DDM Materials

DFW contractor seizes opportunity, grows with need for flex base made from recycled materials

Demand for recycled flex-base aggregate in the Dallas-Fort Worth Metroplex has been strong for several years. In fact, companies producing it could not keep up with the burgeoning market.

“A lot of competitors were running out, and we believed there was a great opportunity,” stated DDM Materials Vice President Jacob Markwardt. “We’re crushing right at our permitted limit of 2,000 tons per day. As long as we can maintain that, keep customers happy and make sure our products stay on spec, we’ll continue to thrive.”

DDM Materials has met specifications on flex base and its other products since it began crushing construction rubble approximately two years ago. In addition to flex base, it produces an oversized material and makes asphalt millings at its yard just north of Fort Worth, along Interstate 35 near the Texas Motor Speedway.

“DDM Materials was founded through its sister company, DDM Construction’s, needs for reliable on-site ready mix concrete,” explained Jacob. “Through various project demands, trucking and material recycling became a large part of our business.”

In addition to Jacob, the Justin, Texas-based company is owned and operated by his brother Luke, who is Operations Manager, and their father, David, who serves as President. Another brother, Zach, is Vice President of DDM Construction, which brings old concrete and asphalt to DDM Materials for recycling.

“One of DDM Construction’s specialties for the past 20 years has been building large auto auction lots,” said Luke. “We clear the area, put it to grade and provide stabilization, if necessary. In addition, we place recycled concrete flex base and cap it with recycled asphalt. That’s the aspect that introduced us to the crushing industry. Originally, this was a way to feed our needs because we were having trouble getting the flex base. With demand in the area, we saw there was potential to grow into supplying others.

“We take in all forms of concrete and road pavement from DDM Construction and other contractors,” he added. “The cleaner the better, but we will take and process all materials. We try to do our part to reduce the amount of material that is sent to a landfill.”
 

Crusher exceeds expectations

DDM Materials operators remove steel, such as rebar, and process the raw materials into 12- to 24-inch pieces. Those are fed into a Kleemann Mobirex MR 130 Zi mobile impact crusher, which the firm purchased from Kirby-Smith Machinery last year.

“Quality is a big factor in our machinery buying decisions,” Jacob emphasized. “Additionally, we wanted a diesel-electric crusher and one we could easily get parts and service for locally. We looked at 15 different machines, and the Kleemann backed by Kirby-Smith’s support was the only one that checked all of the boxes.

“We’re overproducing compared to our original expectations,” he continued. “So much so, that we’ve cut our hours of operation. The benefit is less wear and tear and downtime, which reduces operating costs.”

Luke added that the MR 130 Zi is user-friendly and easy to operate. “It walks you through the startup process, and the maintenance is simple. It’s one of the best designed machines we’ve ever seen.”

The right fit reduces downtime

DDM Materials feeds the Kleemann crusher with a Komatsu WA470-8 wheel loader. Finished products run from the crusher to a stockpile on a Masaba Magnum telescoping conveyor that stacks up to 52 feet. Kirby-Smith Territory Manager Bill Hitchcock assisted DDM Materials with the setup and purchase of the equipment.

“Bill ensured that everything was the right fit for our operations,” said Jacob. “We appreciate everything that he, (Product Support Sales Representative) Phil Hearrean and the Kirby-Smith team do for us. They have a wide variety of equipment as well as the support to back it. We rarely have an issue or downtime, although if we do, they address it quickly. Usually it’s taken care of the same day or the next; where in the past, other dealers said they would get to us in two to three weeks.

“Downtime is why we turned to Komatsu and Kirby-Smith,” Jacob added. “We had a competitive machine that just didn’t perform. It would constantly go down; the repairs by the dealer were made slowly and were followed by a large ‘voided-warranty’ bill. We decided to give Komatsu a chance, and we are certainly glad we did.”

Looking at future locations

The first Komatsu equipment DDM Materials purchased was a D65EX dozer, which is used at its second location in Euless, where the company takes in clean fill dirt for a mining reclamation bond. The Markwardts are currently working on permitting that facility as another recycling operation.

“Our intention is to take the Kleemann crusher mobile and set up a permanent plant at our Fort Worth location someday,” shared Luke. “We would also like to open a couple of other facilities around the DFW area. The plans are dependent on current and future material inflow, so there is no particular time frame for growth; however, we certainly want to expand.”

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