Companies are increasingly investing in drill rigs and rockbreakers within the quarrying and aggregates sector with positive results.
Collins Earthworks has earned its reputation as a capable operator on some of the biggest and most challenging earthmoving projects in the UK.
A fundamental part of its recent success has been the 2023 purchase of the Ball Eye Quarry, near Cromford in the Peak District in Derbyshire. The famed quarry was once a hive for the extraction of lead, fluorite, baryte and limestone, but had fallen by the wayside when it was abandoned in 2014.
“The purchase of the Ball Eye quarry was of strategic importance for us. Owning a quarry gives us the opportunity both to obtain high-quality aggregates for our projects and to supply them to our customers through the transport division,” Collins Earthworks chief executive officer David Collins said.
The UK-based operator was determined to restart operations at the quarry. Since taking it over under Collins Earthworks, the quarry has become known for its high-quality limestone aggregates.
The company has taken a sustainable approach to developing the quarry including investing in a fleet of Volvo FMX electric vehicles, off-grid rapid charging stations and numerous other initiatives.
The UK-based producer has also invested in a portfolio of Indeco demolition hammers from long-standing distributor Derek Fitzgerald Plant in Leicestershire. Collins Earthworks’ portfolio includes a range of Indeco demolition hammers ranging from small HP 621/700 versions to the medium and large HP 1500, HP 2500, HP 5000 and HP 7000 models, up to the giant HP 12000. A key feature of the Indeco hammers is the automatic variable blow technology that adjusts the power and the frequency of the blow to match the material’s hardness.
The HP 12000 has been in constant use at Ball Eye Quarry since it arrived.
The largest Indeco demolition hammer plays a key role in primary and secondary pulverising of limestone at the quarry while mounted on a Volvo EC700 excavator. Collins Earthworks has estimated that the hammer works for around eight hours a day on about 1700–2000m³ of material.
“We are very happy with our HP 12000. It works non-stop with no problems at all. No hammer from any other manufacturer compares to it in terms of power and production capacity,”Collins said. “It amazes me that every rock quarry in Britain doesn’t have one.
“We now have a fleet of Indeco equipment, and we are very satisfied with its performance at the various worksites.
“They have proved to be hard-wearing and efficient with low maintenance requirements, which means less time lost in repairs and more time dedicated to productive work. When assessing demolition equipment, we look for machinery that can ensure high productivity with minimum downtime – and Indeco meets these expectations.”
Bulls eye for Luck Stone
Epiroc engaged Luck Stone to launch the SmartROC D65 drill rig in the US aggregate market, which the manufacturer has heralded as a first for the worldwide quarry sector.
The two companies, in partnership with James River Equipment, will work together long-term in the project, which will include local service, training and technical support.
Luck Stone director of engineering Chuck Stilson said the company is committed to investing in autonomous technology.
“Our philosophy has always been about doing the work in the best possible way,” he said. “Partnering with Epiroc on autonomous drilling aligns perfectly with that vision.
“We’re not only improving productivity and safety, we’re providing new opportunities for our associates and rethinking what’s possible in aggregates.
Epiroc and Luck Stone will share data from the performance of the SmartROC D65 MKII, which both said will deliver broader insights for the industry relating to automation.
Established in 1923 by Charles Luck Jr, the Luck Stone, part of Luck Companies, has several operating locations, including Virginia, North Carolina, South Carolina and Georgia. In recent times, Luck Stone has been a proven adopter of autonomous technology, including autonomous plants and autonomous haulage systems (AHS).
Earlier in the year, Luck Stone marked one million tonnes hauled autonomously at its Bull Run Quarry in Virginia. Bull Run Quarry was one of the first in the aggregates sector to deploy Caterpillar’s autonomous Cat 777 trucks with a full autonomy technology stack and site integration services.
At the announcement, Luck Companies president and chief executive officer Charlie Luck said the milestone reaffirmed the company’s belief in autonomous technology.
“This autonomous journey with Caterpillar has been one of the most powerful and transformative projects in our 100-year history. What once felt like a dream at our Bull Run site is now a reality, thanks to the trust, collaboration and shared commitment between our teams,” he said.
“Reaching the one-million-tonnes-hauled milestone has engaged every part of our operation, from training and mine planning to operating efficiency and teamwork, proving that this technology can work, and work well, in a quarry environment. Most importantly, it’s creating opportunities for our associates to grow, lead and be part of something groundbreaking.
“This project is an example of what’s possible when people, purpose and progress come together.”
Now, in partnership with Epiroc and James River Equipment, Luck Stone has expanded its autonomous technology.
The SmartROC D65 MKII features Epiroc’s advanced automation technology, which is capable of supporting complete drill patterns without an operator in the cab. It is compliant with Global Mining Guidelines Group Level 4 standards for fully autonomous equipment. The SmartROC D65 MKII drill rig is capable of operating under remote supervision through Epiroc’s Common Automation Panel and Link Open Autonomy (LinkOA) platform. The platform also provides data integration and fleet management.
“Luck Stone’s leadership and commitment demonstrate that autonomy in quarries isn’t future vision, it’s current reality,” Epiroc USA business line manager Ron Hankins said.
“Our partnership is not about a proof-of-concept; it’s about meaningful operational gains that the next generation of drilling will bring in the US.” AB
