Just 30 miles from the Louisiana state line in San Augustine, Texas, Attoyac Rock has become a cornerstone of the East Texas quarrying industry.
The quarry produces about 2 million tpy, with materials supporting local infrastructure projects. Spanning 300 acres, Attoyac Rock’s quarry is composed of multiple layers of sand, 60/40 mix and shell rock.
To ensure the highest-quality product, operators grind the mountain face rather than blasting it, which allows for better control and consistency in the final product, while also adhering to strict planning permission in place for the abandoned mine structures left underground by now-gone industries.
One benefit of this grinding process is that it ensures proper mixing of the different layers of sand and rock, resulting in a blend that meets customer expectations.
Once that rock is ground, it heads to the backbone of Attoyac Rock’s operation: a pair of Powerscreen Chieftain inclined screeners, supplied by Powerscreen Texas.
Partnership built on trust
Attoyac Rock was founded in 2006 by Robert Birdwell, but his relationship with Powerscreen Texas goes back to well before Birdwell took over the San Augustine quarry.
In the 1990s, Birdwell connected with Jake Cernoch of Powerscreen Texas while operating another quarry in East Texas. The initial connection laid the groundwork for a partnership that has continued for decades.
“The reputation of Powerscreen Texas gave me the confidence to purchase the Powerscreen Chieftain 1700 and 1400,” Birdwell says. “These guys are knowledgeable in what they do. I have a long-standing friendship with Jake, and I know I can trust his expertise.”
The trust Birdwell puts in Powerscreen Texas has been justified by the performance of the equipment he’s purchased. The Chieftain 1400, acquired in 2022, was Attoyac Rock’s first step in improving its production capabilities. Less than a year ago, the operation added the Chieftain 1700 to its fleet.
Prior to purchasing the Chieftains, Attoyac Rock struggled to keep up with growing customer demand for fine aggregates. Charles Stacker, head mechanic at Attoyac Rock, recalls that time and knew something had to be done.
“We were not able to meet the demands of our customers, particularly for the smaller product sizes,” he says. “Now, we can successfully produce more products than we originally planned on selling.”
Proven performance
With the increased efficiency the Chieftain 1400 and 1700 have been delivering, Attoyac Rock has seen its annual throughput soar to about 2 million tons. The operation now produces a range of filtered rocks, including: 0.5 in., 1 in., 2 in., 2 in. x 4 in., 3 in. x 5 in., 5 in. x 8 in., riprap and road base, all of which are needed for local roads and driveways in East Texas.
According to Powerscreen, the Chieftain 1700 offers high capacity with its double-deck screenbox that has a screening area of 16 ft. x 5 ft. This opening allows the screen to deliver precise separation at a high throughput when separating material by size, the company adds.
The 1400 features a slightly smaller screenbox (11 ft. x 5 ft.) but can produce higher volumes with what Powerscreen calls an aggressive shaker box.
Together, Powerscreen says these two machines maximize screening efficiency while handling a variety of materials and sizes. Attoyac has also achieved minimal downtime while working with its two Chieftains.
The quarry’s operations are managed to balance productivity with environmental stewardship. The lowest point in the quarry is currently just one level above the natural ground, showcasing the precision of its extraction. This careful management of resources has enabled Attoyac Rock to supply a range of materials to both residential and commercial clients within a 100-mile radius of San Augustine.
Working together
One aspect of its partnership with Powerscreen Texas that stands out to Attoyac Rock is the customer service it has received. This level of service has enabled Attoyac Rock to keep its equipment running at peak performance and exceed its production demands.
“I know I can rely on the Powerscreen Texas parts team,” Stacker says. “There have been plenty of times when I call them for parts, and they show up the next day.
“With the use of the two Powerscreen Chieftains, we are able to hit our production demands, so much so that we can stand down the machines for a couple of days and still have enough product to meet the needs of our customers, but also give us time to complete maintenance work safely and effectively,” Stacker adds.
Information for this article provided by Powerscreen of California.
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