Construction Aggregate Production Line

This solution produces controlled sand and aggregate fractions for concrete, asphalt, road base and general construction. The circuit is designed not only to reduce rock size, but also to manage grading, particle shape and product cleanliness.

Project parameters

• Capacity: 80–400 t/h

• Products: several project-specific sand and aggregate fractions

• Crushing: jaw + cone or jaw + impact, according to the feed

• Optional stages: VSI shaping, washing and dust separation

About the solution

The end use of the product comes first in an aggregate plant. Concrete requires controlled coarse and fine aggregates; asphalt places particular emphasis on grading and particle shape; road-base materials follow their own grading envelope. Crusher type, screen apertures, recirculation and washing must therefore follow the project specification or laboratory requirement.

Hard, abrasive granite and basalt commonly use a jaw crusher followed by a cone crusher. Softer limestone and dolomite may use an impact crusher where product shape is important. A VSI stage can be added for cubical fine aggregate or manufactured sand. High clay, dust or excess-fines content may require a separately designed dry-classification or water-washing circuit.

Process flow

1. A hopper and feeder provide controlled flow and may scalp natural fines.

2. A jaw crusher performs primary reduction.

3. A cone or impact crusher prepares the material for product screening.

4. A vibrating screen separates several saleable fractions.

5. Oversize returns for further crushing.

6. VSI shaping, sand washing, dewatering or dry classification is added where required.

Product-quality control

• Screen apertures match the commercial product sizes

• Closed-circuit operation controls the top size

• Crusher chamber and setting affect particle shape and fines generation

• Moisture and clay content determine whether washing is needed

• Separate conveyors and stockpiles prevent product contamination

Applications

• Aggregate for ready-mix concrete

• Mineral aggregate for asphalt

• Road base and precast concrete

• Sand and crushed stone for general construction

Information required for final engineering

Provide material hardness and abrasiveness, feed grading, required products and standards, hourly capacity, moisture and clay content, available process water, stockpile area and electrical supply.