm wide, 4200mm long crawler tracks, which enable the machine to navigate a 20-degree slope.

After falling in love with the Sandvik UJ440i, the company has acquired a Sandvik QE440 mobile scalping screen unit to enhance the two-product output at Cazadero.

The QE440 boasts the largest total scalping area in its class and features three broad hydraulic material conveyors with high discharge heights for major stockpiling. It is able to produce up to 900 tph.

“We are really happy with the QE440,” Jonathan Trappe said. He conceded the family was not sure if the machine would be able to handle larger rocks conveyed to it by the crusher, but added: “It handles the tonnage the UJ440i gives it with no problem, and has enough throw to clear itself.”

Helping Canyon Rock enormously is the fact it has long-standing relationships with Sandvik Construction’s mobile crushing and screening equipment.

The Trappes first worked with Keegan when he was a representative for Extec Screens and Crushers (acquired by Sandvik in 2007).

Through this relationship, Canyon Rock has grown to rely on the knowledge and support of someone with experience in the industry, and who is able to provide aftermarket support.

“We were worried that parts would be a problem,” James Trappe, who manages the Cazadero quarry, said. “When something goes down we can’t be shut down for a couple of weeks waiting on a part. Having a dealer who will stock parts and take care of issues that might come up was important.”

Being able to efficiently churn out rip rap in volume is what drove the purchase of the new Sandvik screen and crusher.

Thanks to Sandvik Construction and Interval Equipment, Canyon Rock now has the critical equipment in place to meet urgent demand for the coarse rock and, vitally, the back-up that ensures its customers get the materials they demand, when they want it.

In Australia, Sandvik mobile plant and equipment is distributed by Precisionscreen.

Source: Sandvik Construction

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