October 2002
In the mobile-track vs. wheeled-portable debate, contractors say there’s a place in the market for both
By Bill Riel
With mobile crushers, contractors can profitably tackle jobs as small as 2,000 tons and quickly and easily move around the job site to process several smaller piles of material rather than one large stockpile.
In the buzz over mobile track crushers, there remains much debate on how they fit into the U.S. market. Will they open new markets for crushing equipment? Can they survive competition from widely popular wheel-mounted plants?
Manufacturers’ perspectives have dominated the debate. Articles have included the markets in which manufacturers perceive mobile track crushers will be sold, how these markets will evolve, and the advantages and shortcomings of mobile tracks vs. traditional wheel portable plants. Contractors’ perceptions and experiences, however, are key elements to the outcome of this debate.
The Mobile Advantage
The most obvious advantage mobile track crushers provide is quick and easy movement around a tight job site. “On a large demo site, you don’t have to haul all of the material to one pile,” said Brian Baumann, president of Cleveland, Ohio-based contract crusher American Eagle, a subsidiary of B&B Wrecking. “You can have multiple piles, saving time and money on the job.”
Mobile track crushers can quickly move to and crush separate piles or move with the face of a larger pile. It is possible to move wheel-mounted portable crushers on site with dollies, but “crushers on dollies aren’t the easiest things to maneuver,” said Baumann.
Equally important to mobility, tracked crushers give contractors the ability to profitably tackle applications previously considered too small for traditional all-in-one portables. “I believe that we can profitably do jobs as small as 2,000 tons with a mobile track crusher,” said Derwin Charles, president of International Aggregates, a Timberlake, N.C.-based contract crushing company. The company operates three Irock portable crushing and screening plants and is considering purchasing Irock’s RTS-15 mobile track crusher.
The market for mobile tracks are not only small jobs, but also medium-sized applications up to 20,000 tons, according to Charles. “There used to be a lower break even point with the size of the job (between using a mobile track vs. a portable crusher),” he said. “But with some of the latest mobile tracks on the market, that line is being blurred.”
Baumann not only agrees with Charles’ assessment of applications, but he demands use of mobile tracks on medium-sized jobs. “There are not enough small jobs out there to make it financially feasible to purchase a mobile crusher just for them,” Baumann said. “It has to be interchangeable with our portable crusher and be just as profitable on these jobs.”
To Screen or Not to Screen
Traditional portables have a leg up on their mobile competition in screening. Many portable crushers on the market are all-in-one, closed-circuit crushing and screening plants. Many of these plants will separate up to three saleable products at one time. Mobile tracks are open circuit, requiring a separate screening plant to make a spec product.
This limitation and the additional cost of a separate screening plant is keeping Ron Brocco, operations manager of Cleveland, Ohio-based recycle crusher, Independence Recycling, from purchasing a mobile track crusher. The company operates nine wheel-mounted portable crushers throughout the eastern United States.
“All our customers require a spec product,” said Brocco. “We would have to run a separate screening plant. We could really do something with an all-in-one mobile track unit (where the screen and crusher are on the same frame).”
Initially this was Baumann’s position as well. However, after operating a mobile track crusher, he sees advantages to having the screening plant separate from the crusher. “We run into some applications where the spec isn’t as tight,” he said. “On these projects, we just use our mobile track and move the screening plant to another site. It makes us more flexible.”
Additionally, production from closed-circuit portable crushing and screening plants often is limited by the size of the on-board screen. Crushers on these portable units may be able to operate at capacities exceeding 500 tons per hour, but this production level will typically flood the screens. “There’s nothing more frustrating than knowing you could be producing more, but the screen size won’t allow it,” said Baumann.
We Need Clearance
A general consensus among contractors is the need for as much clearance as possible under the crusher and the lack of enough clearance on most mobile tracks. “We would take 10 ft. of clearance between the crusher and the belt if we could get it,” said Brocco. But he realizes that there is a necessary balance between clearance and portability with mobile track crushers.
Due to their compact size, most mobile track designs are very tight under the crusher. This is especially detrimental to production when crushing recycled concrete. The rebar can get tangled between the crusher and conveyor, making it a nightmare to clean out. “Tight clearances are what originally kept me away from mobile tracks,” said Charles. “Irock’s design has opened this area a great deal.”
Tight clearance also affects the discharge conveyor’s lifespan. Lower clearance appears to be a significant contributing factor in reducing belt wear life. “With our portable crushers, we get almost 18 months from the belt, but with the first mobile track we operated we only got one month,” said Baumann.
Manufacturers anticipated the size of the feed hopper on the mobile track design to be a drawback. To help with over-the-road portability, hopper lengths are typically shorter than portable plants, requiring mobile tracks to be loaded with smaller loaders or excavators.
The mobile track crusher’s ability to move with the face of the pile, however, allows the plants to be efficiently loaded with an excavator, which many crushing contractors already use to load their portables. “We get into some asphalt recycle applications that you cannot break through the pile with a (wheel) loader and have to use an excavator. We don’t see loading a mobile track with an excavator as a problem,” said Charles.
Room Under the Hood
Going hand-in-hand with clearance, contractors need accessibility to service areas on mobile track crushers. Service points such as the impactor and under the crusher must be easily accessible for quick adjustments and repairs. The problem is that mobile track crushers are very compact and some designs can make it difficult to reach common service points.
Baumann likens servicing portable plants and mobile track crushers to working on cars. “Servicing a portable plant is like working on a 1967 Ford pick-up, whereas working on a mobile track is like servicing a 2000 model pick-up — everything is shoehorned in there,” he said.
A service area where manufacturers are more concerned than contractors is the undercarriage. Repairs to track undercarriages cost more than servicing axles on portables. “We have the occasional problem of a loader running into our portable plants and damaging the wheels and axles,” Charles said.
However, crushing contractors do not see the undercarriage as an issue, because they do not track the units much. “The rest of the plant will wear out before we have to overhaul the undercarriage,” said Baumann.
A Growing Market
Contractors see the market growing for both traditional portable and mobile track crushers. The original European track unit designs are evolving into more productive plants that will be able to handle most small- and medium-sized applications.
Charles sees a broad base of contractors turning to mobile tracks to crush the smaller jobs they currently are subbing out to contract crushers or hauling to landfills. “Mobile tracks may grow to be as common as excavators, with contractors renting them to handle the occasional crushing application,” predicted Charles.
Baumann agrees that the markets for both mobile tracks and portables will continue to grow. But, he is skeptical of the rental idea because there is a significant learning curve to operating a crusher. Costs are too high for contractors the first month while they are learning to operate the crusher, and it can cost them more to crush the material than it would to purchase it, according to Baumann. “I have yet to hear a contractor say (in the first month), ‘Boy, I’m glad I rented that crusher,’” he said.
Whatever the size and application, because of the evolution of mobile track crushers in response to U.S. market demands, these crushers are here to stay, and the market will continue to grow. However, design limitations will not allow mobile tracks to overtake the portable market entirely. There will be room for both.
One advantage to portable crushers is their on-board screens, capable of separating multiple spec products simultaneously.
The concept of mobile track crushers is not new, even in the United States. Traditionally, U.S. versions of track units have been large, heavy primary jaw or impact crushers operating predominantly in quarries. Their main benefit is the ability to move with the face, improving efficiencies and lowering operating costs. The design of these mobile track crushers were for in-pit — not over-the-road — portability.
Coming to America
Today, most mobile track crushers are lighter and nimbler and geared to the portable contract crushing market. Although new to the United States, European countries have used this concept for years. As manufacturers try to open a virtually untapped U.S. market, there is debate whether European-concept mobile crushers are a viable solution for U.S. contractors.
Bill Riel is a designer/engineer for Irock Crushers, a manufacturer of portable wheel- and track-mounted crushers.
Site conditions challenge equipment choices
Kansas producer’s custom equipment is suited to quarry-site conditions and production goals
By Bob Drake
Quarry operations are complicated by five limestone ledges of varying quality separated by shale layers.
Having reached a 50-year milestone, Holland Corp. undoubtedly has learned a few lessons through the years about overcoming obstacles. Holland started as a construction company in the Kansas City area, began quarry operations in the early 1960s, and today operates an asphalt plant, a quarry, and a construction company focusing on public and private road building and development work.
The company remains family owned and operated with three family members currently involved in management: Jim Holland, president; Mac Holland, vice president of construction operations; and Harold Holland, vice president of quarry operations.
Seven years ago, when Holland Corp. opened its current quarry on property it owns in Olathe, Kan., about 20 miles south of Kansas City, it had to plan not only for community-friendly quarry development, but also for overcoming a number of less-than-optimum site conditions. There are five limestone ledges in the quarry separated by shale layers. In addition, the reserves are overlain with a hard cap rock.
“In eastern Kansas, we are blessed with an abundance of good limestone,” said Jim Holmes, quarry manager. “What makes quarrying the rock a challenge is that some of the ledges aren’t very thick and the quality varies from ledge to ledge. The bulk specific gravity, absorption, soundness, wear, and soft or friable particles are different in all five of the ledges.
“One of our goals when opening the quarry was to be able to make a quality, marketable, crushed rock product utilizing all five of our limestone ledges,” Holmes said. “One day we may be crushing a ledge of rock to make a very specification-sensitive asphalt and concrete stone. The next day we may be in a ledge that is more suited to make base rock and commercial stone. Our crushing plant needed to have the capabilities to make many different products by blending different sizes of rock together to meet gradation specifications.”
Holland worked with G.W. Vankeppel Co. of Kansas City, Kan., and Akron, Iowa-based Masaba Mining Equipment to design and fabricate first a portable plant and then a stationary plant to address the quarry-site conditions. “Harold Holland and Jim Holmes challenged us for ideas on different projects and are truly some of the people that make this business fun,” said Justin Higman, vice president of business development for Masaba.
To make a large variety of aggregate products, Holland uses a Cedarapids 5348 SIIB horizontal shaft impactor (HSI) primary crusher. Secondary and tertiary crushing is handled by a Cedarapids 5065 HSI and Cedarapids 2600 vertical shaft impactor (VSI).
Masaba custom built and shipped to the site conveyors, stackers, a feed hopper, and support structures for the VSI and Cedarapids 5- x 16-ft. horizontal screen and JCI 7- x 20-ft. screen.
Holland began operations at the Olathe site with the plant in a portable mode. That allowed the company to move the plant around the site as needed for stripping, initial quarry development, and excavation of a site for a newly purchased Cedarapids Magnum E-500 asphalt plant, Holmes said.
Three years ago, Holland modified the plant to a more permanent configuration. The 5348 impactor and feed hopper were added and the portable components were mounted on concrete foundations and the undercarriages removed.
With an appropriately designed plant in place, Holland Corp.’s Olathe quarry produces about 900,000 tons of crushed limestone per year. But, like most Midwestern or northern U.S. operations, extreme weather variability — rain, drought, heat, and freezing — can cause some of the biggest problems, according to Holmes.
The company normally uses a Caterpillar 988B wheel loader for production loading into one Cat 775D and one Cat 773 haul truck. In wet conditions when the shale floor is soft, the wheel loader is replaced with a Cat 375 mass excavator. The excavator’s primary function is loading Cat 773B haul trucks in stripping overburden and removing the shale between the limestone ledges.
the bottom line...
Holland Corp. started with a portable plant to develop a new quarry, then converted it to a more permanent configuration. The plant is designed to produce specification stone and other products from five quarry ledges of varying quality.
Coping With Fleet Costs and Skilled Worker Shortages
New technology provides centralized command and control for equipment and fleet managers
Editor’s Note: This monthly column is supplied exclusively for AggMan by the Association of Equipment Management Professionals (AEMP).
Equipment and shop managers willing to combine remote location, condition, and productivity tracking technologies with optimal mobile-asset and labor-management practices can eliminate excess fleet assets and better cope with long-term skill shortages.
Remote asset location and condition tracking are defined as methods by which equipment locations can be tracked and operating conditions can be monitored from hundreds of miles away. It can also be applied to track operators and work crew location and activities. Therefore, remote tracking technologies can be applied to predict work crew financial and operational performance levels.
Some of these technologies give management the capacity to centralize command and control over a wide range of activities previously considered uncontrollable. They provide the ability to measure the performance of field activities in near-real-time. Such centralized command and control is a prerequisite to optimizing fleet, shop, and work-crew functions.
In the next five years, decreasing technology costs and increasing labor shortages — including mechanics, tradesmen, drivers, operators, laborers, and managers — will make remote GPS location tracking, on-board conditions monitoring and messaging, and work crew productivity measuring an affordable and necessary option, according to Kelly Walker, president, Kelly Walker Associates.
The key to maximizing this technology is to use the data to keep important contacts inside and outside the company informed of significant operational issues and to identify and resolve any exceptions that arise. Objectives for remote electronic asset locating, conditions monitoring, and work crew productivity measuring include the following:
• Identify assets, including class, make, model, VIN, serial number, and fleet number;
• Locate each asset’s physical address;
• Quantify asset utilization rates measured in miles, hours, gallons, and frequency of use;
• Qualify each asset’s mechanical condition as inside or outside manufacturers’ recommendations;
• Identify each asset’s immediate needs for mechanics, lube trucks, fuel trucks, and haul trucks;
• Quantify asset costs;
• Quantify revenues generated by each asset;
• Increase the timeliness and accuracy of data by using single, electronic data entry for operator, and mechanic man-hours; and
• Enable managers and workers in the field to remotely access company and supplier information, including equipment availability.
Efficient Data Capture
When reviewing data-capture models, answer the following questions:
• Is data capture labor or technology intensive?
• Will data capture be paper-driven or paperless with multiple or single entry of the same data?
• Will data capture be at the end of the day or near-real-time?
• Do the reporting and decision-making capabilities support next-day or same-day results?
• Is data capture from a secondary or primary source; and
• Is data capture from a compromised or independent source?
Using new technologies, fleet and shop departments have the capacity to independently measure the following work crew performance indicators: movement, frequency, duration, quantities of inputs and processes consumed, and quantities of outputs produced.
A word of warning. The amount of remote monitoring information received by fleet, shop, and work-crew departments can be overwhelming. A communication-link provider should integrate the data streams into useful information that helps managers optimize decision-making.
There are numerous career opportunities and room for professional advancement for equipment, fleet, and shop managers who combine remote monitoring technology with world-class mobile asset and labor management practices.
Excerpts of this month’s column are from the textbook, “Apply Remote GPS Tracking and Onboard Monitoring and Messaging to Manage Mobile Work Crews and Assets.” Kelly Walker, president, Kelly Walker Associates, can be reached at (214) 320-3006 or by e-mail at kellywalker@kelly
walker.com.
The Association of Equipment Management Professionals (AEMP), formerly the Equipment Maintenance Council (EMC), is an individual membership organization comprised of equipment maintenance and management professionals. Its members are responsible for the purchase, maintenance, employee training, shop facilities, and parts management of leading corporations and government entities that use heavy, off-road equipment. Its members also represent the major manufacturers and suppliers of the heavy equipment industry. AEMP provides end users with cutting-edge education, and it is the only organization to offer a certification program for the industry, the Certified Equipment Manager (CEM).
For more information, contact Stan Orr, CAE, AEMP executive director, at (970) 384-0510, e-mail at ceo@equipment.org or visit AEMP’s website at www.equipment.org.
A Maze of Moveable Machines
By Bob Drake
Despite an increase in the size and permanance of aggregates operations since the peak of interstate highway construction, portable crushers, screens, and sand plants remain important industry tools. In additon to construction- or demolition-site processing, today these moveable machines are used to serve multiple operations, improving asset utilization; to move with working mine faces, reducing or eliminating truck haulage; to supplement stationary plant production, fulfilling short-term contracts or making special products; and to simplify permitting, more readily opening greenfield operations or replacing aging stationary plants.
But, portable plants have limitations. They are most practical where production requirements are 250 to 400 tons per hour of one to three products, according to Jay Giltz, sales application manager for Eagle Crusher Co. Operators often try to do too much or to make too many products, he said.
Sam Sawant, president of Innotech Solutions, said common mistakes made when selecting portable plants include insufficient flexibility to meet changing customer demands, poor compatibility between plant components, inadequate screening capacity, and insufficient knowledge of available equipment.
Newer plant features, however, are expanding capacity restraints and making portable plants easier to operate. Paul Smith, product manager for JCI, cited the following trends:
• Hydraulic foundations that speed setup and tear down and eliminate the need for cribbing.
• Automation that maximizes crusher throughput and allows on-the-fly adjustment.
• Larger screens and dual screens on a single chassis that increase separation efficiency and reduce material carryover to crushers.
• Folding, on-board conveyors that ease setup and reduce the number of loads when moving.
The following review only begins to navigate the maze of wheel- and track-mounted crushers and portable screen and sand plants. Only one or two models from each manufacturer are highlighted here; many manufacturers offer broad product lines. Also, vertical shaft impactors (see AggMan, August 2002, page 29) are conspicuously missing from this roundup. Most, if not all, VSI manufacturers offer portable versions.
Wheel-mounted crushers
1. Eagle Crusher UltraMax 1000-15CV
Eagle Crusher Co.’s UltraMax 1000-15CV plant is designed for high production of 3/4-in. roadbase, according to the company. The three-load system includes an open-circuit crushing plant with Eagle’s UM15 HSI powered by an on-board 375-hp diesel; a screening plant with a 6- x 20-ft. triple-deck, horizontal screen and 30-in. x 50-ft. cleated return conveyor; and 30-in. x 50-ft. stockpiling conveyors.
2. Grasan Jaw Plants
Grasan offers road- and pit-portable jaw crushing plants in sizes from 2232 to 4248, featuring various crusher brands and axle configurations with diesel or electric power. The company will customize plants, including using customer-supplied new or used jaw crushers. Plant chassis are built with high-strength, wide-flange steel beams; hoppers have 3/4-in. plate walls. Standard grizzly feeders have variable-speed hydraulic hydrostatic drives.
3. Inertia Closed-Circuit Impactor
Inertia Machine’s Model 40485162CC is a self-contained, closed-circuit HSI plant with a double-deck screen with overhead vibrator. Inertia’s crusher has a 40- x 48-in. rotor, two adjustable breaker plates with Hardox liners, and a labyrinth seal to protect the system from dust. The plant is powered by a 275-hp Cummins diesel and 75 kW generator.
4. Irock Magnum Series
Irock Crushers’ Magnum 4043, 4056, and 5060 are open-circuit, primary impactor plants with capacities ranging from 250 to 800 tons per hour, according to the company. Vibrating grizzly feeder, hopper, crusher feed opening, HSI, and power source are matched in size to eliminate bottlenecks, Irock said. The Magnum 5060 can be equipped with Irock’s Hydraset Hopper, which has a dedicated power source and outriggers to hydraulically remove it from the main chassis without external lifting devices.
5. JCI/KPI Fast Pack
Johnson Crushers International (JCI) and Kolberg-Pioneer (KPI) joined forces to design the Fast Pack portable crushing-screening-stockpiling system. The system is built around self-contained, open-circuit plant segments — jaw crusher, cone crusher, and screen (see page 27) — that use hydraulic foundations and folding hoppers, bulkheads, and discharge/transfer conveyors to minimize transport and setup time. Rated at 500 to 600 tons per hour, the entire system can be set up in less than 4 hours, the companies said. The jaw plant is equipped with a Pioneer 3042, 2854, or 3350 Vanguard series jaw crusher and plant-mounted bulkhead. The JCI Kodiak 400 cone plant features an on-plant surge hopper with level sensor to ensure choke feeding. The plants can be combined or used separately. With self-contained power on each chassis, all of the plants can be wired to the control center with a single communications cable.
6. Lippmann 4800 Series
Lippmann Milwaukee’s 4800 Series plants feature the company’s 4248LP HSI with a 34- x 48-in. feed opening. The 47-in. x 16-ft. feeder has a 4-ft. grizzly section and by-pass chute. A pan feeder under the crusher protects the 48-in. discharge conveyor, particularly in recycling applications involving rebar. The plant is powered by a 360-hp diesel and 75-kW generator. A closed-circuit version also is available with a 62-in. x 10-ft. double-deck screen and 18-in. return conveyor.
7. Metso HP Cone Plants
Metso’s NW400HP and NW500HP portable cone plants are built around its Nordberg HP400 and HP500 cone crushers. A remote controlled hydraulic system has independent bowl clamping, clearing, and setting adjustment. Major components are serviced from the top and front of the crusher. The crusher discharge hopper is a radial design with AR steel wear surfaces and a large access door. An integrated operator platform and drive guard also has large access doors for checking and tensioning belts or cleaning sheaves. Each model has three discharge conveyor options: rear, side, or rear feed-side. Conveyors are a straight-line design for reduced spillage and improved belt tracking, Metso said. They feature C5 troughing idlers, rubber disc returns, and impact idlers at the load point. A range of chassis options is offered.
8. Telsmith Jaw, Impactor, and Cone Plants
Telsmith offers portable primary jaw and HSI and secondary/tertiary cone crushing plants. The primary plants can be customized with a wide range of feeders, hoppers, and bypass and discharge options for almost any application, the company said. Conventional or low-profile configurations are available. Portable secondary/tertiary plants feature the Telsmith Gyrasphere cone in 38-, 44-, 52-, 57-, and 68-in. models. The crushers feature hydraulic relief, unlocking, adjustment, and anti-spin. Plants are available in open- or closed-circuit configuration.
9. Universal 5160 Impact Master
Universal Engineering’s new 5160 Impact Master portable plant has an Andreas-style primary impactor, 20-ft. vibrating grizzly feeder, and front discharge conveyor. The system is mounted on a four-axle chassis and is rated at 550 tons per hour, according to the company. Fold-down hopper wings and leveling jacks provide quick setup and tear down, Universal said.
Track-mounted crushers
10. Cedarapids CobraTrack
Cedarapids’ CobraTrack line of mobile crushers includes three impactor models and two jaw plants. The 70,650-lb. CobraTrack 1000 incorporates a Cedarapids 4040 HSI capable of producing up to 200 tons per hour, according to the company. The crusher has a three-bar, solid steel rotor. Once the impactor’s clutch is engaged, all plant functions are operated from ground level. The machine can be moved and the grizzly feeder turned on and off with a remote control unit. Two ground-level accessible panels hold controls for the front and side discharge conveyors, the feeder variable speed, and the 294-hp diesel engine. Cedarapids said it also is introducing a closed-circuit cone/screen tracked plant.
11. DBT Mineral Processing Roll Impactor
DBT Mineral Processing’s primary roll impactor can be skid- or track-mounted. The units, intended for low-silica stone, do not require feed hoppers. Material is dumped directly on a flighted chain feeder and fed in a straight line through the crusher. A rotor with impact heads mounted above the chain feeder crushes the rock. Maximum feed sizes range from 40 in. to 6 ft., the company said.
12. Extec C-10
Extec’s C-10 track-mounted primary crusher uses a 225-hp diesel engine through a clutchless hydraulic transmission to power the 25- x 40-in. jaw. Hydraulics also adjust the jaw’s closed-side setting, raise the entire machine for cleaning and track servicing, and automatically adjust material flow from the vibrating feeder to the crusher.
13. HR International Big Track
Single-toggle jaw crushers manufactured by U.S.-incorporated HR International, formerly known as Hewitt-Robins International (the former European subsidiary of Hewitt-Robins USA), are used on the Big Track plant. Two jaw sizes are available: 24 x 36 in. and 30 x 42 in. The larger unit is powered by a 275-hp Cummins diesel and is rated at up to 297 tons per hour at a 5-in. closed-side setting. The plant weighs 110,000 lbs.
14. Irock Rapid Track System
Irock Crushers’ RTS-15 (Rapid Track System) plant features an Irock 4043 HSI, 40-in. x 12-ft. vibrating grizzly feeder, and 36-in. discharge conveyor mounted on 20-in.-wide tracks. A radio remote control unit allows a loader or excavator operator to control machine tracking, the impactor, the Cat 250-hp diesel engine, the variable-speed feeder, emergency shutdown, and other plant functions. Operating capacity is 250 tons per hour, Irock said.
15. Kolberg-Pioneer Rocky Trax
Kolberg-Pioneer’s 105,000-lb., RT 2649 Rocky Trax is powered by a 250-hp diesel with full hydraulic controls for the feeder, conveyors, tracks, and Pioneer 2649 jaw crusher. The 50-in. x 15-ft. grizzly feeder has a 5-in. step deck and an 11-ft. 5-in. loading height. The machine has a 24-in. x 15-ft. side discharge conveyor and a 48-in. x 36 1/2-ft. under-crusher end discharge conveyor.
16. Komatsu America Tracked Crushers
Using the tracked undercarriages from it excavators, Komatsu America developed the BR550JG-1 jaw and BR480RG-1 impactor plants. Both machines have a 306-hp Komatsu diesel to provide power for the fully hydraulic drive systems. The jaw has a 44- x 30-in. feed opening; the impactor’s feed opening is 52 x 40 in. InfoExpress 716
17. McLanahan Feeder-Breaker
McLanahan impact feeder-breakers can be skid- or track-mounted for in-pit limestone crushing. Units incorporating a heavy-duty drag chain feeder allow loaders or haul trucks to dump directly onto the feeder. Capacities range from 500 to more than 2,500 tons per hour, according to McLanahan.
18. Metso LT Crusher/LL Mobile Conveyor
The Nordberg LT series tracked jaw crusher from Metso Minerals can be combined with its Lokolink (LL) series conveyors to form a mobile and flexible primary system enabling feeding with an excavator, according to Metso. The crushers for the system, available in four models — LT1415, LT125, LT140, and LT160 — have maximum rated capacities from 900 to 2,200 tons per hour. Maximum feed sizes range from 30 to 41 in. Optional equipment includes AC generator, hydraulic boom and breaker, hydraulic setting control, dust removal kit, remote radio control, and operators’ cabin. LL conveyors, available in 48- or 63-in. widths and 80- or 120-ft. lengths, transfer material from the crusher to a field conveyor or secondary plant. The wheel-mounted conveyors move with the LT crusher.
19. BL-Pegson Primary and Secondary Plants
BL-Pegson manufactures track-mounted crushers for primary and secondary applications incorporating jaws (Premiertrak), HSIs (Trakpactor), and cones (Maxtrak). The Premiertrak has a single-toggle jaw, twin-step grizzly, side-discharge “dirt” conveyor and dust suppression sprays. Pegson’s 4242SR is a new closed-circuit HSI plant based on the Trakpactor. It has a 5- x 11-ft. double-deck screen, vibrating grizzly, underscreen and folding side conveyors, and dust-suppression sprays. The new 1300 Maxtrak features a 51-in. Automax cone with a choice of liners for secondary or tertiary crushing. An on-plant feed hopper and level probes help choke feed the crusher.
Portable Screens
20. AEI bivi-TEC
Aggregates Equipment’s (AEI) portable bivi-TEC screens are available in single- or double-deck configurations in sizes up to 8 x 24 ft. The screens use alternately tensioned and relaxed urethane screen panels to dry screen fine materials. Self-contained portable bivi-TEC plants have hydraulics to raise and lower the inclined screen box, diesel generator, feed hopper, and feed and discharge conveyors. A variable-speed drive on the hopper discharge conveyor controls screen feed rate.
21. Finlay Hydrascreens 653
The wheel- or track-mounted 653 screen plant from Finlay Hydrascreens functions as a stand-alone unit or can be fed from a portable crusher. Standard equipment includes a 4- x 10-ft. top deck, 4- x 8-ft. bottom deck, 32-in.-wide feed conveyor, and one 40-in. and two 26-in. discharge conveyors.
22. Grasan 620HD-H
Grasan’s 620HD-H plant features a Deister 6- x 20-ft. triple-deck, horizontal screen mounted on a tandem-axle trailer. The plant has a rear discharge fines conveyor and side conveyor. Top deck and second deck oversize can be blended. Discharge chutes allow ample room underneath for radial stackers, Grasan said. Plant travel dimensions are 51 ft. 4 in. long and 13 ft. 6 in. high.
23. JCI 8203 Fast Pack Screen
The JCI 8203 screen plant, which the company claims is one of the largest portable screen loads ever designed, is part of the JCI/KPI Fast Pack system (see page 24). The self-contained plant has a diesel engine/generator capable of powering the horizontal screen, on-plant conveyors, and transfer conveyors. A chute/reversing-conveyor configuration allows rejection of a percent of fines while making a base product. Screen speed, stroke, and stroke angle are adjustable.
24. PEP PSP and Super Series III Dry Screens
Production Engineered Products’ (PEP) PSP VV2618M is designed for dry chip sizing and fines removal at up to 500 tons per hour, according to the company. The plant includes a 10-cu.-yd. hopper; feed and discharge conveyors; on-board Cummins diesel and generator; and a 6- x 18-ft., double-deck, high-frequency screen capable of making up to four products. PEP’s Super Series III combines a 6- x 12-ft. Duo-Vibe high-frequency dry screen with a 6- x 20-ft. horizontal JCI screen. The 98,000-lb. triple-axle unit has a transport height of 13 ft. 11 in.
25. Vibrotech Vibroscreen
Vibrotech offers three Vibroscreen models with production capacities from 160 to 750 tons per hour under continuous-flow operations, according to the company. The two largest models have a vibrating grizzly option. Oversized material can be discharged on the ground or onto an optional conveyor. Grizzly bar spacing is adjustable to as small as 3 in.
Portable Sand Plants
26. AEI Ortner
Aggregates Equipment’s (AEI) Ortner can be mounted on a portable chassis with power supplied by a diesel engine/generator or hydraulics. A variable-speed drive controls the pan rotation speed and a product conveyor removes the washed sand or stone. The Ortner is designed to remove fines from concrete sand, de-dust stone up to 2 in., or de-water, the company said.
27. Eagle Iron Works Sand Sections
Eagle Iron Works offers 22 configurations of portable and semi-portable Sand Sections with capacities up to 800 tons per hour, EIW said. They are complete sand washing, classifying, and dewatering systems, incorporating a scalping-classifying tank mounted over two single-screw fine material washers. Each screw has separate settling areas, feed inlets, gear reducers and V-belt drives to produce two gradations, if desired. A choice of three EIW classifier controllers are available: DialSplit, AutoSpec III, or AutoSpec Mark V.
28. GreyStone Aggre-Spec
GreyStone’s line of portable sand classifiers includes eight models ranging in size from 8 x 24 ft. to 10 x 40 ft. that produce up to three products, including two specification products. They have from seven to 11 classifying stations, twin 36-in. or 44-in. screws, and produce up to 350 tons per hour, according to GreyStone. Semi-portable systems are available in 18 models, producing up to 820 tons per hour, the company said. Plant control is achieved with GreyStone’s Windows-based Aggre-Spec III sand-reblending system.
29. Kolberg-Pioneer Classifiers
Kolberg-Pioneer offers 12 semi-portable and seven portable sand classifying systems capable of making two specification products and a “fill” material. Semi-portable classifying tanks range in size from 8 x 20 ft. with twin 36-in. screws to 12 x 48 ft. with twin 60-in. screws. Portable tanks range from 8 x 28 ft. with twin 36-in. screws to 10 x 40 ft. with twin 44-in. screws.
30. McLanahan Sand Manager
McLanahan Corp.’s portable and semi-portable plants are low-profile modular units with a Sand Manager classifying tank and a fine material double-screw washer. Seven plant sizes range from a portable configuration with a 10- x 24-ft. classifying tank and 36-in. double screw to a semi-portable skid-mounted unit with 12- x 48-ft. tank and 54-in. double screw. One or two products can be produced from the double screws, McLanahan said.