Aggregates. Harry H Bush PE Director, Technical Services Southwest Division

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1 Aggregates Harry H Bush PE Director, Technical Services Southwest Division 1

2 Take Aways Aggregate Strategic Outlook Finding Good Rock (AQMP) Brief look at Quarry Operations Quality and consistency are priorities 2

3 Aggregates Strategic Outlook September

4 37% drop from 2006 to 2009 Source: USGS 4

5 Share of Total US Aggregates Production Source: USGS 5

6 Texas Aggregates Production Outperforming US 1975= =1.0 * CAGR TX Agg TX Pop US Agg US Pop 40 Years* 3.0% 2.8% -1.8% 1.0% 30 Years* 0.6% 1.6% 1.6% 1.2% 20 Years* 4.4% 1.8% 2.5% 1.0% 10 Years* 0.7% 1.8% -3.4% 0.8% 6

7 Source: USGS 7

8 Source: Internal estimates 8

9 U.S. DEMOGRAPHIC GROWTH 2015 TO 2025 BY STATE POPULATION HOUSEHOLDS EMPLOYMENT Share of Total Share of Total Share of Total Rank State U.S. Growth State U.S. Growth State U.S. Growth 1 Texas 18% Florida 14% California 13% 2 Florida 17% Texas 13% Texas 12% 3 California 13% California 12% Florida 10% 4 North Carolina 7% North Carolina 6% New York 4% 5 Georgia 6% Georgia 5% Georgia 4% 6 Arizona 6% Arizona 4% North Carolina 4% 7 Washington 3% Washington 3% Ohio 3% 8 Colorado 3% New York 3% Arizona 3% 9 Nevada 3% Colorado 2% Washington 3% 10 Virginia 2% Virginia 2% Illinois 3% Top 10 Subtotal 78% 65% 57% All States Served by Vulcan: 79% 71% 63% Note: Vulcan-served states shown in bolded, blue text. Source: Moody's Analytics 18% of population growth, 13% of household formations, and 12% of employment growth is forecast to be in Texas! 9

10 Where do we get Rock to meet the Texas Demand and the AQMP??

11 Existing Quarry Expansion?

12 Existing Quarry Expansion?

13 Predominate Rock Types above & Below the Fall Line Coastal Planes Alluvial Gravels 1 3

14 The Fall Line (with some exceptions) Stone Above Sand & Gravel Below

15 Predominantly Sand & Gravel below the Fall Line. Stone below the Fall Line is a younger formation. PS: All the dots in Texas does not represent an AQMP approved source.

16 Igneous (Class A) Granite, Basalt, Ryolite Sedimentary Limestone (Class B) Dolomite (Class B) Sandstone (Class A) Metamorphic (Both) Marble (from limestone) Schist (from basalt) What Rock Types?

Geologic Model Example The stratigraphic column consists of five geologic formations Seven members of the Edwards group are also present Geologic units encountered: Buda Limestone Del Rio Clay

18 Geologic Model Example The stratigraphic column consists of five geologic formations Seven members of the Edwards group are also present Geologic units encountered: Buda Limestone Del Rio Clay Georgetown Formation Edwards Group Upper Edwards Member (Person Formation) Cyclic & Marine Leached & Collapsed Regional Dense Member Lower Edwards Members (Kainer Formation) Grainstone Kirschberg Evaporite Dolomitic Basal Nodular Glen Rose Limestone

19 Core Drilling a Site (not cheep)

20 Core Logging Geologist (Rock Lickers) log and photograph all cores

21 Evaluate Rock 21

22 Petrographic Analysis 22

23 Characterize Core Samples Chemical Analysis LA Abrasion Micro Deval Mag Sulfate Sodium Sulfate CoTE ASR Acid Insolubility Freeze Thaw Specific Gravity

24 Model Geology Section

25 Develop Mine Plan

26 Submit Permits Time consuming & expensive Wait Wait... Wait. Wait Deal with NIMBY.

27 Aggregate Production / Mining Process

28 Plant Automation Total computer controlled. Real-time plant data available to plant operator and plant manager. Plant automation can allow remote operation. It s not the ole Throw the switch and see if she runs

32 Aggregate Production Stripping Blasting Hauling Crushing Screening Washing Crushing Screening Stockpiling

33 Stripping / Overburden Dirt Chert 100 ft Limestone 33

34 Drill the Shot 34

35 Load the Shot 35

36 Shoot the Quarry Face 36

37 Shoot Something! (NOT a Vulcan Site!) 37

38 Under-water shot Calica (Mexico) 38

39 Let s have a Blast!

40 Load & Haul 40

41 Primary Crushing

42 Typical Primary Crushers Gyratory & Cone Crushers For Very Hard Stuff! Jaw Crusher Vertical Shaft Impactor (VSI) For Limestone/Dolomite

43 Scrubber Remove Clay, Fines & Friable Particles

44 Process Crushing, Screening, and Sizing (Some Wet Plants Some Dry Plants) Material is screened Re-crushed Re-screened until proper sized products are made

45 Secondary & Tertiary Crushing

46 Secondary Crushing Horizontal Shaft Impactor HSI Low Operating Cost High Production High Fines production Cubical Rock Production Primary & Secondary Use Not for Salacious Rock

47 Secondary & Tertiary Crushing Vertical Shaft Impactor Great Cubical Shape More fines generated Can be slowed to reduce fines High wear cost with harder rock The Finisher

48 Secondary & Tertiary Crushing High Speed Cone Hard Rock Crusher Reduced Fines production Lower wear costs-harder rock Higher Flat & Elongated

49 Product Difference Impact Crusher Product Compression Crusher Product

voids on fine Compression crusher More flat and

50 Product Specs Impact crusher More cubical on coarse and fine aggregates Lower F & E on coarse Lower voids on fine Compression crusher More flat and elongated (angular) on coarse and fine Higher voids on fines

51 Particle Shape Analysis-Gradations Aggregate Gradations % Passing Manufactured Sand No #16 #8 #4 3/8" 1/2" 3/4" Sieve Sizes Raised to 0.45 Power

52 Particle Shape Analysis-Voids Comparison of Voids Tests Voids, % Product Compression Crusher Impact Crusher Voids Manufactured Sand No. 11 Method Compression Impact Compression Impact FAA T-19 (Loose) T-19 (Rodded)

53 Particle Shape Analysis-Mix Volumetrics Mix A Mix B 30% No. 8 55% Compression Crushed Mfg. Sand 10% Compression Crushed No. 11 5% Screenings 30% No. 8 55% Impact Crushed Mfg. Sand 10% Impact Crushed No. 11 5% Screenings

54 Particle Shape-Mix Volumetrics Sieve Size Mix "A" JMF Mix "B" JMF 1/2" / No No No No No No No AC Content 5.7% 5.7% Air Voids 4.2% 3.4% VMA 16.2% 15.4%

55 Screening & Sizing

56 Sand Classifier Clean & Grade sands Reduce pond waste New units - Electronic adjustments C33 Manufacture Concrete Sand

57 Water Separators (Water conservation) Dewatering Screens Hydrocyclones Thickeners & Clarifiers Screw Washers

58 Stockpiling

59 AQMP & Quality Control AQMP Function (Rock Soundness) Magnesium Sulfate Micro Deval LA Abrasion CoTE ASR Acid Insolubility Corp of Engineers & FAA Freeze Thaw Durability ASR 1260 & 1567 Quality Control Coarse Aggregates Sieve Analysis Decant / Sand Equivalency Specific Gravity/Absorption Unit Weights Resistivity, Chlorides & Ph ASR & CoTE Flakiness Index / F&E Crushed Stone Base Plasticity Index Wet Ball Mill Triaxial Strength Moisture/Density 59

60 Mining for Quality Control 60

61 Mining for Quality Control Leached & Collapsed Member Cyclic & Marine Member 61

62 Mining for Quality Control 62

63 Sampling and Testing 63

64 Sampling Stockpile (BAD) Stockpile Pad Belt Cuts Automated Belt sampling Truck Rack Bad Bad Bad

65 Data Analysis Fast Response Accurate Readily available to Operations Mngmt

66 Question What is one of the most important qualities an asphalt or ready mix producer expects from the aggregate supplier?

67 Product Consistency 6 7

68 A Troubling Trend - Taste for Steak Ribs Short-Loin 25% Sirloin If everybody wants steak, then do you have to throw away the rest of the cow?

69 Aggregate Producers Serve Several Customer Groups Asphalt Plants Ready-Mix Concrete Plants Paving Contractors Homebuilders Site & Utility Contractors Commercial Building Contractors Government Agriculture What happens when everybody wants steak? In many cases they are using same products

70 Strategic Outlook for Aggregates The more times you crush it the more it costs. Typical Aggregate Plant Cows don t just produce steak you have to make some hamburger, brisket, roast, tongue, liver, heart 22% 33% 25% 20% ¾ Base 1 x ½ ½ x #4 -#4 (Premium Aggregates) Base Large Small Screenings

71 Strategic Outlook for Aggregates The more times you crush it the more it costs. Plant production slowed 50% Typical Aggregate Plant 22% 6% 42% 30% ¾ Base 1 x ½ ½ x #4 -#4 Recrush 1 x ½ Premium Aggregates Mfg. Sand & Large Small Screenings

72 Questions

Aggregates. AAPA training

Aggregates. AAPA training Aggregates AAPA training Topics Aggregate sources and rock types Aggregate Production Aggregate Properties Coarse and fine aggregates in Asphalt Mixes Aggregates in Sprayed Seals Filler in asphalt mixes