County engineers recommend replacing loader engine and buying asphalt after plant leak shuts production

Public works staff told the Bourbon County Commission on Oct. 20 that a loader at the county rock quarry has a failing engine and the county's asphalt plant has a punctured burn-cavity (oil) tank that has stopped asphalt production.

Dustin Hall reported on the quarry loader: a Murphy Tractor quote to replace the engine is $82,702; a head-gasket repair was estimated at about $30,000 but public works staff said a head-gasket repair would be a temporary fix and that several cylinders showed low compression. The loader carries about 10,000 hours and staff said a rebuilt or replacement engine carries a one-year unlimited-hours warranty; staff recommended replacing the engine rather than doing a potentially short-lived gasket repair.

Hall said the county plans to fund the engine work from a split between road-and-bridge funds and sales tax revenues; he told the commission the cost is budgeted and that carryover funds appear sufficient if no other major costs arise.

Separately, Hall said the asphalt plant has a burn-cavity that compromised the oil tank and is leaking internally; the vendor the county contacted (manufacturer) had not yet provided repair options. If the county cannot safely repair or patch the tank, Hall said replacing the tank could cost $100,000–$200,000 and installation by the manufacturer or contractor could raise the total to the order of $400,000–$500,000. He said an internal patch would be much cheaper but the county is awaiting the manufacturer's guidance.

Because the plant is offline and a half-mile of Yale Road is prepped and ready for paving, Hall asked whether the commission wants the county to buy hot-mix asphalt from an outside producer in Mound City at about $70 per ton. He said producing the material at the county plant would have cost about $52.47 per ton and that the original estimate to finish the half-mile was about $101,000; buying the mix now would raise that cost to roughly $136,000, increasing the project by approximately $25,000–$35,000 depending on final tonnage and hauling.

Hall also summarized related equipment issues: the quarry crusher loader has new tires purchased last year (about $6,000 each), the transmission was serviced last year, and staff said they are projecting additional tire replacements next year. Used machines with similar hours were quoted at $200,000–$300,000 in online searches, making engine replacement the more cost-effective near-term option, Hall said.

Commissioners asked about operational impacts and cross-subsidies: Hall said the county will still be able to pay labor and operate other functions, but relying on outside asphalt purchases would change the budget and staffing plan and could reduce in-house production that currently helps other municipalities.

Outcome and next steps: commissioners indicated support for proceeding with the engine replacement and for purchasing asphalt to finish Yale Road rather than delaying the paving; public works will continue to seek the manufacturer's repair plan for the asphalt tank and return to the commission with firm costs if replacement is required.

Ending: the county faces a near-term tradeoff between a roughly $25,000–$35,000 project overrun to finish paved work this year or delaying roadwork until the plant is repaired; staff recommended replacement of the loader engine and specified that the plant repair estimate could range into the hundreds of thousands if a full tank replacement and external installation are required.