Scheduled Maintenance Program for Quarry Site: Maximize Uptime, Minimize Failure

In the high-impact environment of a quarry, heavy machinery is under constant pressure. Loaders, crushers, conveyors, pumps, and processing systems are exposed to dust, debris, vibration, and weather—making routine equipment failure a costly reality for operations without a proactive plan.

That’s why smart quarry managers implement a scheduled maintenance program to reduce unexpected breakdowns, extend equipment life, and improve production efficiency. This case study shows how Industrial & Mining Services (IMS) partnered with a mid-size quarry in Georgia to launch a site-wide preventive maintenance program that dramatically reduced downtime and improved safety across the board.

Why Scheduled Maintenance Matters for Quarries

• Reduces emergency repair costs
• Prevents long-term damage from wear and vibration
• Improves safety for machine operators and ground crews
• Extends the service life of capital equipment
• Boosts throughput and productivity by ensuring availability

Client Background: Mid-Sized Aggregate Quarry in North Georgia

Our client operates a 200-acre granite quarry with:

• 3-stage crushing plant
• Jaw crushers and cone crushers
• Conveyors and stackers
• Wheel loaders and haul trucks
• Dust suppression and wash systems

They moved from a reactive to a preventive strategy with IMS after repeated costly failures.

Step 1: Equipment Audit and Risk Assessment

IMS performed a full audit and risk evaluation using tools such as:

• Thermal cameras
• Oil sampling kits
• Vibration meters
• Digital belt alignment tools

Step 2: Maintenance Schedule Development

IMS created a custom maintenance calendar based on OEM specs, usage hours, and failure history. The plan included:

• Daily: Greasing, fluid checks, belt inspections
• Weekly: Filter changes, hose reviews
• Monthly: Wear part measurements, torque checks
• Quarterly: Vibration analysis, deep washouts
• Annual: Full inspection and rebuild plans

Step 3: Implementation and Field Servicing

IMS delivered:

• Operator checklists
• Shared digital tracking tools
• Monthly technician visits
• Parts inventory coordination

Results After 6 Months

Metric	Before IMS	After 6 Months
Emergency Downtime	21 hrs/month	6 hrs/month
Availability	88%	97%
Failures per Month	5–7	1–2
Operator Complaints	40+	12

Safety Enhancements

• Greasing access improved
• Belt guards installed
• Hydraulic load checks added
• LOTO protocol training provided

Common Quarry Maintenance Tasks We Perform

• Jaw and cone crusher liner replacements
• Conveyor belt tracking and changeouts
• Bushing and pin wear correction
• Hydraulic hose replacements
• Oil sampling and gear flushing
• Motor thermal and vibration tests

Tools and Techniques

• Laser alignment kits
• Ultrasonic testers
• Mobile welders
• Heavy-duty torque tools

Why Choose IMS?

• MSHA-trained field techs
• Custom plans per quarry
• Full reporting and compliance logs
• Emergency repair support included

Search Keywords Covered

• scheduled quarry maintenance
• crusher preventive maintenance
• aggregate plant service schedule
• loader maintenance program
• field diagnostics quarry equipment

Client Testimonial

“IMS completely changed our mindset. Instead of chasing fires, we now have a plan. Our uptime is the best it’s ever been—and it’s saved us more than we expected.”
— Site Manager, Aggregate Quarry, GA

Need a Maintenance Plan for Your Quarry?

Contact IMS for a customized, proactive scheduled maintenance program for your quarry. We serve clients across Georgia, Alabama, Tennessee, and the Southeast with affordable, on-site service plans that keep your machines moving and your crews safe.