Key Responsibilities and Required Skills for a Gravel Plant Mechanic

🎯 Role Definition

The Gravel Plant Mechanic is a hands-on, skilled trades professional dedicated to the inspection, diagnosis, repair, and preventative maintenance of all machinery and equipment within a gravel or aggregate processing plant. This includes crushers, screens, conveyors, washing equipment, and associated mobile heavy equipment. The role is fundamental to plant safety, productivity, and efficiency, requiring a proactive approach to minimize downtime and ensure all operations comply with stringent safety and environmental regulations. This individual is a problem-solver who can work independently and as part of a team to keep the plant running smoothly.

📈 Career Progression

Typical Career Path

Entry Point From:

Heavy Equipment Mechanic
Industrial Millwright or Mechanic
Welder / Fabricator with mechanical aptitude

Advancement To:

Maintenance Lead / Foreman
Plant Supervisor / Manager
Maintenance Planner / Scheduler

Lateral Moves:

Mobile Heavy Equipment Mechanic
Field Service Technician
Quality Control Technician

Core Responsibilities

Primary Functions

Conduct comprehensive daily pre-shift inspections of all plant equipment, including jaw crushers, cone crushers, screen decks, and conveyor systems, to identify and address potential issues before they cause downtime.
Execute a robust preventative maintenance program on all stationary and mobile equipment according to manufacturer recommendations and operational schedules to maximize plant availability.
Diagnose and troubleshoot complex mechanical, hydraulic, and pneumatic system failures using technical manuals, diagnostic tools, and hands-on inspection techniques.
Perform major and minor repairs on a wide range of aggregate processing equipment, ensuring all work is completed to manufacturer specifications and rigorous safety standards.
Skillfully perform advanced welding (SMAW, MIG) and fabrication tasks to repair or modify worn or damaged components like chutes, hoppers, screen frames, and structural supports.
Operate and inspect mobile equipment such as loaders, haul trucks, and man-lifts as required to facilitate maintenance and repair activities around the plant.
Replace and repair key components of conveyor systems, including belts, rollers, bearings, pulleys, and gearboxes, and perform belt splicing and vulcanizing as needed.
Maintain and rebuild crushing equipment, which involves changing out liners, mantles, and bearings, and ensuring proper settings for optimal material production.
Service and repair screen plants, including changing screen media, repairing screen boxes, and ensuring proper tensioning and operation for accurate material sizing.
Perform routine lubrication and oil changes on all machinery, maintaining detailed logs and ensuring the use of correct lubricants for each application.
Maintain a clean, safe, and organized work environment in the maintenance shop and around the plant, adhering to all company and MSHA safety policies.
Respond promptly to equipment breakdowns during production shifts to diagnose the problem and execute repairs efficiently, minimizing operational delays.
Read and interpret equipment manuals, blueprints, and technical schematics to understand machinery operation and guide repair procedures accurately.
Assist in the installation and commissioning of new plant equipment and machinery, ensuring it is set up correctly and integrated into existing systems.
Document all maintenance and repair activities meticulously in a maintenance log or computerized maintenance management system (CMMS) for tracking and historical analysis.
Identify and order necessary parts, supplies, and tools for repairs and inventory, working with supervisors and the parts department to ensure availability.
Safely perform rigging and lifting operations for heavy components and equipment using cranes, forklifts, and other lifting devices.
Conduct general plant upkeep and housekeeping tasks, including shoveling spillage and cleaning around equipment to ensure safe access and operation.
Monitor plant operations to anticipate maintenance needs and proactively address signs of wear and tear on mechanical components.
Collaborate effectively with plant operators and supervisors to schedule maintenance windows and communicate the status of repairs and equipment availability.

Secondary Functions

Assist in maintaining an accurate inventory of spare parts, tools, and maintenance supplies, performing cycle counts and organizing storage areas.
Contribute to the plant's continuous improvement initiatives by suggesting process, safety, and equipment modifications.
Provide guidance and mentorship to apprentices or less experienced maintenance personnel on proper repair techniques and safety protocols.
Participate actively in daily toolbox talks, safety meetings, and all required MSHA safety training sessions.

Required Skills & Competencies

Hard Skills (Technical)

Advanced Welding & Fabrication: High proficiency in welding techniques (SMAW/Stick, MIG) and torch cutting for heavy steel repair and fabrication.
Hydraulic & Pneumatic Systems: Strong ability to diagnose, troubleshoot, and repair complex hydraulic and pneumatic systems, including reading schematics.
Crusher & Screen Maintenance: In-depth knowledge of the mechanics of jaw crushers, cone crushers, impact crushers, and vibrating screens.
Conveyor System Repair: Expertise in maintaining and repairing all components of conveyor systems, including belt splicing (mechanical and/or vulcanized).
Power Transmission Systems: Proficient in the repair and alignment of bearings, gearboxes, chains, sprockets, and couplings.
Diesel & Heavy Equipment Mechanics: Solid understanding of diesel engines and the mechanical systems of mobile heavy equipment (loaders, excavators).
-Electrical Troubleshooting: Basic ability to troubleshoot and diagnose simple electrical issues (e.g., motors, sensors, control circuits) up to 480v.
Rigging & Lifting: Certified or highly experienced in safe rigging practices and the operation of cranes and forklifts for heavy lifts.

Soft Skills

Problem-Solving: A systematic and analytical approach to diagnosing mechanical failures under pressure.
Safety-First Mindset: An unwavering commitment to personal and team safety, with a deep understanding of MSHA regulations and lockout/tagout procedures.
Work Ethic & Initiative: Self-motivated with the ability to work independently and manage time effectively with minimal supervision.
Teamwork & Communication: Ability to collaborate effectively with operators, supervisors, and other team members to achieve common goals.
Resilience & Adaptability: Capacity to work in physically demanding conditions, including inclement weather, heights, and confined spaces.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED equivalent.

Preferred Education:

Vocational or Technical Degree/Certificate in Diesel Technology, Industrial Maintenance, Welding, or a related field.

Relevant Fields of Study:

Industrial Mechanics
Welding Technology
Heavy Equipment Technology

Experience Requirements

Typical Experience Range: 3-7 years of hands-on mechanical experience in a heavy industrial, mining, or construction environment.

Preferred: Direct experience as a plant mechanic in an aggregate, sand and gravel, or crushed stone operation is highly preferred. Experience working under MSHA regulations is a significant asset.