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A heavy-duty mobile solution to a crushing problem

When Northern California company, Canyon Rock, recently acquired a second quarry in 2014, they found they required a primary crusher that would be able to handle heavy duty quarrying applications easily, and for many years to come. The solution was provided in the form of a Sandvik Construction UJ440i tracked jaw crusher supplied by Sandvik's distributor Interval Equipment.

A heavy-duty mobile solution to a crushing problemJonathan Trappe (Canyon Rock), Martin Keegan (Interval), James Trappe (CR), Gareth Orritt (Sandvik), Wendell Trappe (CR)

In 2014 Canyon Rock acquired its second quarry. The reason for this acquisition was to provide material for rip rap, and stone, for the Sonoma–Marin Area Rail Transit project; a 70 mile long rail and bikeway which crosses the region. The family owned company's reputation for operating with optimal efficiency was at stake, so it was essential that the company 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 that many are not. Fortunately for Canyon Rock they were informed about the excellent capabilities of the Sandvik Construction UJ440i tracked mobile jaw crusher.

A step-up from what we are used to
"The UJ440i is a step-up," said Canyon Rock co-owner, Jonathan Trappe when emphasizing 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 15-20 years". The fact that the UJ440i crusher is able to efficiently turn out two finished products from the quarried rock was the real deal clincher for Canyon Rock. "The jaw can handle major openings," stated Jonathan Trappe. "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 metric tons per hour. Push buttons also operate the hydraulic close 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.

A heavy-duty mobile solution to a crushing problem

Cost efficient power plant
Power is provided by a 425-horsepower Volvo diesel engine that directly drives the crushing processes. The engine is able to operate without critical loss of power whilst consuming a meagre eight gallons of fuel per hour. "The fuel consumption on the Volvo engine is absolutely phenomenal" – so said Martin Keegan of Interval Equipment, Sandvik Construction's distributor for Mobile Crushers and Screens in the area, who continued: "We saw one working in Europe on our factory visit and even when the customer changed the Close Side Setting on the Jaw from 150mm down to 75mm on a very hard competent granite, the fuel consumption only jumped by half a gallon 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 the fitment of a 300 gallon fuel tank, which enables the crusher to process rock all day without interruption for fueling. Yet should the need for interrupting the operation be required, emergency stop buttons are located at several appropriate places on the frame of the machine. This latter point is of major importance to a company as safety conscious as Canyon Rock.

Seeing is believing
Before finally settling on their new crusher Canyon Rock received many promises from various crusher manufacturers. Sandvik were so sure of the UJ440i they decided to invite the Trappe brothers, Jonathan and James, to the UK, in order to see the UJ440i in action. Jonathan Trappe commented: "It meant a lot to receive an invitation from Gareth Orritt (Sandvik Construction) to tour a Sandvik factory." He continued, "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 that was what we were looking for."

One of the features of the UJ440i that really impressed Canyon Rock was the pre-screen which enables them 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. Gareth Orritt, Sandvik Construction Business Line Manager, explains: "the pre-screen on the UJ440i is a superb addition for eliminating the fines quickly. Because of the large screening capacity up to 150tph, and the large screening area, it ensures that Canyon Rock put 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 their customer base".

A heavy-duty mobile solution to a crushing problemWendell Trappe, Gareth Orritt (Sandvik), Martin Keegan (Interval), Jonathan and James Trappe (Canyon Rock)

The only way was Mobile
When the Trappe family began quarrying some 70 years ago it was as a sideline to its dairy business, which Wendell Trappe's father (father of the current managers / operators) began operating north of San Francisco. From a small quarry on the dairy farm, the Trappe's 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, entailing the use of equipment that could produce rip rap and allow Canyon Rock entry into the market for the sub-base and erosion control material. During its previous operations the Trappe family had become familiar through use of Allis-Chalmers aggregate equipment, considering them to be good crushers. Sandvik subsequently purchased and upgraded the Allis Minerals product line, later named Svedala, with the family purchasing a Svedala H4800 cone crusher and then a Sandvik CH660 cone from local Sandvik Construction dealer for stationary crushing and screening equipment, ACS.

Despite the excellence of the Allis-Chalmers, Svedala and latterly, Sandvik Construction static crushing and screening equipment, when it came to purchasing their new crusher Canyon Rock knew they required a mobile unit. This was essential as not only is the jaw crusher able to follow the contour of the quarry face under its own power as the quarry is blasted away, but also essential when there are drops and increases in the operating areas of the quarry. All of these elements are easily accomplished due to the 74 metric ton QJ440i travelling on its 500mm wide, 4200mm long crawler tracks, which enables the machine to navigate a 20 degree slope.

New addition aids productivity
After falling in love with the Sandvik UJ440i, the company has now 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 metric tons per hour. "We are really happy with the QE440," says Jonathan Trappe. He acknowledged that the family wasn't 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."

First class support and advice
Helping the company enormously is the fact that Canyon Rock has long-standing relationships with Sandvik Construction's mobile crushing and screening equipment. This goes back to when the Trappe's first worked with Martin Keegan of local Sandvik Mobile Crushers and Screeners dealer, Interval Equipment, 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 somebody with experience in the industry, and who is able to provide aftermarket support. "We were worried that parts would be a problem," explains James Trappe, who manages the Cazadero quarry, who continues, "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 both the new Sandvik screener and crusher. Thanks to Sandvik Construction and Interval Equipment, Canyon Rock now has the critical pieces of equipment in place to meet urgent demand for the coarse rock, and vitally, the back-up which ensures that its customers get the materials they demand, when they want it.

For further information please contact:

Virginia Varela-Eyre
Marketing Manager Construction Americas
Office Phone: +1 404 589 2823
Mobile: +1 404 263 8788

Related products: UJ440i tracked jaw crusher

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