Fossvélar leads the way with low-carbon crushing in Iceland

The way forward: Low carbon crushing and screening powered by electricity 

Using electricity in crushing and screening production is nothing new for Fossvélar, founded in 1971 and based in Selfoss, Iceland. The company has operated electric and diesel-electric crushers since 1985, including fixed, wheel-mounted, and track-mounted machines. Therefore, the Lokotrack® LT400J mobile jaw crusher was a clear choice for Jón Örn Ingileifsson, owner of Fossvélar, when expanding the mobile crusher fleet for an upcoming bid on a new power plant project. 

The Lokotrack LT400J jaw crusher ticked all the boxes: electric power for low-carbon operation, high capacity, safe and easy operation for workers, low fuel consumption when diesel is needed—and the fact that it’s a Metso, a trusted brand from dealer Velafl ehf, with whom Fossvélar has partnered for decades. 

”When I saw the LT400J at Hillhead 2024, I immediately contacted Hjálmar Helgasson and told him I wanted to buy the machine,” says Jón.  

“We’ve built a strong, long-standing partnership with Fossvélar, grounded in trust and mutual respect. It’s been a pleasure to see the company grow under new ownership while continuing to strengthen our collaboration around large mobile crushers,” says Hjálmar Helgason, Owner of Vélafl ehf.  

Winning bids with low-carbon solutions 

”Fossvélar has been using Metso’s diesel-electric mobile crushers since the 1990s. We saw the shift to electric power as an opportunity to win more jobs. The scoring system for project bids favors contractors who offer low-carbon solutions. In our quotation for the LT400J and Jonsson 550, we stated CO₂ emissions as zero for the crushing process,” explains Jón.

“The cubicity of the GP550 is excellent. With a pre-screen and a hanging screen, we produce 0–63 mm, 0–90 mm, 0–150 with the Lokotrack jaw crushers and with the GB550 we produce all sub-base and top layer for the road e.g. 0–22mm, 8–22 mm, 0–63 mm, 0–45 and 8–16 mm,” he continues.

Electric powerline boosts capacity and cuts fuel use

“The LT400J is very easy to operate. The discharge height is high, all maintenance points are accessible at ground level, and you can get under the crusher by lowering the main conveyor,” says Anton Waagfjord, operator at Fossvélar. “I especially like the remote control for moving the machine and the Remote IC system for adjusting the feeder and crusher settings from the excavator,” he continues.

National power plant company provides electricity on-site within the project 

During our visit Fossvelar was working on two major energy projects for the national power company Landsvirkjun: Vaðalda and Hvammsvirkjun. Vaðalda is a wind power project, while Hvammsvirkjun is a hydroelectric power plant. Both projects are essential for Iceland's energy transition and its commitment to sustainable energy practices.  

At Vaðalda, Fossvelar produced road-building aggregates for a new access road using the electrically powered Lokotrack LT400J jaw crusher. The crushing job lasted 5–6 months during the spring and summer. With a capacity of 400 t/h, they have crushed 85,000 cubic meters of 0–90 mm material in just two months. Since then, the LT400J has been relocated to work alongside the GP550, producing approximately 60,000 cubic meters of sub-base layers and base course for the road infrastructure related to the Hvammsvirkjun hydropower plant. Accompanying this pair is the Lokotrack® LT130E mobile jaw crusher, which is set to crush over 100,000 cubic meters of material during the fall and winter.  

Electricity is affordable in Iceland, and Landsvirkjun provides it as part of the contract. The rock material has low abrasiveness, requiring jaw plate changes only after 2,000 hours, lowering the operational costs of the job significantly.  

Quick setup and transport between sites without heavy cranes 

“Both the LT130E and LT400J are quick to set up and transport to new locations. Despite its 128-ton weight, the LT130E splits into two parts with hydraulic feet lifting the feeder and crusher for separation onto two trucks. No crane is needed on-site, only one part requires lifting, which can be done with an excavator. The LT400J despite its 70 ton weight can be transported in one piece and is even faster to set up using remote control, compared to our old Lokomo wheeled crusher that took four hours to prepare for transport. The development has been impressive,” says Jón.  

Remote work, reliable people – crushing in Iceland’s high season 

As summer is also peak tourism season in Iceland, and the sites are in remote locations, workers stay on-site with room and board for 10-day work periods followed by 4 days off. Shifts last 10–12 hours, and with up to 19 hours of daylight, workdays can be extended when needed. 

“We provide room and board to our workers to make it easier for them to stay at remote locations. Staff turnover is low—we’ve had people with us for 50 years. We value a strong team. After all, they do the work. It is our responsibility to ensure that our staff feel comfortable at work and enjoy being at work. We do that by providing them with top of the line machinery, good food and decent housing," says Elísabet Edda Guðbjörnsdóttir, Managing Director of Fossvélar. 

Looking ahead: a bright future for electric crushing in Iceland 

The future looks promising for electric-driven crushing in Iceland. With more sustainable energy infrastructure being built, low-carbon machinery is increasingly favored in project bids—placing Metso’s diesel-electric solutions at the forefront of the transition.