Soil Recycling in Australia

Explore how Soil Recycling Co. improved soil management with ALLU’s DN 3-12 TS 25 Axe bucket, enhancing efficiency in recycling practices.
Case study

Soil Recycling Management in Australia

Victoria, Australia

Material Soil

Industry Agriculture, Landscaping, Recycling, Soil Remediation

Application Soil Screening and Recycling

Function Screening, Crushing, Aerating

Model DN 3-12 TS 25/50 Axe Variable Drum

Soil Recycling Co. is at the forefront of soil screening in Australia, dedicated to promoting the reuse of soil as a valuable resource rather than disposing of it in landfills. This innovative company specializes in soil handling and recycling, collaborating with major waste management firms like ResourceCo to transform organic waste into usable products such as soil mixes for gardening and landscaping. Currently, Soil Recycling Co. is working at the South Gippsland Highway, Hampton Park in Victoria.

Founded in 2012, Soil Recycling Co. emerged from a passion for soil and organics, recognizing the inefficiencies in how materials were handled. The company saw countless trucks transporting soil and organic materials, only for them to return to the site soon after. This inefficiency sparked the mission to make onsite resources usable, eliminating unnecessary transport and fostering sustainable practices in the industry.

Chris Keay, the Director of Soil Recycling Co.

When Chris Keay, the Director of Soil Recycling Co., faced the challenge of processing wet, clumped soil that affected the performance of the Terex Ecotec Trommel, he recognized the necessity for a more effective solution. Two main issues arose due to the damp and wet soil:

  • Less aerated soil resulted in clumps clogging the hopper and Trommel.
  • The operator, Craig Jameson, had to clean the trommel multiple times a day, leading to significant downtime and fatigue, thus affecting productivity.

Initial attempts with another type of screening bucket featuring outdated drum technology failed to break down the lumps and dense soil, resulting in clogging and drastically reduced production. In search of a more reliable option, Chris Keay reached out to Walkers Hammers on September 16th, 2024, and discovered the innovative screening solutions from ALLU.

After reaching out to Walkers Hammers, Chris was introduced to Sami Rahman, the ALLU area sales manager based in Melbourne, Victoria. Together, they identified the ALLU DN 2-12 with TS 25 Axe as the optimal bucket for the demo. Sami, along with Carlo Costanzo from Walkers Hammers, prepared the rental bucket for a demonstration scheduled for September 17th. Upon arriving at the site, it became clear why the Trommel Screener had been struggling; persistent rain had saturated the soil, complicating the processing.

Once installed on the Hidromek excavator, the ALLU bucket quickly demonstrated its capabilities. The unique TS drum setup, designed for anti-clogging, optimal flow and self-cleaning, allowed for effective processing, leading to significant improvements in output. Impressed by its performance, Chris decided to keep the rental bucket for ongoing use, ensuring he had the right equipment to tackle his challenges effectively.

To further enhance productivity, the decision was made to switch from TS 25 to TS 50 blades, allowing for better fragmentation of larger soil lumps. Carlo from Walkers Hammers took the bucket back for the blade change, although it could have been done onsite. The bucket was delivered the next day with the blades changed to TS 50, ready for action.

Operational Highlights:

September 18: ALLU bucket installed in the morning; processed 310 m³ of topsoil for the remainder of the day (measured from the monitoring system installed on the Terex Ecotec Trommel).

September 19: Next full day of operation with the ALLU bucket, processing 280 m³ of topsoil due to the poor weather with heavy rain.

September 20: To be able to compare the customer decided to use the GP bucket the full day which resulted in approximate 20% lower efficiency than the ALLU bucket, and required frequent cleaning due to clogging issues.

The following are production figures with ALLU and GP bucket after the demo/test:

In addition to enhancing productivity, the ALLU Variable Drum allows customers to bid on smaller jobs, reducing reliance on larger trommels. Immediately, the productivity of the Terex Trommel increased by 10-20% with the smaller ALLU rental bucket, and with the new purchased DN 3-12 TS VD further great efficiency is anticipated. This capability not only streamlines operations but also promises a quick return on investment, making it an attractive option for contractors looking to optimize their resources.

This collaboration highlights the strong partnership between ALLU and Walkers Hammers, reflecting our commitment to delivering efficient solutions. Together with Walkers Hammers and our valued customer, Soil Recycling Co., we are dedicated to providing sustainable solutions and efficient waste management.

Screening Bucket – D-Series

Carriers 6 – 45 t
Versatile DN-, DS- and DH-Series Screening Buckets serve in a wide range of applications ensuring high-quality material processing on-site.

Other case studies

We solve problems

ALLU helped Kurdeez Minerals improve their lime screening process

Lime Screening for Kurdeez Minerals

Kurdeez Minerals improved their lime screening process by incorporating the ALLU DH3-17 TS 25 with double TS50 Axe blades. This change helped break down lime lumps, streamline material flow, and…

Explore customer story

ALLU Processor Stabilizing Road Foundation

The high water content found in sludge on a road foundation job site was making the land unfit for use with insufficient load-bearing capacity.

Explore customer story
Quarry waste screening with the ALLU bucket

Efficient Quarry Waste Handling

ALLU DH3-23 TS35 transforms quarry waste into valuable resources. By efficiently separating stone and clay, larger stones are ready for resale, and fine materials are repurposed for road construction or…

Explore customer story
Limestone crushing with the ALLU screening bucket on a Hitachi excavator

Limestone Crushing with a screening bucket

Limestone crushing with a screening bucket on a Hitachi excavator: efficiently reduce 0-300 mm boulders to 0-90 mm for road construction.

Explore customer story

Compost Happens

Screening Bucket DN 2-12 transforms manure and straw into rich compost by efficiently separating contaminants like stones, and string while enhancing aeration. In Australia, this solution has helped farmers reduce the need for multiple machines, delivering nutrient-rich compost.
Case study

Compost Happens

Victoria, Australia

Material Farm waste, manure, straw, compost

Industry Aerating, Agriculture, Composting, Farming

Application Composting, soil improvement, farming

Function Convert farm waste into nutrient-rich compost, separate contaminants, enhance aeration

Model DN 2-12 with TS 16 Axe

A Central Victorian contractor and ALLU buckets are giving nature a helping hand to create healthier soils.

A Central Victorian contractor and ALLU buckets are giving nature a helping hand to create healthier soils.

To the right is a ramshackle pile of, well let’s be blunt, manure. Straight from the farm, it’s mixed with straw, dirt, and all manner of contaminants. And a little unpleasant on the nose.

Just a few meters away is a mound of compost. A dark earthy brown in color, it’s rich and moist to the touch and smells natural. It’s difficult to believe that both piles looked the same just weeks ago. Even a seasoned farmer such as Gino is impressed by the result.

“It looks a picture,” Gino says. “The quality of the product is amazing once you send it through that bucket.”

That bucket is an ALLU Transformer DN 2-12 Screening Bucket which, for the past two years, has lived up to its name and transformed Gino’s compost. Through his Natural Compost Co. in central Victoria, Gino is cultivating a move away from synthetic farming and giving nature’s processes a helping hand, working with farmers to convert manure to compost on-site.

Working on-farm means there are contaminants in the compost piles—stones, string, and steel are the usual culprits. Early attempts to run the piles through a hired trommel proved expensive and often difficult to organize.

Gino even bought a shaker bucket—“a big bucket with holes in it”—but it wasn’t up to the job. (He’s since put a metal plate in the bottom of it and is using it as a digger.)

A bit of research led him to ALLU buckets and, as the saying goes, the rest is history.

“Sami Rahman, Area Sales Manager for ALLU, called me the next day to talk about the problems I was having and what he thought could do the job,” Gino says. “He got the measurements of what machine I was using, organized a trial on-site, and soon after had two buckets on a trailer to Newbridge.”

Gino spent that afternoon “playing” with the recommended buckets. He says he was so impressed; Sami and Carlo Costanzo, a service technician with Walkers Hammers who commissioned the demonstration buckets, went home that day with just one bucket—Gino was going to rent the other.

The next day, he ordered a new bucket with TS 16 Axe blades, enabling a homogenous end product.

“The compost fell out of the bottom of the machine like rain,” Gino says. “It looks like a picture, all nicely processed and sifted. Any contamination and oversize items – we’ve got it set to 40 mm – are left sitting in the bucket.”

“It’s magnificent.”

The ALLU screening bucket is set to 40-millimetres to provide a consistent
end product. (Image: Natural Compost Co)
Rows of compost on site. Customers are noticing the difference in quality since the ALLU screening bucket has been used. (Image: Natural Compost Co)

The ALLU Transformer D-Series bucket is compatible with excavators, loaders, and other earth-moving machinery. It’s designed to screen and separate various materials including soil, sand, gravel, compost, and demolition waste on-site, reducing the need for extra equipment and transport costs while minimizing environmental impact.

Carlo provided support with the installation of the new bucket and operator training, a service Walkers Hammers offers to all Victorian businesses that purchase ALLU products.

Gino uses the bucket on two excavators. To make switching the bucket between the machines easy, ALLU built a head bracket to cater for the two different pin sizes and spaces. He says it makes what is already a productive machine even more so.

Last year, Gino was contracted to process about 5,000 tonnes of compost for farmers. He’s currently working with a wastewater facility to convert sludge removed from a dam several years ago into compost that can be used on-site. He says since buying the Transformer bucket in 2021, his clients are also noticing the difference in the quality of compost produced.

He cites a local farmer who in 2022 had three rows of compost on his farm, one of which was processed through the ALLU bucket. When Gino returned recently to consolidate the rows, the farmer singled out the ALLU-processed row.

“The other two rows, they were good,” Gino says. “But that row that was sifted was like sand. From a quality perspective, running it through that bucket made a difference. Nature will get it there, but the bucket helps me get it there quicker.”

Manure screening and composting in Australia with ALLU screening bucket
Natural Compost Co is using the ALLU bucket to make compost from manure on central Victorian farms.
(Image: Total Rockbreaking Solutions)

Credit: Originally published by Waste Management Review Magazine.

For more information, visit: www.attachmentspecialists.com.au/allu

Screening Bucket – D-Series

Carriers 6 – 45 t
Versatile DN-, DS- and DH-Series Screening Buckets serve in a wide range of applications ensuring high-quality material processing on-site.

Other case studies

We solve problems

ALLU helped Kurdeez Minerals improve their lime screening process

Lime Screening for Kurdeez Minerals

Kurdeez Minerals improved their lime screening process by incorporating the ALLU DH3-17 TS 25 with double TS50 Axe blades. This change helped break down lime lumps, streamline material flow, and…

Explore customer story

ALLU Processor Stabilizing Road Foundation

The high water content found in sludge on a road foundation job site was making the land unfit for use with insufficient load-bearing capacity.

Explore customer story
Quarry waste screening with the ALLU bucket

Efficient Quarry Waste Handling

ALLU DH3-23 TS35 transforms quarry waste into valuable resources. By efficiently separating stone and clay, larger stones are ready for resale, and fine materials are repurposed for road construction or…

Explore customer story
Limestone crushing with the ALLU screening bucket on a Hitachi excavator

Limestone Crushing with a screening bucket

Limestone crushing with a screening bucket on a Hitachi excavator: efficiently reduce 0-300 mm boulders to 0-90 mm for road construction.

Explore customer story

Limestone Crushing

Limestone crushing with a screening bucket on a Hitachi excavator: efficiently reduce 0-300 mm boulders to 0-90 mm for road construction.
Case study

Limestone Crushing with a screening bucket

Oman

Material Limestone

Industry Crushing, Quarrying, Roadworks

Application Limestone Crushing

Function Break down large limestone boulders

Model M 3-25 X75

Crushing large volumes of limestone effectively calls for equipment that guarantees speed and accuracy. In the demanding environment of Oman, a customer chose the ALLU M 3-25 screening bucket, mounted on a Hitachi 90-tonne excavator, to handle limestone boulders with precision and speed. This solution not only eliminated the need for a conventional crusher but also transformed operations into a one-step process that saved time, reduced costs, and minimized environmental impact.

The Challenge: Crushing Limestone Boulders for Road Construction

The customer’s challenge was to break down large limestone boulders ranging from 0 to 300 mm into smaller, manageable pieces, specifically between 0 and 90 mm. The material needed to be prepared as sub-base for the internal road construction at the Royal Oman Police Headquarters. Conventionally, this would require multiple machines and permits to set up a traditional crusher on-site, causing additional costs and logistical complexities.

The ALLU Solution: One-Step Operation with M 3-25 Screening Bucket

Choosing the ALLU M 3-25 X75 over a traditional crusher setup, the customer valued its capacity to condense several stages of the process into one seamless operation. Mounted on a Hitachi 90-tonne excavator, the ALLU screening bucket ensured a smooth, efficient workflow throughout the operation. The excavator simply picked up the boulders, crushed them to the desired size, and loaded them directly onto trucks for transport.

This one-step operation not only saved the customer significant time and reduced the need for additional equipment but also minimized environmental impact by reducing fuel consumption and the overall number of machines on-site. The crushed material was perfectly sized for the sub-base application, helping ensure that the project was completed efficiently and on time.

Key Benefits of the ALLU Screening Bucket:

  1. Cost-Efficient Versatility: By choosing this screening bucket, the customer bypassed the permits and costs of a conventional crusher, while handling a large-scale operation with one versatile attachment.
  2. One-Step Process: The ALLU screening bucket streamlined the operation into a single process, from picking up material to crushing and loading it onto trucks.
  3. Sustainable Precision: Fewer machines on-site meant reduced emissions and fuel consumption, while the bucket’s precision ensured perfectly sized material for sub-base road construction.

Why ALLU Stands Out for Material Processing

ALLU’s innovative screening and crushing buckets, like the M 3-25, are engineered for large-scale operations in industries such as construction and mining. Designed for efficiency, they reduce the need for multiple machines while boosting productivity and streamlining job site processes. Whether you’re crushing limestone, screening soil, or preparing materials for road construction, ALLU delivers reliable, durable equipment that can handle even the toughest materials, transforming how you approach material handling.

Learn more about the ALLU M 3-25 bucket and how it can help streamline your next project. Visit our website or contact us today to explore the full range of ALLU solutions.

Screening Bucket – M-Series

Carriers 50 – 120 t
Large M-Series Screening Crushing Bucket is designed for large-scale material processing and screening applications. It’s compatible with large excavators and wheel loaders.

Other case studies

We solve problems

ALLU helped Kurdeez Minerals improve their lime screening process

Lime Screening for Kurdeez Minerals

Kurdeez Minerals improved their lime screening process by incorporating the ALLU DH3-17 TS 25 with double TS50 Axe blades. This change helped break down lime lumps, streamline material flow, and…

Explore customer story

ALLU Processor Stabilizing Road Foundation

The high water content found in sludge on a road foundation job site was making the land unfit for use with insufficient load-bearing capacity.

Explore customer story
Quarry waste screening with the ALLU bucket

Efficient Quarry Waste Handling

ALLU DH3-23 TS35 transforms quarry waste into valuable resources. By efficiently separating stone and clay, larger stones are ready for resale, and fine materials are repurposed for road construction or…

Explore customer story
Limestone crushing with the ALLU screening bucket on a Hitachi excavator

Limestone Crushing with a screening bucket

Limestone crushing with a screening bucket on a Hitachi excavator: efficiently reduce 0-300 mm boulders to 0-90 mm for road construction.

Explore customer story

Efficient Quarry Waste Handling

Case study

Efficient Quarry Waste Handling

China

Material Quarry tailings, stone, and clay

Industry Quarrying, Roadworks, Screening

Application Screening and separation of quarry waste

Function Waste recycling and resource repurposing

Model ALLU DH3-23 TS35

Problem

ALLU Bucket Delivers Efficient Quarry Waste Handling in China In the world of quarrying, managing waste efficiently is more than a necessity—it's a responsibility. Quarry owners often face the challenge of dealing with a mix of stone and clay, leftover materials that don’t seem valuable at first glance. But what if those materials could be turned into something profitable and even environmentally friendly? This is where the ALLU DH3-23 TS35 screening bucket makes a difference. Working alongside the CAT 336 excavator, this combination does more than just handle waste—it transforms it. Quarry owners found themselves searching for a solution that would allow them to handle waste effectively while still being cost-efficient. ALLU delivered just that.

Solution

From Waste to Resource in 3 Steps Handling leftover tailings and waste during quarry operations can be challenging. Often a mix of stone and clay, these byproducts are typically hard to sell or repurpose. But using the ALLU Transformer DH3-23 TS35, this waste gets a new life. The process follows three simple steps: 1. Raw Material Collection: Quarry waste, often seen as byproducts, is collected for screening. 2. Screening and Separation: ALLU's bucket separates larger stones (over 3 cm) from finer material (below 3 cm). The large stones are ready for direct sale to stone processing plants. 3. Resource Utilization: The finer material, perfect for road construction and landscaping, is repurposed, turning waste into valuable resources. The ALLU screening bucket separates materials by size, repurposing both large and fine particles. Larger stones are sent to processing plants for resale, while finer materials are used in road construction or landscaping. This process boosts the market value of the stone and provides additional economic benefits to quarry owners.

Benefit

Dual Benefits for Profit and Sustainability ALLU Transformer offers quarry owners an efficient, one-step screening service. By separating larger stones for resale and finer materials for road construction, this process maximizes resource use and brings financial returns. The recovered stones often hold more market value than raw materials, while the finer products serve environmental remediation purposes like land restoration. This solution reduces waste accumulation and promotes recycling, helping quarry owners balance profitability and environmental responsibility. It’s a win-win scenario: fewer waste piles, more revenue, and a positive environmental impact. Conclusion: Balancing Profit and Responsibility ALLU has proven that in today’s quarrying industry, efficiency, sustainability, and profitability don’t have to be at odds. By reducing waste accumulation and promoting resource reuse, ALLU helps quarries strike the perfect balance between economic growth and environmental responsibility. With the DH3-23 TS35 in hand, quarry owners can meet regulatory requirements, generate additional revenue streams, and contribute to a cleaner, greener future. It's not just about screening—it’s about turning challenges into opportunities. And that’s the power of ALLU.

Related Products

Lime Screening

Kurdeez Minerals improved their lime screening process by incorporating the ALLU DH3-17 TS 25 with double TS50 Axe blades.
Case study

Lime Screening for Kurdeez Minerals

Australia

Material Lime

Industry Agriculture, Quarrying, Soil processing

Application Lime Screening

Function Breaking down lime lumps and improving material flow

Model ALLU DH3-17 TS 25 with double TS50 Axe blades

Kurdeez Minerals, based in Victoria, Australia, produces a range of natural products for soil improvement in agriculture, horticulture, and more. Their products are widely used in crop and biological farming to enhance soil quality and animal health. But they encountered a significant challenge in breaking down lime lumps to meet the 4mm size required for sale.

After a successful trial with Walkers Hammers using the ALLU DN 2-12 TS 25, Kurdeez Minerals invested in the ALLU DH3-17 TS 25 with double TS50 Axe blades. The ALLU unit not only broke down the lime lumps but also improved the flow of material into the ASTEC screener, significantly boosting productivity.

ALLU’s impact on Kurdeez Minerals can be seen in five key areas:

  1. Increasing overall productivity.
  2. Efficiently breaking down lime lumps.
  3. Streamlining material flow into the screener.
  4. Aerating the material during the process.
  5. Delivering long-term reliability, even after five months of use.

Aidan, the quarry manager, was thrilled:

“This is the best attachment I have ever worked with after using it for 5 months.”

ALLU helped Kurdeez Minerals improve their lime screening process

The addition of ALLU allowed Kurdeez to optimize their entire process, getting more done with fewer headaches and delivering higher-quality products to their customers.

The experience shows how the right equipment can turn challenges into opportunities, helping a business thrive with greater efficiency and ease. With ALLU, Kurdeez Minerals unlocked the full potential of their existing equipment, turning a slow, frustrating process into a highly productive and efficient workflow. This success highlights the power of smart investment in the right tools! We’re proud to have been part of Kurdeez Minerals’ journey and thank them for allowing us to share their success story.

Screening Bucket – D-Series

Carriers 6 – 45 t
Versatile DN-, DS- and DH-Series Screening Buckets serve in a wide range of applications ensuring high-quality material processing on-site.

Other case studies

We solve problems

conversion of recycled soil into beneficial products like manure and garden mixes

Soil Recycling Management in Australia

Soil Recycling Co. is at the forefront of soil screening in Victoria, dedicated to promoting the reuse of soil as a valuable resource rather than disposing of it in landfills.

Explore customer story
ALLU helped Kurdeez Minerals improve their lime screening process

Lime Screening for Kurdeez Minerals

Kurdeez Minerals improved their lime screening process by incorporating the ALLU DH3-17 TS 25 with double TS50 Axe blades. This change helped break down lime lumps, streamline material flow, and…

Explore customer story
Quarry waste screening with the ALLU bucket

Efficient Quarry Waste Handling

ALLU DH3-23 TS35 transforms quarry waste into valuable resources. By efficiently separating stone and clay, larger stones are ready for resale, and fine materials are repurposed for road construction or…

Explore customer story
Limestone crushing with the ALLU screening bucket on a Hitachi excavator

Limestone Crushing with a screening bucket

Limestone crushing with a screening bucket on a Hitachi excavator: efficiently reduce 0-300 mm boulders to 0-90 mm for road construction.

Explore customer story
Case study

Transforming your waste into profits!

USA

Material Topsoil

Industry Screening, Soil processing, Topsoil

Application Composting and landscaping

Function

Model DN 3-17 25

Problem

Ware Excavator Inc in USA recognised that Topsoil is in demand in the area, yet there are limited suppliers. ALLU Transforms the raw material

Solution

ALLU Group Inc based in NJ works through a dealer network. CAT Stowers is our local ALLU dealer and they offered us the perfect solution. We brought a wheel loader to do pipework’s, but then added the ALLU Transformer. Initially I wasn’t sure on how long this would take to pay back for the ALLU, but within 6 months it has transformed our business model!

Benefit

Our main business was in commercial and residential developments. The wheel loader we brought from CAT Stowers was to do pipework’s. Since we added the ALLU for screening the soil, the CAT wheel loader only left the yard once! It no longer leaves the yard; it remains on site to screen the dirt which is much more effective and profitable. On average we do 10 loads a day making $600 per load. It’s much more profitable. Our original business model haling for a customer’s we were lucky to make $50 per load, by the time we had paid the taxes, and costs. ALLU Transformer has given us a stable other income and is becoming our prime focus. Local landscapers, building contractors, City of Cleveland, Cleveland utilities, now come and take the raw material we made with the ALLU and it makes it look nice and need and new for their projects. I’m so happy that we have also invested in a 5-17FD Crusher and now do Asphalt and concrete recycling too. ALLU has transformed my business, cutting down our transport costs, operating costs and increasing our profits by far! I’m happy with the ALLU Transformer, its reliable, efficient solution which has increased our productivity and business profits. We have now bought some more land to expand our business using the ALLU. WARE EXCAVATOR WITH CAT STOWERS AND ALLU

Related Products

Case study

BAURECYCLING LEICHT GEMACHT

France

Material Construction waste

Industry Construction, Waste material handling

Application Construction and Demolition

Function Construction and Demolition

Model ALLU D-Series

Problem

Having to transport waste from a construction site to a waste center. This increases costs due to transportation and material purchases.

Solution

ALLU Screening Bucket is an ideal choice whenever you need to screen, crush, mix, separate, sort, pulverize, or load these materials to the desired fragment size. Reducing the waste to smaller or more uniform fragment sizes makes it easier and faster to reuse them. The debris that is generated in construction and demolition sites is bulky and heavy to handle, traditionally increasing your transportation costs and double handling operational costs. ALLU takes these issues away, increasing your operational efficiency. The ALLU recycling bucket sorts materials from actual waste. Doing this lowers the transportation and landfill costs, increasing your efficiency and productivity at the work site along with your sustainability credentials. Helping you to increase your sustainability ALLU enables you to recycle construction and demolition debris in an environmental way. Turning waste material into profit by producing aggregates and reusable materials such as bricks, concrete, metals, wood, cardboard, and bitumen. Bringing your waste to life!

Benefit

Increased the sustainability of the business, reducing costs and time yet increasing the business profits and efficiency.

Related Products

Case study

Pipeline Padding in France

France

Material Pipeline padding

Industry Pipeline Padding

Application Pipeline padding

Function Pipeline

Model ALLU D-Series

Problem

Excavated material unrefined cannot be used to backfill for pipeline padding. The customers costs were increasing to remove the material and bring in correct material to site.

Solution

The ALLU D-Series of screening buckets with TS drums for pipeline padding is an absolutely ideal addition to pipeline job sites worldwide. The unique ALLU TS structure enables two different fragment sizes from the same ALLU Screening Bucket, giving you more flexibility at the site. Due to TS’s self-cleaning design, you can be certain to get the best possible capacity even with wet and sticky materials. ALLU TS structure features various blade thicknesses, making the TS structure perfectly suited to the pipeline industry to screen, reuse, and recycle the excavated soil.

Benefit

The customer increased efficiency and reduced costs and time. As they do not need to bring in separate materials to the jobsite or take those materials away.

Related Products

ALLU to the rescue

Case study

Solutions for handling coal ash

USA

Material Coal Ash

Industry Soil Improvement, Solidification, Stabilising

Application Soil Improvement

Function Coal Ash

Model Soil Improvement System

We are all aware of the environmental impact of coal ash in the US. With potential hazards to both the air and water being a concern to all parties involved. Loose particles of fly ash can float in the air to surrounding communities, causing various respiratory issues to nearby residents. Both abandoned and operational ash ponds have a high potential to seep into the groundwater carrying chemicals such as lead, arsenic and mercury to the municipal water supply.

What to do with these ponds has been the center of much debate throughout the power generation providers along with environmental advocates. Finding an acceptable solution that would provide a safe permanent, solution that was economically feasible has been a challenge. The EPA permits two methods, closure in place and closure by removal. Each method presents its own challenges and downsides.

Closure in place or “capping” the pond is typically done using a process known as “bucket mixing” which is accomplished by dumping sacks of powdered binder (usually Portland Cement) onto the surface of the pond. The binder is then mixed using the buckets of a tracked excavator. A shallow cap is formed as the cement hardens. Though much less expensive than removal. The main problem exists beneath the “cap” moisture remains in the unstable contaminated soil allowing continued seepage into the groundwater. The capped ground is unsuitable for building and difficult to repurpose, additional dust pollution is also created during the bucket mixing process.

Removal minimizes the overall risk of groundwater pollution but presents its own set of problems. Compared to closure-in-place costs, removal costs and time can add up to more than five times that of in-place closure. Relocation to an approved dump site (landfill) may also prove difficult with dust and contaminants being released during transport. Regulation of the dump site can also be difficult. If not properly maintained these sites can be affected by the wind carrying the reclaimed dust at great distances. Stormwater can seep through the ash and continue to contaminate groundwater.

Deep pond stabilization provides an innovative solution that solves problems present in both capping and removal. The ALLU Soil Stabilization system has been used throughout Europe for more than a decade. The system uses a powerful mixing head attached to the boom of a mid-sized excavator. The mixing head is fed a dry binder by a computer-controlled high-pressure feeder creating a homogeneous mix. Unlike bucket mixing; the system is capable of depths beyond 20’. The ash pond is stabilized from the bottom up and not just at the surface. The feeding system regulates with precision the exact amount of binder prescribed by the engineer to fully encapsulate the contaminated site.

Because it is now a solid mass. Potential groundwater contamination along with dust pollution from wind, rain, or during transportation are eliminated. Costs are controlled by removing the need to build and maintain dump sites. Less fossil fuels are used without the need to transport to an off-site location. A solid surface remains that continues to harden over time allowing a re-purposing of the existing ash containment pond. A truly green solution.

There are hundreds of coal ash ponds in the USA, ash pond waste contains heavy metals, which leach into nearby groundwater, and surface water is the second biggest flow of waste material in the USA.
Coal combustion residuals (CCRs), commonly known as coal ash, are by-products of the combustion of coal at power plants operated by electric utilities and independent power producers. The environmental impacts are high with many sites leaking into the water course, causing pollution and major issues as you can see from the map. Many sites are not lined, and the raw waste material continues leaking into the water course.

Finding a permanent solution to this ongoing environmental issue has been a challenge for over a decade. The traditional method known as “bucket mixing” has no binder control which can, high cost and a lot of dust pollution with non-homogenized results. The treated site is only stabilized on the surface which allows continued leeching into the soil beneath the surface.

Solution

ALLU is one step ahead reducing costs up to 40%, providing a fast effective and environmentally friendly work method for the hardening and dynamic strengthening contaminated soft soils, as well as improving the soil’s deformation properties. It is designed to improve soft soils by mixing a binder into clay, peat, mud, or dredged sediments. The method can also be used in the treatment of contaminated soils, by encapsulating contaminants within the ground and preventing migration to the surrounding areas.

The Allu system consists of three components:

The first is the power mix attachment mounted to the dipper arm of a suitable excavator, using a pin mounting or quick-hitch adaptor plate. At the end of this substantial attachment, a pair of mixing/ cutting drums are used to mix the binder material into the ground in a controlled manner. The unit can process different materials to a depth of six meters, depending on the choice of the power mix model, the excavator’s reach and the quality of the material.

The second component is the pressure feeder mounted on a powered crawler chassis. This injects the binder into the ground by compressed air via hoses. The amount of binder per square meter can be controlled, depending on the requirement for the prevailing ground conditions.

The third component in the Allu system is the data acquisition control (DAC), located in the excavator’s cab. This controls, measures and stores data on the stabilisation project. On site, the flow and pressure of the binder are adjusted by the excavator operator via the DAC, and it seems reasonably easy to use and enables the binder to be fed at optimum rates. Back in the office, the DAC provides an extensive report for the entire duration of a project, the data being transferred into a computer via a USB port.

Its potential as a sustainable solution with a valid mixing method and homogeneous results, causing less dust pollution and reducing binder costs, demonstrates why the system has already been successfully used in different ground conditions and interest is certainly being generated.

ALLU PF Pressure Feeder

The double tank ALLU Pressure Feeder PF 7+7 NextGen allows for continuous feeding and precise dosing of dry binders in soil improvement projects.

ALLU Processor Power Mixer

Carriers 25 – 40 t
The ALLU Processor is a power mixer attachment for conventional excavators. This attachment converts the excavator into a powerful and versatile mixing tool.
Case study

ALLU Transforming your waste

USA

Material ASPHALT

Industry Screening

Application CRUSHING AND SCREENING

Function CRUSHING AND SCREENING WASTE ASPHALT MATERIAL

Model ALLU TRANSFORMER DL 2-17 TRANSFORMER WITH 16/32MM AXE BLADE SET UP

Problem

Asphalt construction waste typically would be sent to landfill at a cost of $1000 a time, and costs were going up, profits were going down. With the increasing pressure to remain competitive in our market we were struggling to maintain our profits and win contracts.

Solution

ALLU Group Inc based in NJ down the road from us, offered us the perfect solution, the ALLU Transformer DL 2-17 Transformer Series. Initially I wasn’t sure on how long this would take to pay back, but im converted, and wont ever look back. Its changed the way we do business and helps us win bids!

Benefit

By processing the waste with the ALLU DL Transformer, there were considerable savings made in landfill fees and transportation costs as only about 10% was transported to landfill. The waste paving we used to send to landfill we are now able to crush ourselves and reuse. Its saved us $40K USD in one season! Also has helped us win more work, as we can prove that we are offering a full service, and recycling solutions for the customer. Joe says “Im super happy with the ALLU DL Transformer, and happily recommend to anyone in the industry. Its reliable, efficient solution which has increased our productivity and business profits. Its paid for itself within a season. ALLU Group Inc has been hands on and always happy to help you” ALLU One Step Ahead - TRANSFORMING YOUR WASTE INTO PROFITS, INCREASING YOUR GREEN CREDENTIALS.

Related Products