The crushing operation of aggregate is a key process in the production of construction materials like concrete, asphalt, and road base. It involves reducing large rocks, gravel, or other raw materials into smaller, uniformly sized particles suitable for various applications.
Steps in Aggregate Crushing Operation
1. Primary Crushing
– Large rocks (from quarries or mines) are fed into a jaw crusher or gyratory crusher.
– Output: Coarse aggregates (typically 6–12 inches).
2. Secondary Crushing
– Further reduction using cone crushers or impact crushers.
– Output: Medium-sized aggregates (0.5–2 inches).
3. Tertiary/Quaternary Crushing (if needed)
– Fine crushing using specialized crushers (e.g., vertical shaft impactors).
– Output: Fine aggregates (sand-like particles, <0.5 inches).
4. Screening & Classification
– Vibrating screens separate crushed material into different sizes (e.g., ¾", ½", etc.).
– Oversized material may be recirculated for further crushing.
5. Washing & Scrubbing (Optional)
– Removes dirt, clay, and impurities using log washers or sand screws.
6. Stockpiling & Storage
– Aggregates are stored in segregated piles based on size for future use.
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Types of Crushers Used
– Jaw Crusher: Best for primary crushing (high compression strength).
– Cone Crusher: Efficient for secondary/tertiary crushing.
– Impact Crusher: Good for softer rocks and producing cubical-shaped aggregates.
– Vertical Shaft Impactor (VSI): Produces high-quality sand for concrete.
Key Considerations
– Feed Size & Hardness: Determines the type of crusher needed.
– Moisture Content: Affects screening efficiency and clogging risks.
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tion Capacity: Influences equipment selection and plant layout.
Applications of Crushed Aggregates
– Concrete production
– Asphalt mix for roads
– Railroad ballast
– Drainage systems
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