2005 Gough CAT Travel Award


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Jim Greenlaw, Quarry Manager, Levels Quarry, Timaru

Jim was first appointed Quarry Manager October 1990. His role involves all the day to day operations running this very efficient plant. With 3 full time and one part time staff member the quarry operates 12hrs / day, 5 days per week. Saturday mornings are set aside for regular pro active maintenance. This has resulted in increased production through less down time during the week.

At Jim’s inception a major upgrade of the plant was commenced in the winter of 2003 with improvements continuing to this day. All were designed and implemented to increase productivity and efficiency, improve safety and reduce running costs. This has been particularly evident by the streamlining of the plant by removing excess conveyors with their associated head and tail drums and moving parts.

Placing additional accessways and guarding has made the plant more user-friendly and creates a safer working environment for all those involved.

Since 2003 the following improvements have been made

  • Replaced the1950?s sand wash with a new FH triple deck screen and 3 x 17m3 hoppers.
  • Relocated the dust screen, eliminating 4 conveyors and associated drive gear.
  • Improved raw feed hopper with accessways and hand rails for increased safety.
  • Installed Weighbridge and office
  • Replaced silt discharge line from pond to clean fill. More efficiency ?decreased cost.
  • Replaced control room. Better visibility
  • Added many additional walkways to improve safety and access.
  • Improved stockpile layout to improve loader efficiency.
  • Use of recycled tilt panels around plant as clean walking areas.
  • Use of irrigation water from local scheme ? decreased pumping costs from on site deep bore.
  • Commencement of Clean Fill operation. (35yr consent)

Plans for 2005 winter include the replacement and relocation of 30yr old chip bins, with increased capacity to allow less running time for quarry truck at lower costs. The current 6900 Barmac will also be replaced with a MK 2 Rotopactor.

Jim has a no nonsense common sense approach to quarrying and crushing and is continually looking for ways to do things more safely, improve efficiency, increase productivity and reduce cost. He has been able to achieve this through the backing of Fulton Hogan, but without the intimate knowledge of crushing and pro active stance this would not have happened in the same time frame.

Jim Holds a B Grade Quarry Managers Certificate and also has a National certificate in Extractive Industries Operations Surface Extraction gained in February 2003. Training is ongoing, with Jim and his team regularly holding and attending tailgate meetings and compulsory industry training.

The safety record at Levels Quarry has been intact since records have been kept and no LTIs have been recorded since Jim?s appointment in 1990. The same can be said for environmental incidents with no cautions or prosecutions.

The static plant at Levels has an output of over 100,000t per annum and has been described as one of the most clean, tidy and environmentally conscious quarries in Fulton Hogan?s livery.

Jim Greenlaw has earned the term Quarryman. The Gough CAT Award is an accolade well deserved.