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When your company runs the largest impact crushing recycle yard on the East Coast, has 10 asphalt plants that consume large volumes of RAP, and operates a highway and heavy contracting business that requires thousands of tons of recycled concrete for its municipal and private customers, you have to have a big crusher to keep up with the demand.

So Rick Stavola, president of the 50-year-old, family-operated contracting business faced a dilemma. Would he continue to pay large sums of overtime expenses to his employees to produce more than 250,000 tons of recycled concrete and asphalt annually, or would he make the investment in an ultra-high production impactor and circuit to keep pace with consumption?

After some market research on mega production impactors, Stavola found a solutions to his problem. It was in the form of a colossal horizontal-shaft impact crusher from Eagle Crusher Company and its dealer, Capitol, that would easily crush enough material to feed Stavola Contracting’s huge appetite for recycled materials and even leave room for expansion.

“We already have UltraMax 1400-45 impactor circuits at our two other recycling facilities, and we use a portable 1200-25 closed-circuit crusher for our contract crushing. Eagle Crusher Company and their dealer (Capitol) have supported our other crushers very well and have earner our trust,” comments Stavola.

The 56-inch by 68-inch solid-steel rotor lies at the heart of the three-stage crushing action, and the impactor is capable of producing between 400-600 TPH, in which Stavola Contracting currently operates its UM69 at 500 TPH. With the industry’s heaviest rotor, the impactor forces necessary for secondary reduction. Even with the large feed material encountered at the Tinton Falls facility, Stavola estimates the impactor crushes more than 85 percent of the feed to a 1.5-inch minus spec product on the first pass.

Efficient Operation
Through a collaborative effort between Stavola Contracting and Capitol, the circuit’s design was laid out for efficiency and to lower costs.

Since Installing the new UM69 impact crusher and circuit, which began operation in June, Stavola’s plan has been realized. Significant overtime hours are now a thing of the past with the new crusher’s increased production. According to Stavola, “We now run the crusher approximately 4.5 days a week and only 8 hours per day, eliminating the need for overtime.”

The impactor’s durability and ability to handle massive slabs of heavily reinforced concrete have also impresses Stavola Contracting. We loaded a complete 6-foot-long, 2,500-pound Jersey barrier into the crusher, and the UM69 ate it up in a matter of seconds.

Switching from crushing concrete to an asphalt final recycled product could not be any easer. It takes just a matter of minutes to clear the circuit and move the 100-foot radial stacker a couple hundred feet to begin stockpiling the different product.

Extremely Quiet
The mammoth UM69 also runs surprisingly quiet when devouring feed material, leading the way to a very quiet overall crushing circuit – one that is well within the state guidelines for noise regulations. The NJ State regulations require that continuous airborne sound levels be less than 65 decibels (dBA) at adjoining properties.

Sound measurements taken next to the impactor show that it runs quieter than the average lawn mower. At a 50-foot distance, sound levels generated by the impactor are comparable to that of the dreaded morning alarm clock, and at 100 feet are approximately the same as conversational noise levels. “This is one of the quietest impactors and crushing operations that I have been around. Even in the control room, which is right beside the hopper and impactor, the noise levels register only 74 dBA,” says Mrozinski.

Now that the crushing circuit is in full swing, if demand requires, Stavola has plenty of room to boost production. “We are extremely pleased with our new Eagle Crusher impactor and crushing circuit. The UM69 has helped us to save approximately $0.40 per ton in overtime costs alone, and its performance has exceeded our expectations.”

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Built in the 1960s, the Ecolab facility encompassed 24 acres of land in the heart of Woodbridge’s industrial are. Located at the port and right off the NJ Turnpike with nearby rail service, the site is a prime location for warehousing and distribution. Over the years, Ecolab built onto the original building and added multiple levels to where today’s facility encompassed more than 235,000 square feet of factory and office space.

Three-Inch Centered Rebar
By far the lion’s share of the recyclable material on-site came from the concrete building and asphalt parking lot. An estimated 45,000 tons of material – 35,000 tons of concrete, masonry block and brick and another 10,000 tons of asphalt – was crushed via the company’s Eagle Crusher UltraMax 1000-15CV horizontal shaft impact crushing plant.

Crushing both the concrete and asphalt materials were prime examples of the twists commonly found on this project. The larger and more heavily reinforced footings and foundations posed a challenge for the demolition crew. “On a scale of one to 10 (10 being the toughest to recycle), I would rank this a 9.5 to 10,” says Carl Franzetti, site supervisor for Dallas Contracting. “This building was built like a bunker.”

The foundation’s construction included rebar positioned on 3-inch centers. At the height of the demolition, Dallas Contracting and the crusher were churning out three to four 30-yard containers of rebar a day. “The builders went crazy with the rebar and concrete.”

The impactor’s 44-inch by 41-inch solid steel rotor withstands the abuse delivered by the reinforced concrete. In tough recycle applications such as this, Dallas Contracting opts for medium chrome blow bars to offer the right balance of wear life without bar breakage. “Even when recycling this type of heavily reinforced concrete, we will get 20,000 tons out of a set of blow bars,” says Kozul. The plant’s in-line magnet separates the rebar from the concrete.

Switching from crushing concrete to asphalt did not pose a problem. “We just moved the conveyor, so the asphalt discharged into a separate pile,” said Franzetti. Although the impactor may be able to get better wear with an Eagle Crusher high chrome blow bar when crushing asphalt, on a job this small it was more efficient to crush with the medium bars.

Significant Savings
According to Dallas’ Kozul, owning a portable crushing plant like the UltraMax 1000-15CV made economic sense. Developer Adler agreed, adding: “It saves us money at both ends, first hauling the old material off-site and second bringing in new for construction. It’s good for everyone involved.”

“Buy crushing on-site, we typically save our customers $13 per ton in trucking and dumping fees associated with hauling the materials to a recycling yard,” claims Kozul. On a job the size of Ecolab, this adds up to more than $500,000 savings for the customer, just on the recycling costs alone.

Another key to the savings, according to Kozul, was selecting a crushing plant that was truly portable. Dallas Contracting can move its machine on-site within an hour. “We have to remind our customers that the same day we move in the plant we want to be crushing,” says Kozul. With such a portable plant, Dallas Contracting can process small custom-crushing jobs as well as the large demolition projects, and it gives the company some scheduling flexibility. “When we crushed the first material stockpile at the Ecolab project, we were able to quickly move the plant and crush another job while we were waiting for the excavators to size more concrete in Woodbridge.”

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With the price of crude oil skyrocketing over the past winter, everyone is feeling the crunch. With this dramatic increase in liquid asphalt costs, H&K is producing as much RAP as possible. H&K is producing their mix designs to help offset the cost of making virgin asphalt.

Established in 1968, the Skippack, Pennsylvania-based Haines & Kibblehouse (H&K) employs approximately 1500 people and provides construction aggregates and materials, asphalt paving materials, and site construction and demolitions services from 50 locations throughout Eastern Pennsylvania, New Jersey, Delaware, and Maryland. Its 15 asphalt plants serve a market area consisting of Eastern Pennsylvania, parts of Delaware, and New Jersey with about 50% of the asphalt produced going towards its own paving projects and the other 50% supplying local paving contractors.

The key to H&K’s success is “Keeping costs down,” according to Rush. This is the reason they are running at least 15% recycled asphalt in about 95% of their current mix designs, the exception being ¼” topcoat mixes. By running a reasonably high percentage of RAP, H&K saves considerably on production costs because not only do they use far less virgin aggregate, but they also use far less liquid asphalt. That is why you will find an asphalt crushing/recycling system at each of the 15 asphalt plants H&K operates.

After exploring several alternatives to their current crushing equipment, even considering trying larger screens to handle the increase in oversized materials, H&K decided to test an Eagle Crusher UltraMax 04 (UM04) stationary impact crusher. The UM04 uses the industry’s heaviest, solid-steel, 3-bar rotor design to efficiently crush recycled asphalt. Its 3-stage crushing action produces a consistent, uniform cubical product.

A manually adjustable primary apron and hydraulically adjustable secondary apron allow for precise product gradation control and its blow bars, aprons and liners are designed for long wear life.

So Rush kept track of all the maintenance records of their old crushers for 1 year and compared them with the projected maintenance costs for the Eagle Crusher UM04 impactor. When taking into account all the down time and wear parts with the existing hammermills alone, he concluded that it cost between 50 cents to several dollars per ton to process their RAP. The projected costs with the UM04 would be less than 10 cents per ton. Rush concluded that with the reduction in required maintenance alone, each impactor would pay for itself in a single paving season.

Rush’s findings definitely go the attention of upper management, and his analysis was the deciding factor in switching out all of their old crushers and going with the UM04 impactors.
They are currently crushing approximately 20,000 tons of RAP per set of blow bars, 10,000 tons per side. To this, Ron Granteed exclaimed, “Our blow bars last about 6 months, which is fantastic!” With the hammermill, H&K was only processing about 1,200 tons per set of hammers and grates before they needed to be rebuilt.

When asked if the Eagle Crusher UM04 impactor has saved H&K on anything else, Rush immediately replied, “Yeah, our sanity!” And you have everyone else (at H&K) that are currently running the hammermills begging to get an impactor.

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December 5, 2001

Dear Shawn:

Karabinchak Bros. Inc. (KBI) has been doing business with the Eagle Crusher Co. and its dealer, Capitol, since 1995. In 1995 KBI purchased a 500.05 portable impactor impact crusher and subsequently purchased (2) 1000.15 impact crushers.

We at KBI are extremely pleased with Eagle’s quality, performance and reliability. Eagle’s commitment to 24 hour parts delivery anywhere is critical because down time costs erase profits quickly. Eagle has done “whatever it takes” for us many times to meet our needs. Both their parts and service representatives are very knowledgeable, courteous and “customer friendly” at all times.

KBI has processed well over 700,000 tons of debris: concrete, asphalt, brick, block, limestone and rock. We have a very satisfied list of clients who continually all us for additional jobs.

Mike Crotty of Capitol told me when we purchased our first crusher “ You will not be sorry for buying this piece of equipment”; that was 1995. Reflecting on that statement today, KBI has enjoyed much success in this very demanding area of the construction industry. We could not have achieved this success without Eagle’s remarkable products and their support team in service and parts. Eagle, along with their dealer Capitol, have been with us every step of the way.

Very Truly Yours,
Karabinchak Bros., Inc.

Jamie Karabinchak, Vice President

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ADAMS CONTRACTING
Virginia
Application: Recycled Asphalt
RAP- Big Tonnage No Hassle

1998 meets growing needs by increasing crushing capacity and portability

In 1998, Virginia based Adams Contracting was struggling to meet the their ten (10) Asphalt Plants’ needs for crushed RAP. Adam’s Contracting was using a small hammermill type crusher and would move from site to site. Then Vice President for equipment and Maintenance, Richard Zerkel said “ Our crusher wasn’t fast enough and it wasn’t mobile enough.” Zerkel’s crews were working from dawn to dusk to relocate the crusher and to move the crusher they had a dedicated truck-crane. “It took 3/4 of a day to breakdown, created multiple transport loads and ¾ of a day to assemble.” Adams Contracting was losing time & money.

Adams Contracting and Richard Zerkel chose Eagle Crusher’s Ultramax 1000-15 CC . The heart of the Eagle 1000-15 cc plant is the Ultramax UM-15 Impactor with its’ massive 3-bar sculptured, solid steel rotor and 5-year warranty. Portable and easy the Eagle plant is fitted with a gas-powered hydraulic lift/leveling system for quich setup. Eagle closed circuit plants are truly self-contained with on board diesel engine, generator, 2-deck screen and complete electric system to plug and go 2-stacking conveyors.

Zerkel says,” the Eagle plant has met our needs in two ways.” “It has increased our RAP production so that we can meet our needs without overtime and when we move into a new site we can be crushing in 3-hours or so. “
“If somebody was to call me, I’d tell them to come see the capabilities of it.” “I know all contractors are different…but as far as I’m concerned, for Adams contracting, it’s the ideal machine.”

Adams contracting 2006
Eight years have passed and Adams has grown from ten (10) processing centers to twenty-one (21) and Gilbert Peters is now responsible for equipment decisions. Obviously, the demand for RAP has increased with the doubling of the number of processing facilities and the sky-rocketing price of liquid asphalt. Gilbert Peters contacted Capitol Equipment, the Eagle Crusher dealer, to purchase another, identical crushing plant. He said, the Eagle 1000-15 cc plant had done a great job, that it was easy to transport, service and production met their needs.

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Impacting the Bottom Line
A switch to horizontal shaft impactor pays dividends for V.S. Virkler.
by Rick Zettler


Conventional wisdom says to stay with what you know. There is little risk in choosing a piece of equipment which you have already operated and know the production capabilities and limitations. But, then again, there is little reward in standing still.

V.S. Virkler & Son of Lowville, New York, found itself in a situation where the company could have stagnated with the status quo. For years, it operated sand and gravel facilities to supply aggregate for the company’s three concrete plants. In these pits, located in Martinsburg, Lowville, and Watson, New York, the producer used jaw/cone circuits for aggregate processing. A few years ago, however,  V.S. Virkler jumped into the unknown to take advantage of an opportunity that has expanded its business and more than double its workforce.

Impetus for change
The company began the new millennium by purchasing a competitor’s limestone quarry in Martinsburg, and Richard (Chip) Virkler, president of V.S. Virkler, had to buy new crushing equipment for the operation. With its vast crushing experience resting solely in sand and gravel processing, there was a question as to what type of crushing equipment would work best in the quarry. “Prior to this acquisition, our only equipment experience was with jaws and cones,” says Chip Virkler.

Conventional wisdom, experience, and several equipment manufacturers led Virkler to believe that a jaw/cone circuit would work best for the limestone quarry. After all, the company had the experience with this type of crushing equipment, and it worked in the company’s sand and gravel operations.

Mike Crotty of Capitol, the Eagle Crusher Company dealer in New York, analyzed V.S. Virkler’s equipment needs and expressed a dissenting opinion. “After looking at the overall operation, we told Chip that he didn’t need a jaw/cone circuit,” says Crotty. “It was over-kill for the quarry, and operating and wear costs would be high.” Capitol suggested a low-cost solution for the producer.

Big return
The dealer’s recommendation was to crush with a horizontal shaft impact crushing plant, specifically the portable Eagle Crusher UltraMax 1400-45 open-circuit plant, in the new limestone quarry. Initially, V.S. Virkler wanted only to make a 4-inch minus, gabion product for road base material, so there was no need for a screen to sort the processed material. The company took Capitol’s advice and bought the impact crushing plant in what turned out to be phase one of a three-phase purchase.

The open-circuit UltraMax 1400-45 portable plant incorporates a three-stage UM45 impactor into its design. The UM45 has a 50- by 56-inch rotor diameter and width and a feed opening of 56 by 35 inches to easily handle the 2-foot, sized limestone feed material from the quarry.
To make the 4-inch minus product, V.S. Virkler’s crew sets the primary apron at 6 inches for initial reduction and the secondary apron at approximately 3 inches for final reduction. Gap settings are easily checked through a side access door in the impactor’s main housing. Hydraulic power assist facilitates gap settings changes for the secondary apron.

Although new to impact crushing, V.S. Virkler quickly picked up the plant’s nuances and, after some minor adjustments, began to profitably produce the gabions. Wear costs, as Chip Virkler would soon learn, were lower than anticipated and significantly lower than if the company had gone with a jaw/cone circuit, which prompted an equipment expansion.

Screening phase
Later that year, V.S. Virkler moved forward with phase two of the new equipment circuit for the quarry by purchasing an Eagle Crusher portable 6- by 20-foot triple-deck screening plant from Capitol Equipment. By adding the screening capabilities, the company began producing a New York State Department of Transportation-spec number-4 material, a 1-inch minus aggregate used as asphalt base-course material.

With the number 4s and gabion material, V.S. Virkler was able to expand its spec product offering and customer base. However, the new crushing and screening circuit was not being used as efficiently as it could be. Although top screen deck oversized material could have been recirculated back into the impactor plant, it was being stockpiled and, when enough overs were collected, trucked to one of the company’s nearby sand and gravel operations for further reduction. While this was a workable short-term solution, trucking costs cut into the company’s profitability.

Secondary solution
The third and final phase of V.S. Virkler’s Martinsburg quarry equipment purchase eliminated the need for oversized material trucking. Last year, the company added a secondary crushing circuit by purchasing an Eagle Crusher UM04 impact crusher along with a second portable 6- by 20-foot triple-deck screening plant. Any material not passing through the top screen deck is sent to the UM04 for further reduction.

The secondary UM04 horizontal shaft impactor accepts the oversized feed material with its 27- by 32-inch opening. The solid steel, 40-inch-diameter by 29-inch-wide rotor quickly delivers final reduction, and the screening plant quickly sorts up to three spec products simultaneously.
The secondary crushing circuit has helped V.S. Virkler to significantly increase overall production and lower costs. According to Larry Virkler, vice president, “We’ve noticed a doubling in spec product output, and we anticipate the UM04 and second screening plant to pay for itself within three years just by figuring the trucking savings.”

More importantly, V.S. Virkler has increased the number of saleable products at the limestone quarry. “We can now make up to six different spec products at one time,” says Joe Virkler, general manager and a fourth generation member of the family business. In addition to the gabions and number 4s previously produced, the primary/secondary crushing circuit now makes NY State DOT 1-A’s, number 1s, number 2s, and fines passing through the 1400-45’s grizzly bars in the feeder.
“We couldn’t be happier with the performance of our Eagle impactors and with the support received from Capitol,” adds Chip Virkler.

Selecting the portable crushing plant and screening plant is proving to be another wise decision made by V.S. Virkler. This season, it bought another competitor, which had a limestone quarry in Lowville adjacent to one of the producer’s sand and gravel pits.

In July, V.S. Virkler moved its portable UltraMax 1400-45 crushing plant to the new quarry to get it into shape for full-scale production. Chip Virkler says that the plant could not be any easier to move, with only the control panel and discharge conveyor requiring removal for transport. “We arrived at the new quarry at noon and had the plant running by 3:00 pm that same day,” he says.
Even with the recent quarry acquisitions, significant expansion of the business and a doubling of the workforce, Chip, Larry, and Joe Virkler continue to remain focused on delivering personalized service to the customer. “We cannot lose perspective on delivering a quality product to the customer. They are the reason why we remain in business and are successful,” says Joe Virkler. 

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Capitol EQ2, LLC   376 Broadway  Suite 27    Saratoga Springs, NY 12866    518-664-6161   capeq2@nybiz.rr.com