AGGREGATE

PRODUCTION PLANT
CE 516 - CONSTRUCTION MANAGEMENT
REPORTERS:
Sasheen T. Dela Cruz
Andrew P. Magbanua
January 2018
This report discusses the total process of
aggregate production from
extraction through processing.
OBJECTIVES
1. AGGREGATE
1.1 IMPORTANCE
1.2 GRADATION
2. EXTRACTION
2.1 Stripping
2.2 Drilling and Blasting
2.3 Shotrock or Gravel Bank
3. COMPONENT OF AN AGGREGATE PRODUCTION PLANT
3.1 Vibrating Feeder, 3.2 Jaw Crusher, 3.3 Impact Crusher,
3.4 Screen, 3.5 Belt Conveyor
4. FACTORS AFFECTING PRODUCTION TATES
5. METHODS OF PRODUCTION RATE IMPROVEMENTS
6. SAFETY PRECAUTIONS
7. CONCLUSION
 OUTLINE FOR JAW AND IMPACT
CRUSHERS
• BASIC PARTS
• BASIC OPERATING PROCEDURE
• CAPACITY
• CYCLE OPERATION AND PRODUCTION RATES
• SAMPLE PROBLEM
1.1 IMPORTANCE OF AGGREGATE
“Aggregates are literally the “foundation” of
our economy and society.”
-Ontario Stone, Sand & Gravel Association

“Aggregates are the most mined materials in the world.”

-www.rocksandminerals.com/aggregate.htm

“Aggregates are the building blocks of modern civilization”

-www.rocksandminerals.com/aggregate.htm
1.1 IMPORTANCE OF AGGREGATE
IMPORTANCE IN TERMS OF WORKABILITY
• A workable concrete can be achieved by adding more water,
but as we know the more water present in concrete the poor
strength it gives. The most efficient way to achieve workable
of concrete is by adopting a good gradation of aggregate.
• Also aggregate comprises 80 - 85% of the volume of
concrete. So we can definitely say that, most of the
requirement of concrete in its plastic state is affected by
aggregate properties and, “gradation of aggregate” is one
of them.
1.1 IMPORTANCE OF AGGREGATE
IMPORTANCE IN TERMS OF DURABILITY
• We use cement paste to bind all the
aggregates (i.e. fine and coarse) so as to give a
compact mass, and this is why concrete is
considered as a two phase material, namely,
paste phase and aggregate phase.
1.2 GRADATION OF AGGREGATE
Coarse aggregates used in concrete making contain aggregates
of various sizes.
This particle size distribution of the coarse aggregates is termed
as "Gradation".
The sieve analysis is conducted to determine this particle size
distribution
1.2 GRADATION OF AGGREGATE
Proper gradation of coarse aggregates is one of the most
important factors in producing workable concrete. Proper
gradation ensures that a sample of aggregates contains all
standard fractions of aggregate in required proportion such that
the sample contains minimum voids.
1.2 GRADATION OF AGGREGATE
EXTRACTION
2. EXTRACTION: QUARRYING
AGGREGATE
In operating a quarry and crushing plant, the
drilling pattern, the amount of explosives, the size
of shovel or loader used to load the stone and the
size of the primary crusher should be coordinated
to assure that all stone from the quarry can be
economically utilized.
2.1 STRIPPING
• As a first step, a Producer is required to designate a detailed
stripping procedure for each and every deposit that is mined.
This phase often is overlooked, yet has a great influence on
the quality and variability of the product. Inadequate removal
of overburden from the mineral deposit often may be the
source of excessive variation in minus No. 200 material and
may even have a deleterious affect on nearby vegetation and
other aspects of the mine.
FACTORS AFFECTING
PRODUCTION RATE
• Excessive knobs and depressions on the surface of a stone
deposit may necessitate the use of smaller equipment or
special techniques to clean the stone.
• Inexperienced equipment operators may easily corrupt good
stripping practices (which are somewhat of an art and site
specific).
• Spillage over the working face and other sloppy practices can
also affect the cleaning process.
2.2 DRILLING AND BLASTING
Quarry operators commonly design fragmentation shots for
safety, economy, ease of use at the primary crusher, and even
public relations, but they often forget about quality.
2.2 DRILLING AND BLASTING
The shot layout is required to be properly engineered,
documented, and adhered to for maximum consistency.
Varying the shot pattern may mean changes in product size
throughout the operation. Smaller shot rock, resulting in less
crushing in the secondary and tertiary stages, may mean less
improvement through crushing. Therefore, the mineral quality
and/or changes in physical properties of the product may be
affected.
2.2 DRILLING AND BLASTING
Hole detonation-sequencing and blast intensity also are required
to be properly engineered. Size changes resulting from
inattention to detail can have the same effects as mentioned
above.
Also, an erratic blast that throws the shot rock over a large area
tends to cause variation in size gradation that is delivered to the
primary crusher. Any deviation from previously established shot
patterns, sequencing, and intensity should be carefully thought
out as to the effect on product quality.
2.3 SHOTROCK OR GRAVEL
BANK
A constant problem of gravel pit and quarry operators is the
difficulty in maintaining uniform load-out from either the shot rock
pile or the gravel bank. Even the best shot has some variation
from side to side and from front to back. Only experienced and
well-trained equipment operators may accomplish the mixing
from around the shot for the most uniform feed to the processing
plant
 AGGREGATE
PRODUCTION PLANT
Aggregate Production Plant
In mines and quarries, stones and rocks of different sizes are
broken to obtain small stones or sand. The installations that
carry out this process are called crushing plant. A crushing
plant has different stations (primary, secondary, tertiary, ...)
where different crushing, selection and transport cycles are
done in order to obtain different stone sizes or the required
granulometry. With this process, the aggregate used for
mortars and asphalt elaboration is obtained.
Basic Parts of Aggregate
Crushing Plant
Usually Crusher machine includes following machines:
1. Vibrating Feeder
2. Jaw Crusher
3. Impact Crusher
4. Vibrating Screen
5. Belt Conveyor

PLAY VIDEO: 2
Vibration Feeder
A vibratory feeder is an instrument that uses vibration to "feed"
material to a process or machine. Vibratory feeders use both
vibration and gravity to move material. Gravity is used to
determine the direction, either down, or down and to a side, and
then vibration is used to move the material. They are mainly used
to transport a large number of smaller objects.
A belt weigher are used only to measure the material flow rate but
weigh feeder can measure the flow material and also control or
regulate the flow rate by varying the belt conveyor speed.
These machines feed the jaw and impact crusher with the rocks
and stones to be crushed.
INSTALLATION
FEEDER AT REST
Feeder trough length is
determined by the material’s
static angle of repose and
through slope. The feeder
trough must be of sufficient
enough length to assure
complete material shut-off when
the feeder is at rest.
INSTALLATION
FEEDER OPERATION
The dynamic angle of repose is
the angle the material seeks
while being vibrated and
conveyed.
 INSTALLATION
PROJECTED VERTICAL OPENING
The projected length and width of the
vertical opening should be two or
three times greater than the largest
particle dimensions. Materials with
bridging tendencies require sufficient
openings to assure good product flow.
The projected horizontal opening is
determined by particle size and bed
depth requirements. The minimum
horizontal opening should be
approximately two times the largest
particle dimension, but no less than
the required bed depth.
Jaw Crusher
• Operate by allowing stone to flow into the space
between two jaws, one of which is stationary while the
other is movable.
• The distance between the jaws diminishes as the stone
travels downward under the effect of gravity and the
motion of the movable jaw, until the stone ultimately
passes through the lower opening.
Jaw Crusher
Basic Parts of Jaw Crusher
Jaw Crusher
• Jaw crushers are usually designed with the toggle as
the weakest part. The toggle will break if the machine
encounters an uncrushable object or is subjected to
overload. This limits damage to the crusher.
• In selecting a jaw crasher, consideration must be given
to the size of the feed stone.
Sizes of Stone Produced by
Jaw Crusher
• Even though the setting of the discharge opening of a
crusher will determine the maximum-size stone
produced, the aggregate sizes will range from slightly
greater than the crusher setting to fine dust.
• For any given setting for jaw crusher approximately
15% of the total amount passing through the crusher
will be larger than the setting.
Sizes of Stone Produced by
Jaw Crusher
• If the opening of the screen which receives the
output from such crusher are the same size as
the crusher setting, 15% of the output will not
pass through the screen.
Sizes of Stone Produced by
Jaw Crusher
This table provides
the percent of
material passing or
retained on
screens having the
size opening
indicated.

Figure 1. Analysis of the

Size of Aggregate.
Sizes of Stone Produced by
Jaw Crusher
To read the chart:
• Select the vertical line corresponding to the crusher setting.
• Then go down this line to the number which indicates the size
of screen opening.
• From the size of the screen opening proceed horizontally to
the left to determine the percent of material passing through
the screen or the right to determine the percent of material
retained on the screen.
Jaw Crusher Sample Problem
Jaw Crusher Sample Problem
Jaw Crusher Sample Problem
Impact Crusher
• In impact crusher stones are broken by the application
of high-speed impact forces.

Types of Impact Crusher:

1. Single rotor
2. Double rotor
3. Hammer mills
Impact Crusher (Single Rotor)
• The single rotor-type impact crusher breaks the stone
both by the impact action of the impellers striking the
feed material and by the impact which results when
the impeller-driven material strikes against the aprons
within the crusher unit.
Impact Crusher (Double Rotor)
• These units are similar to the single rotor models and
accomplish aggregate-size reduction by the same
mechanical mechanisms. They will produce a
somewhat higher proportion of fines.
• With both single and double rotor crushers, the
impacted material flows freely to the bottom of the
units without any further size reduction.
Impact Crusher (Single and
Double Rotor)
Impact Crusher (Double Rotor)
Impact Crusher (Hammer Mill)
• Most widely used impact crusher
• May be used for primary or secondary crushing
• The basic parts of a unit include a housing frame, a
horizontal shaft extending through the housing, a
number of arms and hammers attached to a spool
which is mounted on the shaft, one or more
manganese-steel or other hard-steel breaker plates,
and a series of grate bars whose spacing may be
adjusted to regulate the width of openings through
which the crushed stone flows.
Impact Crusher (Hammer Mill)

Cutaway of
Hammer Mill Rock
Crusher Showing
Breaking Action
Impact Crusher (Hammer Mill)

Table 5. Representative Capacities for Hammer Mills

Impact Crusher (Hammer Mill)

Table 5. Representative Capacities for Hammer Mills

Screens
• Screening of crushed stone is necessary in order to separate
the aggregate by the size ranges.
• Most specifications covering the use of aggregate stipulate
that the different sizes shall be combined to produce a blend
having a given size distribution.
• Persons who are responsible for preparing the specifications
for the use of aggregate realize that crushing and screening
cannot be done with complete precision, and accordingly they
allow some tolerance in the size distribution.
Screens
The corrected capacity of a screen is given by the following equation
Q = ACEDG
Where
Q = capacity of screen, tons per hour
A = area of screen, sq ft
C = theoretical capacity of screen, tons per hour per sq ft
E = efficiency factor
D = deck factor
G = aggregate factor
Screens
The minimum area of a screen to provide a given capacity is
determined from the following expression

Tables 6.7 and 8 give the efficiency, deck, and aggregate – size
factors for use:
Screens
Screens
Screens
Screen – Capacity Chart
Belt Conveyor
Belt Conveyor
After stone is crushed and screened to provide the desired size
rangers, it is necessary to handle the stone carefully or the large
and small particles may separate, thereby destroying the blend in
sizes which is essential to meeting gradation requirements. If
aggregate is permitted to flow freely off the end of a belt
conveyor, especially at some height above the storage pile, the
material will be segregated by sizes.
Belt Conveyor
Belt conveyors are used to move materials from one place to
another. The conveyor belt is the most frequently used
transportation machines today due to a wide range of substances
can be done to move the coupled with the flexibility of the overall
design is his. Belt conveyor could save a lot of money on labor.
Belt Conveyor
The type of Aggregate conveyors totally depends on the
requirement of the manufacturer to manufacture the product,
material needed to be moved on, task to be performed, use of
machine, etc. The dimension and the whole scenarios
matters. The choice of Aggregate Conveyors is totally made as
per the work.
Belt Conveyor
A Flex Pocket Belt Conveyors – is used where it is needed to
move material into a temporary storage bin or into mixing
container is commonly used. These machines can accommodate
and be installed in small spaces and serve the purpose.
Belt Conveyor
A Belt Conveyor – This type of Belt Conveyor is also one of
the space conserving form of aggregate conveyor, which, are
commonly used to move materials across the floor of a work
space parallel to the ground. These Belt Conveyors can move
materials at most volumes, whether to move the material, at a
slight incline or decline, But these Belt Conveyors are best suited
specifically for smaller workloads. As to mention, infact the
material on the belted conveyor is moved along on a flat surface
means that it is not suited to raise or lower its workload at too
steep of an angle, as it may, lead the material to spill or stall
around a steeper incline.
Belt Conveyor
Radial Stacker Conveyors – These machines are one of the
Aggregate Conveyor, best suited only for outdoor purpose. They
are huge conveyor systems, which come in a variety of sizes and
workload capacities, larger than a standard conveyor system.
They are large in size but are portable to be moved and serves
the purpose of making pile of the desired material construction
yard or quarry. These Radial Stacker Conveyors are ruggedly
built, as they perform task outdoor and are subject to greater
wear and tear.
Belt Conveyor
Screw or Auger – These conveyor system are used at steep
inclined that uses the threads of a revolving screw to transport
material. The Screw or Auger Conveyors are very useful in
moving liquid material that may have difficulty staying in the
pockets of a flex pocket conveyor. Although this type of conveyor
system is usually smaller than most others, but, it can be made
custom made to larger sizes as needed by the manufacturer.
4. FACTORS AFFECTING
PRODUCTION RATE
Plant Setup
The importance of proper site preparation and proper stationing
of the plant cannot be overemphasized. Your site for stationing
the plant should be flat, level, and well compacted. Crushing and
screening plants may be operated for short periods of time from
the wheelbase. However, from a maintenance standpoint it is
advantageous on longer and more deliberate jobs not to operate
the plant until it has been blocked and leveled with the tires clear
of the ground.
4. FACTORS AFFECTING
PRODUCTION RATE
Plant Setup
The plant should be leveled before initial operation and should be
frequently checked while in operation. Leveling should be done
on the frame for longitudinal leveling
4. FACTORS AFFECTING
PRODUCTION RATE
The entire quarry and rock production operation depends on
proper and adequate maintenance of equipment. A regulated
program of maintenance, including step-by-step procedures, is
recommended for each piece of equipment.
In contrast to other types of construction equipment, procurement
of repair parts and new units for crushing and screening
equipment requires a much greater lead time. Without proper
parts and units, production either slows down or stops altogether.
5. METHODS OF PRODUCTION
RATE IMPROVEMENTS
INSPECTION
To prevent damage and eventual breakage, you should visually
inspect the plant constantly to detect any misadjustment or loss
of adjustment. Visual inspections should be made from ground
level, from the platform, and from walkways. All adjustments
should be checked with the components operating while empty
and rechecked while loaded with aggregate.
5. METHODS OF PRODUCTION
RATE IMPROVEMENTS
Quarry equipment is subject to exceptionally hard wear due to
the abrasive action of rock and rock dust; therefore, the
operator’s maintenance procedures contained in the
manufacturer’s maintenance and service manuals must be
strictly followed. Safety is always the number one factor when
planning maintenance, so you must ensure that everyone
involved in the maintenance evolution is properly trained
5. METHODS OF PRODUCTION
RATE IMPROVEMENTS
As the supervisor in charge of quarry operations, it must be
ensured that a schedule is posted and understood by all crew
members. Ensure that the operator’s maintenance is performed
by the book and that all cutting edges, end bits, teeth and
shanks, dozer tracks, tires, blades, and conveyors are checked
daily for wear.
5. METHODS OF PRODUCTION
RATE IMPROVEMENTS
Because of the working conditions around a crushing operation,
the entire crew must be totally familiar with the manufacturer’s
requirements and any special conditions that may exist. This
ensures proper maintenance and the safe and productive
operation of the crusher equipment.
6. SAFETY PRECAUTIONS
4.1 Inspection and Testing
- Must be carried out regularly by an authorized person to check if the
plant and its equipment still fall under safety standards
- Factors to consider includes: conditions, suitability, location and
abnormal situations.
4.2 Maintenance, Repair and Cleaning
- Ensure that plant is maintained and repaired according to the
manufacturer’s specifications or, in the absence of such
specifications, in accordance with a competent person’s
recommendation
- Make sure that plant should be isolated and shut down before
maintenance, service or cleaning commences.
6. SAFETY PRECAUTIONS
4.3 Emergency Stops
- Be prominent, clearly and durably marked, for example
“EMERGENCY STOP- PRESS”
- Immediately accessible to each operator of the plant, have
handles, bars or push buttons that are coloured red.
- Not be adversely affected by electrical or electronic circuit
malfunction
4.4 Electrical Connection
Do not connect electrical power or operate the equipment if the
ground connection is not properly installed. Death by electrocution
could result from improperly grounded equipment.
6. SAFETY PRECAUTIONS
4.5
Be sure the main power sources remain “OFF” and are
properly “red-tagged” while personnel are working on electrical
equipment. You should make frequent inspections during
operations to ensure that the equipment is not being abused,
that the units are level and cribbed, that calibrations are
correct, and that proper shutdown procedures are being
followed.
7. CONCLUSION
The demand for aggregates will continue to grow in the future.
Provisions to assure adequate supplies will have to be made.
Long-range planning and zoning regulations will have to take
into account current and future community needs for this
valuable natural resource. All groups and individuals will need
to work together to ensure adequate community and
environmental protection, while ensuring the availability of
aggregates at a reasonable cost that will allow growth and
prosperity.
7. CONCLUSION
The demand for aggregates will continue to grow in the future.
Provisions to assure adequate supplies will have to be made.
Long-range planning and zoning regulations will have to take
into account current and future community needs for this
valuable natural resource. All groups and individuals will need
to work together to ensure adequate community and
environmental protection, while ensuring the availability of
aggregates at a reasonable cost that will allow growth and
prosperity.
7. CONCLUSION
(Crashing Equipment Selection)